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A Level-DT > Metals And Alloys > Flashcards

Metals And Alloys Flashcards

1
Q

What is aluminium

A

Aluminium is a pure metal that is soft, malleable and conductive

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2
Q

What is low carbon steel

A

Low carbon steel (mild steel) is an alloy that is soft and weak but it is very ductile

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3
Q

What is high carbon steel

A

High carbon steel (Tool steel) is an alloy that has very high stength, resistance and moderate ductility

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4
Q

What is zinc

A

Zinc is a pure metal that is brittle and is malleable at temperatures between 100-150°C

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5
Q

What is copper

A

Copper is a strong pure metal that has very good heat and electricity conductivity but it isn’t magnetic

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6
Q

What is cast iron

A

Cast iron is an alloy which is high in strength extremely hard and also very brittle

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7
Q

What is brass

A

Brass is the generic term for a range of copper-zinc alloys they are all electrically and thermally conductive and most are strong

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8
Q

What are the 3 types of metals

A

Ferrous (containing iron)
Non-ferrous (doesn’t contain iron)
Alloys

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9
Q

Name 3 ferrous metals

A

Low carbon steel, medium carbon steel, tool steel, cast iron

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10
Q

Name 3 non ferrous metals

A

Aluminium, zinc, copper, tin, titanium

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11
Q

Name 3 ferrous and 3 non ferrous alloys

A

Ferrous:
Steel-stainless, die, tool,low carbon

Non ferrous:
Bronze, brass, pewter, duralumin

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12
Q

What are the 3 types of press forming and briefly explain them

A

Regular press forming-shapes SHEET metals by pressing them using a driving force and vices to hold the edges
Cupping-shapes TUBE metals by pressing them into shape the same way
Deep drawing-shapes tube metals by pressing them but it the depth of the press exceeds the diameter of the tube

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13
Q

What is spinning

A

Spinning is when a metal blank (sheet) is spun
and pressed over a rotating mould called a mandrel
then a roller tool is used to apply uniform pressure on the metal sheet while it is spinning
this forms the metal around the mandrel

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14
Q

What is the difference between forging and drop forging

A

Forging is done by hand with a hammer therefore it takes more skill
Drop forging is done using an upper and lower die with the heated metal in between and therefore takes less skill

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15
Q

What is rolling

A

Rolling is when a metal is passed through sets of rollers to reduce the thickness

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16
Q

What are the 4 types of casting

A

Sand casting
Investment casting
Die casting
Low temperature casting

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17
Q

Describe sand casting

A

Sand casting is the process where a compressed sand mould is made by using a replica of the product and making a sand mould in two halves.
Then on the second half, a pouring cavity, vents and a riser are dug out and molten metal is poured in until the riser is full which indicates to the worker enough metal had been poured in.
Then the sand is removed and the metal piece is machined

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18
Q

Describe investment casting (lost wax process)

A

A wax replica of the product is made and then dipped in clay mould
this is then put in a kiln which both melts the wax and hardens the clay
molten metal is then poured into the clay mould and left to cool

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19
Q

Describe die casting

A

Die casting involves injecting molten metal into a mould
using a plunger and pressure chamber (similar to injection moulding)
and then the metal is left to cool

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20
Q

Describe low temperature casting

A

Low temperature casting is a process which involves heating up metals such as pewter of silver that have low melting points
then pouring them into moulds and leaving them to cool
The low temperatures allow the moulds to be made of different materials such as MDF

21
Q

What are the 4 types of welding

A

MIG, TIG, Spot and oxy-acetylene

22
Q

What are the similarities and differences between MIG and TIG welding

A

Both melt metal and stick the edges together while molten then leave the joint to cool
MIG welding uses a wire which is heated in the welding gun and fed through into a molten weld pool
TIG welding generates heat by electricity jumping between a tungsten electrode and the metal surface, a filler rod is then fed in externally

23
Q

What is spot welding

A

An addition processes which uses a nugget in between two sheets where two electrodes apply pressure and heat to melt the nugget and join the sheets

24
Q

What is oxy-acetylene welding

A

A welding process that uses two gasses-oxygen and acetylene to create an intense flame that burns at 3,500°C
This is then used to melt a filler metal rod along a ‘v’ shaped valley in between the two metals you want to join

25
Q

What is soldering and brazing

A

Soldering uses melted solder as an adhesive to join two metals
Brazing uses the same principle but burns as 880° and uses a brazing rod
Before both processes the metal has to be cleaned and degreased

26
Q

Describe the addition process of riveting

A

A rivet is inserted through a hole in two overlapping sheets
a dome head is on one side with a tail on the other side
the tail is then hammered down to fix the rivet in place and join the sheets

27
Q

Describe the process of galvanising

A

Galvanising is a hot dip process in which the product is dipped into a bath of molten zinc to coat the metal in a protective layer. It adds lots of durability to the material however the material must be able to withstand the heat of the process or it cannot be applied.

