Brainscape's Knowledge GenomeTM

Browse over 1 million classes created by top students, professors, publishers, and experts.


See full index

A-Level Design > Metal Manufacturing Processes > Flashcards

Metal Manufacturing Processes Flashcards

1
Q

What is planishing?

A

Giving a final finish to metal by hammering or rolling to produce a smooth surface.

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
2
Q

What is normalising?

A

A heat treatment applied to steels to make the material stronger and tougher.

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
3
Q

Give four example of heat treatments.

A
  • Annealing
  • Hardening
  • Tempering
  • Normalising
How well did you know this?
1
Not at all
2
3
4
5
Perfectly
4
Q

What is annealing?

A

A process to reverse the internal stress caused by work hardening.

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
5
Q

Describe the process of annealing.

A
  • The material is heated to a temperature at which the crystals grow.
  • The material is “soaked” at this temperature.
  • The material is then cooled very slowly.
How well did you know this?
1
Not at all
2
3
4
5
Perfectly
6
Q

What is hardening?

A

A process that involves heating metal to a high temperature followed by rapid cooling.

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
7
Q

What is tempering?

A

A process carried out after hardening to remove brittleness.

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
8
Q

What happens to hardness and toughness as the tempering temperature increases?

A
  • Hardness is reduced

- Toughness is increased

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
9
Q

What colour will steel go at a low tempering temperature?

A

Pale straw

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
10
Q

What colour will steel go at a high tempering temperature?

A

Blue

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
11
Q

Give a use of steel that has been tempered at a low temperature.

A

Drills

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
12
Q

Give a use of steel that has been tempered at a high temperature.

A

Springs

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
13
Q

What is quenching?

A

The rapid cooling of a metal following heat treatment.

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
14
Q

Give four examples of quenching media.

A
  • Brine
  • Water
  • Oil
  • Air
How well did you know this?
1
Not at all
2
3
4
5
Perfectly
15
Q

What is the softest quenching medium?

A

Air

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
16
Q

What is the harshest quenching medium?

A

Brine

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
17
Q

What is age hardening?

A

A process in which aluminium and copper alloys are left for a period of time in which the material becomes stronger and harder.

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
18
Q

What is case hardening?

A

A process by which carbon is added to the outer skin of steel which can then be hardened.

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
19
Q

Describe the process of case hardening by carburising.

A
  • The component is placed in a carbon rich ceramic box.

- The atmosphere temperature is increased to 760° so the carbon atoms can enter the material’s structure.

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
20
Q

Give two examples of case hardening.

A
  • Carburising

- Nitriding

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
21
Q

Give two advantages of case hardening.

A
  • Steels that don’t have sufficient carbon for heat treating can be hardened.
  • The process leaves a tough inner core.
How well did you know this?
1
Not at all
2
3
4
5
Perfectly
22
Q

Give a disadvantage of case hardening.

A

Grain growth occurs requiring the need for machining.

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
23
Q

Give five advantages of nitriding.

A
  • No additional hardening is necessary.
  • It removes the chance of cracking
  • Increased resistance to corrosion.
  • Clean process.
  • Economical for large numbers
How well did you know this?
1
Not at all
2
3
4
5
Perfectly
24
Q

Give two disadvantages of nitriding.

A
  • High setup costs

- Potential for permanent loss of hardness.

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
25
Q

Give two advantages of flame and induction hardening.

A
  • Localised areas of the product can be hardened.

- Grain growth doesn’t occur.

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
26
Q

Give four examples of wasting processes.

A
  • Sawing and filing
  • Drilling and milling
  • Grinding and sanding
  • Blanking and piercing
How well did you know this?
1
Not at all
2
3
4
5
Perfectly
27
Q

Give three examples of addition processes.

A
  • Bolts and screws
  • Welding
  • Adhesives
28
Q

What are the four main types of redistribution processes?

A
  • Casting
  • Forging
  • Forming
  • Sintering
29
Q

Give two examples of casting.

A
  • Sand casting

- Die casting

30
Q

Give two examples of hot forging.

A
  • Drop forging

- Hot pressing

31
Q

Give two examples of forming.

A
  • Press forming

- Embossing and coining

32
Q

Give four examples of processes for cutting metals.

