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AQA A-Level Design & Technology: Product Design > 1.16 Metal Processes > Flashcards

1.16 Metal Processes Flashcards

1
Q

Describe the term forming

A

No material is removed, but materials are deformed to produce required shapes

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2
Q

Describe the term redistribution

A

The material is changed from one form to another, e.g. liquid metal poured into a mould to take a solid shape

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3
Q

Describe the term wastage

A

Material is cut away to leave the desired shape

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4
Q

State two features of press froming

A

Process form: Forming

  • Shapes sheet metal into 3D forms
  • Often used in conjunction with robots for lifting the sheet into place
  • Suitable for mass production or large-scale batch production
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5
Q

State two features of wrought iron forging

A

Process type: Forming

  • Uses wrought iron (carbon content less than 0.8%)
  • Can be hand or hydraulic press process
  • Suitable for one-off or small-batch production
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6
Q

State two features of cupping and deep drawing

A

Process form: Forming

  • Starts with a metal blank
  • Metal is stretched into shape
  • Used for large-scale mass or continuous production
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7
Q

State two features of drop forging

A

Process type: Forming

  • Use for products that need to be tough and hard
  • Maintains the internal grain structure which retains the strength
  • Hot metal billet shaped on an anvil or die and then pressed into shape and cooled
  • Suitable for mass production
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8
Q

State two features of spinning

A

Process form: Forming

  • Product may show parallel lines where the sheet has been forced onto the mandrel
  • Suitable for mass production or small-batch production
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9
Q

Describe the term addition/fabrication

A

Process where components and products are made by adding pieces together

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10
Q

State two features of sand casting

A

Process type: Redistribution

  • Labour-intensive process
  • Not a high-quality surface finish
  • Suitable for one-off or small-batch production
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11
Q

State two features of bending

A

Process type: Forming

  • Does not include any punching or trimming of the metal
  • Simple bending can be carried out in school or college workshops
  • Used for large-scaled batches in industry
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12
Q

State two features of rolling

A

Process type: Forming

  • Hot rolling metal results in uniform mechanical properties, no deformation or stress
  • Surface is usually coated with carbon deposits, which must be removed using acid pickling
  • Cold rolling results in a material that has a tighter tolerance and better surface finish
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13
Q

State two features of gravity die casting

A

Process type: Redistribution

  • Lower melt point metals such as aluminium, aluminium alloys and zinc-based alloys
  • Relies on gravity to help the metal flow into the mould
  • Used for thicker mould sections
  • Used for very large-batch and mass production
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14
Q

State two features of pressure die casting (hot chamber)

A

Process type: Redistribution

  • Lower melt point metals such as aluminium, aluminium alloys and zinc-based alloys
  • Molten metal stored in a shot of molten metal is forced into the die
  • Fast process
  • Used for very large-batch and mass production
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15
Q

State two features of pressure die casting (cold chamber)

A

Process type: Redistribution

  • Lower melt point metals such as aluminium, aluminium alloys and zinc-based alloys
  • Molten metal ladled into shot chamber and hydraulically pushed into the chamber
  • Used for very large-batch and mass production
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16
Q

State two features of investment casting (lost wax casting)

A

Process type: Redistribution

  • Used for intricate or awkward shapes that would be difficult or impossible to mould using any other casting process
  • High quality, excellent finish
  • Wax patterns are cast from a master mould repeatable quality process
17
Q

State two features of low temperature pewter casting

A

Process type: Redistribution

  • Used for school or college workshops
  • Can be used with a simple MDF mould
  • Suitable for one-off production or small batch (with aluminium moulds)
18
Q

State two features of MIG welding

A

Process type: Addition

  • Uses an electrode wire
  • Suitable for thin-gauge metals, medium carbon steel or aluminium
  • Uses an inert gas such as CO2 or argon
  • Suitable for one-off fabrication or on an assembly line e.g. car chassis
19
Q

State two features of TIG welding

A

Process type: Addition

  • Uses a filler rod
  • Accurate, strong welds but requires high skill levels and is quite a slow method
  • Uses an inert gas (argon/helium)
20
Q

State two features of oxy-acetylene welding

A

Process type: Addition

  • Uses a steel filler rod
  • Useful for quick repair jobs or in remote locations where there is no electric power supply
21
Q

State the feature of spot welding

A

Process type: Addition

  • Sheet held between two copper electrodes that form a weld when the charged electrodes make contact with the metal
22
Q

State the feature of soldering

A

Process type: Addition

  • Uses a filler material of a lower melting point than the metal being joined. Typically, solders are an alloy of tin and copper
23
Q

State two features of brazing (hard soldering)

A

Process type: Addition

  • Uses a brass filler rod
  • Carried out using either oxy-acetylene or a gas and compressed air brazing hearth suitable for one-off production or small batch (with aluminium moulds)
  • Used to join dissimilar metals such as mild steel sheet to aluminium copper and nickel
24
Q

State the feature of riveting

A

Process type: Addition

Riveting uses two pieces that are overlapped and drilled. The end of the shaft is then hammered over to join

25
Q

State the feature of soldering

A

Process type: Addition

Uses a filler material of a lower melting point than the metal being joined. Typically, solders are an alloy of tin and copper

26
Q

State the feature of pop riveting

A

Process type: Addition

Pop riveting uses a rivet gun (or riveting pliers) and a rivet and pin. Good for where the underside of the joint is inaccessible

27
Q

State the feature of milling

A

Process type: Wastage

The milling machine can run in the x-direction (left and right horizontally), y-direction (forward and backward horizontally), and z-direction (up and down vertically) to cut slots, shape edges, or thread holes.

28
Q

State the feature of turning

A

Process type: Wastage

The workpiece is held with a three or four jaw chuck in the headstock whilst the cutting tool moves in two axes.

29
Q

State the feature of flame cutting

A

Process type: Wastage

  • Uses oxy-acetylene gas and a special flame-cutting torch to deliver a very intense and focused flame above 3,500°C.
  • Difficult to maintain a parallel line with high levels of tolerance
30
Q

State the feature of plasma cutting

A

Process type: Wastage

  • Plasma is a super-heated ionised gas that is electrically conductive.
  • Plasma cutting generates a faster, cleaner cut than flame cutting
31
Q

State the feature of laser cutting

A

Process type: Wastage

  • More accurate and uses less energy than plasma cutting but cannot cut the same thickness of the material
  • Lower-powered lasers are used in schools and colleges to cut acrylic sheets and manufacture boards such as MDF and plywood.
32
Q

State the feature of punching/stamping

A

Process type: Wastage

  • Uses computer-controlled machines that stamp out sections of sheet material
  • Suitable for small and medium-size production runs and it is normally used for processing metals from 0.5mm to 6mm thickness.
33
Q

State the three types of temporary fasteners and joining methods

A
  • Self-tapping screws
  • Machine screws
  • Nut and bolt

AQA A-Level Design & Technology: Product Design (52 decks)

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