Metal Fabrication Flashcards
Nuts and bolts
Metal fasteners are of two kinds—those producing a permanent bond and those requiring either a releasable or a sliding bond. Screws, nuts and bolts, rivets, retaining rings and clamps are examples from the first category. Non-permanent fasteners include quick-release couplers and clamps intended for removal at a specified time and pins, which allow relative movement of fastened parts.
Metal fasteners must be strong to bear significant loads. In many cases they can be manufactured by casting techniques. Iron is a constituent of many types of metal fasteners, although titanium increasingly is coming into use in applications where strength must be balanced against light weight. In most applications where permanent bonding is required metal fasteners are replaceable by some form of welding or soldering.
Seams
The lap seam is a basic metal seam where one piece overlaps the other. A “lap” is created by making a fold across the edge, then laying the lap over the other piece of metal, pounding flat and soldering, welding or securing with rivets. Lap seams are often used to connects two ends to make a cylinder and are used in making boilers, auto bodies, wall panels, metal sculpture and metal roofing.
Brazing
Brazing is where 2 pieces of metal are joined together by melting a DIFFERENT type of metal to form a joint
Casting
Casting is a way of melting metal and pouring it into a mould to make a complex shape.
Die casting
Die Casting is where a metal Die (mould) is used and the molten (liquid) metal in injected in under pressure
Die casting costs
The machine is large and expensive but once set up the cost is low for each product
Sand casting materials
Steel or aluminium
Sand casting
Sand Casting is where there is no Die but a mould made of sand that can only be used a few times
Sand casting costs
The equipment and mould is cheaper to buy and make but it takes a LONG time so is no good for making lots of products
Sand casting products (3)
One off sculptures/ornaments
Pipes
anything else that could be die cast but could also be sand cast if you only wanted a small number.
Die casted products (4)
Engine parts
Toy cars
Handles cooking pans
Handles
Sand casting advantages
Scrap can be reused in the process
Cheap
Many material options
In soft soldering, what materials do you use to join metals?
Lead alloys
Gap fill - ARC welding
Arc welding is the process of _______ two metal workpieces together using a ____ covered electrode which is melted in an electric ___ and becomes a fused part of the pieces being welded.
Joining, Flux, ARC,
