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Industrial Mechanic (Millwright) > Metallurgy (160102d) > Flashcards

Metallurgy (160102d) Flashcards

1
Q

Define a Metal.

A

A metal is an element or mixture of elements.

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2
Q

What are 6 characteristics of metals?

A 
It is solid at room temperature  
It is opaque  
It conducts heat and electricity  
It reflects light when polished  
It expends when heated and contracts when cooled (expect bismuth) 
It has a crystal structure
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3
Q

What are Ferrous Metals? Give a few examples of the types of metals.

A

Ferrous metals are metals that have iron as the major ingredient and are usually magnetic.

Carbon steel

Cast iron

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4
Q

What are Non Ferrous metals? Give a few examples of the types of metals.

A

Non-ferrous metals do not have iron in large enough amounts to have any major influence on the properties od the metals.

Aluminum 
Magnesium 
Zinc 
Copper 
Lead 
Brass
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5
Q

You can identify metals by their appearance, what is the difference between HRS and CRS?

A

Hot-rolled steel has a black mill scale or heat scale surface, while cold-rolled steel has a shiny and smooth surface.

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6
Q

Describe SAE grade 4142 steel.

A

Chromium-molybdenum steel with 0.42% carbon

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7
Q

Define the Mechanical properties of metals?

Hardness

A

Hardness – is the ability of a metal to resist penetration and plastic deformation.

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8
Q

What has better machining properties? Aluminum vs Tool steels

A

Aluminum

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9
Q

Describe how structural steel is formed. What is the most common steel used for building?

A

Structural steel is manufactured by forming a red-hot billet of steel into the desired shape, which could include angle iron, channel iron or beams. This process results in the formation of a single piece of steel. The hot rolling process produces a structural shape that is much stronger than if the pieces were welded together.

Carbon steel is the most common material used for building steel and most other structures.

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10
Q

When identifying structural steel we use inches for imperial and millimeters for metric, what are three characteristics we would look for when selecting this steel.

A

Cross section
Composition
Strength

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11
Q

What are three common shapes you see at your shop? Answer as a symbol.

A

HSS – Square
HSS – Round
L

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12
Q

Which of these shapes have a fillet corner?

A

L

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13
Q

On a “C” & “MC” shape piece of structural steel identify the following sizes:

A 
C6x10.5= nominal size 6 inches and 10.5lb/ft 
C150x16= nominal size 150 mm and 16kg/m
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14
Q

HSS is available in two shapes, what are they?

A

Rectangular

Round

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15
Q

The process of pulling a steel rod through one or more dies is known as which process?

A

Cold-drawing

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16
Q

Describe the difference between a pipe and a tube?

A

Pipe is any tubular product that is producec in a size commonly used for piping systems. Tubing is any tubular product, other than pipe and include square and rectangular shapes, as well as round.

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17
Q

For pipes over 14” in diameter the nominal size equals what?

A

The outside diameter of the pipe.

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18
Q

Metals produced in round, square or flat form are known as ______ stock.

A

Bar

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19
Q

What size (thickness) is sheet steel available in?

A

28 ga to 18 ga

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20
Q

Steel plate is available in thicknesses of _______ or greater.

A

3/16

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21
Q

The seven classification of metals are:

A 
Carbon steel 
Alloy steel
Tool steel 
Stainless steel 
Aluminum and its alloys 
Copper and its alloys 
Cast iron
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22
Q

Describe the make up of 4140 steel?

A

Chromium-molybdenum type steel with 0.40% carbon content.

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23
Q

List the following percentages in carbon steel:

A

Low carbon: 0.02% – 0.30%
Medium carbon: 0.30% - 0.60%
High carbon: over 0.60%

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24
Q

What percentage of carbon in steel will make it into cast iron?

A

Anything over 1.7% is considered to be cast iron

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25
Q

At what temperature does Maraging steel harden?

A

480°C or 896°F

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26
Q

What are the six types of tool steels?

A
  • Water hardening
  • Cold work
  • Hot work
  • Shock resisting
  • Mold steel
  • High speed
27
Q

List the alloys in brass

A

copper and zinc

28
Q

Three main structures we see under a microscope when looking at iron and carbon atoms are?

