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Second Year Welding > Production Of Metals > Flashcards

Production Of Metals Flashcards

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Welding Inspection Basics flashcards
1
Q

Ingredients in a blast furnace

A

Iron ore, coke, limestone

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2
Q

Coke is….

A

Refined coal.

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3
Q

Blows oxygen rich air to remove carbon as CO2 that bubbles out (blast furnace)

A

Tuyeres

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4
Q

Pig iron

A

4-5 percent carbon
Raw ingredient

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5
Q

Cupola furnace

A

Charged with pig iron and scrap cast iron. (Makes cast iron)

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6
Q

Main hardening agent in steel

A

Carbon

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7
Q

Induction furnace

A

Makes cast iron
Uses electricity instead of fire

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8
Q

Basic oxygen steel making furnace (bos)

A

Loaded with 70-80 percent scrap steel and molten pig iron

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9
Q

Electric arc furnace

A

Graphite electrodes
Controlled environment
Highest quality steel and alloys
Carefully selected scraps

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10
Q

Tundish

A

A reservoir with a drain
(Continuous casting process)

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11
Q

Hot rolled steel

A

Formed while hot
Mill scale
Rounded corners
Greater ductility
Less exact dimensions

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12
Q

Cold rolled

A

Formed below lower critical temp
Shiny and smooth
Sharp corners
Greater strength
Precise dimensions

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13
Q

Carbon content in
Pig iron…..
Cast iron….
Steel…

A

Pig iron: 4-5 %
Cast iron: 2-4.5%
Steel max: 2%

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14
Q

Grey cast iron

A

2.5-4%
Brittle
Extreme hardness
Absorbs vibration
Excellent wear resistance

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15
Q

White cast iron

A

Grey cast iron poured into a chilled mold
Harder and more brittle than grey
Better wear resistance than grey cast

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16
Q

Malleable cast iron

A

Annealed white cast iron
Has a small amount of ductility
(Plumbing fittings)

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17
Q

Ductile cast iron

A

Highest strength and ductility of cast irons
Alloyed with rare earth elements and manganese
(Valves and crankshafts)

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18
Q

0.05 - 0.30 carbon content

A

Low carbon

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19
Q

0.30 - 0.45 carbon content

A

Medium carbon

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20
Q

0.45. - 0.75 carbon content

A

High carbon

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21
Q

0.75 - 1.50 carbon content

A

Very high carbon

22
Q

Killed steel

A

Fully deoxidized
Highest quality

23
Q

Semi killed

A

Some deoxidizers added
Medium quality

24
Q

Rimmed

A

No deoxidizers added
Lowest quality

25
Q

Capped

A

No deoxidizers added
Cap added to slow cooling
Slightly better than rimmed

26
Q

With the basic oxygen steel making process what is the purpose of blowing in oxygen

A

To combine with the carbon

27
Q

What is the continuous casting process

A

Where molten metal is solidified into billets, blooms, blanks, rounds or slabs
From a ladle to a tundish then to continuous casting

28
Q

What is the carbon content for cast irons

A

2 - 4.5%

29
Q

Highest strength and ductility
Crankshafts and valves
Alloyed with rare earth elements and manganese (which cast iron)

A

Ductile or nodular cast iron

30
Q

Used as a flux in the blast furnace to help remove impurities

A

Limestone

31
Q

Pig iron is refined to produce either …

A

Cast iron or steel

32
Q

Process where molten steel is solidified into billets, blooms, blanks, rounds or slabs…

A

Continuous casting
(Improve yield, quality, productivity and cost efficiency)

33
Q

Based on the deoxidization process, what are the four classes of steel

A
  1. Rimmed
  2. Capped
  3. Semi killed
  4. Killed
34
Q

Which metal leaves the steel making furnace and is poured into a mould that is in the shape of the final product

A

Cast iron

35
Q

4 types of cast iron

A
  1. Grey
  2. White
  3. Malleable
  4. Ductile or nodular
36
Q

Why is limestone added to the blast furnace

A

To act as a flux to remove impurities

37
Q

Engine blocks, tools, machinery and fly wheels are made from which cast iron

A

Grey

38
Q

Two main ing in steel are

A

Iron and carbon

39
Q

Level of quality in deoxidization process

A
  1. Killed - fully deoxidized
  2. Semi killed - some deoxidizers added
  3. Capped - no deoxidizers added cap added to slow cooling
  4. Rimmed - no deoxidizers
40
Q

Which cast iron is crushing and grinding equipment

A

White cast iron
Better wear resistant more brittle than gray, rapidly cooled not weldable

41
Q

Which cast iron is annealed, rounded carbon particles, greater ductility ex plumbing fittings

A

Malleable cast iron

42
Q

Which steel making process is commonly used for making high quality alloy and tool steels

A

An electric arc furnace

43
Q

The first step in separating the iron from the oxygen in the naturally occurring iron ore

A

Blast furnace

44
Q

Carbon content in coke

A

98 %

45
Q

Molten metal starts to cool and gets a thin shell of solidified metal in outside the middle is still molten and is now called

A

A strand

46
Q

Why is continuous casting preferred to stationary moulds

A

Increase control through automation
Lower cost
Improve yield
Quality productivity

47
Q

5 types of moulds

A

Billets
Blooms
Blanks
Rounds
Slabs

48
Q

Which type of cast iron has extreme hardness due to rapid cooling

A

White cast iron

49
Q

Which type of cast iron has the highest strength and can be used for making valves

A

Ductile or nodular cast iron

50
Q

Which type of cast iron undergoes an annealing process

A

Malleable cast iron

51
Q

What is the carbon content range for steels

A

Less than 2 %

52
Q

What is rimmed steel used for

A

Core wire, electrodes, bar stock, plate and some structural steel

Second Year Welding (13 decks)

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