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
The deformation of a metal sheet along a
straight axis to create bends or angles, typically achieved using a press brake, and it’s used to shape the sheet into various geometric forms
Bending
A specific bending technique where the edge of a metal sheet is folded back onto itself, creating a closed, smooth, and safe edge that is commonly used in applications like automotive body panels.
Hemming
A continuous metal shaping process that
involves passing a long strip of metal through a series of rollers with specific profiles to gradually form it into a desired cross-sectional shape, often used for producing items like structural components, profiles, or rails.
Roll Forming
A flat sheet of metal is drawn into a three-
dimensional shape, typically a cup or cylindrical container, using a punch and die set.
Deep Drawing
A metal sheet is clamped around its edges and stretched over a die to form it into a desired shape, often used for creating curved or contoured parts with high precision.
Stretch Forming
Uses hydraulic fluid pressure to shape a metal sheet into a die, enabling the production of complex and lightweight components, particularly in the automotive and aerospace
industries.
Hydroforming
Involves rotating a flat sheet or tube of metal while applying pressure to form it into a cylindrical or conical shape, typically used for producing items like cookware, lampshades, and aerospace components
Spinning
Uses electromagnetic forces to shape a metal workpiece by subjecting it to a high-intensity magnetic field in a very short time, enabling rapid and precise forming of parts with minimal material thinning.
Magnetic pulse forming
Manufacturing techniques used to shape and manipulate polymers, which are large molecules composed of repeating subunits to create various plastic and composite
products
Polymer Processing
Heated polymer material is forced through a die to produce a continuous, uniform profile or shape, often used for creating items like plastic pipes, films, and sheets
Extrusion
Melted thermoplastic material are injected into a mold cavity, allowing it to cool and solidify to form a specific shape
Injection Molding
A hollow, heated plastic parison (thermoplastic hollow tube) is inflated like a balloon within a mold to take its shape, frequently used for producing items with hollow sections, such as bottles and containers
Blow Molding
Involves heating a thermoplastic sheet until it is soft and pliable, then forming it over a mold using vacuum or pressure to create three-dimensional shapes
Thermoforming
Continuous fibers are impregnated with a
thermosetting resin and then pulled through a heated die to create products with a consistent cross-sectional shape, such as rods, tubes, or profiles
Pultrusion
Involves placing the material in a mold and sealing it within a flexible vacuum bag. Vacuum pressure is applied to remove air and compact the material to the desired shape before curing, resulting in strong,
lightweight components.
Vacuum bag forming
Involves melting the thermosetting material in a separate chamber and then forcing it into a closed mold cavity where curing occurs under pressure, suitable for manufacturing products with intricate
details and complex shapes.
Transfer Molding
Uses a laser to solidify layers of liquid photopolymer resin one at a time, creating a three-dimensional object layer by layer, often used for producing high-
resolution, detailed prototypes
Stereolithography
A thermoplastic filament is heated and extruded through a nozzle, layer by layer, to build up a model, making it a widely accessible and cost-effective method for creating prototypes and functional parts
Fused Deposition Molding
Digital models are translated into physical objects by
adding material layer by layer, offering flexibility in
material choices and applications.
Three-dimensional printing
Involves layering and bonding sheets of paper, plastic, or other materials, which are then cut and shaped using a laser or knife, to create a 3D model, often used for creating full-color prototypes and
functional parts with relatively low-cost materials
Laminated object manufacturing
Involves combining two or more separate
components or materials to create a unified structure, often through methods like welding, soldering, adhesive
bonding, and mechanical
fastening
Joining Processing
A welding process where an electrode coated with a flux is used. The electrode is melted to create an arc that joins the workpieces together while the flux
shields the molten weld pool from contamination
Shielded Metal Arc Welding
Employs a continuously fed wire electrode and a shielding gas to protect the welding area from atmospheric contamination. It is commonly used in various industries for its speed and versatility in joining materials like steel, aluminum, and stainless steel
Gas Metal Arc Welding
Uses a continuously fed tubular electrode with a flux core. It can be used with or without shielding gas, making it suitable for outdoor and high-wind conditions, and it is often employed in heavy construction and shipbuilding.