A
  • Pearlite
  • Martensite
  • Austenite
29
Q

What are the basic heat treating process for steel?

A
  • Hardening
  • Tempering
  • Annealing
  • Normalizing
30
Q

What is the minimum carbon content needed for hardening?

A

0.20%

31
Q

How do we quench a long thin part?

A

Plunge it straight in to the quenching medium.

32
Q

What color we want to see when tempering back our heat treated steel? Roughly at 230˚C(445˚F)

A

Light straw color

33
Q

What is the difference between tempering vs annealing?

A

Tempering draws out brittleness and strain from the previously hardened steel. Annealing makes a hardened workpiece soft again.

34
Q

What are the two ways we can check for hardness and which on is more common?

A

Rockwell hardness testing – more common

Brinell hardness testing

35
Q

Is Rockwell testing a form of destructive testing?

A

Yes, it leaves a small mark by the penetrator.

36
Q

What are the two types of penetrators used for rockwell testing?

A
  • Diamond penetrator (brale)

- Steel ball penetrator

37
Q

What are the different scales for Rockwell testing? Describe one.

A

“A” – for extremely hard materials such as cemented carbides and for thin, hard sheets.

38
Q

What are four different ways we can identify a metals carbon content?

A
  • Chip test
  • Spark test
  • File test
  • Flame test
39
Q

The most precise way to identify the composition of a metal?

A

Mill test report (MTR)

40
Q

Which number can be found on both the MTR and metal specification tags?

A

Heat number

41
Q

List the alloys in bronze

A

Originally - copper and tin

Now - any copper alloy other than brass

42
Q

Define the Mechanical properties of metals?

Ductility

A

Ductility – is the ability of a material to be stretched permanently without breaking.

43
Q

Define the Mechanical properties of metals?

Toughness

A

Toughness – is the ability of metal to withstand shock and impact without breaking or shattering.

44
Q

Define the Mechanical properties of metals?

Tensile strength

A

Tensile strength – is the ability of a metal to withstand pull without breaking.

45
Q

Define the Mechanical properties of metals?

Machinability.

A

Machinability – measures the ease with which you can cut and shape a metal.

46
Q

A ferrous metal has a high content of:

A

Iron

47
Q

A non-ferrous metal:

A

contains little or no iron and is usually non-magnetic

48
Q

A metal is a red or yellow color is most likely what type of metal?

A

Copper or brass

49
Q

What is the normal color for steels and cast irons?

A

Silvery gray

50
Q

Which property allows a metal to be formed by bending?

A

Ductility

51
Q

Given two identical pieces of metal, zinc die cast and aluminum, what would be the simplest way to identify them?

A

By their weight

52
Q

If an object is irregularly shaped, what might you conclude about the object?

A

It is a casting

53
Q

If an piece of metal has a smooth outer surface, what might you conclude about the object?

A

It has been formed

54
Q

In using a chip test to identify a metal, what would a smooth continuous chip indicate?

A

A soft material like aluminum

55
Q

How is cast iron distinguished from low carbon steel in a spark test?

A

The sparks given off by cast iron are short with red bursts near the grinder.

56
Q

How can using a new hand-held file give you an estimate of a metal’s hardness?

A

If the file bites into the metal easily, it is likely a soft material.

57
Q

If you are told a workpiece has a Rockwell C-65, what would that mean?

A

It has been hardened

58
Q

Which metal, when ignited using the flame test, burns violently?

A

Magnesium

59
Q

What is the minimum amount of carbon content required in steel for hardening?

A

0.20%

60
Q

What is the proper specification for an unequal leg angle iron that has legs of 60 mm and 40 mm and is 5 mm thick?

A

60 x 40 x 5

61
Q

What shape is the designation L6 x 6 x 1

A

Equal leg angle

62
Q

When the heat code identification number is cut from a piece of plate, what should you do?

A

Transfer the ID number to the remaining plate

63
Q

What is the most precise method for the identification of a metal that has been shipped from a steel mill?

A

Study the mill test report

64
Q

In addition to the mill test report, what else do steel mills usually attach to the straps that hold bundles of bar stock together?

A

Metal specification tags

Industrial Mechanic (Millwright) (11 decks)

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