Adaptive Metallurgy Flashcards
Extract Metal from ore/ mineral concentrate
Extractive Metallurgy
Conversion of extracted metals into usable forms
Adaptive Metallurgy
Adaptive Metallurgy
- Also known as ____/____
- ____ is the term used to describe the making of products
- Started since the ____ to the present
- Industrial Revolution (2nd half of the 19th century)- ____
- Is the conversion of either ____ or____ into finished parts
- Metal Processing/Manufacturing
- Manufacturing
- Tool Age
- Mechanization
- raw, semi-finished materials
RAW MATERIALS TO FINISHED PRODUCT
usually refers to the conversion
of ores into metallic materials.
Primary Manufacturing
CLASSIFICATION OF METALS
- ____ - contain iron and steel.
- ____- do not have iron content (such as copper and aluminum).
- ____ - mixture of two or more metals.
- Ferrous
- Nonferrous
- Alloys
RAW MATERIALS TO FINISHED PRODUCT
conversion of the products from the primary operation into semi- finished or finished parts.
Secondary Manufacturing
PRIMARY MANUFACTURING PRODUCTS
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Steel
Aluminum
Stages (?) of STEELMAKING
Smelting
Converting
Alloying
(1)________
- Performed in Blast Furnace; product is (2)____ (>3% Carbon)
- Reduction of Iron ore to Iron with amounts of carbon
- Smelting
- Pig Iron
(1) ____
Maybe performed in Bessemer Converter, Open Hearth Converter or Basic Oxygen Steelmaking Converter to reduce carbon content upto (2)____
- Converting
- 0.002%
- Metals such as nickel, chromite, manganese, tungsten and so on.
Alloying
____ PRODUCTION
- **Most abundant metallic element **in the earth’s crust.
- Ore - ____, which contains about ____ hydrated
alumina (Al203.3H20 and Al203. H20) - Bayer process and Hall-heroult process – 1800s
- Aluminum
- Bauxite, 75%
BAYER PROCESS
MEMORISA TO KAY TAASAY
- The conversion of primary products into secondary finished or semi-finished components can take place by one of several alternative routes.
- Alternatively, it may be forged (bulk deformation) from a primary billet, bar, or metal powder preform. Regardless of the technique used to obtain the secondary shape, it is almost always heat treated and finish machined.
SECONDARY MANUFACTURING
- Large set of manufacturing processes in which the material is deformed plastically to take the shape of the die geometry. The tools used for such deformation are called die, punch etc. depending on the type of process.
- Plastic deformation: Stresses beyond yield strength of the workpiece material is required.
METAL FORMING
It is a severe deformation process resulting in massive shape change. The surface
area-to-volume of the work is relatively small. Mostly done in hot working conditions.
Bulk Forming
CATEGORIES OF METAL FORMING
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Bulk Metal Forming
Sheet Metal Forming
similar to extrusion, except that the workpiece is pulled through the die opening to take the cross section
BULK FORMING: WIRE DRAWING
In this process, the workpiece in the form of slab or plate is compressed between two rotating rolls in the
thickness direction, so that the thickness is reduced. The rotating rolls draw the slab into the gap and compresses it. The final product is in the form of sheet.
BULK FORMING: ROLLING
The workpiece is compressed between
two dies containing shaped contours. The die shapes are imparted into the final part.
BULK FORMING: FORGING
In this, the workpiece is compressed or pushed into the die opening to take the shape of the die hole as its cross section
BULK FORMING: EXTRUSION
involves forming and cutting operations performed on metal sheets, strips, and coils. The surface area-to-volume ratio of the starting metal is relatively high. Tools include punch, die that are used to deform the sheets.
Sheet metal forming
In this, the sheet material is strained by punch to give a bend shape (angle shape) usually in a straight axis.