28
Q

Describe the process of electroplating

A

Electroplating is a process via electrolysis in which the metal is placed in a rinse bath to prepare the metal and then after into an electrolyte with nickel particles which bond with the metal to give a consistent shiny layer.

29
Q

Describe the process of Anoidising

A

Anodising is a process used for aluminium where the product is dipped into an electrolysis tank where the aluminium acts as the anode and is oxidised. This creates a layer of aluminium oxide over the surface which protects the aluminium and provides a smooth finish which can be coloured.

30
Q

Describe the process of bead blasting

A

Small ceramic beads are fired at high speed at the metal part to clean and decontaminate the surface, it is like sanding for metal so it is useful for preparing a surface but it changes the dimensions

31
Q

What are the stock forms of metals

A

Sheet, bar, plate, tube, structural

32
Q

What is annealing

A

Annealing is the process by which metal is made easier to work with, it is essentially heating the metal up and then allowing it to slowly cool in order for the crystals to grow and slowly move into place

33
Q

What is case hardening and what are the two stages of it

A

It is a process for steel by which the outer layer is made into a hard, high carbon content steel and the inside is left as a softer steel
Carburising
Quenching

34
Q

What is carburising

A

A process that changes the chemical composition of steel so it can absorb more carbon and become harder, usually needs temperature of around 900-950°C

35
Q

What is quenching

A

When a head treated metal is rapidly cooled by placing it in water

36
Q

What is tempering

A

Tempering is a process for when the metal is made too hard and starts to become brittle.
To temper a metal it is heated to below the critical temperature and then allowed to slowly air cool

37
Q

What is critical temperature

A

The temperature at which atoms of carbon and steel mix freely before bonding to become a solid

38
Q

What are differences between polymer and metal dip coating

A

Polymer: the material itself is heated up to 230°C and dipped in powder
Metal: the material is dipped in a molten bath of the donor metal

39
Q

Explain powder coating

A

The product is negatively charged and the sprayed with positively charged polymer resin. The difference in charge helps attract the spray into all on the product and then it is baked in an oven and this melts to powder to give an even and protective coat

40
Q

What is varnishing

A

Varnishing is a finishing process in which the metal is polished to a shine and then the varnish layer is applied by either spray or a fine brush, this allows the metal to be more aesthetic and clear

41
Q

What are sealants

A

Sealants are tough polymer based coatings that protect polished surfaces from decay and weathering. The sealant is applied with a cloth or pad and then left for up to 15 mins and then buffed to a shine-usually used in automotive bodywork and freshly polished metal trims

42
Q

What is press forming

A

Press forming is the process in which a sheet metal is placed on a female die and a male die or punch is used to force the sheet into shape.
This could include a cutting blade to make punch holes and trim excess metal off.

43
Q

What is cupping and deep drawing and what is the difference between them

A

Cupping and deep drawing is when a press ‘blank’ aka a circular sheet
is held at the sides and a punch draws it out into a cup shape.
Difference is deep drawing is when the depth exceeds the diameter.

44
Q

What is the name of the metal process which is similar to calendaring

A

Rolling

45
Q

What is the difference between self tapping screws and machine screws

A

Self tapping screws are more day to day use-will cut their own thread as they are drilled into the material they are holding together
Machine screws are more industrial-they will have a pre made thread along the entire length of the shaft which they will catch on to and then be tightened with a spanner or Allen key.

46
Q

What is a nut and bolt

A

The bolt is like a screw except the thread is on the main shaft of the bolt.
The nut is a small (usually hexagonal) ring which is screwed onto the end of the bolt after it is inserted through the piece to hold it together

47
Q

Describe flame cutting

A

Oxy-acetylene gas is used to create a very intense flame that burns at 3,500°C
This creates a melt pool (similar to welding) where the metal is molten
Another jet of oxygen is forced through the middle which intensifies the flame and also forces a jet of melted metal out the other side (known as slag)

48
Q

Describe plasma cutting

A

A plasma arc is formed by a AC voltage which burns at up to 28,000°C
thus quickly cuts through any material and blows it away
The beam is then moved around in the shape of the cut

A Level-DT (12 decks)

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