IME Flaschards Final Exam
Terms
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- The equation that relates the load to the stress is given by
- S = P/Ao = load/area
- The equation that relates te strain to the deformation is given by
- e = ΔL/Lo = deformation/gage length
- Hooke's Law is given by the equation
- S=Ee
- Fully-recoverable strain is called...strain
- elastic
- The two unit cell configurations that we will discuss in this class are
- bcc (body centered cubic) and fcc (face centered cubic)
- A material that creates a neck prior to fracture is called a .... material
- ductile
- a material that exhibits more than one phase is called either a .... or ... material
- allotropic or polymorphic
- The process whereby a material gains strength as it deforms is called....
- strain hardening
- Plastic strain is considered as
- non-recoverable
- the amount of energy that a material can absorb prior to fracture is called its
- toughness
- the maximum stress that a material can withstand is called the
- ultimate tensile strength (UTS)
- the basic building block of metals is called the
- unit cell
- deformation that occurs before reaching the yield strength is called ... deformation
- elastic
- one ksi is equal to
- 1000 psi
- Tensile test properties are considered to be....properties
- macroscopic
- the slope of the linear portion of the stress-strain curve in the elastic region is called....
- elastic modulus or Young's modulus
- when elastic strain is recovered after deformation, this is called
- springback
- elastic strain is considered as
- fully recoverable
- the physical change in shape of a tensile specimen after exceeding its UTS is called
- necking
- when a material fails without creating a neck in the specimen, the sample is said to be a ... material
- brittle
- deformation that occurs between the yield strength and the ultimate tensile is....deformation
- plastic
- when unit cells are combined into a single unit, that unit is called a
- crystal
- the stress that separates the elastic from the plastic strain regions is called the
- yield strength
- a block of metal is made up of many
- grains
- Grains are in turn composed of many
- unit cells
- a steel called 8620 would have a carbon content of approximately
- .20%
- Attaching....the the name designates phases of a metal
- greek letters
- hardness is a measure of a material's resistance to
- surface indentation
- to change the properties of a material using heat, the process is called
- heat treatment
- cast iron is an alloy of iron and
- carbon
- a steel called 4140 would be considered as a (plain carbon or alloy) steel
- alloy
- the high temperature phase of iron is called
- austentite
- the lowest temperature that a particular composition of material will remain fully liquid lies on a line called the
- liquidus
- all iron-carbon mixtures less than 2.0% carbon are of the family called
- steel
- a preoload on the indenter is used with the ... hardness test
- Rockwell
- the indenter with a 1/16" hardened steel ball is used with the...hardness test
- Rockwell
- a steel called 4140 would be called a (low, medium, high) carbon steel
- medium
- iron with more than 2% cabron is called
- cast iron
- the uppermost line on an equilibrium phase diagram is called the
- liquidus
- the reaction where the material goes directly from a liquid to a solid without an intervening phase of liquid and solid is called the
- eutectic
- a 1010 steel would qualify as a (plain carbon, alloy) steel with a (low, medium, high) carbon content
- plain carbon, low
- the room temperature phase of iron is called
- ferrite
- gamma iron has the name
- austentite
- converting only the ferrite to austentite upon heating and then cooling back to ferrite and cementite is called
- full anneal
- steel is an alloy of iron and
- carbon
- when a material goes directly from one solid phase to another without a mixture of phases, it does so only at the .....reaction conditions
- eutectoid
- hardness test that uses the largest indenter ball
- brinell
- Cementite
- Fe3C
- Occurs at the composition that has the lowest possible heating point
- eutectic
- Ferrite, room temperature form of iron, is also called
- alpha iron
- Shaping the desired metal chemistry into semi-finished or finished shapes
- finishing
- steel is made up of
- iron and carbon
- All ferrite and Fe3Cis transformed to austentite upon heating and back to ferrite and Fe3C upon cooling
- normalizing
- A form of a material possessing a single characteristic structure. It is physically distinct, chemically homogenous, mechanically separable
- phase
- A steel designated as 1010 is considered as this
- plain carbon
- Changing the chemistry of the base metal by adding alloying elements to achieve specific properties
- refining
- removing the impurities from the ore to get to the base metal
- smelting
-
The temperature below which the material will be fully solid is this
The lowest line on the phase diagram - solidus
- Unit Cell Structure of austentite
- FCC
- Unit cell structure of ferrite
- BCC
- to make a hole in a casting, a mold feature called a...is required
- core
- to allow the easy removal of the pattern or casting from the mold, a mold feature called a ... is provided
- draft angle
- the vertical portion of the flow channel for a green sand casting is called the
- sprue
- the indication on the casting showing where the mold halves met is called the
- parting line
- the mold in a lost wax casting is considered as a ... mold
- unit (expendable)
- the green sand casting flask is composed of the following parts in order from top to bottom
-
Cope
Drag
Bottom Board - green sand consists of moisture in addition to....
