Joining and Assembling

Question 1

___________ is putting two or more parts together

Answer 1

Joining

Question 2

___________ is the sequence of multiple joining operations to make a product

Answer 2

Assembling

Question 3

Joining and Assembly (J&A) can account for up to ________ of a
products total manufacturing cost and __________ of its total
manufacturing time

Answer 3

30%, 50%

Question 4

_____________are often the points where products fail

Answer 4

Joints

Question 5

What are the 5 types of joining processes?

Answer 5

Welding, Brazing, adhesive bonding, Mechanical, Joining using Form

Question 6

What are the 6 most common joint geometries?

Answer 6

Butt, Lap, Sleeve, T, Edge, Corner

Question 7

___________ welding involves heating material beyond its melting point

Answer 7

Fusion

Question 8

__________________ welding heats the material until it is soft.

Answer 8

Solid-State

Question 9

Welding can generally combine _________ material and can create local joints called __________ welds or continuous ones called ___________________ welds.

Answer 9

similar, spot, seam

Question 10

When welding Stainless Steel and Aluminum, a good selection of _______ is important

Answer 10

Alloy

Question 11

Welding is the most important joining process for _____________ steel which is generally __________________ steel,

Answer 11

Structural, Low carbon

Question 12

Welding can undo __________________ or _________________ and can cause residual stress due to _____________________. It can also cause ____________ which degrades material properties.

Answer 12

Work hardening, Heat Treatments, Temperature Gradients, Oxidation

Question 13

In ___________________________ welding , fuel acetylene is burned with oxygen to ___________ the metal

Answer 13

Oxy-acetylene gas welding, melt

Question 14

What Welding method is best for thin sheets and tubes of aluminum, magnesium and titanium

Answer 14

TIG

Question 15

What welding process is best for thin, low carbon steel products?

Answer 15

Oxy-acetylene gas welding

Question 16

_______________ welding clamps sheet parts (usually low carbon steel) between ________________and discharging a large current

Answer 16

Resistance Spot welding, Copper Electrodes,

Question 17

In Resistance Spot welding, no ______ is needed, it is fast and it can be automated, but ____________ welds are not very strong

Answer 17

Filler, spot

Question 18

_____________ Welding uses a laser to provide heat to make spot or continuous welds and can weld _____material in a single pass. It has a high investment cost and is mostly used with ____________

Answer 18

Laser, thick, low carbon steel

Question 19

___________________ is a relatively new welding method in
which heating is caused by the ___________ of a rapidly rotating
tool with a protruding probe.

Answer 19

Friction Stir Welding, friction

Question 20

Friction stir welding (FSW) is a ___________ process where no filler is used and small welds can be made with ______________, but larger welds need dedicated equipment

Answer 20

Solid-state, CNC

Question 21

Friction stir welding (FSW) was made for making long _______________ welds in _________________ extrusions but is also a common choice for titanium

Answer 21

continuous, aluminum

Question 22

______________ is done by heating the plastic above its glass
temperature (amorphous plastic) or melting temperature
(_______________)

Answer 22

Plastic welding, crystalline plastic

Question 23

Welding plastic is mainly done when you need ____________________ bonds

Answer 23

Strong airtight

Question 24

What are the two main processes of plastic welding?

Answer 24

Ultrasonic and Hotplate

Question 25

___________________ plastic welding uses a piezoelectric element to generate ultrasound that creates enough _________ to allow the interface to be joined

Answer 25

Ultrasonic, heat

Question 26

________________ uses a hot metal plate that applies the heat and then is removed before the parts are ____________

Answer 26

Hot Plate Welding, pressed together

Question 27

Soldering is done below __________C and brazing is done at much _____________ temperatures

Answer 27

450C, higher

Question 28

Brazing is typically performed on _______ alloys such as _______

Answer 28

copper, brass

Question 29

Brazing and soldering require much ________ heat than welding and therefore do not produce as much thermal distortion or ____________

Answer 29

less, residual stress

Question 30

In brazing, lap and sleeve joints will be stronger than __________ or ________ joints

Answer 30

tee, butt

Question 31

what are the two brazing methods?

Answer 31

Torch brazing, Furnace brazing

Question 32

_____________: common manual method of brazing in which a skilled worker manipulates a torch and a reel of filler material

Answer 32

Torch Brazing

Question 33

_______________: Is when the parts are prepared, mounted in a jig with the filler material applied in the right places, and placed in a furnace where the filler material permeates the joint

Answer 33

Furnace Brazing

Question 34

Soldering creates electrically _____________ joints and is used in electronics and _______________________

Answer 34

Heat Exchangers

Question 35

Adhesives are slow but are the method of choice for combining _______________

Answer 35

composites

Question 36

Adhesives should be loaded in ______________ only

Answer 36

Shear

Question 37

Adhesives are weak in tension so _________ and ____________ joints work best

Answer 37

Lap, sleeve

Question 38

What are the 4 types of adhesives?

Answer 38

Drying Adhesives, multi-component reactive adhesives, single-component reactive adhesives, hot melts

Question 39

________________ use the dispersion of active adhesive in a solvent. When the solvent evaporates, the adhesive hardens.

Answer 39

Drying adhesives

Question 40

______________________________ Are mixtures of two different compounds that when mixed set off a chemical reaction that will harden the mixture.

Answer 40

Multi-component reactive adhesives

Question 41

_________________________________ are single compounds that cause a chemical reaction when subject to an external trigger (e.g., UV light, heat, moisture). Epoxies are an example.

Answer 41

Single-component reactive adhesives

Question 42

___________________ are thermoplastics that are heated until they liquefy, applied to a surface and allowed to cool o Allow for higher production speeds and do not require chemical reactions (so less fumes)

Answer 42

Hot Melts

Question 43

Bolts can be used with a nut in a _______________ or by themselves in a ___________________

Answer 43

through hole, blind hole

Question 44

Bolts are most often made of ________________

Answer 44

Carbon Steel

Question 45

Bolts are often forged by ________________

Answer 45

Cold Heading

Question 46

Unlike bolts, screws do not have ______________ and transmit force in shear

Answer 46

shanks

Question 47

Screws are _____________, that is they form their own thread when screwed into a hole

Answer 47

self-tapping

Question 48

Rivets are permanent mechanical fasteners that start out as shanks about __________ thinner than the hole in the two parts needing to be joined

Answer 48

10%

Question 49

___________ rivets require access to just one side of the joint, but are relatively _____________

Answer 49

pop, weak

Question 50

Form closures can be divided into two categories based on whether they induce __________ or ______________ deformations

Answer 50

elastic, plastic

Question 51

_____________is a form closure method where folding two metal sheets over each other like hooks to create a continuous seam

Answer 51

Seaming

Question 52

______________, often known as press fits, rely on compressive force and friction at the joint to hold it together elastic plastic

Answer 52

Clamp Fits

Question 53

_____________: Like seaming, but locally interlocks two pieces of metal together

Answer 53

Clinching