Unit 9

Question 1

What is press forming used for?

Answer 1

Shaping sheet metal in mass production, e.g. car body panels.

Question 2

What is metal spinning?

Answer 2

Rotating sheet metal on a lathe to form hollow shapes like lampshades.

Question 3

What is cupping and deep drawing used for?

Answer 3

Making hollow shapes like drinks cans (cupping = shallow, deep drawing = deeper).

Question 4

What is forging?

Answer 4

Shaping hot metal with force; traditional blacksmithing.

Question 5

What is drop forging?

Answer 5

Shaping heated metal using a hammer and die—strong parts like spanners.

Question 6

What is bending used for?

Answer 6

Creating curves or angles in sheet or bar metal, e.g. brackets.

Question 7

What is rolling?

Answer 7

Reducing metal thickness using rollers—used in large-scale production like I-beams.

Question 8

What is sand casting suitable for?

Answer 8

One-off or low-volume parts like engine blocks—rough finish.

Question 9

What is die casting used for?

Answer 9

High-volume, detailed products like toy cars—good surface finish.

Question 10

What is investment casting used for?

Answer 10

Complex, detailed parts like jewellery—accurate but expensive.

Question 11

What is low-temperature casting (e.g. pewter)?

Answer 11

Used for craft or jewellery work—easy and safe to handle.

Question 12

What is MIG welding?

Answer 12

Fast, semi-automated welding ideal for mild steel and mass production.

Question 13

What is TIG welding?

Answer 13

Precision welding for stainless steel and aluminium—used for bikes, aircraft.

Question 14

What is spot welding?

Answer 14

Fuses sheet metal at points using electrodes—common in car manufacturing.

Question 15

What is oxy-acetylene welding?

Answer 15

Flame-based welding—good for repairs and metal art.

Question 16

What is soldering used for?

Answer 16

Joining metals with low heat—soft solder for electronics, hard solder for jewellery.

Question 17

What is brazing?

Answer 17

Stronger than soldering—joins metals with a brass filler at higher temps.

Question 18

What is riveting?

Answer 18

Permanent mechanical join—used in aircraft and metal cladding.

Question 19

What are common temporary metal fasteners?

Answer 19

Self-tapping screws, machine screws, nuts and bolts.

Question 20

What is milling?

Answer 20

Removing material with rotating cutters—used for slots and surfaces.

Question 21

What is turning (on a lathe)?

Answer 21

Shaping cylindrical parts—used for bolts, rods.

Question 22

What is plasma cutting?

Answer 22

Cutting metal with an ionised gas arc—faster and neater than flame.

Question 23

What is laser cutting?

Answer 23

Precise cuts on thin metals—used for signage and decorative work.

Question 24

What is punching/stamping?

Answer 24

Cutting or shaping sheet metal with a die—used for electrical enclosures.

Question 25

What is cellulose or acrylic paint used for?

Answer 25

Colour and protection—general metalwork.

Question 26

What is electroplating?

Answer 26

Coating metal with another (e.g. chrome-plating a tap) for looks and protection.

Question 27

What is flame cutting?

Answer 27

Cutting thick steel using oxy-fuel—used in construction.

Question 28

What is dip coating?

Answer 28

Dipping metal in plastic—used for tool handles.

Question 29

What is powder coating?

Answer 29

Tough plastic coating baked on—used on bike frames, appliances.

Question 30

What is galvanising?

Answer 30

Zinc coating to prevent rust—used on outdoor products like fencing.

Question 31

What are metal sealants and preservatives for?

Answer 31

Prevent corrosion and prolong life—used in marine and outdoor applications.

Question 32

What is anodising?

Answer 32

Electrochemical process for aluminium—adds colour and corrosion resistance.

Question 33

What is cathodic protection?

Answer 33

Prevents rust by using a sacrificial metal—common in pipelines and boats.