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Processes Flashcards

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1
Q

What is the definition of ductility?

A

A materials ability to be drawn out (under tension) without rupture, and retain its new shape

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2
Q

What is the definition of malleability?

A

A materials ability to be pressed, rolled or beaten out (under compression) without rupture, and retain its new shape

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3
Q

What is the definition of toughness?

A

A materials ability to withstand impact and shock loads

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4
Q

What is the definition of strength?

A

A materials ability to withstand tensile, compressive or shear (offset) forces, resisting without rupture

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5
Q

What is the definition of brittleness?

A

A materials ability to fracture without deformation

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6
Q

What is the definition of hardness?

A

A materials ability to withstand wear and abrasion, and the ability to cut other softer materials

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7
Q

What is the definition of elasticity?

A

A materials ability to deform under load and return to its normal size and shape after the load is removed

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8
Q

What is the definition of corrosion resistance?

A

A materials ability to resist chemical and electrochemical attack

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9
Q

What is the definition of electrical conductivity?

A

A materials ability and rate at which a material will conduct electrical current

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10
Q

What is the definition of thermal conductivity?

A

A materials ability and rate at which a material will conduct heat

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11
Q

What are the advantages of plastics?

A

Ease of moulding
Low densities
Good electrical insulation
Low co-efficient of friction
Resistant to corrosion and chemical attack
Damps out vibration

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12
Q

What are the limitations of plastics?

A

Lower strength, rigidity and shock resistance
Low service temperature
Soft and scratch easily
Generally expensive except for large batches
Tendency to change shape due to shrinking, warping, creep and cold flow
Deterioration due to strong sunlight and air exposure

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13
Q

What are the main reasons for testing materials?

A

Research, design and development
Quality control
Investigation of failures

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14
Q

Define stress?

A

Stress = applied force (N)/cross sectional area (mm2)

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15
Q

Define strain?

A

Strain = change in length/original length

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16
Q

What are the three types of stress?

A

Tensile stress
Compressive stress
Shear stress

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17
Q

Define Hooke’s law?

A

Within the elastic range, the strain is directly proportional to the stress. Stress/strain = constant

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18
Q

What is creep?

A

The progressive deformation of a material under constant load over an extended time period

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19
Q

What is fatigue?

A

Caused by cyclical stress. When a material is repeatedly bent or twisted back and forth or repeatedly stretched then squashed

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20
Q

What are the four ways to reduce fatigue?

A

Good design
Improved surface finish
Avoid corrosion
Surface harden

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21
Q

What are the four methods of corrosion protection?

A

Design
Environment
Coating
Galvanic protection

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22
Q

What four ways could you protect a ships hull and components from corrosion?

A

Paint hull
Use sacrificial anodes
Good design (stainless steel and phosphor bronze)
Control moisture levels

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23
Q

What are the four heat treatment processes?

A

Annealing
Normalising
Hardening
Tempering

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24
Q

Describe annealing?

A

Heat to a specific temperature below lower critical temperature and then allow to cool in a controlled manor