- clay and sand
- the physical or virtual representation of the item you wish to cast is called hte
- pattern
- shell molding has a pattern that is considered as a ....pattern
- permanent
- EPS is used as a pattern material for the casting process called
- lost-foam casting
- the mold feature that allows air to escape from the cavity and provides a second source of molten metal is the
- riser
- the three allowances in casting pattern design are
- shrinkage, machining, distortion
- the pattern for green sand casting is considered as a .... pattern
- permanent
- the recess in the mold that holds the core in place is called the
- core print
- the mold material for an investment casting is made from
- ceramic
- the ceramic casting process that we discussed is called
- investment casting
- the pressure casting process where the material to be cast is melted at the casting machine is called
- hot chamber die casting
- The pressure casting process where the material to be cast is melted away from the casting machine
- cold chamber die casting
- all sand casting processes have a mold that is considered...(permanent or unit)
- unit
- the pattern for shell molding is considered as(permanent or unit)
- permanent
- the casting process where dry sand is used for the mold material is called
- lost-foam casting
- to make a hollow casting, a core is often used. Please name two casting processes that Do Not use a core to make a hollow casting.
- slush casting and centrifugal casting
-
arrange the following processes in order of increasing minimm thickness for an allowable casting section by numbering 1 for the thinnest and 4 for the thickest.
die casting
green sand casting
investment casting
permanent mold -
die casting 1
green sand casting 3
investment casting 2
permanent mold casting 4 - Name three different casting processes that are considered as sand casting processes
- shell molding, green sand casting, lost-foam casting
- Name three of the permanent mold casting processes
-
cold chamber die casting
hot chamber die casting
centrifugal casting - green sand consists of moisture plus
- clay and sand
- a cast iron pipie is made by the process called
- centrifugal casting
- The pattern material for evaporative casting is made from this
- EPS (Expanded Polystyyrene Foam)
- Lost foam casting, evaporative casting
- full mold casting
- The last mold feature that the liquid metal flows through before entering the mold cavity
- gate
- the process where a multipoint tool has each tooth cutting slightly depper than the tooth before it as the tool passes through the owkrpiece is called
- broaching
- the movement of the tool in boring is
- parallel to the axis of rotation
- the lathe process that decreases the outside diameter of a bar is called
- turning
- the controls for a lathe are located in the
- headstock
- to create a hole in drilling that is the correct size and direction, a process called...is used
- reaming
- the part of the lathe that rides on the ways and carries the cross-slide is the
- carriage
- the metal removal rate is measured in units of
- in3/min
- to square the end of a workpiece on a lathe, the process is called
- facing
- in horizontal milling, when the tool and workpiece are moving in opposite directions, the process is called
- conventional milling (up)
- a tool with flutes is used in the process called
- milling
- the chip slides on the...of the tool
- rake face
- the broaching tool is considered as a ... tool
- multitooth
- the localized increase of a workpiece diameter in forging is called
- upsetting
- to make a hole in an extrusion, a ... must be fitted to the ram
- mandrel
- when plastic deformation of the workpiece takes place after heating the material to a temperature below the recrystallization temperature, the deformation is called
- warm working
- to make a thick sheet into a thin sheet, the process is called
- flat rolling
- the clearance to use in shearing metal is
- 10% of metal thickness
- grain refinement brought about by hammers or rollers generates a product called
- wrought
- the forging process that uses a hammer and anvil is called
- open die forging
- when using the forging process with the tooling as rolls with grooves cut in them the process is called
- roll forging
- to make a channel from a bloom, the process is called
- shape rolling
- the four parts of the cut edge as indicated below are:
- rollover, burnish, fracture, burr
- the 3 deformation modes in sheet metal forming are called
- drawing, bending, and stretching
- when a desired circular part is cut from a large sheet, the process is called
- blanking
- the sheet metal process called....only takes place along a straight line
- bending
- the rotary process for bending sheet metal is called
- roll forming
- forcing a material through a die using compressive forces is called
- forward extrusion
- when a tube is forged between mating rolls to form a new shape for the tube walls, the process is called
- ring forging
- to make a cup from sheet metal, the process is called
- drawing
- in extrusion, when the material is forced around the punch and not though a die, the process is called
- backward extrusion
- the one sheet metal deformation process that deforms around the punch and not over the punch is called
- drawing
- when steam is used both to raise the forging hammer and to drive it against the workpiece, the process is called
- high energy rate forming
- to make a round disk to be used later from a rectangular sheet of metal, the process ... is used
- blanking
- when the forging process called .... is used to increase the diameter of the workpiece
- upsetting
- a pizza pan is an example of a drawing operation called
- shrink flanging
- cold working occurs at a temperature
- room temperature
- warm working occurs at a temperature
- below recrystallization temperature
- hot working occurs at a temperature
- above recrystallization
- material that undergoes grain refinement through hammering or rolling is called a
- wrought material
- a crescent wrench handle uses a form of forging called
- closed die
- a nail or a bolt uses a form of forging called .... to make the shape
- heading
- ...metl metals use the process called melt atomization to make their powders
- low temperature
- in order, afte the powders are made, the processes necessary to accomplish making a P/M part are...
