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Principles of Metallurgy > Adaptive Metallurgy > Flashcards

Adaptive Metallurgy Flashcards

1
Q

Extract Metal from ore/ mineral concentrate

A

Extractive Metallurgy

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2
Q

Conversion of extracted metals into usable forms

A

Adaptive Metallurgy

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3
Q

Adaptive Metallurgy

  1. Also known as ____/____
  2. ____ is the term used to describe the making of products
  3. Started since the ____ to the present
  4. Industrial Revolution (2nd half of the 19th century)- ____
  5. Is the conversion of either ____ or____ into finished parts
A
  1. Metal Processing/Manufacturing
  2. Manufacturing
  3. Tool Age
  4. Mechanization
  5. raw, semi-finished materials
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4
Q

RAW MATERIALS TO FINISHED PRODUCT

usually refers to the conversion
of ores into metallic materials.

A

Primary Manufacturing

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5
Q

CLASSIFICATION OF METALS

  1. ____ - contain iron and steel.
  2. ____- do not have iron content (such as copper and aluminum).
  3. ____ - mixture of two or more metals.
A
  1. Ferrous
  2. Nonferrous
  3. Alloys
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6
Q

RAW MATERIALS TO FINISHED PRODUCT

conversion of the products from the primary operation into semi- finished or finished parts.

A

Secondary Manufacturing

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7
Q

PRIMARY MANUFACTURING PRODUCTS

tong duha kabuok yot

A

Steel
Aluminum

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8
Q

Stages (?) of STEELMAKING

A

Smelting
Converting
Alloying

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9
Q

(1)________

  • Performed in Blast Furnace; product is (2)____ (>3% Carbon)
  • Reduction of Iron ore to Iron with amounts of carbon
A
  1. Smelting
  2. Pig Iron
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10
Q

(1) ____

Maybe performed in Bessemer Converter, Open Hearth Converter or Basic Oxygen Steelmaking Converter to reduce carbon content upto (2)____

A
  1. Converting
  2. 0.002%
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11
Q
  • Metals such as nickel, chromite, manganese, tungsten and so on.
A

Alloying

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12
Q

____ 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
A
  1. Aluminum
  2. Bauxite, 75%
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13
Q

BAYER PROCESS

A

MEMORISA TO KAY TAASAY

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14
Q
  • 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.
A

SECONDARY MANUFACTURING

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15
Q
  • 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.
A

METAL FORMING

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16
Q

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.

A

Bulk Forming

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16
Q

CATEGORIES OF METAL FORMING

2 kabuok

A

Bulk Metal Forming
Sheet Metal Forming

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17
Q

similar to extrusion, except that the workpiece is pulled through the die opening to take the cross section

A

BULK FORMING: WIRE DRAWING

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18
Q

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.

A

BULK FORMING: ROLLING

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19
Q

The workpiece is compressed between
two dies containing shaped contours. The die shapes are imparted into the final part.

A

BULK FORMING: FORGING

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20
Q

In this, the workpiece is compressed or pushed into the die opening to take the shape of the die hole as its cross section

A

BULK FORMING: EXTRUSION

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21
Q

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.

A

Sheet metal forming

22
Q

In this, the sheet material is strained by punch to give a bend shape (angle shape) usually in a straight axis.

A

SHEET FORMING: BENDING

23
Q

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.

A

SHEET FORMING: DEEP DRAWING

24
Q

*This is nothing but
cutting of sheets
by shearing action.

A

SHEET FORMING: SHEARING

25
Q

WORKING TEMPERATURE

Generally done at room temperature or slightly above RT

A

Cold Working

26
Q

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

A

Warm Working

27
Q

WORKING TEMPERATURE

Involves deformation above recrystallization temperature, between 0.5Tm to 0.75Tm

A

Hot Working

28
Q

COLD WORKING

ADVANTAGES

  1. ____ tolerances can be achieved
  2. good ____
  3. because of ____, higher strength
    and hardness is seen in part
  4. ____ flow during deformation provides the
    opportunity for desirable directional properties
  5. since no heating of the work is involved,
    furnace, fuel, electricity costs are ____
  6. ____ are minimum resulting in possibility of near net shaped forming
A
  1. closer
  2. surface finish
  3. strain hardening
  4. grain
  5. minimized
  6. Machining Requirements
29
Q

COLD WORKING

DISADVANTAGES

  1. higher ____ and ____ are required
  2. strain hardening of the work metal ____ the amount of forming that can be done
  3. sometimes cold forming ____ cycle should be followed
  4. the work piece is not ____ enough to be
    cold worked
A
  1. forces , power
  2. limit
  3. annealing-cold forming
  4. ductile
30
Q

WARM WORKING

ADVANTAGES

  1. enhanced ____ properties
  2. lower ____ required
  3. intricate work ____ possible
  4. annealing stages can be ____
A
  1. plastic deformation
  2. forces
  3. geometries
  4. reduced
31
Q

HOT WORKING

Advantages

  1. significant ____ can be given to the sample
  2. significant ____ in workpiece shape
  3. ____ forces are required
  4. materials with ____ can be hot formed
  5. absence of strengthening due to ____
A
  1. plastic deformation
  2. change
  3. lower
  4. premature failure
  5. work hardening
32
Q

