Metals

Question 1

______ employed for various engineering purposes and requirements
________ is the most popular metal in the field of engineering
 ALL the metals have a _______

Answer 1

metals
 iron
crystalline structure

Question 2

________ is a mixture or compound of two or more elements, at least one of
which is metallic
 ______ enhances some properties, as required by engineering applications,
such as strength and hardness in comparison to pure metals
 Classified into _________ and ________

Answer 2

An alloy
Alloying
solid solution and intermediate phase

Question 3

__________
atoms of solvent element are
replaced in its unit cell by
dissolved element.

Answer 3

Substitutional solid solution

Question 3

________ is an alloy in which one element is dissolved in another to form
a single-phase structure
 In a solid solution, the solvent or base element is _______, and the dissolved
element can be either _________
 Solid solutions can be __________ or ____________

Answer 3

Solid solution
metallic
metallic or nonmetal
Substitutional Solid Solution or Interstitial Solid Solution

Question 4

_________ atoms
of dissolving element fit into
vacant spaces between base
metal atoms in the lattice
structure.

Answer 4

Interstitial solid solution -

Question 5

There are usually limits to the solubility of one
element in another. When the amount of the dissolving element in the alloy
exceeds the solid solubility limit of the base metal, _________ fo______ is used to describe it because its
chemical composition is intermediate between the two pure elements. Its
crystalline structure is also different from those of the pure metals.

Answer 5

a second phase
intermediate phase

Question 6

IMPORTANCE OF METALS
 _________ – can be alloyed for high rigidity, strength, and
hardness
 ________ – capacity to absorb energy better than other classes of materials
 ________ – metals are conductors
 ___________ – conduct heat better than ceramics or polymers
____ – the price of steel is very competitive with other engineering materials

Answer 6

High stiffness and strength
Toughness
Good electrical conductivity
Good thermal conductivity
Cost

Question 7

METALS USED IN MANUFACTURING PROCESS
 _______ - starting form is a casting
 _________ - the metal has been worked or can be worked
after casting
 _________ - starting form is very small powders for
conversion into parts using powder metallurgy techniques

Answer 7

Cast Metal
Wrought Metal
Powdered Metal

Question 8

CLASSIFICATION OF METALS
___________
 These metals contain iron as main constituent
are classified as cast iron, wrought iron, and steel depending
upon ingredients and percentage of carbon content
____________
 These metals practically do not contain iron

Answer 8

FERROUS METALS
NON-FERROUS METALS

Question 9

_______ contains a higher percentage of carbon ranging from _______
________ is manufactured by melting of pig Its properties
1. It can be hardened by heating and sudden cooling, but it cannot be tempered.
2. It does not rust easily.
3. It is fusible.
4. It is hard and at the same time brittle.

Answer 9

Cast Iron
2 to 4.23
Cast Iron
CUPOLA.

Question 10

Cast Iron (C.I.) Classification
1. ___________ - The carbon content is about ____ ad when fractured gives a
grey appearance. It is soft and readily melts. Its strength is weak and is used
for casting cylinders, pistons, manholes etc.
2. _________ - Its carbon content is ______. It contains carbon in
chemical form and on fracturing gives silver white luster. It is hard, not
workable on machines and is used for preparing pump liners, drawing dies
etc.,
3. ___________ its carbon content is 3.3%. It is produced by casting the
molten metal against a metal chiller to obtain a surface of white cast iron.
This is hard to a certain depth from the outer surface, which indicates the
white iron. The inner portion of the body is made up of grey iron which is soft.
It is used for manufacturing rail car wheels, dies, sprockets etc.

Answer 10

Grey Cast Iron
3%
White Cast Iron
2.0 to 2.5%.
Chilled Cast Iron

Question 11

4. ___________- Its carbon content is __. The composition of this is
   so adjusted that it becomes malleable. It is done by extracting a portion of
   carbon from cast iron. It has high field strength and used for manufacture of
   automobile and railway equipment such as rail cars, crank shafts gear boxes
   etc.
5. _________- It is obtained by melting cast-iron with wrought iron
   scrap. The proportion of wrought-iron scrap is about _________ of cast-iron.

Answer 11

Malleable Cast Iron
2.3%
Toughened Cast Iron
1/4 to 1/7th

Question 12

It is an almost pure iron. Its carbon content is 0.15%

Stages
_____________________

Properties
1. It is _____ at white stage of heat. It can be easily forged and welded.
2. It is ductile, malleable and tough.
3. Its melting point is ________
4. It is resistant to ________.

