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ETM 2180 > midterm 10/17 > Flashcards

midterm 10/17 Flashcards

1
Q

what does ‘manus’ mean?

A

hand

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2
Q

what does ‘factus’ mean?

A

make

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3
Q

what does manufacture mean?

A

handmade or “made by hand”

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4
Q

what is modern manufacturing?

A

mechanized or automated equipment that is supervised by human workers

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5
Q

what is technology manufacture?

A

application of physical and chemical processes to alter the geometry, properties, and/or appearance of a starting material to make parts or products

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6
Q

what is economic manufacture?

A

transformation of materials into items of greater value by one or more processing and/or assembly operations

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7
Q

what is considered low production?

A

1 to 100

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8
Q

what is considered medium production?

A

100 to 10,000

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9
Q

what is considered high production?

A

10,000 to millions

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10
Q

what are metals composed of two or more elements?

A

alloys

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11
Q

what is elasticity?

A

deformation under a load that is not permanent

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12
Q

what is plastic deformation?

A

permanent deformation after a load is removed

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13
Q

what is stress?

A

the force applied to a material

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14
Q

what is strain?

A

the change in length in a material under stress

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15
Q

Which are the two main subdivision of Metals?

A

ferrous and nonferrous

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16
Q
  • true or false?
    Turning, welding and bending are considered material removing processes.
A

false

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17
Q
  • true or false?
    Forging is considered a deformation process.
A

true

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18
Q
  • true or false?
    Particulate processing requires the mixing of metal or ceramic powders with binders, then the powders are loaded in a die with the shape of the desired part to be pressed and finally the part is sintered.
A

true

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19
Q

what are the main three (3) Chrystal Structures that metal can form into?

A
  • Body-Centered Cubic (BCC)
  • Face –Centered Cubic (FCC)
  • Hexagonal Closed packed (HCP)
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20
Q

what is the first step in making a risk assessment?

A

determine the hazard

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21
Q

all but which of the following are protective clothing required for Casting?

A

cotton coveralls leaving no exposed skin

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22
Q

which of the following is NOT a type of “point of operation” GUARD?

A

pressure-sensing barrier

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23
Q

what clothing should be NOT be worn when welding?

A

cotton (natural fiber) gloves

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24
Q

when electric arc welding, what eye protection should you wear?

A

dark glass with a protective lens

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25
Q

which is not a general hazard associated with welding?

A

excessive noise

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26
Q

when welding, to minimize the effects of noxious fumes, you should…

A

assure there is adequate ventilation around the weld sight

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27
Q

what is not a good reason to train employees?

A

minimizes employee fear of safety hazards

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28
Q

when performing electric arc welding, what is the BEST approach to minimizing the risk of electrocution?

A

avoid making yourself the circuits easiest path to ground

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29
Q

in a shear press, how are treadles (foot pedals) “guarded”?

A

With counter weights or springs

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30
Q

what is tensile stress?

A

material being stretched

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31
Q

what is compressive stress?

A

material being squeezed

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32
Q

what is shear stress?

A

material being forced to slide

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33
Q

what is barreling?

A

increase in area at the middle of the specimen as a consequence of friction with the supporting surfaces

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34
Q

what is hardness?

A

a material’s resistance to permanent indentation

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35
Q

what is hot hardness?

A

the ability of a material to retain hardness at elevated temperature (ceramics, tooling materials)

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36
Q

what is viscosity?

A

resistance to fluid flow

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37
Q

what is fluidity?

A

ease with which a fluid flows

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38
Q

what is a stamping press?

A

typical machine tool used
– punch and die (tooling)

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39
Q

what is springback?

A

when the pressure is removed at the end of the deformation operation, elastic energy remains in the bent part, causing partial recovery of the material towards its initial shape

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40
Q

what is welding?

A

fabrication process that joins materials using a coalescence process

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41
Q

what are some advantages to welding?

A
  • permanent joint or bond
  • weld can be stronger than the parent metal depending on filler
  • material
  • economical and faster
  • not restricted to the factory
  • can be mechanized or automated
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42
Q

what are some disadvantages to welding?

A
  • does not allow for convenient
    disassembly
  • labor cost – can be high – requires skills
  • can be dangerous
  • some quality defects are difficult to detect (internal defects)
  • high temp can result in rapid oxidation (rust)
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43
Q

examples of fusion welding?

A
  • Arc Welding
  • SMAW (Stick welding)
  • GMAW (MIG, MAG, CO2)
  • FCAW (Flux-cored)
  • SAW (Submerged)
  • GTAW (TIG) PAW or PAC (Plasma)
  • Resistance Welding
  • Oxyfuel Gas Welding
  • Electron Beam Welding
  • Laser Beam Welding
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44
Q

examples of solid state welding?

A
  • Diffusion Welding
  • Friction Welding
  • Ultrasonic Welding
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45
Q

what are the five types of welding joints?

A
  • Butt
  • Corner
  • Tee
  • Lap
  • Edge
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46
Q

examples of types of welds?

