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A Level AQA Design and Technology: Product Design > Metals > Flashcards

Metals Flashcards

1
Q

What types of metals are there?

A

Ferrous, non-ferrous, alloys.

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2
Q

What are the performance characteristics of metals?

A
  • hardness
  • toughness
  • malleability
  • elasticity
  • tensile strength
  • density
  • thermal / electrical conductivity
  • melting point
  • ability to form an alloy
  • ability to be joined with a heating process
  • ability to take applied coats and finishes
  • resistance to corrosion
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3
Q

What are the metal stock forms?

A
  • sheet
  • plate
  • bar (flat, round, square, hexagonal)
  • tube (round, square, rectangular, hexagonal)
  • structural (H/I beam, tee, channel, angle)
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4
Q

Where do metals come from?

A

Metals are generally found underground with rocks, together known as ore.

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5
Q

What are ferrous metals?

A

Ferrous metals are metals that contain iron. They are magnetic.

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6
Q

What are non-ferrous metals?

A

Non-ferrous metals are metals that do not have iron.

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7
Q

What are the re-distrubution processes?

A
  • press forming
  • spinning
  • cupping
  • deep drawing
  • forging
  • deep forging
  • bending
  • rolling
  • casting
  • investment casting
  • die casting
  • low temperature casting
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8
Q

What are the addition/ fabrication processes?

A
  • (MIG) welding
  • (TIG) welding
  • spot welding
  • oxyacetylene welding
  • soldering
  • brazing
  • riveting
  • temporary joining methods and fasteners
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9
Q

What are the wasting processes?

A
  • milling
  • turning
  • flame cutting
  • plasma
  • laser cutting
  • punching/ stamping
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10
Q

What is press forming?

A

Press forming is a metal forming process that uses a press machine to shape and form metal into a desired shape. The process involves placing a flat sheet of metal, called a blank, into a press machine, which uses a punch and die to shape the metal by applying pressure and force.

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11
Q

What is press forming used for?

A

Press forming can be used to create a wide range of shapes and designs, such as simple flat parts, complex 3D shapes, and hollow or tubular parts. Can be used to produce a wide range of products, including automotive parts, electronics, appliances, and household items. Press forming can be used to work with a variety of metals, including steel, aluminium, and brass, and it’s a cost-effective process that can be automated for high-volume production.

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12
Q

What is spinning?

A

Spinning is a metal forming process that involves shaping metal by rotating it on a lathe and using a tool to shape and form the metal. The process starts with a flat sheet of metal, called a blank, which is clamped onto a spinning mandrel or arbor. A tool, called a forming tool or a roller, is then used to shape the metal by pressing against the spinning blank while it’s rotating.

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13
Q

What is spinning used for?

A

The spinning process stretches and thins the metal as it’s being shaped, allowing it to form into a desired shape. Metal spinning is mainly used to create cylindrical or conical shapes, such as pots, pans, lighting fixtures, and other household items. Can be used to produce a wide range of products, including aerospace and automotive parts, and it’s a cost-effective process that can be automated for high-volume production.

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14
Q

What is cupping?

A

Cupping, also known as flanging, is a metal forming process that involves shaping metal by applying pressure to the edges of a metal sheet or plate, causing it to form a cup or flange shape. The process typically involves placing a flat sheet of metal, called a blank, into a press machine, which uses a punch and die to shape the metal by applying pressure and force.

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15
Q

What is cupping used for?

A

The cupping process stretches the metal along the edges, causing it to form a cup or flange shape. Metal cupping is mainly used to create hollow parts with a flange or edge, such as cups, trays, pans, and other household items. Can be used to produce a wide range of products, including automotive parts, electronics, appliances, and household items.

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16
Q

What is deep drawing?

A

Deep drawing is a metal forming process that involves shaping metal by drawing it into a forming die using a punch. The process starts with a flat sheet of metal, called a blank, which is placed over a die. A punch, which is typically a hardened steel tool that has the shape of the desired final product, is then pressed into the blank, causing it to stretch and flow into the die. The punch and die are designed to create a precise and detailed shape with minimal material thinning.

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17
Q

What is deep drawing used for?

A

Deep drawing can be used to create a wide range of shapes and designs, such as simple flat parts, complex 3D shapes, and hollow or tubular parts. It’s commonly used in the production of automotive parts, electronic components, and household items. This process is also used to manufacture a wide range of cylindrical parts such as cans, cups, tanks, and many more. Deep drawing process is particularly useful for producing large parts with a deep depth-to-diameter ratio, or parts that require a high degree of accuracy and uniformity. It’s a cost-effective process that can be automated for high-volume production.