SHEET FORMING: BENDING
In this operation, forming of a flat metal sheet into a hollow or concave shape like a cup, is performed by stretching the metal in some regions. A blank-holder is used to clamp the blank on the die, while the punch pushes into the sheet metal. The sheet is drawn into the die hole taking the shape of the cavity.
SHEET FORMING: DEEP DRAWING
*This is nothing but
cutting of sheets
by shearing action.
SHEET FORMING: SHEARING
WORKING TEMPERATURE
Generally done at room temperature or slightly above RT
Cold Working
WORKING TEMPERATURE
In this case, forming is performed at temperatures just above room temperature but below the recrystallization temperature. The working temperature is taken to be 0.3 Tm where Tm is the melting point of the workpiece
Warm Working
WORKING TEMPERATURE
Involves deformation above recrystallization temperature, between 0.5Tm to 0.75Tm
Hot Working
COLD WORKING
ADVANTAGES
- ____ tolerances can be achieved
- good ____
- because of ____, higher strength
and hardness is seen in part - ____ flow during deformation provides the
opportunity for desirable directional properties - since no heating of the work is involved,
furnace, fuel, electricity costs are ____ - ____ are minimum resulting in possibility of near net shaped forming
- closer
- surface finish
- strain hardening
- grain
- minimized
- Machining Requirements
COLD WORKING
DISADVANTAGES
- higher ____ and ____ are required
- strain hardening of the work metal ____ the amount of forming that can be done
- sometimes cold forming ____ cycle should be followed
- the work piece is not ____ enough to be
cold worked
- forces , power
- limit
- annealing-cold forming
- ductile
WARM WORKING
ADVANTAGES
- enhanced ____ properties
- lower ____ required
- intricate work ____ possible
- annealing stages can be ____
- plastic deformation
- forces
- geometries
- reduced
HOT WORKING
Advantages
- significant ____ can be given to the sample
- significant ____ in workpiece shape
- ____ forces are required
- materials with ____ can be hot formed
- absence of strengthening due to ____
- plastic deformation
- change
- lower
- premature failure
- work hardening
HOT WORKING
Disadvantages
- ____ tool life
- ____ surface finish
- ____ dimensional accuracy
- sample surface ____
- shorter
- poor
- lower
- oxidation
A ____ is a factory that produces metal castings
Foundry
BASIC PROCESSING IN CASTING
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Melting and Degassing
Mold Making
Pouring
Shakeout, Degating, Heat Treatment
Surface Cleaning and Finishing
- Performed in a Furnace
- Charges may be a:
Virgin material
External Scrap
Internal Scrap
Melting
MELTING: ____
____ are refractory-lined vessels that contain the material to be melted and provide the energy to melt it
Furnace
- is a process that may be required to reduce the amount of hydrogen present in a batch of molten metal.
- Prevents ____ in the
resulting cast
Degassing,
porosity
DEGASSING : TECHNIQUES
Way of removing hydrogen from the melt by creating a ____ using a ____, ____ gas through the melt by ____ or ____.
Bubble,dry,insoluble, purging or agitation
DEGASSING: INERT GASES USED
FERROUS METAL
Carbon Monoxide
DEGASSING: INERT GASES USED
Non-Ferrous Metals
Chlorine
Nitrogen
Helium
Argon
MOLD
- ____ — Green or resin bonded sand mold.
- ____ — Plaster mold.
- ____ — Metal mold.
- ____ —Wax or similar sacrificial pattern with a ceramic mold.
- ____ — Polystyrene pattern with a mixture of ceramic and sand mold.
- ____ —Vacuum with thermoformed plastic to form sand molds. No moisture,
clay or resin required - ____ — Simple mold for producing ingots of metal, normally for use in
other foundries.
- Sand Casting
- Ceramic mold casting
- Die Casting
- Investment Casting
- Lost-foam casting
- V-process casting
- Billet (ingot) casting
MOLD
- Sand casting — ____ or ____ bonded sand mold.