Flux-cored Arc Welding
Uses a non-consumable tungsten electrode and a separate filler material when necessary. The weld area is shielded with an inert gas, typically argon, making it ideal for applications where precision and control are crucial
Gas-Tungsten Arc Welding
Uses a rotating, non-consumable tool to generate frictional heat between the workpieces, which are then joined together without melting, making it ideal
for materials that are difficult to weld by traditional methods.
Friction Stir Welding
Involves the joining of metals by applying pressure and passing an electrical current through the materials at the joint. This localized heating fuses the workpieces
together
Resistance Welding
Joining dissimilar metals by creating a high-velocity impact at the interface between the two materials using explosives. The intense pressure and heat
generated result in a metallurgical bond, making it possible to join metals that would be challenging to weld by conventional methods.
Explosion Welding
Two clean metal surfaces are pressed together at room temperature, creating a molecular bond.
Cold Welding
Involves the use of adhesives or glues to join materials by forming a strong bond at the interface. This method is used in a wide range of industries for joining
materials that may not be easily welded, such as composites or dissimilar materials
Adhesive Bonding
Involves using bolts, screws, or other mechanical fasteners to join two or more components by clamping them together.
Bolted Connection
A soldering process used primarily in electronics manufacturing. Components are placed on a printed circuit board, and the board is passed over a wave of molten solder, which solders the components to the board as it passes over the wave, creating electrical connections
Wave Soldering
Uses a filler metal with a lower melting point than the base metals being joined. The filler metal is heated to its melting point and flows into the joint, forming a
metallurgical bond between the materials
Brazing
Involves removing material from a
workpiece to create a desired shape or finish
Machining
Involves post-machining operations
to improve the appearance, functionality, or durability of a machined part or product.
Finishing Processes
A workpiece is rotated while a cutting tool removes
material to create cylindrical or conical shapes. It is
commonly used for creating cylindrical parts like shafts
and pins
Turning
A machining operation that creates round holes in a
workpiece by rotating a cutting tool called a drill bit
Drilling
Uses rotary cutters to remove material from a
workpiece, creating a variety of shapes, slots, and
complex features.
Milling
Uses a special cutting tool called a broach to remove
material progressively, creating features like keyways,
splines, or other irregular profiles in a workpiece. It’s
often used for applications requiring high precision and
close tolerances
Broaching
Uses a thin, electrically conductive wire to erode
material from a workpiece through a series of electrical
discharges, creating highly precise and complex
shapes
Wire EDM (Electrical Discharge Machining)
Selectively removes material from a workpiece by
immersing it in a chemical etchant. It is employed for
producing intricate patterns or etching on metal parts
and is widely used in the production of aerospace
components and electronic circuits
Chemical Machining
Utilizes a focused laser beam to cut, engrave, or ablate
material from a workpiece. It is employed in various
industries for precise cutting, marking, and drilling of
materials such as metals, plastics, and ceramics
Laser Machining
Uses a high-pressure stream of water mixed with
abrasive particles to remove material from a
workpiece. It is suitable for cutting a wide range of
materials, including metals, composites, and ceramics,
with minimal heat-affected zones and environmental
benefits.
Water Jet Machining
A grinding wheel with abrasive grains is used to
remove material from the surface of a workpiece,
producing a flat and smooth finish. It is commonly
used to achieve tight tolerances and excellent surface
quality on metal and non-metal materials.
Surface Grinding
A machining process that does not require a center
point, and it involves feeding a cylindrical workpiece
through two abrasive grinding wheels
Centerless Grinding
Involves rubbing two surfaces together with abrasive
slurry in between. It is used to create highly accurate
and flat surfaces, often in the manufacturing of optical
components and precision gauges
Lapping
Uses electrochemical reactions to remove a thin layer
of material from the surface of a workpiece. It’s
employed to enhance the smoothness and appearance
of metal surfaces, such as stainless steel or aluminum,
for applications like food processing equipment and
medical devices.
Electrochemical Polishing
