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Millwright Level 2 > Metallurgy > Flashcards

Metallurgy Flashcards

1
Q

The point at which a material ruptures

A

Ultimate strength

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2
Q

The force per unit area acting on an object to change it’s dimensions

A

Stress

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3
Q

The ability of a material to resist being pulled apart by external forces

A

Tensile strength

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4
Q

The ability to resist external forces that push into or against the material

A

Compressive strength

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5
Q

The ability to resist forces that try to slide part of the object along itself

A

Shear strength

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6
Q

The ability to withstand repeatedly alternating stresses

A

Fatigue strength

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7
Q

The ability of a material to return to it’s original dimensions after it has been acted on by a force

A

Elasticity

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8
Q

The maximum force that a solid can withstand without being permanently deformed

A

Elastic limit (yield strength)

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9
Q

The ability for material to retain a shape permanently after a deforming force is removed

A

Plasticity

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10
Q

The ability to stretch and maintain the new shape

A

Ductility

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11
Q

The ability of a material to be permanently deformed by compression forces

A

Malleability

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12
Q

Material that breaks without noticeable plastic deformation

A

Brittleness

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13
Q

The ability of a material to withstand shock loads and impact without breaking or shattering

A

Toughness

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14
Q

The materials ability to resist a force that is trying to penetrate it

A

Hardness

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15
Q

The ability of a material to conduct an electric current

A

Electrical conductivity

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16
Q

This determines the rate of heat-flow through a material

A

Thermal conductivity

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17
Q

For every 150F change is temperature, each inch of diameter and length changes by _____

A

0.001”

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18
Q

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

A

Ferrous metals

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19
Q

Do not have iron in large enough amounts to have any major influence on the properties of the metals

A

Non-ferrous metals

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20
Q

Non-ferrous metals are usually non-magnetic except which metal?

A

Nickel

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21
Q

How do you distinguish between hot-rolled and cold-rolled steel?

A

Hot-rolled steel has a black mill scale, cold-rolled has a shiny smooth surface

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22
Q

Name the type of ways to identify metal

A

Visual, weight, texture, shape

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23
Q

Measures the ease with which you can cut and shape a metal

A

Machinability

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24
Q

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

A

Carbon steel

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25
Q

The smooth inside round corner on the L shape is called what?

A

Fillet corner

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26
Q

How are Hollow structural steel squares classified?

A

Outside dimensions and wall thickness

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27
Q

HSS is available in what shapes?

A

Square, rectangular, round

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28
Q

Recognized by it’s black oxidized surface and is produced by drawing red hot billets through rollers

A

Hot-rolled steel

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29
Q

Which steel is made a little larger than it’s nominal size?

A

Hot-rolled

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30
Q

Recognized by it’s smooth, grey surface and is produced by cleaning the scale from hot-rolled billets and drawing through rollers or dies.

A

Cold-rolled steel

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31
Q

The process of cold-rolling sets up what?

A

Internal stresses

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32
Q

Cold-rolled bar may be ______, _____, and ________ to improve it’s surface finish and accuracy.

A

Turned, ground and polished

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33
Q

The process of making wire or tubing by pulling a steel rod through one or more dies

A

Cold-drawing

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34
Q

Any tubular product, other than pipe and and includes square and rectangular shapes, as well as round

A

Tubing

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35
Q

For tubes the nominal size equals what?

A

Outside diameter

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36
Q

Which ways can pipes and tubes be produced

A

Welded at the seam, seamless

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37
Q

Metals produced in round, square, or flat form

A

Bar stock

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38
Q

Thickness range of Sheet steel

A

28-18 ga

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39
Q

Widths and lengths of sheet steel

A

Width - 36, 48, 60, 72 inches

Length - 96, 120, 144

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40
Q

Steel plate has a thickness of ___ or greater and a width of __ inches or greater

A

3/16 inches and 8 inches

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41
Q

Have developed a system for identifying steels

A

SAE and AISI

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42
Q

The AISI-SAE system for designating carbon and alloy steel uses a __ or __ digit number

A

4 or 5

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43
Q

In the AISI-SAE system the first two digits denote ______. The last two or three digits denote ______.

