Final Test
MCP - Metal Coating Process, LLC
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1. 1. What gas is at the anode?
___a) nitrogen
___b) hydrogen
___c) oxygen
___d) helium
2. What gas is at the cathode?
___a) helium
___b) oxygen
___c) hydrogen
___d) nitrogen
3. Describe the characterization curve.
___a) volts vs. temperature
___b) volts vs. amps
___c) S.G. vs. temperature
___d) none of the above
4. The amount of metal removed is proportional to what two things?
___a) tanksize, temperature
___b) temperature, S.G.
___c) S.G., time
___d) current, time
5. Define the term passivation.
___a) passivation implies removal of free iron from the surface
___b) passivation results in decreased activity with the environment
___c) a passive film is non-crystalline or glassy
___d) all the above
6. What is the typical average thickness of the oxide layer?
___a) 15 angstoms
___b) 35 angstroms
___c) 45 angstroms
___d) 50 angstroms
7. What ratio is used to determine quality?
___a) nickel:iron
___b) iron:chrome
___c) chrome:iron
___d) oxygen:chrome
8. What elements are removed from the surface?
___a) nickel
___b) manganese
___c) iron
___d) all the above
9. Describe the preferential removal of the elements in their respective order.
___a) chromium, iron, nickel, manganese
___b) iron, chromium, nickel, manganese
___c) iron, manganese, nickel, chromium
___d) iron, nickel, manganese, chromium
10. To determine S.G. correctly what other parameter needs to be tested?
___a) % Hydrogen
___b) % Fe
___c) % Oxygen
___d) % Nitric
11. What is the rule of thumb for metal removal?
___a) 1200 amp-min/Ft² removes 0.0002”
___b) 1500 amp-min/Ft² removes 0.0005”
___c) 2000 amp-min/Ft² removes 0.0002”
___d) 2500 amp-min/Ft² removes 0.0005”
12. How much can you expect to improve the Ra?
___a) 60-70%
___b) 70-80%
___c) 40-50%
___d) 50-60%
13. Where will the highest current density be located on a part that is the shape of a cylinder 1-inch in diameter and 16-inches in length?
___a) at the mid-section
___b) at the ends
___c) at 1/3 the height
___d) at 2/3 the height
14. What should the sulfur content limitation be for 300-series stainless steel to be electropolished?
___a) 0.005%
___b) 0.050%
___c) 0.003%
___d) 0.030%
15. What is the best choice of sheet metal finish designation for electropolishing of the material?
___a) No. 2B
___b) No. 2D
___c) No. 6
___d) No. 8
16. How many amps can a piece of copper carry if the copper is 3/8” x 1”?
___a) 725 amps
___b) 600 amps
___c) 500 amps
___d) 375 amps
17. What will likely happen to the end parts on a rack of several parts?
___a) parts will be elongated
___b) nothing
___c) excessive metal will be removed
___d) parts will be dull
18. Name the recommended wet process steps in proper sequence.
___a) alkaline clean>rinse>EP>rinse
___b) alkaline clean>rinse>deox>rinse>EP>drag out>CFR>nitric>rinse>hot rinse
___c) alkaline clean>rinse>deox>rinse>EP>nitric>CFR>hot rinse
___d) alkaline clean>rinse>nitric>rinse>EP>rinse
19. Name three things the acid bath can be used for in the pre-treatment process.
___a) remove weld scale, remove heat tint, remove anodic film
___b) remove nitric acid, remove alkaline, remove nitrogen
___c) remove anodic film, remove gas streaks, remove EP residue
___d) remove heat tint discoloration, remove weld scale, neutralize alkaline carryover
20. What chemical is suitable for neutralization of the cleaner?
___a) sulfuric acid
___b) hydrochloric acid
___c) nitric acid
___d) sodium bicarbonate
21. What is the preferred cathode:anode ratio?
___a) 4:1
___b) 1:4
___c) 1:2
___d) 2:1
22. How do you correct for ripple factor?
___a) increase current
___b) add choke filter
___c) increase voltage
___d) remove some parts
23. Why is there a nitric acid tank in the recommended process line?
___a) to etch parts
___b) to passivate parts
___c) to remove by-products of EP solution
___d) to create matte finish
24. If your rectifier maximum output at 24 volts is 5000 amps, how much surface area can you polish during one run to achieve maximum EP. Assume you are starting at 20Ra and need to achieve 10Ra. Assume you are using Hydrite #4000 electrolyte at 160 Deg. F. Assume bath does not have excessive metal content and S.G. is within proper range.
___a) apply 600 ASF; 5000A/600ASF = 8.33 Ft²
___b) apply 300 ASF; 5000A/300ASF = 16.67 Ft²
___c) apply 1000 ASF; 5000A/1000ASF = 5 Ft²
___d) apply 750 ASF; 5000a/750asf = 6.67 Ft²
25. If you want to polish 316L to 14Ra, with a starting value of 28Ra, and you have a 24-volt rectifier with #4000 solution in your tank, how many amps will you apply to a part with a surface area of 360 sq.in. and for how long?
___a) 300A x 360 In² = 108000 amps {108000 amps x 50 min.} 1500 amp-min x 360 = 540000 108000/54000 = 50 min.
___b) 28Ra / 14Ra =2 2 x 300 = 600 amps {600 amps x 3.47 min.} 300 amp-min/Ft² x 600 = 180000 180000/360= 500 500/144in²/ft² = 3.47
___c) 300ASF x 360 In²/144 In²/Ft² = 750 amps {750 amps x 5 min.} 1500 amp-min/Ft² x 360 In²/144 In²/Ft² = 3750 amp-min 3750 amp-min/750A = 5 min.
___d) none of the above
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