Metal processes

Question 1

List the 7 metal forming processes

Answer 1

press forming
spinning
cupping and deep drawing
drop forging
wrought iron forging
bending
rolling

Question 2

List the 6 metal distribution processes

Answer 2

sand casting
gravity die casting
pressure die casting (hot chamber)
pressure die casting (cold chamber)
investment casting 
low temperature pewter casting

Question 3

List the 7 metal addition processes

Answer 3

MIG welding
TIG welding
Oxy-acetylene welding
Spot welding
Soldering
Brazing
Riveting and pop riveting

Question 4

What is metal forming?

Answer 4

processes in which no material is removed, but materials are deformed o produce required shapes

Question 5

What is metal redistribution?

Answer 5

processes where material is changed from one form to another without loss o material

Question 6

What is metal wastage?

Answer 6

processes that cut away material to leave the desired shape

Question 7

Describe press forming

Answer 7

shapes sheet metal into 3D forms
suitable for mass production
e.g. metal seats, car body panels

Question 8

Describe spinning

Answer 8

product may show parallel lines where sheet has been forced into mandrel
suitable for mass p
e.g. saucepan, kettles

Question 9

Describe cupping and deep drawing

Answer 9

starts with metal blank
metal is stretched into shape
high initial tooling cost 
mass p
e.g. tube like shapes

Question 10

Describe drop forging

Answer 10

used for products that need to be tough and hard
uses billet stock form
hot metal billet shaped on an anvil or die and then pressed Ito shape and cooled
e.g. spanner, pliers

Question 11

Describe wrought iron forging

Answer 11

uses bar stock form
uses wrought iron (low carbon content)
can be hand or hydraulic press processes
suitable for one off p
e.g. decorative metalwork such as fencing

Question 12

Describe bending

Answer 12

does not include and punching or trimming
large scale
e.g. seams on metal edges, bending sheets for product casings

Question 13

Describe rolling

Answer 13

hot rolling metal results in uniform mechanical properties
surface usually coated with carbon deposits
e.g. beams, channels railway tracks
cold rolling results in tighter tolerance and better surface finish surface
e.g. filing cabinets, steel drums

Question 14

Describe sand casting

Answer 14

labour intensive
not high quality surface finish
one off
e.g. railway carriage wheels, bollards

Question 15

Describe gravity die casting

Answer 15

relies on gravity to help the metal flow into the mould
used for thicker mud sections
mass p
alloy wheels, engines

Question 16

Describe pressure die casting hot chamber

Answer 16

molten metal stored in chamber then shot of molten metal is forced into the die
fast
e.g. decorative door knobs, toy cars

Question 17

Describe pressure die casting cold chamber

Answer 17

molten metal ladled into shot chamber and hydraulically pushed into chamber
e.g. decorative door knobs, toy cars

Question 18

True or false : all the die casting processes use lower melt point metals such as aluminium and some alloys

Answer 18

TRUE

Question 19

Describe investment casting

Answer 19

used for intricate shapes
high quality excellent finish
e.g. cast jewellery , hip replacements

Question 20

Describe low temperature pewter casting

Answer 20

used for school projects
MDF moulds
e.g. jewellery, key fobs

Question 21

Describe MIG welding

Answer 21

uses electrode wire and inert gas
suitable for this gauge metals
e.g. tubular products

Question 22

Describe TIG welding

Answer 22

uses filler rod and inert gas
accurate strong weld but require high skill and time
e.g. stainless steel ladders for boats or swimming pools

Question 23

Describe Oxy-acetylene welding

Answer 23

uses steel filler rod
useful for quick repair jobs
no electricity needed
e.g. used to weld mild steel sheet

Question 24

Describe spot welding

Answer 24

sheet held between two copper electrodes that form weld when the charged electrodes are contact with the metal
e.g. weld mild steel sheet metal at points along a length

Question 25

Describe soldering

Answer 25

uses filler materials of lower melting point

e.g. lightweight applications and thin huge metals

Question 26

Describe brazing (hard soldering)

Answer 26

uses brass filler rod
used to join dissimilar metals
e.g. lower temperature than welding so suitable for joining thinner gauge mild steel

Question 27

Describe riveting and pop riveting

Answer 27

riveting - uses two pieces the and overlapped and drilled
end of shaft hammered over to join
pop riveting - used when underside of joint is inaccessible
e.g. sheet metal or plate joining