MATEPRO Module 3 Flashcards
Involves the use of molten
material, usually metal. This molten material is then poured into a mold cavity
that takes the form of the finished part.
Casting Process
A wax or thermoplastic pattern is used to create a ceramic mold. Molten metal is then poured into the mold, replacing the wax or plastic pattern
Investment Casting
It uses expandable polystyrene (EPS) foam patterns that are coated with a refractory material. The foam pattern is placed in sand, and molten metal is poured into the mold.
Lost Foam Casting
Involves carefully controlling the solidification process to ensure that a single crystal structure is formed, which provides exceptional mechanical properties.
Single Crystal Casting
A metal alloy is heated until it melts and then forced through a spinneret with fine holes. The molten metal is rapidly cooled as it exits the spinneret, forming a solid ribbon or filament.
Melt Spinning Process
Pattern/Design is imprinted into a mold filled with sand to form mold cavity where liquid metal will be poured
Sand casting
Sand and resin mixture is used to coat/invest the design/pattern to serve as mold cavity.
Shell Mold Casting
The mold cavity is made using ceramic slurry and refractory materials. Good precision
Ceramic Mold Casting
Involves pouring molten metal into a mold where it cools and solidifies. The mold is then opened, the casting removed, and the mold is reused.
Permanent Mold Casting
Similar with permanent molding but focusing more on small to medium-size parts that are made up of non-ferrous metals like zinc, aluminum, and magnesium.
Die Casting
A method to produce pipes by pouring molten metal into a rapidly spinning cylindrical mold in which centrifugal force from the rotation exerts pressure on the molten metal
Centrifugal Casting
Pressure is implemented immediately after the liquid alloy starts to solidify and is kept on until the entire casting has solidified
Squeeze Casting
Involve changing the shape of a material by applying forces and stresses, typically
through compression or extension. These processes are used for shaping large pieces of material, like metal, plastic, or ceramics, into desired forms.
Bulk Deformation Process
Reduces the thickness of a metal sheet or strip by passing it through a pair of rollers to create a flat, uniform product.
Flat Rolling
A heated metal workpiece is passed through a series of rollers to change its cross-sectional shape, often used for producing profiles like I-beams or railroad tracks.
Shape Rolling
A technique for shaping metal rings or hollow cylinders by reducing their diameter through radial compressive forces, commonly employed in manufacturing parts like bearings, flanges, and gear blanks.
Ring Rolling
Metal bars or billets are subjected to compressive forces between two rolls, leading to the desired change in shape and size, often used in the production
of long, cylindrical parts such as shafts and axles.
Roll Forging
The workpiece is hammered or pressed between flat dies to deform it into a desired shape, typically used for
producing large, non-specific, and often irregularly shaped metal parts.
Open Die Forging
Involves the use of two or more dies with specific shapes to compress a workpiece into a precise and intricate shape, suitable for manufacturing high-
precision components.
Closed Die Forging
A cold-working metal forming process used to reduce the diameter of a rod, wire, or tube and create a head, often employed in the production of fasteners like screws and bolts
Heading
Involves creating a hole or opening in a solid metal workpiece using a punch and die set, commonly utilized to manufacture items like pipes and tubing with hollow sections.
Piercing
A solid rod or billet is pushed through a die to create a
desired shape or profile, with the material following
the same direction as the force applied
Direct Extrusion
A specialized form of direct extrusion that is used to produce thin, intricate gold wires, often employed in jewelry making and electronics
Gold Extrusion
Metal or wire, is pulled through a die to reduce its diameter and increase its length, resulting in a thinner and longer product.
Drawing
A specific type of drawing process used to reduce the diameter and wall thickness of a tube or pipe, often employed in the manufacturing of precision tubes
Tube Drawing
Involve a variety of techniques for shaping, cutting, bending, and forming thin metal sheets into desired shapes and
components.
Sheet Metal Process
Cutting a flat sheet to create a specific shape or outline, producing a single piece of material with precise dimensions, which can serve as the initial workpiece for further manufacturing
processes
Blanking
Cutting a metal coil or sheet into narrower strips or coils, typically for the purpose of creating materials with reduced width or for further processing, such as roll forming.
Slitting
Involves using a punch and die set to create holes, notches, or openings in a metal sheet or workpiece, often employed for creating functional features or fastening points in sheet metal components.
Punching
Material is removed from a metal workpiece to form holes, slots, or other openings, commonly used in sheet metal processing to introduce ventilation, fastening points, or decorative
features into the material.
Piercing