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Design And Manufacture > Metals > Flashcards

Metals Flashcards

1
Q

What is a ferrous metal ?

A

Any metal that contains iron

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2
Q

What is a non ferrous metal ?

A

It doesn’t have a significant amount or any iron in the alloy metal

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3
Q

What is the basis of all ferrous metals ?

A

Iron is the basis of all ferrous metals

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4
Q

What are ferrous metals used for ?

A

Metal cutting tools and car bodies

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5
Q

What are the principle elements in ferrous metals ?

A

Iron mixed with carbon

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6
Q

What affects the properties of alloys ?

A

The percentage of carbon and iron in each will be different for each alloy allowing for varying properties

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7
Q

What does it mean if an alloy has low carbon content ?

A

It means that the metal will be very soft and malleable

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8
Q

What does it mean if an alloy has a high carbon content ?

A

It means that the metal will be brittle and very hard

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9
Q

Name 3 ferrous metals

A

Iron
Cast Iron
Stainless Steel

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10
Q

Name some properties of iron

A

The carbon content is very low
It is soft and easy to work with
Sift enough to cut with a knife
Used for decoration

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11
Q

Name some properties of Cast Iron

A

It has a very high carbon content
It is brittle and casts well
It is used for machine tools and vices in workshops

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12
Q

Name some properties if Stainless Steel

A

The carbon content is relatively high
It is hard and toughen
It is water resistant and doesn’t rust
It is used for cutlery, sinks, dishes etc

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13
Q

What does it mean that non ferrous metals can withstand moist conditions ?

A

It means that they do not have iron so they can be wet and see no effects

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14
Q

Name 3 non ferrous metals

A

Aluminium
Brass
Zinc

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15
Q

Name some properties of aluminium

A

It’s strength to weight ration is very good
It casts easily
Used for window frames, food packaging and kitchen utensils

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16
Q

Name some properties of Brass

A

It’s an alloy including copper and zinc
It’s corrosion resistant
Casts well polishes well and is a good conductor
It is used for taps boat fittings and casting

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17
Q

Name some properties of zinc

A

Usually alloyed with titanium or copper
It’s weak and difficult to work with
Used for galvanising, bins and casting

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18
Q

Name all the types of metal processes

A 
Turning 
Milling 
Die casting 
Press forming
Sand casting 
Casting 
Piercing and blanking 
Drop forging 
Joining materials
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19
Q

Explain metal turning

A

Using the centre lathe to turn the metal or alloy

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20
Q

Explain the process of milling

A

A milling machine is a piece of equipment that uses a multi toothed rotating cutters to shape the metal or alloy.

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21
Q

Explain the process of die casting

A

A molten metal is poured into a metal die by a hydraulics ram and is now in the mould, ready to be cooled when the outside of the mould is pulled apart to give a final product left in the bottom of the mould and there i the product.

22
Q

Explain the process of press forming

A

Press forming is when sheet metal is placed between two metal dies are pushed together with the sheet metal in the middle and the sheet metal is distorted and moulded into the right shape for that particular product

23
Q

What is turning metal usually used for ?

A

It’s used for making cylinders out of metal for example ikea uses it in their handles on doors

24
Q

What is milling metals used for ?

A

Car engines

25
Q

What die cast used used ?

A

Traffic lights

Fire alarms

26
Q

What is press forming used for ?

A

Pans, kettles and stainless steel sinks and car bodies

27
Q

Explain the process of sand casting

A

A pattern is placed in the centre of the drag sand is packed around the mould. Turn the drag over and attach the cope then place in the spruce pins and add more sand then remove the cope and spruce pins then there will be a hole in the sand when a runner is placed where the cope was and the rise is also there then the molten metal poured into the mould then its cooled and the product is made

28
Q

Explain the process of casting

A

The difference between cats and sand casting is that the mould used is made of wood so its the same process

29
Q

Explain the process of piercing and blanking

A

Piercing is when a shaped hole is taken out of the metal and blanking is when a metal is punched but a shaped hole is not taken out from the product.

30
Q

Explain the process of drop forging

A

A hot metal billet is put between the dies, the molten metal is forced into the cavity using a power driven hammer. The excess metal is squeezed out forming flashing around the partying lines of the two dies. When formation is finished the flash is removed by using a die trimmer

31
Q

Explain the process of joint materials - knock down fittings

A

Put together putting a screw through the metal from the butt joint the screw is driven through with a driver. These are usually from flat pack furniture

32
Q

Explain the process of joint materials - welding

A

Welding is where metal is heated up to 3000 degrees and when metal can be heated together where the metal melts together so much that it sticks together

33
Q

Explain the process of joint materials - spot welding

A

The metals are heated together between two copper electrodes and it joints the metal together because of the heat

34
Q

Explain the process of joining materials - riveting

A

Setting the joint with a counter sink and Seth with a hammer

35
Q

Explain the process of joining materials - pop riveting

A

This is the same as riveting however there is a pin that attaches to the top of the rivet and the rivet is put through with a pop-riveting gun.

36
Q

Explain the process of joining materials - bolts

A

This is where a bolt is passed through booth parts of the product and is tightened to hold the pieces together.

37
Q

Explain the process of joining materials - screws

A

This is when a screw is put through both materials to fasten both parts of the product together and is usually done with a screw gun or with a screwdriver.
There are countersink heads with wing nuts
Pans heads with spring washers
And machine heads with plain washers

38
Q

Name the 7 properties branches

A 
Mechanical 
Physical
Thermal
Chemical
Electrical
Optical 
Acoustical
39
Q

Mechanical properties ?

A 
The ability to resist and support a force 
Strength
Toughness
Hardness
Stiffness
Ductility 
Malleability
40
Q

Physical properties ?

A

Size, density and surface texture should be considered

41
Q

Thermal properties ?

A

The ability to withstand temperature change

42
Q

Chemical properties ?

A

How a material reacts to corrosion and chemicals

43
Q

Electrical properties ?

A

How materials conduct or resist electrical currents

44
Q

Optical properties ?

A

The abilities to transmit and react light

45
Q

Acoustical properties ?

A

The abilities to absorb and transfer sound

46
Q

What is meant by strength in mechanical properties

A

The ability of the material to resist either.tensile, compressive or shear force

47
Q

What is meant by toughness in mechanical properties

A

A measure of the energy a material can absorb before fracture: a material that is not tough is brittle

48
Q

What is meant by hardness in mechanical properties

A

The ability to resist scratching, abrasion and wear

49
Q

What is meant by stiffness in mechanical properties

A

The ability of a material to deform temporarily under force then return to its original shape when the force is removed (elasticity)

50
Q

What is meant by ductility in mechanical properties

A

The ability of a material to deform temporarily under force permanently by stretching, bending or twisting. Ductile materials must be strong as well as malleable.

51
Q

What is meant by malleability in mechanical properties

A

The ability of a material to be permanently deformed in all directions without rapture

52
Q

Name all of the factors in a systematic approach

A 
Properties 
Cost
Resources available 
Amount that is being produced 
Product complexity 
Environmental factors
Design requirements 
Social factors 
Service requirements

Design And Manufacture (4 decks)

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