A

Type of steel and carbon content

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44
Q

Contains carbon or iron, but no other significant alloying elements

A

Carbon steel

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45
Q

What are the three types of carbon steel

A

Low (0.02-0.30%) cannot be hardened
Medium (0.30-0.60%) can be hardened
High (over 0.60%) found in cutting tools

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46
Q

Anything over __% carbon is considered to be cast iron

A

1.7%

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47
Q

Contains significant elements other than iron and carbon

A

Alloy steel

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48
Q

What are the three types of alloy steels?

A 
High strength low alloy steel (impervious to water)
Quench and temper structural steel
Maraging steel (easy to weld)
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49
Q

Expensive, high quality steel used in manufacture of cutters, tools, dies, molds and jigs

A

Tool steel

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50
Q

The two types of high speed steel

A

tungsten and molybdenum

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51
Q

Alloyed with large amounts of chromium, more corrosion resistant than other steels

A

Stainless steel

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52
Q

What are the three types of stainless steel

A

Austenitic, Ferritic, Marsensitic

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53
Q

Next to steel it is the most used industrial metal

A

Aluminum

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54
Q

The soft chips it produces make it a difficult metal to machine

A

Copper

55
Q

Mixture of copper and zinc, tougher than bronze

A

Brass

56
Q

Originally a combo of copper and tin, now includes any copper alloy other than brass

A

Bronze

57
Q

The structure of soft steel is called

A

Pearlite

58
Q

The structure of hardened steel is called

A

Marstensite (consists of angular needle-like crystals)

59
Q

Exists only at high temperatures

A

Austentite

60
Q

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

A

0.20%

61
Q

Two part process where steel is heated to austentite and then quenched to form martensite

A

Hardening

62
Q

Generally, the higher the carbon content, the _____ the hardening temperature

A

Lower

63
Q

The proper hardening temperature is when a workpiece is what colour?

A

cherry red

64
Q

Quenching should take place how long after heating?

A

Immediately (or it reverts to pearlite instead of martensite

65
Q

The most effective quenching medium

A

Brine

66
Q

Brittleness and strain must be ______ out of the steel

A

tempered (drawn)

67
Q

How can you achieve a more controlled temper?

A

Heating workpiece in oil, sand or a salt and lead bath

68
Q

The opposite of hardening

A

Full Annealing

69
Q

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

A

Normalizing

70
Q

The two types of hardness testing

A

Rockwell and Brinell

71
Q

Rockwell hardness testing scale order

A

Hardest A,B,C, N, T, Softest

72
Q

Testing system that uses a hydraulic press

A

Brinell

73
Q

Other than weight, shape and visual means you may also use

A

Chip, spark, file, and flame test

74
Q

Produces bright, long, straight yellowish colours with very little branching

A

Low carbon (mild) steel

75
Q

Produces dark yellow-orange sparks that branch off more, follow wheel

A

High carbon steel

76
Q

Produces red sparks near grinder, need to apply more pressure

A

Cast iron

77
Q

Produces ball shaped sparks

A

High-speed steel

78
Q

The most precise method for identification of a metal

A

Mill test report (MTR)

79
Q

If a solid metal has a smooth outer surface it’s usually what?

A

Formed steel

80
Q

This metal has a low rate of thermal conductivity

A

Titanium (melts at 1668 C)

81
Q

Oxidizes rapidly and has a thin oxide film on it’s surface

A

Pure aluminum

82
Q

Silver-grey colour

A

Steels and cast iron

83
Q

White to grey colour, smooth velvety texture

A

Nickel

84
Q

Have a red or yellow colour

A

Copper and brass

85
Q

Very soft, malleable, bluish-grey metal. Can scratch with nail

A

Lead

86
Q

Weight of carbon steel

A

490 lbs/ft^3

87
Q

In a forming process called _______, molten metal pour into molds

A

casting

88
Q

What is the carbon content of 4140

A

0.40%

89
Q

This is a low carbon structural steel impervious to water

A

High strength alloy (HSLA)

90
Q

Higher carbon content than high strength steel, can he hardened

A

Quench and temper structural steel

91
Q

Uses elements other than carbon for hardening

A

Maraging steel

92
Q

This stainless steel cannot be hardened and is not magnetic

A

Austenitic

93
Q

Resists corrosion, lacks strength of austenitic stainless steel. Cannot be hardened

