MATEPRO Module 3

Question 1

Involves the use of molten
material, usually metal. This molten material is then poured into a mold cavity
that takes the form of the finished part.

Answer 1

Casting Process

Question 2

A wax or thermoplastic pattern is used to create a ceramic mold. Molten metal is then poured into the mold, replacing the wax or plastic pattern

Answer 2

Investment Casting

Question 3

It uses expandable polystyrene (EPS) foam patterns that are coated with a refractory material. The foam pattern is placed in sand, and molten metal is poured into the mold.

Answer 3

Lost Foam Casting

Question 4

Involves carefully controlling the solidification process to ensure that a single crystal structure is formed, which provides exceptional mechanical properties.

Answer 4

Single Crystal Casting

Question 5

A metal alloy is heated until it melts and then forced through a spinneret with fine holes. The molten metal is rapidly cooled as it exits the spinneret, forming a solid ribbon or filament.

Answer 5

Melt Spinning Process

Question 6

Pattern/Design is imprinted into a mold filled with sand to form mold cavity where liquid metal will be poured

Answer 6

Sand casting

Question 7

Sand and resin mixture is used to coat/invest the design/pattern to serve as mold cavity.

Answer 7

Shell Mold Casting

Question 8

The mold cavity is made using ceramic slurry and refractory materials. Good precision

Answer 8

Ceramic Mold Casting

Question 9

Involves pouring molten metal into a mold where it cools and solidifies. The mold is then opened, the casting removed, and the mold is reused.

Answer 9

Permanent Mold Casting

Question 10

Similar with permanent molding but focusing more on small to medium-size parts that are made up of non-ferrous metals like zinc, aluminum, and magnesium.

Answer 10

Die Casting

Question 11

A method to produce pipes by pouring molten metal into a rapidly spinning cylindrical mold in which centrifugal force from the rotation exerts pressure on the molten metal

Answer 11

Centrifugal Casting

Question 12

Pressure is implemented immediately after the liquid alloy starts to solidify and is kept on until the entire casting has solidified

Answer 12

Squeeze Casting

Question 13

Involve changing the shape of a material by applying forces and stresses, typically
through compression or extension. These processes are used for shaping large pieces of material, like metal, plastic, or ceramics, into desired forms.

Answer 13

Bulk Deformation Process

Question 14

Reduces the thickness of a metal sheet or strip by passing it through a pair of rollers to create a flat, uniform product.

Answer 14

Flat Rolling

Question 15

A heated metal workpiece is passed through a series of rollers to change its cross-sectional shape, often used for producing profiles like I-beams or railroad tracks.

Answer 15

Shape Rolling

Question 16

A technique for shaping metal rings or hollow cylinders by reducing their diameter through radial compressive forces, commonly employed in manufacturing parts like bearings, flanges, and gear blanks.

Answer 16

Ring Rolling

Question 17

Metal bars or billets are subjected to compressive forces between two rolls, leading to the desired change in shape and size, often used in the production
of long, cylindrical parts such as shafts and axles.

Answer 17

Roll Forging

Question 18

The workpiece is hammered or pressed between flat dies to deform it into a desired shape, typically used for
producing large, non-specific, and often irregularly shaped metal parts.

Answer 18

Open Die Forging

Question 19

Involves the use of two or more dies with specific shapes to compress a workpiece into a precise and intricate shape, suitable for manufacturing high-
precision components.

Answer 19

Closed Die Forging

Question 20

A cold-working metal forming process used to reduce the diameter of a rod, wire, or tube and create a head, often employed in the production of fasteners like screws and bolts

Answer 20

Heading

Question 21

Involves creating a hole or opening in a solid metal workpiece using a punch and die set, commonly utilized to manufacture items like pipes and tubing with hollow sections.

Answer 21

Piercing

Question 22

A solid rod or billet is pushed through a die to create a
desired shape or profile, with the material following
the same direction as the force applied

Answer 22

Direct Extrusion

Question 23

A specialized form of direct extrusion that is used to produce thin, intricate gold wires, often employed in jewelry making and electronics

Answer 23

Gold Extrusion

Question 24

Metal or wire, is pulled through a die to reduce its diameter and increase its length, resulting in a thinner and longer product.

Answer 24

Drawing

Question 25

A specific type of drawing process used to reduce the diameter and wall thickness of a tube or pipe, often employed in the manufacturing of precision tubes

Answer 25

Tube Drawing

Question 26

Involve a variety of techniques for shaping, cutting, bending, and forming thin metal sheets into desired shapes and components.

Answer 26

Sheet Metal Process

Question 27

Cutting a flat sheet to create a specific shape or outline, producing a single piece of material with precise dimensions, which can serve as the initial workpiece for further manufacturing processes

Answer 27

Blanking

Question 28

Cutting a metal coil or sheet into narrower strips or coils, typically for the purpose of creating materials with reduced width or for further processing, such as roll forming.

