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AS Design Technology > Metals > Flashcards

Metals Flashcards

1
Q

How is metal marked on?

A

Metal may be marked on with pencil, but markings can rub off easily and are overall less visible. Instead, a scriber can be used to scratch out lines and dividers can be used for scratching arcs or circles.

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2
Q

How do you smooth metal after it has been sawn?

A

A flat of half-round file is typically used to remove small amounts of metal or smooth a rough edge that has just been sawn. File diagonally to remove metal off a surface faster. Then draw file to achieve a very smooth finish.

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3
Q

How do you drill metal?

A

First, the centre of the hole to be drilled should be marked out with a centre punch to ensure the drill bit does not wander off the hole. The hole can then be drilled with a milling machine or a regular electric drill.

  1. Larger holes should be drilled with a drill bit of a smaller diameter first to provide a pilot hole.
  2. A cone bit can be used to cut larger holes in thin sheet metal.
  3. A hole can be widened with a countersink bit so a screw sits flat with the surface.
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4
Q

How do you trim thin metal?

A

Thin metal can be cut or trimmed with a flat or bevel-edged chisel or with tinsnips.

  1. When trimming with a bevel-edged chisel, the metal should be held in a vice and the line to be cut should be level with the top of the vice jaws. The line can then be cut.
  2. Tinsnips can be straight or curved. The metal can be held in hand or secured in a vice when being cut.
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5
Q

How do you cut metal?

A

A hacksaw is used to cut metal because of the adjustable frame and the blade with a high TPI. The metal should be held in a vice when being saw.
If the metal is thin sheet metal, it should be sandwiched between wood when being sawn to prevent it from bending.
When metal tubing is being sawn, a dowl should be placed in it to prevent the tube from collapsing when being sawn.

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6
Q

What are the different grades of TPI?

A
  1. A lower TPI is more is more coarse - 14 - 18 - and cuts through metal faster. Thick metal should be sawn with blades of a lower TPI.
  2. A higher TPI produces accurate cuts - 30 - 34. Thinner metal should be sawn with blades of a higher TPI.
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7
Q

How do you tap a hole?

A

Tapping is cutting an internal thread into the sides of a hole so a screw can be securely inserted.

  1. Choose a tap that is bit smaller than the diameter of the hole.
  2. Insert the tap into the tap wrench.
  3. Rotate the tap wrench clockwise until you feel resistance.
  4. For every full clockwise rotation, make a half rotation anticlockwise.
  5. Continue this process until you have threaded the entire hole.
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8
Q

How do you thread a hole?

A

Threading is cutting an external thread on the outside of a length of rod to connect it with an internally threaded hole or a fixing like a nut. This process is achieved with a die and a diestock.

  1. Place the metal rod upright in a vice.
  2. Input a suitable die into the diestock.
  3. Place the diestock on top of the metal rod.
  4. Twist the diestock in a clockwise direction for the entire length.
  5. Ensure the diestock is always at right angles to the rid to produce a parallel thread.
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9
Q

How do you prepare metal for finishing?

A

Metal should be rubebd with a emery cloth for smoothing and rubbing alcohol for degreasing.

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10
Q

How do you polish metal?

A

Metal can be polished with a buffing wheel with a light abrasive wax. You can also rub the metal surface with a polish liquid and a fine emery cloth.

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11
Q

What is enamel paint and lacquering?

A
  1. Enamel paint offers superior protection against weather damage than regular paint. It is used for outdoor applications.
  2. Lacquering metal involves applying a thin layer of cellulose gum over the surface, giving it a clear protective coat, allowing the colour of the metal to show through.
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12
Q

What is anodising and enamelling?

A
  1. Anodising produces a clear layer protecting aluminium against corrosion.
  2. Enamelling puts melted powdered coloured glass over metal for decorative finish for jewellery and provides protection against corrosion as well.
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13
Q

What ways can you join metal?

A

Metal is joined by brazing, welding, adhesives or mechanical fixings.

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14
Q

How is do braze metal?

A

Brazing or hard soldering is a joining technique that uses a blow torch and a filler metal.

