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Materials & Processes > EVERYTHING > Flashcards

EVERYTHING Flashcards

1
Q

What does EMC stand for?

A

Engineering, Materials and Components

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2
Q

What two forms are available of stainless steel?

A

Wrought and cast iron

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3
Q

Stainless steel does not usually have less than how much iron?

A

50%

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4
Q

What is Galvanic Corrosion?

A

2 dissimilar metals in contact with each other in the presence of an electrolyte
(One is the anode, other is cathode)

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5
Q

Does the anode or cathode corrode?

A

Anode

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6
Q

What are the 3 main crystalline lattice structures?

A

FCC, BCC, and HCP

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7
Q

What crystalline lattice structure is considered ductile and give an example.

A

FCC, ex. iron

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8
Q

What crystalline lattice structure is considered strong and hard and give an example.

A

BCC, ex. iron

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9
Q

What crystalline lattice structure is prone to hardening and give an example.

A

HCP, ex. zinc

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10
Q

What is polymorphic/allotropic?

A

Can exist in more than one crystalline structure.

Ex. Iron - BCC to FCC when heated

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11
Q

What are the properties of a metal that is more ferrite?

A

Softer/more ductile

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12
Q

What are the properties of a metal that is more cementite?

A

More hard/brittle

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13
Q

Coarse grain structures are stronger or weaker than fine grain structures?

A

Weaker. Fine grain structures are stronger

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14
Q

What type of grain structure is better for machinability?

A

Coarse-grained but the surface quality isn’t as good

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15
Q

What is tensile strength?

A

Max stress applied by pulling/stretching prior to fracture

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16
Q

What is the lightest of all commercial metals?

A

Magnesium

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17
Q

Titanium is how much lighter than steel?

A

45%

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18
Q

What material is the best conductor of heat and electricity?

A

Silver

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19
Q

What two elements make up air and what percentage of each?

A

19% oxygen and 81% nitrogen

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20
Q

What is the triple point?

A

When material can exist as a solid, liquid and a gas in equilibrium

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21
Q

How do you know the atomic number?

A

Number of protons

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22
Q

How do you know the mass number?

A

Protons plus neutrons in the nucleus

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23
Q

What is the mass of a proton?

A

One

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24
Q

What determines the element?

A

Number of protons

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25
Q

How much does an electron weigh?

A

1/1840 of a proton

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26
Q

What is the mass of a neutron?

A

One

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27
Q

What is the only element without a neutron?

A

Hydrogen with one proton

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28
Q

Define element:

A

Pure substance with chemically identical atoms

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29
Q

Define compound:

A

2+ elements chemically combined

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30
Q

Define ionic bond:

A

The attraction between 2 oppositely charged ions

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31
Q

Define covalent bond:

A

A chemical bond of a stable balance between attractive/repulsive forces

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32
Q

Define metallic bond:

A

Electromagnetic interaction between delocalized electrons and positive ions

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33
Q

Define amorphous:

A

Solid as such as glass that solidify but don’t take a crystalline structure

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34
Q

What is the carbon content of wrought iron?

A

Usually below 0.08%

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35
Q

What is the carbon content of cast iron?

A

Between 2 and 6.67%

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36
Q

Define composite and give 3 examples

A

2+ elements to produce a different substance. 1) polymer 2) metal 3) ceramic

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37
Q

What is a common example of a laminate material?

A

Fiberglass

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38
Q

Define polymorphic/allotropic:

A

Can exist in more than one crystalline structure

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39
Q

What does the equilibrium phase diagram show us?

A

What happens to a material by increasing the temp/carbon

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40
Q

What is the opposite of strength?

A

Ductility

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41
Q

Define hardness:

A

Ability to withstand surface indentation

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42
Q

Define impact resistance in one word:

A

Toughness

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43
Q

If a material is more ferrite, it will be…

A

Softer and more ductile

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44
Q

If a material is more cementite it will be…

A

Harder and more brittle

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45
Q

Austentite only exists at a high temp of between…

A

910 and 1400 degrees C

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46
Q

Ferrite is ferromagnetic below what temp?

A

768 degrees C

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47
Q

What type of grains are the strongest?

