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A Level DT Paper 1 > Metal Processes 3.1.4 > Flashcards

Metal Processes 3.1.4 Flashcards

1
Q

What is Sand Casting (Metal Redistribution Process)?

A

suitable for one off productions
USES post boxes wood working clamps
Stock form - Molten metal from billet.

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2
Q

What is hot chamber Pressure die casting (Redistribution process)?

A
  • Molten metal is stored in a chamber and then is forced into a die.
    lower melting point metals - ejector pins
  • Fast process
  • Used for large batch and mass production
    USES - toy cars
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3
Q

What is a metal-forming process?

A

A process in which no material is removed but materials are deformed to produce the required shapes.

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4
Q

What is a metal redistribution process?

A

A process where the material is changed from one form to another without losing material

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5
Q

What is a waste metal Process?

A

Process that cuts away material to leave the desired shape.

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6
Q

What is Press forming (Metal Forming Process)?

A

These are usually products made in aluminium / medium carbon steel, as they are more malleable. Process can be automated and can include trimming
e.g car body containers

die , drawing force , punch

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7
Q

What is Spinning (Metal Forming Process)?

A

USES - kettles lamp shades
use a mandrel, clamp, spindle, and headlock.
pit sheet of metal between the mandrel and clamp. uses a head and tail lock.

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8
Q

What is Cupping (Metal forming process)?

A

start with a metal blank, metal is stretched into shape, high initial tooling cost, continuous production.
USES - cans, aerosol cans tube-like shapes.

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9
Q

What is drop forging (Metal Forming Process)?

A

Used for products that need to be tough and hard
- Hot metal billet shaped on an anvil or die then pressed into shape and cooled.
- suitable for mass production
USES - screwdriver shafts

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10
Q

What is wrought iron forging (Metal forming process)?

A

Uses wrought iron carbon
- Can be hand or hydraulic-pressed
- suitable for one-off or small bat h production
USES - decorative metal work, decorative fencing.

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11
Q

What is the process for Bending (Metal forming process)?

A

Punch a metal into a die using pressure
used for large-scale batches in industry.

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12
Q

What is the process for rolling (metal forming process)?

A

**Hot rolling **- uniform mechanical properties
USES - railway tracks
**Cold Rolling **- material that has a tighter tolerance and better surface finishing.
Cold rolling - cabinets, chairs, steel drums

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13
Q

What is cold Chamber Pressure Die casting (Redistribution Metal process)?

A

same as hot chamber pressure die casting
uses a shot chamber and ladle, ejector pins
USES - toy cards door handles

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14
Q

What is Gravity Die casting (Redistribution Metal process)?

A

Lower melting point metals
Relies on gravity to help metal flow into the mould
- Used for thicker mould section
- Used for large batch and mass production
USES - Allow wheels engine components

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15
Q

What is investment Die casting (Redistribution process)?

A

Used for complex shapes that are hard to mould
- high quality excellent finish
- wax patterns are cast from a master mould
USES - cast jewelry, hip replacement joints.

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16
Q

What is low-pressure die Casting(Redistribution process)?

A

Used for school projects
can be used with simple MDF moulds
Suitable for one production or small batch.
USES - jewelry, key fobs

17
Q

What is MIG welding (Addition process )?
metal inert gas

A

Uses an electrode wire.
- suitable for thin-gauge metals, medium carbon steel or aluminum
- uses inert gas such as co2 or argon
USES - tubular products such as climbing frames, bike frames, and vehicle exhausts.

18
Q

What is TIG welding (Addition process )?
Tungsten inert gas

A

Uses a filler rod
- accurate and strong welds , slow method requires high skill

19
Q

What is Oxy acetylene Welding (Metal addition process)?

A
  • Uses a steel filler rod
  • Useful for quick pair jobs or in remote locations where there Is no electric power supply
20
Q

What is spot welding (metal addition process)?

A

sheet held between two copper electrodes that form a weld when the charged electrodes make contact with the metal.
USES - used to weld steel sheet metals at a point along a length

21
Q

What is Soldering (Metal Addition Process)?

A

Uses a filler material of a lower melting point than the metal being a joint
USES - lightweight applications, jewelry

22
Q

What are temporary fasteners and joining methods (metals)?

A

Temporary fasteners are used where a permanent joining method is not required, or in situations where a product may need to be disassembled or accessed for repair.

23
Q

What are examples of temporary fasterners used for metals?

A

Self-Tapping screws - join thin sheet of metal , a pilot hole is drilled through the metal and the scree cuts its own thread holding the screw together.
Machine screws - Used in machines, hold machine parts together , the thread is the whole length of the shaft.
Nut and bolt - bolts go through metal and a nut is tightened to the end to keep it together

24
Q

What is Milling (Metal Wasting Process)?

A
  • work is clamped down to the table of the machine. The table can move in X Y Z directions to be cut and shaped.
25
Q

What is Turning (Metal Wasting Process)?

A
  • Carried out on a lathe
  • a bar is clamped so it can be held in a rotating chuck and machined to reduce the diameter, and to square or face off the end, thread, and drill.
  • Turning can be done manually or using CNC lathes
  • The material can be moved in and out.
26
Q

What is Flame Cutting ( Wating Process)?

A
  • USes Oxy-aceylene gas and a special flame cutting torch to deliver a very intense and focused flame above 3500 degrees
  • used to cut low carbon and allow steel plate
  • Difficult to maintain a parallel line with high levels od tolerance
27
Q

What is Plasma Cutting (Wasting Process)?

A
  • plasma is a superheated ionised gas that is electrically conductive.
    A plasma cutter will use this conductive gas to transfer the energy from the power supply to a conductive material such as a steel plate.
  • heat burns through the material
  • clean and fast cut
28
Q

What is Punching/ Stamping (Wasting process)

A
  • Using CNC machines to stamp out sections of material
  • uses an upper punch and lower tool die
  • The process is suitable for small and medium size production runs.

A Level DT Paper 1 (35 decks)

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