- blended, compacted, and sintered
- Compaction of the powders can achieve nearly 98+% of
- theoretical density
- high temperature melt metals use .. to make their powders
- spark atomization
- one advantage of using P/M is....
- high production rate
- one disadvantage of using P/M is
- material cost
- when determining what current and welding time in cycles to use for ERW, the diagram is called a ... diagram
- weld lobe
- when sound is used for welding energy, the process is called
- USW..Ultra sound welding
- three important factors for gas welding are flame...
- temperature, stand-off, and speed
- the joining process that uses a foreign metal that melts belor 450 degrees celsius is called
- soldering
- when the gas welding process uses a flame with the proper mixture of acetylene and oxygen, hte flame is called
- neutral
- adhesives cure under the following conditions
- elevated temperature, room temperature, anaerobic (no oxygen)
- two part adhesives are always of the type called
- thermoset
- the weld geometry for a t joint is a ...
- fillet weld
- the letters HAZ stand for
- heat affected zone
- the arc welding process that uses a bare, continuous, consumable electrode and flux to physically exclude the oxygen is called
- SAW
- the arc welding processe that uses a tungsten, nonconsumbale electrode is called
- GTAW
- the arc welding process that uses a bare, continuous, consumable electrode and a bottled shielding gas is called
- GMAW
- the welding process that uses the heat generated by electrical resistance is called
- ERW
- When acetylene is used as the fueld for welding, the process is called
- OFW oxyfuel welding
- when the gas welding process uses a flame with too much acetylene, the flame is
- carburizing
- when the gas welding process uses too much oxygen its
- oxidizing
- the strongest orientation for reinforcement in composites for strength is called
- unidirectional
- the weakest orientation for reinforcement in composites for strength is called
- random
- midrange orientation for reinforcement in composites for strength is called
- orthogonal
- the making of foamed polymers id done by the process called
- expansion
- the non-combinable form of a polymer molecule is called the
- monomer
- the combinable form of a polymer molecule is called the
- mer
- when a thermoplastic polymer is forced through a nozzle into a mold, the process is called
- injection molding
- three forms of a composite structure are
- particulate, laminar, and fiber
- pigments and fillers belong to the class of materials used as .... for polymers
- additives
- to make polymers, small molecules are combined to make large molecules in teh form of
- rings and chains
- a one-gallon plastic milk jug would be made by the process called
- blow molding
- a sheet of plastic would probably be made by the process called
- calandering
- when a thermoset polymer is injection molded, the process is called
- RIM
- the polymer forming process most like impression die forging is called
- compression molding
- plastic trash bags are often made by the process called
- blown film
- when a polymer product has a small circle and a short nib protruding from that circle, the product was made by the processs called
- injection molding
- the mickey mouse form that you made in lab was done by the process called
- vacuum forming
- vacuum forming must use a polymer of the...type
- thermoplastic
- transfer moldign uses a polymer of the
- thermoset type
- extrusion uses a polymer of the...
- thermoplastic type
- an extrusion is the intitial or preprocessor for the following polymer processes
- blow molding and blown film
- the form of polymer that can be softened due to heat without change in its chemical properties is called
- thermoplastic
- layers in refinforcement in a composite generate a composite called
- laminar composite
- putrusion is done using the polymer family called
- thermoset
- the form of polymer that can undergo large elastic strains without fracture is called the
- elastomer
- EPS is made by the process called
- expansion
- a home spa or jacuzzi is made by the process called
- spray up
- a composite pressure vessel would be made by the process called
- filament winding
- a skylight would be made by the process called
- free blowing
- a hollow thermoplastic or thermoset ball would be made by the process
- rotational molding
- a blisterpack for selling hardware, packing chewing gum, and pharmaceutical pills would be made by
- vacuum molding
- three processes that use compressed air in the process are
- blown film, blow molding, free blowing