A

Fine grained

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48
Q

What type of grain can be more easily deformed?

A

Coarse grained

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49
Q

What type of grains machine better?

A

Machinability but surface quality isn’t as good

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50
Q

What type of grain ferrous material is easier to harden by heat treat than the other of same composition?

A

Coarse grained

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51
Q

Define tensile strength:

A

Max strength applied by pulling/stretching prior to failure

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52
Q

Define fatigue strength:

A

Ability to undergo cyclic stresses without failure

53
Q

Define yield strength:

A

The stress a material can withstand without permanent deformation OR the point at which it will no longer return to original dimensions

54
Q

Define discontinuity:

A

An interruption in normal physical structure/configuration of an article

55
Q

Define pipe:

A

Inadequate amount of molten metal as ingot solidifies (not enough)

56
Q

Define blowhole:

A

Multiple porosities that have joined, bursting through surface and into each other

57
Q

When multiple porosities or blowholes are present and the material has been rolled, what are they referred to as?

A

Seams

58
Q

Define stringers:

A

Inclusions that’s have been thinned and lengthened in direction of rolling or any other further process of operation

59
Q

What is added to remove oxygen in the deoxidization of steel processing?

A

Silicon and aluminum

60
Q

What is added to remove oxygen from steel processing?

A

Silicon and aluminum

61
Q

5 Common Ingot Discontinuities:

A

1) blowhole
2) centreline shrinkage
3) segregation
4) porosity
5) inclusions

62
Q

Which furnace is for primary processing and which is for secondary?

A

Primary: Blast Furnace
Secondary: Open Hearth Furnace (OHF)

63
Q

What is generally what happens when pre-treating steel?

A

Oxygen forced into molten metal to push out carbon

64
Q

In CONTINUOUS CASTING, molten metal is solidified into 1 of 3 things. What are the 3 things?

A

Billet, bloom or slab

65
Q

Define billet:

A

Steel shape whose cross-sectional area is less than 36 square inches

66
Q

Define bloom:

A

Larger than 36 square inches

67
Q

Define slab:

A

Rectangular steel shape with width at least 3x it’s thickness

68
Q

Inherent discontinuities happen during what process?

A

Casting

69
Q

Define cheek:

A

Intermediate flash inserted between cope and drag to help in moulding difficult shapes

70
Q

Define core:

A

Separate piece inserted into cavity to form an opening in casting

71
Q

Define chaplets:

A

Small metal pieces used to hold the core in place

72
Q

Define progressive solidification:

A

Freezing of liquid is from outside towards centre

73
Q

Define directional solidification:

A

Freezing of liquid from one part of casting to another

74
Q

Define what a chill is the casting process:

A

Device made from metal, inserted into mould to hasten solidification

75
Q

Define segregation:

A

An irregular distribution of molten metal. Alloying elements didn’t blend properly

76
Q

Define cold shut:

A

Different streams of metal, already cooling but not fusing together

77
Q

Define cold shot:

A

Rapidly poured metal causing turbulence and not fusing (metal splashing on sides of walls which dry before the rest)

78
Q

Define a hot/cold crack:

A

Lots of stress pulling on each other

79
Q

Define misrun:

A

Not enough molten metal

80
Q

What casting discontinuity is found commonly in thick to thin section transitions or abrupt changes in section?

A

Hot tears

81
Q

What is the result of cold working?

A

A harder product with lower ductility

82
Q

Define forging:

A

Metal is shaped by individual and intermittent application of pressure

83
Q

What happens to grains in the rolling process?

A

They’re elongated and compressed

84
Q

Define extrusion:

A

Compressing metal and polymer beyond elastic limit then forcing them through and opening or die

85
Q

What is the reverse process of extruding? And define it:

A

Drawing: pulling metal though a die

86
Q

What are the 4 types of stress?

A

Shear, tensile, compressive and torsional

87
Q

Describe what a lamination would look like:

A

Flat, extremely thin and generally parallel

88
Q

What is caused by non metallic inclusions in billets/blooms that have been thinned and lengthened?

A

Stringers

89
Q

What casting discontinuity is shaped like chevrons?