Answer 28

Slitting

Question 29

Involves using a punch and die set to create holes, notches, or openings in a metal sheet or workpiece, often employed for creating functional features or fastening points in sheet metal components.

Answer 29

Punching

Question 30

Material is removed from a metal workpiece to form holes, slots, or other openings, commonly used in sheet metal processing to introduce ventilation, fastening points, or decorative features into the material.

Answer 30

Piercing

Question 31

The deformation of a metal sheet along a straight axis to create bends or angles, typically achieved using a press brake, and it's used to shape the sheet into various geometric forms

Answer 31

Bending

Question 32

A specific bending technique where the edge of a metal sheet is folded back onto itself, creating a closed, smooth, and safe edge that is commonly used in applications like automotive body panels.

Answer 32

Hemming

Question 33

A continuous metal shaping process that involves passing a long strip of metal through a series of rollers with specific profiles to gradually form it into a desired cross-sectional shape, often used for producing items like structural components, profiles, or rails.

Answer 33

Roll Forming

Question 34

A flat sheet of metal is drawn into a three- dimensional shape, typically a cup or cylindrical container, using a punch and die set.

Answer 34

Deep Drawing

Question 35

A metal sheet is clamped around its edges and stretched over a die to form it into a desired shape, often used for creating curved or contoured parts with high precision.

Answer 35

Stretch Forming

Question 36

Uses hydraulic fluid pressure to shape a metal sheet into a die, enabling the production of complex and lightweight components, particularly in the automotive and aerospace industries.

Answer 36

Hydroforming

Question 37

Involves rotating a flat sheet or tube of metal while applying pressure to form it into a cylindrical or conical shape, typically used for producing items like cookware, lampshades, and aerospace components

Answer 37

Spinning

Question 38

Uses electromagnetic forces to shape a metal workpiece by subjecting it to a high-intensity magnetic field in a very short time, enabling rapid and precise forming of parts with minimal material thinning.

Answer 38

Magnetic pulse forming

Question 39

Manufacturing techniques used to shape and manipulate polymers, which are large molecules composed of repeating subunits to create various plastic and composite products

Answer 39

Polymer Processing

Question 40

Heated polymer material is forced through a die to produce a continuous, uniform profile or shape, often used for creating items like plastic pipes, films, and sheets

Answer 40

Extrusion

Question 41

Melted thermoplastic material are injected into a mold cavity, allowing it to cool and solidify to form a specific shape

Answer 41

Injection Molding

Question 42

A hollow, heated plastic parison (thermoplastic hollow tube) is inflated like a balloon within a mold to take its shape, frequently used for producing items with hollow sections, such as bottles and containers

Answer 42

Blow Molding

Question 43

Involves heating a thermoplastic sheet until it is soft and pliable, then forming it over a mold using vacuum or pressure to create three-dimensional shapes

Answer 43

Thermoforming

Question 44

Continuous fibers are impregnated with a thermosetting resin and then pulled through a heated die to create products with a consistent cross-sectional shape, such as rods, tubes, or profiles

Answer 44

Pultrusion

Question 45

Involves placing the material in a mold and sealing it within a flexible vacuum bag. Vacuum pressure is applied to remove air and compact the material to the desired shape before curing, resulting in strong, lightweight components.

Answer 45

Vacuum bag forming

Question 46

Involves melting the thermosetting material in a separate chamber and then forcing it into a closed mold cavity where curing occurs under pressure, suitable for manufacturing products with intricate details and complex shapes.

Answer 46

Transfer Molding

Question 47

Uses a laser to solidify layers of liquid photopolymer resin one at a time, creating a three-dimensional object layer by layer, often used for producing high- resolution, detailed prototypes

Answer 47

Stereolithography

Question 48

A thermoplastic filament is heated and extruded through a nozzle, layer by layer, to build up a model, making it a widely accessible and cost-effective method for creating prototypes and functional parts

Answer 48

Fused Deposition Molding

Question 49

Digital models are translated into physical objects by adding material layer by layer, offering flexibility in material choices and applications.

Answer 49

Three-dimensional printing

Question 50

Involves layering and bonding sheets of paper, plastic, or other materials, which are then cut and shaped using a laser or knife, to create a 3D model, often used for creating full-color prototypes and functional parts with relatively low-cost materials

Answer 50

Laminated object manufacturing

Question 51

Involves combining two or more separate components or materials to create a unified structure, often through methods like welding, soldering, adhesive bonding, and mechanical fastening

Answer 51

Joining Processing

Question 52

A welding process where an electrode coated with a flux is used. The electrode is melted to create an arc that joins the workpieces together while the flux shields the molten weld pool from contamination

Answer 52

Shielded Metal Arc Welding

Question 53

Employs a continuously fed wire electrode and a shielding gas to protect the welding area from atmospheric contamination. It is commonly used in various industries for its speed and versatility in joining materials like steel, aluminum, and stainless steel

Answer 53

Gas Metal Arc Welding

Question 54

Uses a continuously fed tubular electrode with a flux core. It can be used with or without shielding gas, making it suitable for outdoor and high-wind conditions, and it is often employed in heavy construction and shipbuilding.