HOT WORKING

Disadvantages

  1. ____ tool life
  2. ____ surface finish
  3. ____ dimensional accuracy
  4. sample surface ____
A
  1. shorter
  2. poor
  3. lower
  4. oxidation
33
Q

A ____ is a factory that produces metal castings

A

Foundry

34
Q

BASIC PROCESSING IN CASTING

5 ni sila kabuok

A

Melting and Degassing
Mold Making
Pouring
Shakeout, Degating, Heat Treatment
Surface Cleaning and Finishing

35
Q
  • Performed in a Furnace
  • Charges may be a:
    Virgin material
    External Scrap
    Internal Scrap
A

Melting

36
Q

MELTING: ____

____ are refractory-lined vessels that contain the material to be melted and provide the energy to melt it

A

Furnace

37
Q
  • 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
A

Degassing,

porosity

38
Q

DEGASSING : TECHNIQUES

Way of removing hydrogen from the melt by creating a ____ using a ____, ____ gas through the melt by ____ or ____.

A

Bubble,dry,insoluble, purging or agitation

39
Q

DEGASSING: INERT GASES USED

FERROUS METAL

A

Carbon Monoxide

39
Q

DEGASSING: INERT GASES USED

Non-Ferrous Metals

A

Chlorine

Nitrogen

Helium

Argon

40
Q

MOLD

  1. ____ — Green or resin bonded sand mold.
  2. ____ — Plaster mold.
  3. ____ — Metal mold.
  4. ____ —Wax or similar sacrificial pattern with a ceramic mold.
  5. ____ — Polystyrene pattern with a mixture of ceramic and sand mold.
  6. ____ —Vacuum with thermoformed plastic to form sand molds. No moisture,
    clay or resin required
  7. ____ — Simple mold for producing ingots of metal, normally for use in
    other foundries.
A
  1. Sand Casting
  2. Ceramic mold casting
  3. Die Casting
  4. Investment Casting
  5. Lost-foam casting
  6. V-process casting
  7. Billet (ingot) casting
41
Q

MOLD

  1. Sand casting — ____ or ____ bonded sand mold.
  2. Ceramic mold casting — ____ mold.
  3. Die casting — ____ mold.
  4. Investment casting —____or similar ____pattern with a ceramic mold.
  5. Lost-foam casting — ____ pattern with a mixture of ceramic and sand mold.
  6. V-process casting —Vacuum with ____ ____ to form sand molds. No ____, ____ or ____ required
  7. Billet (ingot) casting — Simple mold for producing ____ of metal, normally for use in
    other foundries.
A
  1. Green or resin
  2. plaster
  3. metal
  4. wax or sacrificial
  5. polystyrene
  6. thermoformed plastic, moisture clay or resin
  7. ingots
42
Q

is an ability to fabricate metals that are difficult to shape by other methods.

A

Powder Metallurgy

43
Q

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 ____.

A
  1. exact sizes, metal powders
  2. compacted, sintering furnace
  3. blending,mixing,pressing, sintering
44
Q

Pwder Metallurgy

Advantages

  1. It can be used to make parts that are very difficult to machine like ____ very ____
  2. The surface finish after Powder Metallurgy is complete is very ____ and ____ and so doesn’t need work to file or smooth the parts
  3. It requires relatively ____ ____ ____.
  4. It produces a ____ ____.
  5. There is no ____, so materials are used efficiently.
A
  1. gears, accurately
  2. smooth, shiny
  3. low processing temperature
  4. uniform microstructure
  5. waste
45
Q

____ – most are made from ____,
although steel can also be used. There are many
benefits of metal foams, including a very good
____.

3 ang ans

A

Metal Foams, aluminum, strength-to-weight ratio

46
Q

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 ____.

A

polymers
soundproofing,crash protection
heat sinks

47
Q

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.

A

Gas bubbles, high buoyancy, viscosity, increased, ceramic powders

48
Q

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

A
  1. Injecting Gas
  2. precipitation, dissolved
  3. in-situ, gas-releasing blowing agents
49
Q

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 ____.

A

aluminum, titanium and tantalum

50
Q

The properties of metal foams

The key properties of metal foam are as follows:

  1. Ultralight material (____–____% of the volume consists of void spaces)
  2. Very high ____
  3. High ____ ____ combined with good energy absorption characteristics
  4. Thermal conductivity is ____
  5. ____ strength
A
  1. 75-95%
  2. porosity
  3. compression strength
  4. low
  5. high
51
Q

The engineering applications of metal foams

  1. The closed variety is used for ____ ____ requiring ____ features, and for ____ and____ structures in vehicles
  2. The open variety is ideal for ____ and ____, filtration and catalysis at high temperatures, for heat exchange and in medical devices.
  3. The open variety is also useful in functional applications such as ____ and ____.
A
  1. structural applications, load-bearing, weight-saving, impact-absorbing
  2. vibration, sound absorption
  3. filtration, damping
52
Q

The engineering applications of metal foams

  1. Foam metal is being used as an experimental ____ in animals.
  2. Metal foams with high strengths can act as high-capacity ____-____ ____.
  3. ____ ____ - the foams reduce the number of parts in the car frame, facilitate assembly, thereby reducing costs and improving performance.
A
  1. prosthetic
  2. impact-energy absorbers
  3. automotive industry

Principles of Metallurgy (13 decks)

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