A
  • Fillet
  • Groove
  • Square
  • Single bevel
  • “V” groove
  • “U” groove
  • “J” groove
  • Double groove
  • Plug
  • Slot
  • Spot
  • Seam
  • Flange
  • Surfacing
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47
Q

what are the general properties of metals (Physical and Mechanical)?

A
  • high stiffness and strength
  • toughness (ability to absorb energy)
  • good electrical conductivity (magnetic)
  • good thermal conductivity
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48
Q

what are phase diagrams?

A

graphical means of representing the phases of a metal alloy system as a function of composition and temperature

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49
Q

what is the L phase proportion?

A

CS / (CS + CL)

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50
Q

what is the S phase proportion?

A

CL / (CS + CL)

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51
Q

what is the chill zone in casting?

A

region where the temperature is the coldest (edges in contact with the mold)

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52
Q

what are columnar grains?

A

elongated grains that grow as the material cools down

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53
Q

what are equiaxed grains?

A

internal grains that form from additional nucleation at the thickest regions of the cast material

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54
Q

what is diffusion?

A

a chemical redistribution of atoms in a solid

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55
Q

diffusion can occur either by ________ or by ________.

A
  • heat treatment
  • mechanical deformation
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56
Q

what are the main two factors involved during heat treatment?

A
  • time
  • temperature (furnace and atmosphere must also be
    considered as well as the quenching media)
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57
Q

what is deformation?

A

hot and cold forming through shaping processes

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58
Q

when setting the shielding gas regulator for the GMAW welding process, which units are used to measure the gas flow?

A

cfh

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59
Q

which of the following two stainless steels is magnetic? (austenitic vs ferritic)

A

ferritic stainless

60
Q

permanent deformation in metal crystals after exceeding the Ultimate Tensile Strength is referred as ________.

A

non-uniform plastic deformation

61
Q

the principal alloying element in carbon steel is ________.

A

carbon

62
Q

after bending a sheet metal, the part may recover partially towards its original shape after removing the bending pressure.

what two things can be done to counteract this elastic recovery?

A

bottoming and overbending

63
Q

what process is a solidification process?

A

casting

64
Q
  • true or false?
    a billet is used to create an extrusion of the die geometry.
A

true

65
Q

A manufacturing plant consists of 1)_________ and 2)_________ (and people) to transform a certain limited range of 3)_________ into products of increased value

A

1) processes
2) systems
3) materials

66
Q

what are the three building blocks of manufacturing?

A
  • materials
  • processes
  • systems
67
Q

what are ferrous metals?

A

iron based (steel and cast iron)

68
Q

what are nonferrous metals?

A

other metallic elements (aluminum, copper, nickel, silver, tin, etc.)

69
Q

what are crystal structures?

A

arrangements of atoms, ions, or molecules in a crystalline material

70
Q

how many distinct crystal structures are there?

A

7

71
Q

what is a grain in a block of metal?

A

an individual crystal

72
Q

what are three measures of stress?

A
  • elastic modulus
  • ductility
  • hardness
73
Q

three types of static stresses?

A
  • tensile
  • compressive
  • shear
74
Q

what is density?

A

weight per unit volume

75
Q

what is the coefficient of thermal expansion?

A

measures change in length per degree of temperature

76
Q

what are the two melting characteristics of alloys?

A

solidus & liquidus

77
Q

what is specific heat?

A

mount of heat to increase the temperature of a unit mass by 1 degree

78
Q

what is conductivity?

A

ability to allow current flow

79
Q

what are the four shaping processes?

A
  • solidification processes
  • particulate processing
  • deformation processes
  • material removal
80
Q

what are the two steps of solidifcation?

A

1) casting process
2) cast product

81
Q

what are the three steps of particulate processing?

A

1) starting materials are metal or ceramic powders
2) press the materials
3) they are sintered

82
Q

two ways for deformation processes?

A

a) forging
b) extrusion

83
Q

three ways of material removal processes?

A

a) turning
b) drilling
c) milling

84
Q

what is the objective of design?

A

for the product to withstand stresses without changes in geometry

85
Q

what is the objective of manufacturing?

A

to transform the material (geometry changes) into a product (by applying stresses that exceed the yield strength of the material)

86
Q

what is Hooke’s Law?

A

s = Ee

87
Q

what variable is for the Modulus of Elasticity?

A

E

88
Q

what is necking?

A

localized elongation that occurs to the right of the UTS

89
Q

what is fracture stress?

A

stress calculated just before rupture of the specimen

90
Q

what is good hardness?

A

resistance to scratches and wear

91
Q

most common tests for hardness are the ________ and ________ Hardness tests.

A
  • Brinell
  • Rockwell
92
Q

It is important to know the operating ________ of the product.

A

temperature

93
Q

what are the three typical parts of sheet metal?

A
  • enclosures (boxes)
  • brackets
  • mounting structures (frames)
94
Q

sheet metal is usually how thin?

A

1/16” to 1/4”

95
Q

when sheet metal is above 1/4” thickness, it is referred to as a ________.