  1. The metals should cleaned with alcohol and an emery cloth.
  2. The joint is clamped together.
  3. Flux is applied to the joint (preventing the joint from oxidising).
  4. The joint is heated using gas/air torch.
  5. The brazing rod or filler metal is melted and applied to the joint area.
  6. The joint is left to cool and solidify.
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15
Q

How do you weld metal?

A

Welding is a joinery technique where a blowtorch melts the metals and lets them fuse together and form the joint themselves. A filler metal rod is used to build up the joint and replace the melted joining metal.

  1. Clean and decrease the metals with alcohol and an emery cloth.
  2. Melt the joining area with a blow torch, moving in a circular motion.
  3. Melt the filler rod and apply to the joining area.
  4. Let the joint cool and solidfy.
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16
Q

How do you shape metal?

A

Forging is the shaping of metal be heating it and hammering it. Forging also improves the strength and hardness of the metal. An anvil is the platform on which the metal is forged on. The metal is held with open-mouth (for flat metal) or pick-up (for awkward shapes) tongs.

  1. Metal to be forged should be heated until dull red.
  2. Hold the heated metal with open-mouch or pick-up tongs.
  3. Hit the metal with a metal hammer over the anvil.
  4. Once shaped, submerge the metal in water to let it harden and cool.
17
Q

What are the parts of an anvil?

A
  1. The face - the flat surface for general hammering.
  2. The horn - the front where metal is coiled.
  3. The sharp and rounded edges - the sides for curving metal.
18
Q

How is metal bent into a loop?

A
  1. Bend the length of the circumference of the loop over the rounded edges of the anvil.
  2. Hammer the length over the horn of the anvil into a curved shape.
19
Q

What are machine screws and what are self-taping screws?

A
  1. Machine screws have parallel threads. They need a thread hole to screw into.
  2. Self-tapping screws are used for joining thin sheet metal. When it is screwed into the pilot hole, it cuts its own thread, which holds the screw in place.
20
Q

What is a nut and bolt fixing?

A

Bolts are similar to machine screws, but instead of being inserted into a threaded hole, they are put all the way through both pieces of metal, and then a nut is tightened on to the end of the bolt to keep the pieces together.

Washers can be put under the head of the bolt and under the nut, in order to spread the tightening force over the surface of the material and to stop the bolt head and nut from digging into the surface.

21
Q

How do you join metal with rivets?

A

Rivets are used to join thin pieces of metal, providing support on both sides. Rivest a single piece joinery method and are quick and easy to install and uninstall.

  1. The two pieces to be joined are overlapped and drilled.
  2. The rivet shaft is inserted into the hole.
  3. The head facing downward is placed
    in a snap or set tool.
  4. The shaft of the rivet is then hammered over to squeeze the two pieces together.
  5. The domed rivet head can be made flat by filing.
22
Q

How do you join metal with pop rivets?

A

Pop riveting is also used to join thin sheet metal, but when the underside of the joint is inaccessible.

  1. Pop rivets have a pin inside of them.
  2. The rivet head up is inserted through a hole drilled through the two pieces of metal.
  3. Pop rivet pliers pull the pin and this causes the head of the rivet to be squashed, pulling the two pieces of metal together.
  4. The pin breaks off and is disposed of.
23
Q

How do you apply clear coat paint to metal?

A
  1. Remove any dirt, oil or rust with an emery cloth and alcohol. The surface needs to also be sanded to create smoothness.
  2. A thin primer coat should be added equally over the surface.
  3. Once dry, sand the surface with fine sand paper.
  4. Apply an additional 1-2 layers and repeat the steps 2-3.
24
Q

What is annealing?

A

Annealing is the process of softening metal so it can be shaped.

  1. Clean the metal of oil and dirt residues.
  2. Heat the metal with a blow torch to a specific temperature.
  3. Let the metal air cool for a little bit then it is ready for shaping.
25
Q

How do you produce a dome shape with metal?

A
  1. Anneal the metal to ensure it is soften enough to shape.
  2. Place the softened metal over a dome shaped former.
  3. Hit the metal around the former with a soft faced hammer. Hit in a circular fashion.
  4. Remove the metal from the former and submerge in a cold water bath to cool.

AS Design Technology (5 decks)

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