Answer 12

Wrought Iron
Refining-Puddling-Shingling-Rolling

soft
1500°C.
corrosion

Question 13

__________ is defined as the iron alloy with a carbon content of up to ____%.
Types of steel include low carbon steel or mild steel, medium carbon
steel, and high carbon steel.

Answer 13

Steel
2.0

Question 14

__________ 0.10 to 0.3%  It can be easily hardened and
tempered
 It is malleable and ductile
 It can be forged and welded
 It rusts easily
 Specific gravity is ___
Sheets, Tin Plates

Answer 14

Low Carbon or Mild
7.8

Question 16

________ 0.3 to 0.6% These steels have high strength,
toughness, hardness and stiffness
Boiler plates, Railway
tyres, pressing dies

Answer 16

Medium Carbon

Question 17

________ 0.6 to 1.50%  It can be easily hammered and tempered
Specific gravity is ___
 It can be magnetize permanently
 It is granular in structure
Springs, Hammers,
Drills, Chisel

Answer 17

High Carbon
7.9

Question 18

Steel, to which elements other than carbon are added in sufficient quantity, in
order to obtain special properties, is known as _______.
Examples of alloy steels include chromium steel, cobalt steel, manganese steel,
tungsten steel, vanadium steel and Nickel steel.

Answer 18

Alloy Steel

Question 19

__________ - Chromium up to ____
Vanadium up to _____
Highly ductile, can be easily
worked and welded
Used for locomotive springs,
pistons and bolts

Answer 19

Chromium Steel
0.9%,
0.15%

Question 20

__________ Cobalt is added to high
carbon steel
Possesses magnetic
properties
Used for making permanent
magnet with strong
magnetic field

Answer 20

Cobalt Steel

Question 21

__________ Manganese up to _____ It is hard, strong and ductile.
It gives resistance to
abrasion.
Used for gears

Answer 21

Manganese Steel
1.90%

Question 22

_________
Tungsten content up to _____ It is hard and maintains
cutting power at high
temperature
Used for lathe tools, drill
cutters

Answer 22

Tungsten Steel
or High Speed
Steel
7%

Question 23

________ Nickel up to ____ It is hard and ductile Used for boiler plates,
structural steel propeller
shafts

Answer 23

Nickel Steel
3.5%

Question 24

________ Vanadium content up to 0.2% Strong and ductile, elastic limit is high, resists shocks Used for automobile parts, springs

Answer 24

Vanadium Steel

Question 25

NON-FERROUS METALS _________  It is a very light and useful non-ferrous metal. It is produced mainly from bauxite which is hydrated oxide of aluminum. Properties 1. a tin white metal. 2. good conductor of heat and electricity. 3. malleable, ductile and very light. 4. highly electro positive element. Uses 1. For manufacturing of electrical conductors. 2. Making alloys. 3. For manufacture of cooking utensils, surgical instruments, etc. 4. For making parts of air crafts. 5. In manufacture of paints

Answer 25

Aluminum

Question 26

_____ is one of the most useful non-ferrous metals. It occurs in nature in a free state as well as combined state. Properties 1. Bright shining metal of reddish color. 2. high tensile strength. 3. very malleable and ductile. 4. a good conductor of heat and electricity. 5. It melts at 1083°C Uses 1. For the manufacture of electrical cables and wires and lightning conductors. 2. For making alloys. 3. For house hold utensils. 4. For bolts and nuts. 5. For tubes, etc.

Answer 26

Copper

Question 27

NON-FERROUS METALS ___ is a very important non-ferrous metal which is obtained from ore, tin pyrites or tinstone. Properties 1. When a bar of tin is bent, a peculiar noise takes place which is known as a cry of tin. 2. white metal with brilliant luster. 3. soft and malleable. 4. withstands corrosion due to acids. 5. melts at 232°C. Uses 1. Used for plating. 2. For lining and lead pipes. 3. For making alloys and solders. 4. For making trunks, boxes, cans, pans, etc.

Answer 27

Tin

Question 28

____ is one of the most extensively used non- ferrous metals. Occurs in wide variety of combination in nature. It is manufactured from ores by roasting and subsequent distillation with carbon. Properties 1. bluish white metal. 2. easily fused. 3. brittle when cold, but malleable at a high temperature. 4. can be rolled into sheets. 5. melting point is 420°C Uses 1. Used for galvanizing steel sheets. 2. For making roofing sheets, pipes, ventilators. 3. Used in brass making. 4. For making negative poles of batteries.