A

Cupping (serious of internal ruptures)

90
Q

Describe a forging lap:

A

Smooth, wavy lines that are not usually very pronounced but do not adhere to base

91
Q

Describe hydrogen flakes:

A

Short, internal fissures that are super thin and aligned parallel with the grain

92
Q

Pickling is done prior to what?

A

Plating/cladding

93
Q

How are flash line tears caused?

A

Improper trimming of flash or a dull trimming tool

94
Q

How are grinding cracks positioned on the material?

A

Right angles to the direction of grinding

95
Q

What 2 discontinuities are caused by diffusion of hydrogen during operations?

A

Pickling and plating cracks

96
Q

For a fracture to occur, what must happen to the material?

A

Material is pushed past ELASTIC LIMIT resulting in plastic deformation

97
Q

How many different stresses are there and what are they?

A

1) tension, 2) compression, 3) bending, 4) shear, 5) torsion

98
Q

What is the factor of safety and how is it achieved?

A

The relationship between actual stress and ultimate strength (divide actual stress from unlimited strength)

99
Q

Define fatigue:

A

Progressive stress caused by cyclic loading

100
Q

If a material has reached its elastic limit or yield point, what will happen to it?

A

Won’t return to original shape

101
Q

Plastic deformation is when a load…

A

Exceeds elastic limit/yield point

102
Q

What is the purpose of the stress-strain curve?

A

To identify a material as ductile or brittle

103
Q

Brinell, Rockwell and vickers are all hardness tests that are apart of what subcategory?

A

Resistance to penetration

104
Q

What does the brinell hardness test use?

A

A 10 mm diameter hard steel ball OR carbide sphere of spherical load

105
Q

What does the Rockwell hardness test use?

A

Depth of an impression from a diamond cone shaped indenter

106
Q

What is measured in the vickers hardness test?

A

Measures microhardness in shallow penetration using a square shaped pyramid indenter

**most accurate

107
Q

Cold working does what to the crystal structure?

A

Compacts crystal structure

108
Q

Elevating temps start to do what to the grains?

A

Reform the grains

109
Q

Normalizing is used after casting, rolling or forging to do what 3 things?

A

1) refine grain size, 2) produce a uniform microstructure and 3) improve mechanical properties

110
Q

What type of electrode provides a filler metal?

A

Consumable electrode

111
Q

What is not melted in flow bonding welding?

A

Base metal

112
Q

Define cyclic loading:

A

Repeated/fluctuating stresses BELOW tensile strength

113
Q

What initiates fatigue cracking?

A

Cyclic loading

114
Q

Define over stress:

A

Exceeds ultimate strength

115
Q

4 typical service related discontinuities:

A

1) fatigue cracks/failure
2) over-stress cracks/failure
3) creep failure
4) thermal fatigue failure

116
Q

Fatigue cracks/failure are formed under what?

A

Cyclic stress

117
Q

Over-stress cracks/failure are what type of failure?

A

Mechanical

118
Q

Define creep failure:

A

Tendency of materials to move/deform permanently while under stress

119
Q

Why does thermal fatigue failure happen?

A

Fracture from presence of temp gradients which will vary with time

120
Q

What causes erosion corrosion?

A

An aggressive chemical environment and high fluid velocity

121
Q

Define cavitation:

A

Implosion in cavities of liquid against metal

122
Q

Explain filliform:

A

Localized and in high humidity conditions.. wormlike appearance

123
Q

Define corrosion fatigue:

A

Fluctuated stress in a corrosive environment

124
Q

Define stress-corrosion cracking:

A

Metal subject to constant low TENSILE stresses in corrosive environment

125
Q

Does the anode or the cathode corrode?

A

Anode

126
Q

Name 3 common anodes:

A

Zinc, magnesium and aluminum

127
Q

The cathode acts as a what and removes electrons from metal?

A

Depolarizer

128
Q

Name 5 common cathodes:

A

Stainless steel, silver, gold, platinum and copper

129
Q

Describe what happens in galvanic corrosion:

A

Electrons leave the corroding material (anode) and enter the non corroding material (cathode) where negative ions are formed

Materials & Processes (3 decks)

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