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18
Q

What is forging?

A

Metal forging is a metal forming process that involves shaping metal by applying heat and pressure to it, typically using hammers or presses. The process begins with a piece of metal which is heated to a high temperature. Once the metal is heated to the appropriate temperature, it is placed into a forging press or onto an anvil, where it is struck with a hammer or press to shape it into the desired form.

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19
Q

What is forging used for?

A

Forging can be used to create a wide range of shapes and designs, such as simple flat parts, complex 3D shapes, and hollow or tubular parts. It’s commonly used in the production of automotive parts, aerospace, and heavy equipment components, as well as in the production of hand tools and knives. Forging is known for its ability to create strong and durable parts with excellent mechanical properties, such as high strength, toughness, and fatigue resistance. It also allows for precise control of the grain structure, which improves the properties of the final product.

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20
Q

What is drop forging?

A

Drop forging is a type of forging process that involves shaping metal by dropping a hammer or press onto a workpiece. The process begins with a piece of metal which is heated to a high temperature, typically in a furnace. Once the metal is heated to the appropriate temperature, it is placed between two dies, which are shaped to create the desired final product. The dies are then closed together by a hammer or press that is dropped onto the workpiece, applying a significant amount of pressure and force to shape the metal.

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21
Q

What is drop forging used for?

A

Drop forging is used primarily to produce construction parts for machines such as planes or vehicles. Drop forging is also used to produce tools, e.g. wrenches, pliers and hammers Drop forging is known for its ability to create strong and durable parts with excellent mechanical properties, such as high strength, toughness, and fatigue resistance. The process also allows for precise control of the grain structure, which improves the properties of the final product.

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22
Q

What is bending?

A

Bending is a metal forming process that involves shaping metal by applying a force to it, typically using a press brake or a bending machine. The process starts with a flat sheet of metal, called a blank, which is placed between a punch and a die. The punch is typically a hardened steel tool that has the shape of the desired final product, and the die is typically a hardened steel tool that has the shape of the opposite of the desired final product. The punch and die are designed to create a precise and detailed shape with minimal material thinning.

23
Q

What is bending used for?

A

Bending can be used to create a wide range of shapes and designs, such as simple flat parts, complex 3D shapes, and hollow or tubular parts. It’s commonly used in the production of automotive parts, electronic components, and household items. Bending process can also be used to create edge-bending, roll-bending, and press-bending. Bending process is particularly useful for producing large parts with a deep depth-to-diameter ratio, or parts that require a high degree of accuracy and uniformity. It’s a cost-effective process that can be automated for high-volume production.

24
Q

What is rolling?

A

Rolling is a metal forming process that involves shaping metal by passing it through a set of rolls. The process starts with a flat piece of metal, called a billet, which is placed between a pair of rolls. The rolls are typically cylindrical and are made of steel or other durable materials. As the billet passes through the rolls, they apply pressure and force to the metal, causing it to be shaped and formed into a desired shape. Rolling can be done in a variety of ways, such as flat rolling, where the rolls are parallel, and shape rolling, where the rolls are tapered or have a complex shape. The process can be done by hand or by machine.

25
Q

What is rolling used for?

A

Rolling can be used to create a wide range of shapes and designs, such as simple flat parts, complex 3D shapes, and hollow or tubular parts. Rolling process is commonly used in the production of sheet metal, plates, bars, and other metal products, as well as in the production of large diameter pipes, tubing and other cylindrical parts. Rolling is known for its ability to create strong and durable parts with excellent mechanical properties, such as high strength, toughness, and fatigue resistance. The process also allows for precise control of the grain structure, which improves the properties of the final product.

26
Q

What is casting?

A

Casting is a manufacturing process in which liquid metal is poured into a mould and allowed to solidify, creating a solid object with the shape of the mould. The mould is typically made of a refractory material, such as sand, ceramic or metal, and it’s designed to have the shape of the desired final product. The liquid metal is heated to a high temperature, typically in a furnace, until it becomes molten, and then it’s poured into the mould. Once the metal cools and solidifies, the mould is broken open to reveal the solid object. Casting can be done in a variety of ways, such as sand casting, where the mould is made of sand, investment casting, where the mould is made of a ceramic material and die casting, where the mould is made of metal and the process is done under high pressure.

27
Q

What is casting used for?

A

Casting can be used to create a wide range of shapes and designs, such as simple flat parts, complex 3D shapes, and hollow or tubular parts. It’s commonly used in the production of automotive parts, aerospace components, and household items, as well as in the production of art objects and jewellery.