Answer 28

Zinc

Question 29

NON-FERROUS METALS _____ is extracted from galvena ores. It is a very cheap, but useful nonferrous metal. It is produced from the ores by smelting in a reverberatory furnace. 1. very soft, heavy blush grey in color. 2. can be easily cut with a knife. 3. makes impression on paper. 4. melting point is 327° and boiling point is 1600°C. Uses of Lead 1. For making shots and bullets. 2. Used for making gas pipes. 3. Printers type letters. 4. Flushing tank. 5. Roof covers.

Answer 29

Lead

Question 30

SUPER ALLOYS Three Groups of Superalloys 1. _________ in some cases iron is less than 50% of total composition 2. _________ - better high temperature strength than alloy steels 3. _________ - ~ 40% Co and ~ 20% chromium

Answer 30

Iron-based alloys Nickel-based alloys Cobalt-based alloys

Question 31

SUPER ALLOYS Importance:  Room temperature strength properties are good in comparison to other metals, but not _______  High temperature performance is _________ – tensile strength, hot hardness, creep resistance, and corrosion resistance at very elevated temperatures  Operating temperatures often in the vicinity of _________  Have many applications Example is that it is used in systems in which operating efficiency increases with higher temperatures e.g., gas turbines, jet and rocket engines, steam turbines, and nuclear power plants

Answer 31

outstanding excellent 1100°C (2000°F)

Question 32

_____________  processing of metals should be carried out carefully  Affects the mechanical properties of metals Grain Size Effect  Grains in metals tend to grow ______ as the metal is heated  metals with small grains are ______ but they are less ductile

Answer 32

METAL PROCESSING larger stronger

Question 33

______________  Most steels may be hardened by heating and cooling rapidly  metals are ________ in water or oil  Produce very hard but brittle metal ____________  a softening process in which metals are heated and then allowed to cool slowly ____________  heating a hardened metal and allowing it to cool slowly  produce a metal that is still hard and less brittle  results formation of small Fe3C (iron carbide or cementite) precipitates in the steel, which provides strength

Answer 33

Quenching and Hardening Annealing Tempering

Question 34

____________  refers to the process of strengthening a metal by changing its shape without the use of heat  also known as plastic deformation or work hardening, involves strengthening a metal by changing its shape.  the metal is subjected to mechanical stress so as to cause a permanent change to the metal's crystalline structure___

Answer 34

Cold Working

Question 35

METAL MANUFACTURING: PRODUCTION ___________  _________ - molten metal is poured into a mold cavity where, the metal take on the shape of the cavity once it cools  For small intricate parts (Dies, jewelry, plaques, and machine components )  SHOULD ____ be used for products that require high strength, high ductility, or tight tolerances a. __________ - the mold must be destroyed in order to remove the part b. _________ - the mold is fabricated out of a ductile material and can be used repeatedly.

Answer 35

CASTING Melting and molding NOT Expendable Mold Casting Permanent Mold Casting

Question 36

METAL MANUFACTURING: PRODUCTION _____________  treats powdered metals with pressure (pressing) and heat (sintering) to form different shapes  ______________ is known for its precision and output quality – it keeps tight tolerances and often requires no secondary fabrications  __________ is compacted into the desired shape and heated to cause the particles to bond into a rigid mass.  incredibly costly and generally only used for small, complex parts  Powder processing is _____ appropriate for high-strength applications.

Answer 36

Powder Processing Powdered metallurgy (processing of powdered metals) metal powder NOT

Question 37

METAL MANUFACTURING: PRODUCTION _______  ______ (usually in sheet metal form) is mechanically manipulated into a desired shape  Unlike casting, metal forming allows for higher strength, ductility, and workability for additional fabrications

Answer 37

Forming raw metal

Question 38

METAL MANUFACTURING: FABRICATION _________  bending, rolling, forging, and drawing  include metal forming and sheet metalworking  Application of stresses to the piece which exceed the yield stress of the metal  There are two types a._________ - characterized by large deformations and shape changes  surface area to volume ratio is relatively small  include rolling, forging, extrusion and wire and bar drawing. b. __________ - performed on metal sheets, strips and coils having a high surface area to volume ratio.  use a punch and die to form the workpiece  Bending, drawing and shearing

Answer 38

Deformation Bulk Processes Sheet Metalworking

Question 39

METAL MANUFACTURING: FABRICATION ________  any fabrication method that removes a section of the metal  also known as material removal processing  Cutting, shearing, punching, and stamping are all common types a._____________ - These are cutting operations using cutting tools that are harder than the metal of the product. They include turning, drilling, milling, shaping, planning, broaching and sawing. b. _________ - In these methods material is removed by abrasive particles that normally form a bonded wheel. Grinding, honing and lapping are included in this category. c. __________ - These methods use lasers, electron beams, chemical erosion, electric discharge and electrochemical energy instead of traditional cutting and grinding tools When planning for machining in your supply chain, hardening processes should happen AFTER machining processes. Hardened metals have a high shear strength and are more difficult to cut.

