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151/23/005 > Processes > Flashcards

Processes Flashcards

1
Q

what is the definition of ductility?

A

the ability to be drawn out, under tension, without rupture and retain its new shape

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2
Q

what is the definition of malleability?

A

the ability to be pressed, rolled or beaten out, under compression, without rupture and retain its new shape

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3
Q

what is the definition of toughness?

A

the ability to withstand impacts and shock loads

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4
Q

what is the definition of strength?

A

the ability to withstand tensile, compressive or shear forces, resisting without rupture

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5
Q

what is the definition of brittleness?

A

the ability to fracture without deformation

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6
Q

what is the definition of hardness?

A

the ability to withstand wear, and abrasion and the ability to cut softer materials

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7
Q

what is the definition of elasticity?

A

the ability to deform under load and return to its normal size, shape after the load is removed

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8
Q

what is the definition of corrosion resistance?

A

the ability to resist chemical and electromagnetical attack

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9
Q

what is the definition of electrical conductivity?

A

the ability to and the rate at which a material will conduct electrical current

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10
Q

what is the definition of thermal conductivity?

A

the ability to and the rate at which a material will conduct heat

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11
Q

what are some uses of wrought iron?

A
  • anchor chains
  • crane hooks
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12
Q

what are some uses of mild steel?

A
  • nuts, bolts, rivets
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13
Q

what are some uses of medium carbon steel?

A
  • crank shafts
  • connecting rods
  • axles
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14
Q

what are some uses of high carbon steel?

A

hand cutting tools
ball and roller bearings

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15
Q

what are some uses of grey cast iron?

A

machine tool beds
engine blocks and cylinder heads

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16
Q

what are some uses of pearlitic spheroidal graphite cast iron?

A

crank cases
impellers

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17
Q

what are some uses of high speed steel?

A

machine cutting tools
twist drills

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18
Q

what are some uses of ferritic stainless steel?

A

sinks
exhausts
heat exchangers

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19
Q

what are some uses of martensistic stainless steel?

A

hydraulic and steam pump valves
surgical tools

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20
Q

what are some uses of austenitic stainless steel?

A

pump shafts
propeller shafts

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21
Q

what are some uses of copper?

A

plumbing
wiring

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22
Q

what are some uses of aluminium?

A

drinks cans
motor vehicle body panels

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23
Q

what are some uses of duralumin ?

A

chassis and body parts in automotives
yacht mast

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24
Q

what are some uses of titanium?

