Process

Question 1

Manufacturing Processes is broken down into two parts, what are they?

Answer 1

Processing Operations and Assembly Process

Question 2

Processing Operations is broken down into three parts, what are they?

Answer 2

Shaping Operation, Surface Processing, and Property Enhancement

Question 3

What are some Shaping Operations?

Answer 3

Casting,
Additive manufacturing
Material removal (Subtractive manufacturing)
Powder metallurgy
Deformation

Question 4

What is Property Enhancement

Answer 4

Heat treatment

Question 5

Examples of heat treatment include?

Answer 5

-hardening of steel by quenching
-precipitation hardening of aluminum
-annealing (slowly cooling) taking back to begin
-tempering

Question 6

What are the three parts of Surface Processing?

Answer 6

-Coating & film deposition
-Cleaning Operation
-Surface Property Enhancement

Question 7

What are some examples of Coating & Film Deposition?

Answer 7

-eg painting
-ceramic deposition
-electroplating

Question 8

What are some examples of Surface Property Enhancement?

Answer 8

-Shot peening
-Sand Blasting
-Ion implantation

Question 9

What is Shot Peening?

Answer 9

A cold work process used to impart compressive residual stresses onto the surface of a component (results in modified mechanical properties) The process is used to add strength and reduce the stress profile of components.

Question 10

How does Shot Peening work?

Answer 10

Shot peening works by striking a surface with a shot (round metallic, glass or ceramic particle) with enough force to generate plastic deformation. When a group of shots impact the surface they generate multiple indentations, resulting in the component being encased by a compressive stressed layer on the metal surface

Question 11

What is Sandblasting?

Answer 11

Involves using air pressure to force small, abrasive particles at a surface at high speed to clean it or change its texture. The process used to involve using sand.

Question 12

What is Ion implantation?

Answer 12

Is a low-temperature process by which ions of one element are accelerated into a solid target, thereby changing the physical, chemical, or electrical properties of the target. Ion implantation is used in semiconductor device fabrication and in metal finishing

Question 13

What is an example(s) of Material Removal (subtractive manufacturing)?

Answer 13

-Milling
-Sawing
-Drilling
-Boring
-Grinding

Question 14

What is an example(s) of Industrial Cleaning?

Answer 14

-Sand Blasting
-Pressure washing

Question 15

What is an example(s) of Surface Modification?

Answer 15

-Laser cladding
-shot peening
-Sandblasting

Question 16

What is an example(s) of Metal deformation?

Answer 16

-Rolling
-Bending
-Drawing
-Forging

Question 17

What is an example(s) of Additive Manufacturing?

Answer 17

-3D printing

Question 18

What is carburization?

Answer 18

Carburization is a process that involves taking a low-carbon steel and transforming it into a high-carbon steel. (hardens the exterior of metal pieces)

Question 19

What is the process of carburization?

Answer 19

The four types of carburization are: Vaccum, liquid, pack, and gas

-The Vaccum process uses steel alloys that are put into an oxygen-free, low-pressure environment, and then a gas (most common hydrogen) is pumped into the space making carbon molecules attach to the alloy

-The Liquid process uses a liquid vat filled with a mixture of cyanide and salt. When the alloy is submerged it comes in contact with carbon molecules and diffuses into the alley.

-The Pack process uses a furnace. Steel is placed into a furnace with high-carbon items (carbon powder) the furnace is heated with carbon monoxide causing the carbon to be pulled from the surface of the carbon-dense items. When the carbon molecules aren’t attached they diffuse into the surface of the steel.

-The Gas process also uses a furnace and carbon monoxide but doesn’t need carbon-dense items, because carbon monoxide is continuously pumped into an enclosed environment. The high temperature allows the carbon molecules to diffuse into the steel items being hard-cased.

Question 20

What are the advantages of carburization?

Answer 20

The advantages are that it is inexpensive, results give a very hard exterior and the interior is soft so its easier to manipulate.

Question 21

What are the advantages of Shot Peening?

Answer 21

It improves strength and fatigue resistance. The process is also inexpensive and quality controls to ensure effectiveness. Also, the equipment is readily available.