- Ceramic mold casting — ____ mold.
- Die casting — ____ mold.
- Investment casting —____or similar ____pattern with a ceramic mold.
- Lost-foam casting — ____ pattern with a mixture of ceramic and sand mold.
- V-process casting —Vacuum with ____ ____ to form sand molds. No ____, ____ or ____ required
- Billet (ingot) casting — Simple mold for producing ____ of metal, normally for use in
other foundries.
- Green or resin
- plaster
- metal
- wax or sacrificial
- polystyrene
- thermoformed plastic, moisture clay or resin
- ingots
is an ability to fabricate metals that are difficult to shape by other methods.
Powder Metallurgy
Powder Metallurgy
This is a modern way of producing metal part
to ____ by blending elements or ____ together.
The powders are then ____ (squashed)
in a die (like a mould) and heated in a
____ to bond the particles.
The process of powder metallurgy includes
____, ____, ____ and ____.
- exact sizes, metal powders
- compacted, sintering furnace
- blending,mixing,pressing, sintering
Pwder Metallurgy
Advantages
- It can be used to make parts that are very difficult to machine like ____ very ____
- The surface finish after Powder Metallurgy is complete is very ____ and ____ and so doesn’t need work to file or smooth the parts
- It requires relatively ____ ____ ____.
- It produces a ____ ____.
- There is no ____, so materials are used efficiently.
- gears, accurately
- smooth, shiny
- low processing temperature
- uniform microstructure
- waste
____ – most are made from ____,
although steel can also be used. There are many
benefits of metal foams, including a very good
____.
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Metal Foams, aluminum, strength-to-weight ratio
Metal foams are cellular structures made with metal
rather than ____.
They are often used as ____ in vehicles, or
as ____.
In electronics they can be used as ____.
polymers
soundproofing,crash protection
heat sinks
How metal foams are made
Production Method
Metallic melts can be foamed by creating ____ ____ in the liquid. These gas bubbles in the metallic melt tend to rise to the surface due to the ____ ____ forces in the high-density liquid. In order to prevent this from happening, the ____ of the molten metal has to be ____. This can be done by adding fine ____ ____ or alloying elements to form stabilizing particles in the melt.
Gas bubbles, high buoyancy, viscosity, increased, ceramic powders
How metal foams are made
Three ways of foaming metallic melts are listed
below:
1. ____ ____ into the liquid metal from an external source
2. Causing the ____ of gas that had just been ____ in the liquid
3. Causing an ____ gas formation in the liquid by admixing ____ ____ _____ to the melt
- Injecting Gas
- precipitation, dissolved
- in-situ, gas-releasing blowing agents
The properties of metal foams
Metals that Can Be Used
The metal that is commonly used to make metal foams is ____. However, other varieties of metals can be used to make the foam, such as ____ and ____.
aluminum, titanium and tantalum
The properties of metal foams
The key properties of metal foam are as follows:
- Ultralight material (____–____% of the volume consists of void spaces)
- Very high ____
- High ____ ____ combined with good energy absorption characteristics
- Thermal conductivity is ____
- ____ strength
- 75-95%
- porosity
- compression strength
- low
- high
The engineering applications of metal foams
- The closed variety is used for ____ ____ requiring ____ features, and for ____ and____ structures in vehicles
- The open variety is ideal for ____ and ____, filtration and catalysis at high temperatures, for heat exchange and in medical devices.
- The open variety is also useful in functional applications such as ____ and ____.
- structural applications, load-bearing, weight-saving, impact-absorbing
- vibration, sound absorption
- filtration, damping
The engineering applications of metal foams
- Foam metal is being used as an experimental ____ in animals.
- Metal foams with high strengths can act as high-capacity ____-____ ____.
- ____ ____ - the foams reduce the number of parts in the car frame, facilitate assembly, thereby reducing costs and improving performance.
- prosthetic
- impact-energy absorbers
- automotive industry