Answer 54

Flux-cored Arc Welding

Question 55

Uses a non-consumable tungsten electrode and a separate filler material when necessary. The weld area is shielded with an inert gas, typically argon, making it ideal for applications where precision and control are crucial

Answer 55

Gas-Tungsten Arc Welding

Question 56

Uses a rotating, non-consumable tool to generate frictional heat between the workpieces, which are then joined together without melting, making it ideal for materials that are difficult to weld by traditional methods.

Answer 56

Friction Stir Welding

Question 57

Involves the joining of metals by applying pressure and passing an electrical current through the materials at the joint. This localized heating fuses the workpieces together

Answer 57

Resistance Welding

Question 58

Joining dissimilar metals by creating a high-velocity impact at the interface between the two materials using explosives. The intense pressure and heat generated result in a metallurgical bond, making it possible to join metals that would be challenging to weld by conventional methods.

Answer 58

Explosion Welding

Question 59

Two clean metal surfaces are pressed together at room temperature, creating a molecular bond.

Answer 59

Cold Welding

Question 60

Involves the use of adhesives or glues to join materials by forming a strong bond at the interface. This method is used in a wide range of industries for joining materials that may not be easily welded, such as composites or dissimilar materials

Answer 60

Adhesive Bonding

Question 61

Involves using bolts, screws, or other mechanical fasteners to join two or more components by clamping them together.

Answer 61

Bolted Connection

Question 62

A soldering process used primarily in electronics manufacturing. Components are placed on a printed circuit board, and the board is passed over a wave of molten solder, which solders the components to the board as it passes over the wave, creating electrical connections

Answer 62

Wave Soldering

Question 63

Uses a filler metal with a lower melting point than the base metals being joined. The filler metal is heated to its melting point and flows into the joint, forming a metallurgical bond between the materials

Answer 63

Brazing

Question 64

Involves removing material from a workpiece to create a desired shape or finish

Answer 64

Machining

Question 65

Involves post-machining operations to improve the appearance, functionality, or durability of a machined part or product.

Answer 65

Finishing Processes

Question 66

A workpiece is rotated while a cutting tool removes material to create cylindrical or conical shapes. It is commonly used for creating cylindrical parts like shafts and pins

Answer 66

Turning

Question 67

A machining operation that creates round holes in a workpiece by rotating a cutting tool called a drill bit

Answer 67

Drilling

Question 68

Uses rotary cutters to remove material from a workpiece, creating a variety of shapes, slots, and complex features.

Answer 68

Milling

Question 69

Uses a special cutting tool called a broach to remove material progressively, creating features like keyways, splines, or other irregular profiles in a workpiece. It's often used for applications requiring high precision and close tolerances

Answer 69

Broaching

Question 70

Uses a thin, electrically conductive wire to erode material from a workpiece through a series of electrical discharges, creating highly precise and complex shapes

Answer 70

Wire EDM (Electrical Discharge Machining)

Question 71

Selectively removes material from a workpiece by immersing it in a chemical etchant. It is employed for producing intricate patterns or etching on metal parts and is widely used in the production of aerospace components and electronic circuits

Answer 71

Chemical Machining

Question 72

Utilizes a focused laser beam to cut, engrave, or ablate material from a workpiece. It is employed in various industries for precise cutting, marking, and drilling of materials such as metals, plastics, and ceramics

Answer 72

Laser Machining

Question 73

Uses a high-pressure stream of water mixed with abrasive particles to remove material from a workpiece. It is suitable for cutting a wide range of materials, including metals, composites, and ceramics, with minimal heat-affected zones and environmental benefits.

Answer 73

Water Jet Machining

Question 74

A grinding wheel with abrasive grains is used to remove material from the surface of a workpiece, producing a flat and smooth finish. It is commonly used to achieve tight tolerances and excellent surface quality on metal and non-metal materials.

Answer 74

Surface Grinding

Question 75

A machining process that does not require a center point, and it involves feeding a cylindrical workpiece through two abrasive grinding wheels

Answer 75

Centerless Grinding

Question 76

Involves rubbing two surfaces together with abrasive slurry in between. It is used to create highly accurate and flat surfaces, often in the manufacturing of optical components and precision gauges

Answer 76

Lapping

Question 77

Uses electrochemical reactions to remove a thin layer of material from the surface of a workpiece. It's employed to enhance the smoothness and appearance of metal surfaces, such as stainless steel or aluminum, for applications like food processing equipment and medical devices.

Answer 77

Electrochemical Polishing