Metal Proccess

Question 1

What are the 3 processes to make metals ?

Answer 1

Wasting, Redistribution, Addition

Question 2

What are the metal re-distribution processes ?

Answer 2

• Press forming
• Spinning
• Cupping
• Deep drawing
• Forging
• Drop forging
• Bending
• Rolling
• Casting - Sand casting, die casting, investment casting, low temp casting ( pewter )

Question 3

What are the Addition/ fabrication processes ?

Answer 3

● Metal inert gas (MIG) welding
● Tungsten inert gas (TIG) welding
● Spot welding
● Oxy-acetylene welding
● Soldering (soft and hard)
● Brazing
● Riveting
● Temporary Joining methods and fasteners:
- self tapping screws
- machine screws
- nuts and bolts.

Question 4

What are the wasting processes ?

Answer 4

● Milling
● Turning
● Flame cutting
● Plasma cutting
● Laser cutting
● Punching/stamping

Question 5

What does wasting mean ?

Answer 5

Wasting processes shape the object or component by the removal of material.

Question 6

What is press forming ?

Answer 6

This is used to shape SHEET metal into 3d forms

Example products:
Car body panels, cones, metal seats

So there is a die and a sheet of metal is placed over the die and then a block is used to press the sheet of metal over the die and then the metal gets removed from the die

Question 7

What is spinning ?

Answer 7

Circular sheet metal components which are symmetrical about a central axis can be produced by forcing a metal blank onto a rotating former.

You have a rotating former and then you use a roller tool to press the sheet metal onto the former

Question 8

What is cupping ?

Answer 8

Cupping and Deep drawing process’ are used to form tube like shapes such as Fire extinguishers and high pressure aerosol cans.

It’s the same thing as deep drawing however its deep drawing when the depth of the pressed exceeds the diameter

Question 9

What is deep drawing ?

Answer 9

Drawing is a metalworking process which uses tensile forces to stretch metal

Question 10

What is forging ?

Answer 10

Forging is a manufacturing process involving the shaping of metal using localised
compressive forces.

Question 11

What is drop forging ?

Answer 11

Drop forging is a Forging process where
a hammer is raised and then “dropped”
onto the workpiece to deform it according to
the shape of the die.

Question 12

What is bending ?

Answer 12

Metal can be bent cold or hot and sheet metal can be folded in similar way to heated sheet thermoplastics, although it requires specialist high pressure machinery.

Question 13

What is rolling ?

Answer 13

The stock metal is passed through sets of rollers to reduce the thickness of the material.

Question 14

What are the different types of casting ?

Answer 14

Sand casting, Die casting, Investment casting, low temp casting

Question 15

What is sand casting ?

Answer 15

The oldest form of casting and is still widely used today. This involves pouring molten metal into a prepared cavity in a sand mould and allowing it to solidify.

Question 16

What is investment casting ?

Answer 16

Investment casting is also known as the lost wax process. A shell mould is built up around a wax pattern that can be melted away leaving a cavity which is then filled with molten metal.

Question 17

What is die casting ?

Answer 17

Die Casting is the process of forcing molten metal under high pressure into the cavities of steel moulds. The moulds are called dies.

Question 18

What is low temperature casting ?

Answer 18

Metals such as Pewter and Silver can be cast into jewellery and other items using moulds carved or cut into MDF, Cuttlefish, Silicone or Vucanised Rubber.

Question 19

What is metal inert gas (MIG) welding ?

Answer 19

MIG welding is an arc welding process in which a continuous solid wire electrode is fed through a welding gun and into the weld pool, joining the two base materials together.

Question 20

What is Tungsten inert gas (TIG) welding ?

Answer 20

A precise and high quality form of electric arc welding that uses a non-consumable tungsten electrode.

1. TIG generates heat via an arc of electricity jumping from a (tungsten metal) electrode to the metal surfaces you intend to weld.
2. The heat is sufficient to melt the joint edges.
3. The electrode is coated in flux which when
   melted, prevents the joint becoming oxidised.

Question 21

What is spot welding ?

Answer 21

Spot welding (also known as resistance spot
welding) is a resistance welding process.
This welding process is used primarily for welding two or more metal sheets together by applying pressure and heat from an electric current to the weld area.

Question 22

What is Oxy-acetylene welding ?

Answer 22

Oxyacetylene welding, commonly referred to as gas welding. It is commonly used to permanently join mild steel. This type of welding is suitable for the prefabrication of steel sheet, tubes and plates.

Question 23

What is soldering

Answer 23

Soldering is a technique used to join two or more metal items together by melting and flowing a filler metal (solder) into the joint.

Different soldering tasks require different temperature levels based on the materials being joined and the type of solder being used.