A

plate

96
Q

what is an ingot?

A

large size casting produced in a foundry

97
Q

when the metal product is thinner than 1/4” and has a <24” width, it is known as a ________.

A

strip

98
Q

If thick sheet metal, ________ may be used to assist with deformation.

A

warm working

99
Q

what are the machine tools used for bending generally called?

A

presses

100
Q

what is a stamping press?

A

typical machine tool used

101
Q

in mass production, what 2 things are often used?

A

strips or coils

102
Q

what are two compensations for springback?

A
  • overbending
  • bottoming
103
Q

what is welding?

A

a fabrication process that joins materials using a coalescence process, and joins materials (usually metals or thermoplastics) by using high heat to melt the parts together and allowing them to cool, causing fusion

104
Q

________ and ________ are lower temperature techniques which do not melt the base metal (parent metal).

A
  • brazing
  • soldering
105
Q

examples of fusion welding?

A
  • arc
  • resistance
  • oxyfuel gas
  • electron beam
  • laser beam
106
Q

what does PPE stand for?

A

personal protective equipment

107
Q

what are the general properties of metals?

A
  • high stiffness and strength
  • toughness
  • good electrical conductivity (magnetic)
  • good thermal conductivity
108
Q

Atoms are ________ together making ________.

A
  • bonded
  • solid structures
109
Q

what is a covalent bond?

A

electron-sharing

110
Q

what is an ionic bond?

A

electrostatic forces of attraction and repulsion

111
Q

what is a metallic bond?

A

similar to covalent (electron sharing)

112
Q

what is crystal lattice?

A

geometric array of points

113
Q

what is a unit cell?

A

the smallest subdivision of the lattice

114
Q

what does BCC stand for? (crystal structure)

A

body-centered cubic

115
Q

what does FCC stand for? (crystal structure)

A

face-centered cubic

116
Q

what does HCP stand for? (crystal structure)

A

hexagonal closed-packed

117
Q

An Alloy is a metal composed of two or more ________ of which one is metallic.

A

elements

118
Q

what is the intermediate phase?

A

a second phase formation beyond the dissolving element limit

119
Q

what are phase diagrams?

A

Graphical means of representing the phases of a metal alloy system as a function of composition and temperature

120
Q

three steps to determine the chemical composition?

A

1) draw a horizontal line at the temperature of interest
2) where it intersects the solidus and liquidus lines, draw a vertical line to read the composition
3) apply the inverse lever rule

121
Q

pure iron temperature for Alpha (Ferrite)

A

room temp

122
Q

pure iron temperature for Gamma (Austenite)?

A

912ºC

123
Q

pure iron temperature for Delta (Ferrite)?

A

1394ºC

124
Q

pure iron melting point temp?

A

1539ºC

125
Q

low carbon steels have how much carbon?

A

less than 0.2%

126
Q

medium carbon steels have how much carbon?

A

0.2% to 0.5%

127
Q

high carbon steels have how much carbon?

A

> 0.5%

128
Q

what is Eutectic?

A

solidus and liquidus are at the same temperature

129
Q

what is Eutectoid?

A

solid state reaction

130
Q

what does HSLA mean?

A

high-strength low-alloy

131
Q

for stainless steels, principal alloying element is ______ above 15%.

A

chromium

132
Q
  • true or false?
    Austenitic stainless is the most corrosion resistant.
A

true

133
Q

five types of cast iron?

A
  • grey cast
  • ductile
  • white cast
  • malleable
  • alloy cast
134
Q

what are refractory metals?

A

able to endure high temperatures

135
Q

three examples of precious metals?

A
  • silver
  • gold
  • platinum
136
Q

what are superalloys?

A
  • high temperature performance
  • tensile strength
  • hot hardness
  • creep resistance
  • corrosion resistance
137
Q

what is the microstructure of metals?

A

the size and distribution of a second phase or to the grain size of the principal phase

138
Q

how is microstructure usually observed?

A

under a microscope of a flat polished surface of metal that has been etched with chemicals to reveal different features

139
Q

what is eutectoid microstructure?

A

generally a platelike structure named pearlite in the case of steel

140
Q

for casting, what is the chill zone?

A

region where the temperature is the coldest (edges in contact with the mold)

141
Q

what are two issues with casting?

A

1) nonmetallic inclusions may form mainly in the center due to a push that occurs during solidification
2) shrinkage during solidification may lead to voids as the liquid phase occupies less space than the solid phase

142
Q

what is diffusion?

A

a chemical redistribution of atoms in a solid

143
Q

how can diffusion occur?

A
  • heat treatment
  • mechanical deformation
144
Q

what are the two main factors involved during heat treatment?

A
  • time
  • temperature
145
Q

the most basic heat treatment is called __________.

A

homogenization

146
Q

what is deformation?

A
  • hot and cold forming through shaping processes
  • plastic deformation
  • heat treatment of deformed metals may lead to recovery of properties

ETM 2180 (1 decks)

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