28
Q

What is investment casting?

A

Investment casting, also known as precision casting or lost-wax casting, is a manufacturing process in which a mould is created by first making a wax model of the desired final product, and then encasing it in a ceramic material. The wax model is then heated to a high temperature, typically in an oven, causing the wax to melt and “lost” or drained out. Then the remaining ceramic mould is heated to a high temperature, causing the ceramic to harden, creating a mould that can withstand the heat of the molten metal. Finally, liquid metal is poured into the mould and allowed to solidify, creating a solid object with the shape of the mould. The process of investment casting has several advantages compared to other casting methods. The ceramic moulds are durable and can be used multiple times, the process is capable of producing parts with high dimensional accuracy and surface finish, and it can be used with a wide variety of materials such as metal, ceramics and glass.

29
Q

What is investment casting used for?

A

Investment casting is a precision casting process, which is used to produce complex and intricate shapes with high accuracy and detail. The process is commonly used in the production of aerospace components, medical equipment, and other high-precision parts. It also enables the production of small-scale parts in a cost-effective manner.

30
Q

What is die casting?

A

Die casting is a manufacturing process in which liquid metal is poured into a mould, called a die, under high pressure. The die is typically made of steel or other durable materials and is designed to have the shape of the desired final product. The liquid metal is heated to a high temperature, typically in a furnace, until it becomes molten, and then it’s poured into the die. The die is then closed and the metal is injected under high pressure. Once the metal cools and solidifies, the die is opened and the solid object is removed. There are two main types of die casting: hot chamber die casting and cold chamber die casting. Hot chamber die casting is used with low melting point metals, such as zinc, magnesium, and tin. Cold chamber die casting is used with high melting point metals, such as aluminium and brass.

31
Q

What is die casting used for?

A

Die casting can be used to create a wide range of shapes and designs, such as simple flat parts, complex 3D shapes, and hollow or tubular parts. It’s commonly used in the production of automotive parts, electronic components, and household items.

32
Q

What is low temperature casting?

A

Low temperature casting is a type of casting process where the liquid metal is poured into a mould at a temperature that is lower than the typical casting temperature. This allows for the casting of metal alloys that have lower melting points and are typically more difficult to cast using traditional casting methods. The lower temperature also helps to reduce the chance of warping and cracking in the finished product. Low temperature casting is typically used for alloys such as aluminium, zinc and magnesium which have a lower melting point compared to other metals.

33
Q

What is low temperature casting used for?

A

Low casting temperature is commonly used in the production of automotive parts, electronic components, and household items.

34
Q

What is (MIG) welding?

A

(MIG (metal inert gas)) welding is a type of welding that uses an electric arc to fuse metal together. In MIG welding, a wire feeder supplies a continuously fed wire electrode to the weld area, while an inert gas, such as argon or CO2, is used to shield the weld from the atmosphere. The wire electrode is melted by the electric arc, and it combines with the base metal to form a weld. MIG welding can be used to weld a wide variety of metals, such as steel, aluminium, and stainless steel.

35
Q

What is (MIG) welding used for?

A

(MIG) welding is commonly used in the manufacturing of automobiles, heavy equipment, and other industrial products. It is also used in home repairs and DIY projects. The process is relatively easy to learn and use, making it a popular choice among hobbyists and DIY enthusiasts. It is also relatively fast and efficient, making it suitable for high-volume production.

36
Q

What is (TIG) welding?

A

(TIG (tungsten inert gas)) welding is a type of welding that uses an electric arc to fuse metal together. In TIG welding, a non-consumable tungsten electrode is used to create the electric arc, and an inert gas, such as argon or helium, is used to shield the weld from the atmosphere. The tungsten electrode is held in a hand-held torch and is not consumed during the welding process. The welder uses the other hand to feed a filler metal into the weld, if needed. TIG welding can be used to weld a wide variety of metals, such as steel, aluminium, and stainless steel. TIG welding requires a high degree of skill and expertise, and it is considered to be a more complex welding process than MIG welding.

37
Q

What is (TIG) welding used for?

A

(TIG) welding is commonly used in the manufacturing of aerospace components, medical equipment, and other high-precision parts. It’s also used in the fabrication of fine art and sculpture.

38
Q

What is spot welding?

A

Spot welding is a type of resistance welding that uses heat generated by an electric current to fuse two metal surfaces together. The process involves applying pressure and an electric current to a small localized area, or “spot,” on the metal surfaces, which causes the metal to melt and fuse together. The pressure and current are then released, and the metal solidifies, creating a strong bond between the two metal surfaces.

