Metallurgy

Question 1

What are Ferrous Metals?

Answer 1

Metals that have iron as the major ingredient and are usually magnetic

Question 2

Punches, dies, shears blades, cutting tools all have high what?

What are some names for this steel?

Answer 2

• Carbon content in the steel.
• High speed steel, tool steel.

Question 3

What are Non-ferrous Metals?

Answer 3

Metals that do not have large amounts of iron in them.

Question 4

Name 3 examples of Non-ferrous metals.

Answer 4

Brass, lead, copper, zinc, aluminum, magnesium.

Question 5

Which metal is non-ferrous but has magnetic properties?

Answer 5

Nickel

Question 6

What is the difference between hot rolled steel and cold rolled steel visually?

Answer 6

Hot rolled has black mill scale on the outside while cold rolled has a shiny smooth surface.

Question 7

What metals have these weights?

Answer 7

Question 8

Can you cast aluminum into parts?

Answer 8

Yes

Question 9

What is hardness?

Answer 9

The ability of a metal to resist penetration and plastic deformation.

Question 10

Give two examples of hard materials

Answer 10

Ceramic, carbide

Question 11

What is Ductility?

Answer 11

The ability of a material to be stretched perminently without breaking.

Question 12

What is toughness?

Answer 12

The ability of metal to withstand shock and impact without breaking.

Question 13

What is Tensile Strength?

Answer 13

The ability to withstand pull without breaking.

Question 14

What is Machinability?

Answer 14

The ease with which you can cut and shape metal.

Question 15

How is Hot-Rolled Steel produced?

Answer 15

By drawing red-hot billets through the rollers.

Question 16

Which is the least expensive cold or hot-rolled steel?

Answer 16

Hot-Rolled Steel

Question 17

How is cold-rolled steel produced?

Answer 17

By cleaning the scale from hot rolled billets and then drawing them through rollers or dies until the desired shape and size are reached.

Question 18

Cold-Rolled steel has what problem?

Answer 18

Internal Stresses which causes cold-rolled steel to warp during any machining.

Question 19

What is Brass?

Answer 19

A mixture of copper and zinc.

Question 20

Carbon Steel with 1.7% Carbon is considered to be what?

Answer 20

Cast Iron

Question 21

How much carbon is Low Carbon Steel considered to have?

Can it be hardened?

Answer 21

• 0.02 - 0.30% Carbon
• No, except for casehardening

Question 22

How much carbon is Medium Carbon Steel considered to have?

Answer 22

• 0.30 - 0.60%

Question 23

How much carbon is High Carbon Steel considered to have?

Where is it found?

Answer 23

• Over 0.60%
• Meant to be hardened and found in cutting tools (taps, drills)

Question 24

Alloy Steel contains what?

Answer 24

Carbon, Iron and other significant amounts of elements to give the steel mechanical properties.

Question 25

What is HSLA Steel? What are its properties? What is it used for?

Answer 25

- High Strength Low Alloy Steel - Low Carbon Structural steel. The rust that forms on the outside is impervious to water and prevents further rust. - Bridges, Truck trailers, structures exposed to enviroment.

Question 26

What are the four heat treating processes for steel?

Answer 26

- Hardening - Tempering - Annealing - Normalizing

Question 27

Only steel with a carbon content of at least ___ can be hardened

Answer 27

- 0.20%

Question 28

What are special types of Alloy Steels?

Answer 28

- High Strength Low Alloy Steel (HSLA) - Quench and Temper Structural Steel - Maraging Steel

Question 29

What is Maraging Steel? What is so special about it?

Answer 29

- Steel that uses elements other then Carbon for hardening. In fact carbon is considered a impurity. - Intricate shapes can be machined and then hardened without fear of distortion. Easy to weld.

Question 30

What makes Stainless Steel corrosion resistant?

Answer 30

Large amounts of Chromium

Question 31

What are three types of Stainless Steels?

Answer 31

- Austenitic - Ferritic - Martensitic

Question 32

What is Bronze?

