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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
Q

what are some uses of magnesium?

A

casting and forged components for aircrafts

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26
Q

what are some uses of tin?

A

plain bearings
thin coating on mild steel

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27
Q

what are some uses of lead?

A

radiation shields
roofing material

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28
Q

what are some uses of zinc?

A

roofing materials
sacrificial anode on ships hull

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29
Q

what are some uses of naval brass?

A

nuts bolts washers
fresh water valves

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30
Q

what are some uses of tungum?

A

high pressure air and hydraulic pipe systems

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31
Q

what are some uses of phosphor bronze?

A

heavy duty bearings and gears

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32
Q

what are some uses of gunmetal?

A

seawater valves

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33
Q

what are some uses of nickel aluminium bronze?

A

small boat propellers
pump impellers

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34
Q

what are some uses of magnesium bronze?

A

propellers
casting

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35
Q

what are some uses of monel metal?

A

pump shafts
general marine hardware

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36
Q

what are some uses of nimonic 80?

A

gas turbine rotors and blades

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37
Q

what are the advantage as of using plastics?

A

low densities
ease of moulding
damps out vibration
good electrical insulation

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38
Q

what are the disadvantages of using plastics ?

A

low strength, rigidity and shock resistance
low service temperature
soft and scratch easily

39
Q

what are the uses of perspex?

A

machine guarding
pressure gauge and instrument faces

40
Q

what are some uses of nylon?

A

gears
bearings
ropes

41
Q

what are some uses of PTFE?

A

pumps seals and gaskets

42
Q

what are some uses of tufnol?

A

gears
non-conductive jigs and fixtures

43
Q

what are some uses of melamine?

A

aircraft and distributor parts
handles for electrical equipment

44
Q

what are some uses of epoxy resin ?

A

sealing and encapsulating of electrical equipment
moulded components

45
Q

what are the three reasons we test materials?

A
  • research, design and development
  • quality control
  • investigation of failures
46
Q

what are the three types of fundamental stress?
and draw them

A
  • tensile stress
  • compressive stress
  • shear stress
47
Q

what is the definition of hooks law?

A

witching the elastic range, the strain produced, is directly proportional to the stress producing it

stress/strain = constant

48
Q

what is the definition of creep?

A

creep is the progressive deformation of a material under constant load over an extended time period

49
Q

what is the definition of fatigue ?

A

fatigue is caused by cyclical stress. where a material is repeatedly bent or twisted back and fourth or repeatedly stretched then squashed

50
Q

what methods are used to prevent fatigue?

A
  • good design
  • improved surface finishes
  • avoid corrosion
  • surface harden
51
Q

what are the 4 methods of corrosion protection ?

A
  • desgin
  • environment
  • coating
  • galvanic protection
52
Q

what methods of protection can you use on the ships hull?

A
  • paint the ships hull
  • sacrificial anodes
  • good design
  • controlling moisture levels
53
Q

what are the four heat treatment processes ?

A

annealing
normalising
hardening
tempering

54
Q

explain how hardening is done

A

the material is heated to above the upper critical temperature and the quenched

55
Q

explain how tempering is done

A

the material is heated to a specific temperature below the lower critical temperature and then is quenched

56
Q

explain how annealing is done

A

the material is heated to a specific temperature below the lower critical temperature and then allowed to cool in a controlled manner

57
Q

explain how normalising is done

A

the material is heated up to just above the upper critical temperature and then allowed to cool in air

58
Q

define stress?

A

stress applied = applied force(N)/ cross sectional area (mm2)

59
Q

define strain?

A

strain = change in length / original length

60
Q

what two properties will sand casting metals have?

A

a relatively low melting point
good fluidity

61
Q

explain the process for sand casting

A
  • 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
Q

what are some uses of sand casting?

A

gear blanks
valve chests
angle plates

63
Q

what are some advantages of sand casting?

A
  • cheap
  • quick turn around
    -easy to modify
64
Q

what are some disadvantages of sand casting?

A

not suitable for mass production
rough surface finish
mould is one use only

65
Q

name three type of casting

A

sand casting
die casting
investment casting

66
Q

what are some properties of die casting material?

A

low melting point alloys

67
Q

what is the main difference between sand casting and die casting?

A
  • sand casting uses a one off mould
  • die casting uses a reusable mould
68
Q

explain the process of pressure die casting

A
  • 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
Q

name some uses of pressure die casting

A

engine pistions
fuel pump bodies

70
Q

explain the process of investment casting

A
  • 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
Q

name some uses of investment casting

A

gas and jet engine blades, cams, nozzles and valves

72
Q

list some advantages of investment casting

A

dimensional accuracy
good surface finish
minimal is any final machining

73
Q

explain hand forging

A
  • 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
Q

list some advantages of hand forging

A

uses less raw material than machine components from solid stock
is 3 times stronger than machined components

75
Q

list some disadvantages of hand forging

A

slow and labour intensive
expensive
high degree of skill level required
not suitable for mass production

76
Q

list some uses of drop forging

A

connnecting rods
crank shafts
spanner’s

77
Q

name some types of hardness tests

A

brunel hardness test
vickers dimond hardness test
rockwells hardness test

78
Q

name the two subdivision of joining processes and give some examples

A

permanent joining processes- riveting, welding, hard and soft soldering, brazing
temporary joining processes - nuts, bolts, screws, studs

79
Q

draw three types of rivets

A
80
Q

label the electrical arc welding diagram

A
81
Q

what two things dose the electrode coating provide?

A
  • creates a slag layer to stop it cooling rapidly
  • provides a protective gas to prevent oxidation
82
Q

explain the process of soldering

A
  • 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
Q

name three types of adhesives

A

expoxies
cyanoacrylates
anaerobics

84
Q

define what a screw thread is

A

a screw thread is a helical groove cut around or inside a cyclinder

85
Q

draw a screw thread
include these labels:
- major diameter
- minor diameter
- pitch

A
86
Q

give some examples of a an application of a left hand thread

A

hose connection threads of acetylene on welding torch
bottle screw
cable tensioner

87
Q

when dose a component have good quality?

A

a component has good quality when it meet requirements

88
Q

what’s the main goal of a quality assurance system ?

A

the main goal of a quality assurance system is to ensure that the product fulfils or exceeds the expectations of the customer

89
Q

name three things which you’d expect as a costumer buying a product

A
  • predictable, effective and reliable operating life
  • spare parts will be readily available
  • these parts will be interchangeable with the existing equipment
90
Q

what is there international quality standard ?

A

ISO 9000

91
Q

what do you do if a product is nonconforming to requirements?

A
  • 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
Q

give three examples of 2 part assesmelys that are interchangeable

A

small end bearing/gugien pin
piston/ piston rings
connecting rod/ big end bearing

93
Q

what are the benefits of using written instructions?

A
  • 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
Q

list 6 types of sources for technical information

A
  • Book references
  • joint service publications
  • british standards
  • international standards
  • parts identification lists
  • illustrated parts catalogues

151/23/005 (13 decks)

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