Question 10 AEL01 - Assistant Engineer - Limited

The Correct Answer is B. Welding plates to form sections for assembly is correct because the frames (or 'bedplates' and 'A-frames') of very large marine diesel engines, especially slow-speed two-stroke engines (like MAN B&W or Wärtsilä-Sulzer types), are often constructed using heavy steel plates that are precision-cut and then **welded together**. This method, known as **welded fabrication**, allows engineers to tailor the design for optimal strength-to-weight ratio. Casting large components would be immensely heavy, prohibitively complex, and difficult to manage shrinkage/defect issues. By using high-strength steel plates and welding, engineers can create a stiff, strong structure that is significantly lighter than an equivalent cast iron or fully forged structure, thereby reducing the total engine frame weight. --- **A) casting interlocking components:** Casting large components, especially those subject to immense thermal and mechanical stress like an engine frame, typically results in very heavy structures. While smaller, high-production engines may use cast blocks, very large marine engines prioritize weight reduction and structural integrity achieved through controlled fabrication rather than the inherent weight of massive castings. **C) forging integral components:** Forging is used for high-stress parts like crankshafts and connecting rods. However, the entire frame or block of a massive marine engine cannot practically, or economically, be forged as a single integral unit due to the sheer size and complexity of the required structure. Furthermore, a fully forged frame would likely be heavier than a carefully designed welded fabrication. **D) case hardening integral components:** Case hardening (a surface hardening process) is applied to specific wear surfaces (like camshaft lobes or gear teeth) to increase durability. It is a surface treatment and has no role in the primary method used for constructing the overall massive engine frame or reducing its total weight.