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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.

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2
Q

What is normalising?

A

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

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3
Q

Give four example of heat treatments.

A
  • Annealing
  • Hardening
  • Tempering
  • Normalising
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4
Q

What is annealing?

A

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

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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.
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6
Q

What is hardening?

A

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

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7
Q

What is tempering?

A

A process carried out after hardening to remove brittleness.

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8
Q

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

A
  • Hardness is reduced

- Toughness is increased

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9
Q

What colour will steel go at a low tempering temperature?

A

Pale straw

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10
Q

What colour will steel go at a high tempering temperature?

A

Blue

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11
Q

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

A

Drills

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12
Q

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

A

Springs

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13
Q

What is quenching?

A

The rapid cooling of a metal following heat treatment.

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14
Q

Give four examples of quenching media.

A
  • Brine
  • Water
  • Oil
  • Air
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15
Q

What is the softest quenching medium?

A

Air

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16
Q

What is the harshest quenching medium?

A

Brine

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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.

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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.

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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.

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20
Q

Give two examples of case hardening.

A
  • Carburising

- Nitriding

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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.
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22
Q

Give a disadvantage of case hardening.

A

Grain growth occurs requiring the need for machining.

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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
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24
Q

Give two disadvantages of nitriding.

A
  • High setup costs

- Potential for permanent loss of hardness.

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25
Give two advantages of flame and induction hardening.
- Localised areas of the product can be hardened. | - Grain growth doesn't occur.
26
Give four examples of wasting processes.
- Sawing and filing - Drilling and milling - Grinding and sanding - Blanking and piercing
27
Give three examples of addition processes.
- Bolts and screws - Welding - Adhesives
28
What are the four main types of redistribution processes?
- Casting - Forging - Forming - Sintering
29
Give two examples of casting.
- Sand casting | - Die casting
30
Give two examples of hot forging.
- Drop forging | - Hot pressing
31
Give two examples of forming.
- Press forming | - Embossing and coining
32
Give four examples of processes for cutting metals.
- Piercing and blanking - Profile cutting - Plasma cutting - Laser cutting
33
Give two advantages of plasma cutting.
- There is very little waste material. | - No finishing is required.
34
What does CNC stand for?
Computer Numerical Control
35
Give two three advantages of laser cutting.
- Much finer detail can be achieved. - A wider range of materials can be cut. - Materials can also be engraved.
36
Give two examples of press-formed materials.
- Radiator panels | - Cooker tops
37
What is embossing?
A process used to press decorative details into materials.
38
Give three examples of press-forming.
- Sheet metal can be made into 3D shapes. - The material is given greater stiffness. - The material's structural strength increases.
39
What is the first stage of sand casting?
A pattern is made and is split for more complex shapes.
40
What is the second stage of sand casting?
- Each half of the pattern is placed on a baseboard. | - A mould box is placed over it.
41
What is the third stage of sand casting?
- Green sand is tamped around the pattern forcing it into contact with the pattern. - Backing sand is also placed.
42
What is the fourth stage of sand casting?
- The pattern is removed from the mould half. | - The runner and riser gates are cut into the top half of the sand mould.
43
What is the fifth stage of sand casting?
The mould halves are fitted together with locating pins.
44
What is the sixth stage of sand casting?
- The molten metal is poured into the running gate. | - Degassing tablets reduce the risk of a porous casting.
45
What is the seventh stage of sand casting?
- The sand mould is broken open releasing the product. | - The runner and riser gates are removed.
46
Give four advantages of sand casting.
- 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
Give three disadvantages of sand casting.
- The process gives a poor surface finish. - Not an accurate process. - Low rate of output.
48
What is die casting?
A process used to cast metals with low melting points.
49
Give three examples of metals used in die-casting.
- Zinc - Aluminium - Magnesium
50
What is a flux?
A chemical used to prevent oxidation of the material at the joint area prior to joining.
51
Give five advantages of multi-slide die casting.
- 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
What is the first stage of investment casting?
A wax pattern is produced to a high degree of accuracy.
53
What is the second stage of investment casting?
The pattern is coated in a high temperature ceramic material.
54
What is the third stage of investment casting?
The pattern is melted by placing it in a kiln.
55
What is the fourth stage of investment casting?
Molten metal is poured into the ceramic mould.
56
What is the fifth stage of investment casting?
The ceramic mould is broken open leaving the cast product.
57
Give three advantages of investment casting.
- High quality finish - Complex shapes can be produced. - There is no split line.
58
Give two disadvantages of investment casting.
- The process is expensive | - The size of components is limited
59
When is sintering used?
When materials are too difficult to process any other way.
60
What is sintering?
A process whereby powder particles are fused together.
61
Describe the process of sintering.
- 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
What is forging?
Processes carried out using basic tools.
63
What is drawing down?
Reducing the thickness of a material by hammering into a thinner section.
64
What is punching and drifting?
Hammering a material using a spiked tool, then tidying the whole using a drift..
65
Give three examples of forging techniques.
- Bending - Drawing down - Punching and drifting
66
What is drop forging?
A refining process for large quantities of products.
67
Give an advantage of drop forging.
The grain of materials can be refined making products stronger.

A-Level Design (8 decks)

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