Answer 39

Machining Machining Operations Abrasive Machining Nontraditional Processes

Question 40

METAL MANUFACTURING: FABRICATION ________  one of the last steps of the metal manufacturing process  includes welding, brazing, bolting, and adhesives.  Assembly can be done by machine or by hand, where multiple parts are connected either permanently or semi-permanently to form a new entity. _________  includes everything from galvanization to powder coating, and can take place throughout the manufacturing process

Answer 40

Joining Finishing

Question 41

MECHANICAL PROPERTIES OF MATERIALS __________  It is the capacity of the material to withstand the breaking, bowing, or deforming under the action of mechanical loads on it. _________  It is the property of a material to come back to its original size and shape even after the load stops acting on it. ___________  It is the property of a material that makes it to be in the deformed size and shape even after the load stops acting on it. _________  It is the property of a material that allows it to deform or make into thin wires under the action of tensile loads plastically. __________  It is the property of a material that allows it to deform under tensile loading without breaking under the action of a load

Answer 41

Strength Elasticity Plasticity Ductility Tensile strength

Question 42

the strength of a material per unit material or unit strength

Answer 42

Stress

Question 43

_________  either tensile stress or compressive stress  Tension or tensile force applied results to Tensile Stress (______)  Compression or compressive force applied results to Compressive Stress (__________)

Answer 43

NORMAL STRESS

Question 44

STRESS-STRAIN DIAGRAM __________  The maximum ordinate in the stress-str diagram is __________ the strength of the material at rupture. This is also known as the breaking strength

Answer 44

Ultimate Strength Rapture Strength

Question 45

STRENGTH OF MATERIALS STRESS-STRAIN DIAGRAM ___________  limit beyond which the material will no longer go back to its original shape when the load is removed ___________  The region in stress-strain diagram from O to P is called the _______. The region from P to R is called the _______ _________ the point at which the material will have an appreciable elongation or yielding without any increase in load

Answer 45

Elastic Limit (E) Elastic and Plastic Ranges Yield Point  Yield point

Question 46

__________  the graph of quantities with the stress σ along the y-axis and the strain ε  differs in form for various materials  Metallic engineering materials are classified as either ________  __________is one having relatively large tensile strains up to the point of rupture like structural steel and aluminum  _________ have a relatively small strain up to the point of rupture like cast iron and concrete.

Answer 46

STRESS-STRAIN DIAGRAM ductile or brittle Ductile material Brittle materials

Question 47

__________ results from forces applied parallel to the area of the resisting force ________ contact pressure between separate bodies differs from compressive stress, as it is an internal stress caused by compressive forces

Answer 47

shearing stress Bearing Stress

Question 48

__________ also known as unit deformation, the ratio of change in length caused by applied force to the original strength Dimensionless

Answer 48

simple strain

Question 49

_________  the graph of quantities with the stress σ along the y-axis and the strain ε  differs in form for various materials  Metallic engineering materials are classified as either ______ _______ is one having relatively large tensile strains up to the point of rupture like structural steel and aluminum  ________ have a relatively small strain up to the point of rupture like cast iron and concrete.

Answer 49

STRESS-STRAIN DIAGRAM ductile or brittle Ductile material Brittle materials

Question 50

stress is directly proportional to strain

Answer 50

Proportional Law, Hooke's Law

Question 51

the proportionality k is called ____________ and is equal to the slope of the stress strain diagram from O to P

Answer 51

Modulus of Elasticity E or Young's Modulus

Question 52

STRESS-STRAIN DIAGRAM _____________  limit beyond which the material will no longer go back to its original shape when the load is removed Elastic and Plastic Ranges  The region in stress-strain diagram from O to P is called the _________. The region from P to R is called the ________ Yield Point  _________ is the point at which the material will have an appreciable elongation or yielding without any increase in load

Answer 52

Elastic Limit (E) elastic range plastic range Yield point

Question 53

________  The maximum ordinate in the stress-strain diagram is the ultimate strength or tensile strength Rapture strength is the strength of the material at rupture. This is also known as the breaking strength

Answer 53

Ultimate Strength Rapture Strength