A
  • Piercing and blanking
  • Profile cutting
  • Plasma cutting
  • Laser cutting
33
Q

Give two advantages of plasma cutting.

A
  • There is very little waste material.

- No finishing is required.

34
Q

What does CNC stand for?

A

Computer Numerical Control

35
Q

Give two three advantages of laser cutting.

A
  • Much finer detail can be achieved.
  • A wider range of materials can be cut.
  • Materials can also be engraved.
36
Q

Give two examples of press-formed materials.

A
  • Radiator panels

- Cooker tops

37
Q

What is embossing?

A

A process used to press decorative details into materials.

38
Q

Give three examples of press-forming.

A
  • Sheet metal can be made into 3D shapes.
  • The material is given greater stiffness.
  • The material’s structural strength increases.
39
Q

What is the first stage of sand casting?

A

A pattern is made and is split for more complex shapes.

40
Q

What is the second stage of sand casting?

A
  • Each half of the pattern is placed on a baseboard.

- A mould box is placed over it.

41
Q

What is the third stage of sand casting?

A
  • Green sand is tamped around the pattern forcing it into contact with the pattern.
  • Backing sand is also placed.
42
Q

What is the fourth stage of sand casting?

A
  • The pattern is removed from the mould half.

- The runner and riser gates are cut into the top half of the sand mould.

43
Q

What is the fifth stage of sand casting?

A

The mould halves are fitted together with locating pins.

44
Q

What is the sixth stage of sand casting?

A
  • The molten metal is poured into the running gate.

- Degassing tablets reduce the risk of a porous casting.

45
Q

What is the seventh stage of sand casting?

A
  • The sand mould is broken open releasing the product.

- The runner and riser gates are removed.

46
Q

Give four advantages of sand casting.

A
  • Complex 3D shapes can be produced.
  • Hollow sections can be produced.
  • Small quantities can be produced.
  • The process can be automated for large quantities.
47
Q

Give three disadvantages of sand casting.

A
  • The process gives a poor surface finish.
  • Not an accurate process.
  • Low rate of output.
48
Q

What is die casting?

A

A process used to cast metals with low melting points.

49
Q

Give three examples of metals used in die-casting.

A
  • Zinc
  • Aluminium
  • Magnesium
50
Q

What is a flux?

A

A chemical used to prevent oxidation of the material at the joint area prior to joining.

51
Q

Give five advantages of multi-slide die casting.

A
  • The surface finish is smooth.
  • Accuracy and detail are high.
  • Rapid cooling makes the quality of material better.
  • High scale production is easily achievable.
  • Little heat is needed to heat the metal.
52
Q

What is the first stage of investment casting?

A

A wax pattern is produced to a high degree of accuracy.

53
Q

What is the second stage of investment casting?

A

The pattern is coated in a high temperature ceramic material.

54
Q

What is the third stage of investment casting?

A

The pattern is melted by placing it in a kiln.

55
Q

What is the fourth stage of investment casting?

A

Molten metal is poured into the ceramic mould.

56
Q

What is the fifth stage of investment casting?

A

The ceramic mould is broken open leaving the cast product.

57
Q

Give three advantages of investment casting.

A
  • High quality finish
  • Complex shapes can be produced.
  • There is no split line.
58
Q

Give two disadvantages of investment casting.

A
  • The process is expensive

- The size of components is limited

59
Q

When is sintering used?

A

When materials are too difficult to process any other way.

60
Q

What is sintering?

A

A process whereby powder particles are fused together.

61
Q

Describe the process of sintering.

A
  • The materials are crushed into a fine powder.
  • The powder is compacted into a die.
  • The shape is heated to promote bonding between the materials.
62
Q

What is forging?

A

Processes carried out using basic tools.

63
Q

What is drawing down?

A

Reducing the thickness of a material by hammering into a thinner section.

64
Q

What is punching and drifting?

A

Hammering a material using a spiked tool, then tidying the whole using a drift..

65
Q

Give three examples of forging techniques.

A
  • Bending
  • Drawing down
  • Punching and drifting
66
Q

What is drop forging?

A

A refining process for large quantities of products.

67
Q

Give an advantage of drop forging.

A

The grain of materials can be refined making products stronger.

A-Level Design (8 decks)

Brainscape helps you reach your goals faster, through stronger study habits.
© 2024 Bold Learning Solutions. Terms and Conditions