39
Q

What is spot welding used for?

A

Spot welding is commonly used in the manufacturing of automobiles, appliances, and other industrial products. It’s particularly useful for welding thin sheets of metal together, as it only heats the small spot where the weld is being made, minimizing the heat-affected zone. It’s also relatively fast and efficient, making it suitable for high-volume production.

40
Q

What is oxyacetylene welding?

A

Oxyacetylene welding, also known as gas welding, is a type of welding that uses a flame produced by the combustion of a mixture of oxygen and acetylene gases to fuse metal together. The process involves heating the metal with the flame and then applying a filler metal to the heated area. The filler metal melts and fuses to the base metal, creating a strong bond. Oxyacetylene welding can be used to weld a wide variety of metals, such as steel, aluminium, and stainless steel. The process of Oxyacetylene welding requires the use of a welding torch, which is a handheld device that mixes the oxygen and acetylene gases and controls the flame.

41
Q

What is oxyacetylene welding used for?

A

Oxyacetylene welding is commonly used in the manufacturing of automobiles, heavy equipment, and other industrial products. It’s also used in the repair and maintenance of various types of equipment, and in the construction industry.

42
Q

What is soldering?

A

Soldering is a process that uses a filler metal, called solder, to join two metal surfaces together. The filler metal is melted by heat and then flowed between the two surfaces to create a bond. There are two main types of soldering: soft soldering and hard soldering. Soft soldering, also known as tin-lead soldering, is a process that uses a low-melting-point alloy (solder) typically composed of tin and lead. Hard soldering, also known as silver soldering, is a process that uses a higher-melting-point alloy (solder) typically composed of silver, copper, and zinc. Hard soldering requires higher temperatures and stronger joints than soft soldering.

43
Q

What is soldering used for?

A

Soft soldering is commonly used to join small electronic components and is used in the manufacturing of electronic devices, appliances, and jewellery. It is also used in plumbing and HVAC systems. Hard soldering is commonly used to join heavy-duty equipment and machinery, as well as in jewellery making and metal sculpture.

44
Q

What is brazing?

A

Brazing is a process that uses a filler metal, called brazing alloy, to join two metal surfaces together. The filler metal is melted by heat and then flowed between the two surfaces to create a bond. Brazing typically uses filler metals with a higher melting point than soldering alloys, usually in the range of 800 to 900 degrees Celsius. This allows the brazing alloy to flow at a temperature that does not melt the base metal, but is still high enough to allow the brazing alloy to wet and bond with the base metal. This results in a stronger bond than soldering.

45
Q

What is brazing used for?

A

Brazing is commonly used in the manufacturing of automobiles, heavy equipment, and other industrial products. It’s also used in the repair and maintenance of various types of equipment, and in the construction industry. It’s particularly useful for joining dissimilar metals, where other welding or soldering methods may not be suitable.

46
Q

What is riveting?

A

Riveting is a process that uses a fastener, called a rivet, to join two or more pieces of metal together. A rivet consists of a head on one end and a tail on the other end. The tail end of the rivet is inserted through the holes in the metal pieces to be joined, and then the tail end is flared or upset, creating a head that holds the metal pieces together.

47
Q

What is riveting used for?

A

Riveting process is commonly used in the manufacturing of automobiles, airplanes, heavy equipment, and other industrial products. It’s also used in the repair and maintenance of various types of equipment, and in the construction industry.

48
Q

What are temporary joining methods and fasteners?

A

Metal temporary joining methods and fasteners are methods and devices used to temporarily hold metal parts together before they are permanently joined.

49
Q

What are self-tapping screws?

A

Self-tapping screws are a type of screw that is designed to create its own thread as it is screwed into a material. They are commonly used in situations where a pre-threaded hole is not available.

50
Q

What are machine screws?

A

Machine screws are self-tapping screws that have a cylindrical shape and are designed to be used with a nut or tapped hole.

51
Q

What are nuts and bolts?

A

Nuts and bolts are a common type of fasteners that are used to temporarily hold metal parts together. Bolts are inserted through holes in the metal parts and then tightened with a nut.

52
Q

Give examples of ferrous metals.

A
  • low carbon steel
  • stainless steel
  • high speed steel (HSS)
  • medium carbon steel
  • cast iron
53
Q

Give examples of non-ferrous metals.

A
  • aluminium
  • copper
  • zinc
    -silver

A Level AQA Design and Technology: Product Design (11 decks)

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