Module 2- ferrous metasl manufacturing

Question 1

What are the benefits of Hot Working

Answer 1

Good strength, it is quick, good ductility and toughness

Question 2

What is Cold Working?

Answer 2

Cold working is working under the recrystalization and recovery point of the metal.

Question 3

What is hot working

Answer 3

a manufacturing process that takes place above the recrystallization process.

Question 4

Advantages of Cold working

Answer 4

Increased Strength
Increased Hardness
Improved Surface Finish

Question 5

Disadvantages of Cold Working

Answer 5

HIgher Energy required and expensive

Question 6

What is the downside of Hot working

Answer 6

Bad dimensional accuracy

Question 7

What is Forging?

Answer 7

The compression of a metal held at an elevated temperature

Question 8

What is sand casting?

Answer 8

Sand casting is a metal casting process where sand is used to create a mold for pouring molten metal, allowing for the production of complex shapes. It’s popular for its versatility and low cost but may require post-casting finishing for precision.

Question 9

What is die casting?

Answer 9

a process that involves the injection of molten metal under pressure into a metal die or mould

Question 10

What’s cold rolling?

and what does it do to the material/grain structure

Answer 10

Cold rolling is a metalworking process that involves the rolling of metal at room temperature to reduce its thickness and improve its strength and surface finish.

It elongated the grain, Induces Residual Stresses and increases the strength of the material.

Question 11

What’s hot rolling?

and what does it do to the material/grain structure

Answer 11

Hot rolling is where metal is heated above its recrystallization temperature and rolled to desired thickness and shape, making it more ductile and easier to shape.

It’s cost-effective and improves the toughness. Hot rolling restores the original grain structure.

Question 12

What’s welding?

Answer 12

Welding is a fabrication process that joins materials, by melting the parts together and allowing them to cool, forming a strong joint.

Question 13

What is extrusion?

Answer 13

Extrusion is a manufacturing process where a material, often a metal or plastic, is forced through a die to produce a continuous profile with a fixed cross-sectional shape.

Question 14

What is powder forming?

Answer 14

Powder forming, also known as powder metallurgy, is a manufacturing process where metal powders are compacted into a desired shape using high pressure and then sintered at elevated temperatures to bond the particles together.

Question 15

What does Forging do to ferrous metals.

Answer 15

It improves the mechanical properties of ferrous metals by aligning the grain structure, increasing strength, toughness, and resistance to impact and fatigue.

forging enhances the material’s structural integrity and refines its microstructure, resulting in better performance under high-stress conditions.

Question 16

What does Casting do to ferrous metals?

Answer 16

It produces ferrous metal components with complex shapes but may result in coarse grain structures.

Question 17

What does Extrusion do to ferrous metals?

Answer 17

It elongates the grain structure of ferrous metals, aligning them along the extrusion direction, which enhances mechanical properties such as strength, ductility, and fatigue resistance.

Question 18

What does Powder forming do to ferrous metals?

Answer 18

This process creates ferrous metal components with fine and uniform grain structures, resulting in improved mechanical properties, such as strength, hardness, and wear resistance.