A

Ferritic

94
Q

Can be hardened, but not as corrosion resistant as other stainless steel

A

Martensitic

95
Q

Type of bronze very strong and corrosion resistant

A

Phosphor-bronze (10% tin)

96
Q

Type of bronze that has the strength of machine steel with corrosion resistance of copper

A

Silicon-bronze (up to 5% silicon)

97
Q

Type of bronze used for making bushings and bearings

A

Aluminum-bronze (4-11% aluminum)

98
Q

Type of bronze that has strength and hardness, but is a health hazard

A

Beryllium-bronze (2% beryllium)

99
Q

The structure of hardened steel is called what?

A

Martensite

100
Q

Formed when pearlite is heated to a red heat

A

Austenite

101
Q

Sparks and flashes into flame violently

A

Magnesium

102
Q

Tool steels and high speed steels are steels very high in what?

A

Carbon

103
Q

Tool steel used when high hardness and low cost are the most important consideration (ex. files)

A

Water hardening

104
Q

Tool steel used in trimming and forming dies, produced at room temp.

A

Cold work

105
Q

Tool steels used in forging dies

A

Hot work

106
Q

Pearlite consists of layers of these two things

A

Ferrite (pure iron) and cementite (formed from iron and carbon)

107
Q

What happens if you don’t temper steel immediately after hardening?

A

It will crack

108
Q

Temperature colours as they increase

A

Light straw, dark straw, brown, purple, violet, dark blue

109
Q

How is steel full annealed?

A

Heating ABOVE the UPPER critical temp for steels less than 0.85% carbon, and ABOVE the LOWER critical temp for steels more than 0.85%

110
Q

Whats harder, RC64 or RC52

A

RC64 Higher number higher hardness

111
Q

The diamond tip of the diamond penetrator is called what?

A

Brale

112
Q

The size of the ball in the Brinell test

A

10mm

113
Q

Where is the heat number identified

A

Both the specification tag and the MTR

114
Q

All metal expands when heated and contracts when cooled except what?

A

Bismuth

115
Q

This type of steel is highly ductile

A

Machine steel

116
Q

The lower critical temperature of steel

A

723 C (1333F)

117
Q

Low alloy steel must be quenched ____ _____ than high alloy steel

A

more quickly

118
Q

Hardened steel is tempered by heating it to a temperature _____ the lower critical temperature

A

below

119
Q

Steel is normalized by heating it _____ it’s upper critical temperature and then allowing it to cool in air

A

above

120
Q

Rockwell scale letter for extremely hard materials

A

A (diamond penetrator)

121
Q

Rockwell scale letter for untreated low and medium carbon steels

A

B (1/16 ball penetrator)

122
Q

Rockwell scale for heat-treated steels, high speed steels, hard cast iron, titanium

A

C (diamond penetrator)

123
Q

Rockwell scale for thin, hardened and surface hardened parts

A

N (diamond penetrator)

124
Q

Rockwell scale for thin and soft parts

A

T (1/16 ball penetrator)

125
Q

If your file slides over the specimen then its harder than

A

C56

126
Q

Length of time the load is applied in Brinell test

A

15 seconds on ferrous, 30 on other materials

127
Q

Carbon Content

  1. 65 to 0.80
  2. 80 to 0.95
  3. 95 to 1.10
  4. 10 and over
A 
Hardening temperature
1450 to 1500 F
1410 to 1460 F
1390 to 1430 F
1380 to 1430 F
128
Q

In C shapes the first number gives the ________ and the second number gives it’s ______

A

Nominal size and weight

129
Q

Hardened steel is tempered by heating it _____ the LOWER critical temperature

A

BELOW

130
Q

In process annealing you heat the steel to a temperature

A

BELOW the LOWER critical temperature

131
Q

Steel is normalized by heating it

A

ABOVE it’s UPPER critical temperature

132
Q

Size of steel ball penetrator in Rockwell test

A

1/16

133
Q

Melting temperature of carbon steel

A

1510 C (2750 F)

Millwright Level 2 (10 decks)

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