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25
Describe normalising?
Heat to just above upper critical temperature and allow to cool in air
26
Describe hardening?
Heat to above upper critical temperature and then quench it
27
Describe tempering?
Heat to a specific temperature below lower critical and then quench it
28
What two properties will sand casting metals have?
A relatively low melting point Good fluidity, with the ability to flow into intricate shapes without chilling
29
What is the main difference between sand casting and die casting?
Sand casting uses a one off mould Die casting uses a reusable metal die
30
What are the three types of casting?
Sand Die Investment
31
Explain the process for sand casting?
Place the bottom half of the moulding box (drag) over the half pattern and pack down with sand Turn over and place the top half of the moulding block (cope) onto the bottom half Position the other half of the pattern and pack down with sand Cut holes for the runner and riser Open the mould and remove both halves of the pattern Repair any defects and then coat with plumbago Position core if required Reassemble the drag and cope and pour the molten metal Allow to cool, when cold break open the mould and remove the casting Fettle as required
32
What are the uses for sand casting?
Gear blanks Valve chests Machine tool beds Surface plates Angle plates Manhole covers
33
What properties will die casting materials have?
Low melting point
34
Explain the pressure die casting process?
Force the molten metal at a suitable pressure and temperature into the closed die so that it is completely filled Open the die and eject the casting. The die is sprayed with graphite spray for longevity and ease of casting ejection Close the die in preparation for the first stage again
35
What are the uses for pressure die casting?
Engine pistons Fuel pump bodies
36
Describe the process for investment casting?
Build a ceramic mould around a wax pattern Mould is then heated to harden it and melt out the wax pattern Molten metal is then poured into the mould After cooling, the mould is broken to release the casting
37
What are the uses for investment casting?
Gas and jet engine blades Cams Nozzles Valves
38
What are the advantages for investment casting?
Dimensional accuracy Good surface finish Minimal machining Can cast many materials including super alloys
39
Explain hand forging?
The material is hammered into shape after it has been heated to its plastic state. This forging breaks up and refines the grain structure. The finer the grain structure becomes the stronger and tougher the metal becomes. The grain flow is also changed to follow the contour of the components
40
What are the advantages for hand forging?
Uses less raw material than a component machined from solid stock A forged component is stronger than one machined from solid stock or casting
41
What are the disadvantages for hand forging?
Slow and labour intensive High degree of skill needed Expensive Not suitable for mass production
42
What are the uses for drop forging?
Connecting rods Crankshafts Spanners
43
What are the two processes for joining materials?
Permanent Temporary
44
Give examples of permanent joining processes?
Riveting Welding Soldering Brazing
45
Give examples of temporary joining processes?
Nuts Bolts Screws Studs
46
Give three examples of types of rivets?
Round Flat Countersunk 90 degrees
47
Explain the process of soldering?
Mechanically clean components Chemically clean by applying a flux to remove oxide film when heated Heat joint to above freezing range of solder Apply filler metal to alloy with parent metal Filler metal will fill clearance between components via capillary action
48
What are the three types of adhesives?
Epoxies Cyanoacrylates Anaerobics
49
Give applications for left hand threads and reasons for choice?
Hose connection heads of an oxyacetylene welding torch- safety, hoses cannot be connected to the wrong position on the torch or cylinders Left hand spindle andnutona grinding machine- operation of the grinder will cause each grinding wheel and nut to self tighten
50
How is quality defined?
A component has quality when it meets requirements
51
What is the main goal of quality assurance?
Ensure that the product fulfils or exceeds the expectations of the customer
52
What will the customer expect from a product?
That it will give a predictable, effective and reliable operating life Spare parts will be readily available Spare parts will be interchangeable with the existing equipment
53
What is the international quality standard?
ISO 9000
54
What is the purpose of inspection?
To identify products which do not match their specifications (non-conforming products)
55
What must be done with a non-conforming product?
Make sure that it is clearly identified as non-conforming Quarantine it Decide what to do with it
56
What can be done with non-conforming products?
Scrapping Adjusting Reworking Obtain authority to pass the defective product on to the customer but clearly identify it as below standard
56
Give three examples of assemblies which can be interchanged?
An exhaust valve running in a valve guide A cylinder liner fitted in an engine crankcase A shaft running in a bearing
56
What is interchangeability?
The ability to select components for an assembly at random and fit them together within specified tolerances
57
What forms can work instructions come in?
Detailed step by step instructions Sketches of a finished product Very simple statements
58
What are the benefits of using written instructions?
The supervisor who gives the instruction can be sure the correct information has been received The written instruction can be given clearly, even if the noise in the workplace makes it difficult to give verbal instruction The people who do the work are able to check the written instruction if they forget anything The supervisor and the person doing the work can refer to the instruction if any queries arise
59
What information should be included on a drawing?
Sufficient dimensions to manufacture the component Title block including revision number, scale, originator, angle, surface roughness/finish required The material to be used The tolerances and nominal sizes
60
What sources of technical information are there?
Book references Joint service publications Illustrated parts catalogues Parts identification lists HASAW act and codes of practice British standards International standards Technical publications and manuals
61
What is the purpose of a work plan?
To prevent errors and save time
62
What will a ideal work plan set out?
Activities as a logical sequence of events Key values and times clearly indicated
63
What is the purpose of electrode coating?
Creates slag layer to prevent weld metal cooling too quickly Provides shielding gas to prevent oxidisation

Killicks common (4 decks)

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