A

gas turbine compressor disks and blades
super sonic aircraft construction

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25
what are some uses of magnesium?
casting and forged components for aircrafts
26
what are some uses of tin?
plain bearings thin coating on mild steel
27
what are some uses of lead?
radiation shields roofing material
28
what are some uses of zinc?
roofing materials sacrificial anode on ships hull
29
what are some uses of naval brass?
nuts bolts washers fresh water valves
30
what are some uses of tungum?
high pressure air and hydraulic pipe systems
31
what are some uses of phosphor bronze?
heavy duty bearings and gears
32
what are some uses of gunmetal?
seawater valves
33
what are some uses of nickel aluminium bronze?
small boat propellers pump impellers
34
what are some uses of magnesium bronze?
propellers casting
35
what are some uses of monel metal?
pump shafts general marine hardware
36
what are some uses of nimonic 80?
gas turbine rotors and blades
37
what are the advantage as of using plastics?
low densities ease of moulding damps out vibration good electrical insulation
38
what are the disadvantages of using plastics ?
low strength, rigidity and shock resistance low service temperature soft and scratch easily
39
what are the uses of perspex?
machine guarding pressure gauge and instrument faces
40
what are some uses of nylon?
gears bearings ropes
41
what are some uses of PTFE?
pumps seals and gaskets
42
what are some uses of tufnol?
gears non-conductive jigs and fixtures
43
what are some uses of melamine?
aircraft and distributor parts handles for electrical equipment
44
what are some uses of epoxy resin ?
sealing and encapsulating of electrical equipment moulded components
45
what are the three reasons we test materials?
- research, design and development - quality control - investigation of failures
46
what are the three types of fundamental stress? and draw them
- tensile stress - compressive stress - shear stress
47
what is the definition of hooks law?
witching the elastic range, the strain produced, is directly proportional to the stress producing it stress/strain = constant
48
what is the definition of creep?
creep is the progressive deformation of a material under constant load over an extended time period
49
what is the definition of fatigue ?
fatigue is caused by cyclical stress. where a material is repeatedly bent or twisted back and fourth or repeatedly stretched then squashed
50
what methods are used to prevent fatigue?
- good design - improved surface finishes - avoid corrosion - surface harden
51
what are the 4 methods of corrosion protection ?
- desgin - environment - coating - galvanic protection
52
what methods of protection can you use on the ships hull?
- paint the ships hull - sacrificial anodes - good design - controlling moisture levels
53
what are the four heat treatment processes ?
annealing normalising hardening tempering
54
explain how hardening is done
the material is heated to above the upper critical temperature and the quenched
55
explain how tempering is done
the material is heated to a specific temperature below the lower critical temperature and then is quenched
56
explain how annealing is done
the material is heated to a specific temperature below the lower critical temperature and then allowed to cool in a controlled manner
57
explain how normalising is done
the material is heated up to just above the upper critical temperature and then allowed to cool in air
58
define stress?
stress applied = applied force(N)/ cross sectional area (mm2)
59
define strain?
strain = change in length / original length
60
what two properties will sand casting metals have?
a relatively low melting point good fluidity
61
explain the process for sand casting
- place the bottom half of the moulding box over the pattern and pack down with sand - turn over and place the top half of the moulding box onto the bottom half - position the other half of the pattern and pack down with sand - cut holes for the runner and riser - open the mould and remove both halfs of the pattern - repair any defects and the coat with plumbago - position core if required - reassemble the drag and cope and pour the molten metal - allow to cool, when cold break open the mould and remove the casting - fettle as required
62
what are some uses of sand casting?
gear blanks valve chests angle plates
63
what are some advantages of sand casting?
- cheap - quick turn around -easy to modify
64
what are some disadvantages of sand casting?
not suitable for mass production rough surface finish mould is one use only
65
name three type of casting
sand casting die casting investment casting
66
what are some properties of die casting material?
low melting point alloys
67
what is the main difference between sand casting and die casting?
- sand casting uses a one off mould - die casting uses a reusable mould
68
explain the process of pressure die casting
- the molten metal at a suitable pressure and temperature is forced into the closed die so that is completely filled - the die opens and ejection of the casting. The die is sprayed with graphite spray for longevity of the die and ease of ejection - the die closes to prepare for the first stage again
69
name some uses of pressure die casting
engine pistions fuel pump bodies
70
explain the process of investment casting
- build a ceramic mould around a max pattern - this mould is then heated to harden it and melt the wax pattern out of it - the molten metal is then poured into the mould - after cooling the mould is broken to release the casting
71
name some uses of investment casting
gas and jet engine blades, cams, nozzles and valves
72
list some advantages of investment casting
dimensional accuracy good surface finish minimal is any final machining
73
explain hand forging
- the material is hammered into shape after it has been heated to its above critical temperature. - this breakers up and refines the grain structure - the finer the grain structure becomes the stronger and tougher the material becomes
74
list some advantages of hand forging
uses less raw material than machine components from solid stock is 3 times stronger than machined components
75
list some disadvantages of hand forging
slow and labour intensive expensive high degree of skill level required not suitable for mass production
76
list some uses of drop forging
connnecting rods crank shafts spanner’s
77
name some types of hardness tests
brunel hardness test vickers dimond hardness test rockwells hardness test
78
name the two subdivision of joining processes and give some examples
permanent joining processes- riveting, welding, hard and soft soldering, brazing temporary joining processes - nuts, bolts, screws, studs
79
draw three types of rivets
80
label the electrical arc welding diagram
81
what two things dose the electrode coating provide?
- creates a slag layer to stop it cooling rapidly - provides a protective gas to prevent oxidation
82
explain the process of soldering
- unlike welding, there is no fusion process of the parent metal - the bond is active by -a mechanically and chemically clean joint by a applying flux to remove oxide film when heated - the joint is then heated to above freezing range of the solder - filler metal is applied to alloy with the parent metal - filler metal will fill clearance between components via capillary action
83
name three types of adhesives
expoxies cyanoacrylates anaerobics
84
define what a screw thread is
a screw thread is a helical groove cut around or inside a cyclinder
85
draw a screw thread include these labels: - major diameter - minor diameter - pitch
86
give some examples of a an application of a left hand thread
hose connection threads of acetylene on welding torch bottle screw cable tensioner
87
when dose a component have good quality?
a component has good quality when it meet requirements
88
what’s the main goal of a quality assurance system ?
the main goal of a quality assurance system is to ensure that the product fulfils or exceeds the expectations of the customer
89
name three things which you’d expect as a costumer buying a product
- predictable, effective and reliable operating life - spare parts will be readily available - these parts will be interchangeable with the existing equipment
90
what is there international quality standard ?
ISO 9000
91
what do you do if a product is nonconforming to requirements?
- identify the product, e.g add a tag or sticker - isolate/ quarantine it - decide what to do with it : 1. adjusting 2. scrapping 3. reworking 4. concession
92
give three examples of 2 part assesmelys that are interchangeable
small end bearing/gugien pin piston/ piston rings connecting rod/ big end bearing
93
what are the benefits of using written instructions?
- the personnel who gives the instructions is sure the correct information is received - written instructions can be given clearly, when working in loud environments - workers are able to check written instructions if things are forgotten - all personnel can refer back to the written instructions if any thing where to go wrong/ any queries
94
list 6 types of sources for technical information
- Book references - joint service publications - british standards - international standards - parts identification lists - illustrated parts catalogues

151/23/005 (13 decks)

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