Answer 32

Any copper alloy other then Brass

Question 33

Which is stronger Bronze or Brass

Answer 33

Brass

Question 34

What should you watch out for with Berylium Bronze?

Answer 34

The particales produced during machining are toxic to touch and inhale.

Question 35

What are three atom structures for steel?

Answer 35

- Soft Steel: Pearlite - Hardened Steel: Martensite - Red Hot: Austenite

Question 36

The hardening temperature varies with the __________ content of the steel. Generally the higher the ______ content the ________________________.

Answer 36

- Carbon - the higher the Carbon content the lower the hardening temperature.

Question 37

What is Quenching? Why?

Answer 37

- After heated sufficiently the material must be immersed in water, oil, air or brine immediately until cooled and hardened. - If allowed to slowly cool it reverts to pearlite instead of martensite.

Question 38

Moving the workpiece around in a figure eight pattern during quenching does what?

Answer 38

Ensure workpiece is cooled evenly.

Question 39

What happens after steel has been quenched? What step helps this after?

Answer 39

- The steel is very brittle and has internal stresses and strains caused by the severe quench. - Tempering

Question 40

What is tempering?

Answer 40

Immediately after quenching a piece heat the material to a temperature below the lower critical temerature and then allow the steel to cool at any desired rate.

Question 41

What happens if you do not temper a piece immediately?

Answer 41

It will crack.

Question 42

When tempering hardness decreases as _____________.

Answer 42

Tempering time and temperature increase.

Question 43

Tempering does what?

Answer 43

Gives the piece Toughness

Question 44

What is a more efficient way to temper a piece then torch?

Answer 44

Heating the piece in oil, sand or a salt or lead bath.

Question 45

What is Full Annealing?

Answer 45

The opposite of hardening. It converts Martensitic steel to Pearlite. Make materials soft again for machining.

Question 46

How does full annealing work?

Answer 46

Heat piece to above upper critical temperature for steels with less than 0.85% carbon or above lower critical limit for steels with more than 0.85% carbon. Steel is allowed to cool slowly.

Question 47

What is Process Annealing? How is it done?

Answer 47

- Related to full anealing but is used to restore ductility. - Heat piece below the lower critical temperature point, hold it for a period of time and then let it air cool.

Question 48

What is Normalizing?

Answer 48

The process that eliminates strains and restores the proper grain structure of steel.

Question 49

How is normalizing done?

Answer 49

By heating the piece above its upper critical temperature and then allowing it to cool in air.

Question 50

What are two ways of testing hardness?

Answer 50

- Rockwell Hardness Testing - Brinell Hardness Testing

Question 51

What is Rockwell Hardness Testing considered to be?

Answer 51

Destructive Testing.

Question 52

How does a Brinell Hardness Test work?

Answer 52

Uses a hydraulic press to force a round penetrator into ferrous or non-ferrous specimens.

Question 53

What are four ways other than weight, shape or other visual means of identifying materials?

Answer 53

- Chip Test - Spark Test - File Test - Flame Test

Question 54

Do all metals spark?

Answer 54

No, non-ferrous metals usually do not. But Nickel and Titanium do.

Question 55

What is a spark test usually used to test?

Answer 55

To find the carbon content in steels and distinguish between a cast steel and a cast iron.

Question 56

What do Low Carbon Steel Sparks look like? What is Low Carbon Steel also known as?

Answer 56

- Bright - Long - Straight - Yellowish - Very little branching - Few Carbon Bursts - Mild Steel

Question 57

What do High Carbon Sparks look like?

Answer 57

- Sparks Burst - Branch Off - Dark Yellow-orange - Bursts Nearer to wheel - Sparks curl around wheel

Question 58

What do cast iron sparks look like?

Answer 58

- Many Bursts - Red near grinder and orange-yellow further out. - Stream not as long as carbon steels - Apply considerable pressure for sparks

Question 59

What do High Speed Steel sparks look like?

Answer 59

- Lines orange - Very little branching - End up in ball shaped sparks

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