IMOS Ex2

describe some of the business practices that Carnegie employed that allowed him to take command of the steel industry?

hard driving- Carnegie worked his men and his machines to the limit.

vertical integration - Carnegie controlled different parts of the supply chain. Ex: instead of buying ore, he bought the mining land for the ore.

price making - Carnegie would drive the price of steel low enough to put the upstarts out of business, only to raise the price back up once the coast was clear.

give three methods of making steel:

puddling - Melting pig iron from the heat of a coal fire in a furnace while an experienced "puddler" stirred the molten iron, thus burning off impurities while the purer iron formed a puddle in the furnace.

bessemer process - an egg shaped furnace that tilted once to accept the molten iron and the tilted upwards so that impurities could blow out the top of furnace.

basic oxygen process - blowing oxygen through a lance over the molten pig iron inside the converter

what are the three forms of iron, and what is the associated carbon content of each?

wrought iron (< 0.2%)
steel (0.2-2.3%)
cast iron (2.3-4.2%)

how did Andrew Carnegie use vertical integration to gain control of the steel market?

Carnegie controlled the entire steel making process from mining to final product

who created the best steel for several hundred years while making swords during the 1500's using sound to select the grade of steel and a layered process that put ductile steel in the middle and hardened steel on the outside, and what was it used for?

Japan created the best steel. The steel was made for Samurai Swords (they take about a week to complete the iron conversion to steel)

describe the difference between forging and casting:

Forging involves beating and hammering the metal into the desired shape.

Casting involves pouring the liquid into a mold to shape it.

describe the difference between steel and wrought iron:

Steel has more carbon in it than wrought iron does. You can make Steel through carbonization.

what is the form of iron carbon alloy that has a low melting point and is not forgeable?

Cast iron, 1204 Celsius

what two developments ushered in the transition from the Bronze Age to the Iron Age?

More iron ore and greater ability to change its properties using readily available alloying agent (Carbon).

what do we call iron and what happens to its physical properties when all the carbon is removed?

Wrought iron, becomes ductile and about as strong as Bronze

when you heat steel to 1000C, what phase do you have?

Austenite with lots of carbon dissolved in it (up to 2.1%).
Having austenite with a high carbon content is important for enhancing hardness, strength, wear resistance, and corrosion resistance in certain applications through controlled heat treatment processes.

in 1855, what process replaced puddling, allowing for the mass production of steel for the first time?

Bessemer converter

what is "throughput" and what advancement in steel production led to an increase in throughput?

throughput is a measure of how much comes into a factory and how much comes out, the invention of bessemer converters and hard-driving allowed Carnegie to increase throughput.

give three types of heat treatment for iron and steel:

Slow cool - annealing removes dislocations makes material softer, and slightly stronger than Bronze

Quench (fast cool) - transform to Martensite, excess carbon strains martensite (brittle)

Tempering - Heat again to move carbon around and restore ductility.

how is the term "creative destruction" applicable to the mass production of steel in the mid 1800's?

Creative destruction - describes the process of industrial change, particularly in the face of entrepreneurial activity and the incorporation of new technology.

-Puddlers were put out of business by the bessemer furnace

what is the solid waste left over from the smelting of iron ore called?

Slag

what actually occurs, in terms of hardening, with carbon atoms inside steel when it is cooled after smelting the material?

They form carbide particles which block dislocation motion.

what is the difference in procedure between bloom iron and cast iron?

When bloom iron is beaten wrought iron is squeezed from slag, when cast iron is made it is poured into a mold.

what molten mineral was used to make melting aluminum so much cheaper than producing pure aluminum?

Cryolite (sodium aluminum fluoride)

-Cryolite is added to alumina to lower its melting point

why does aluminum foil have one shiny side and one dull side?

One side hits the roller (the rollers are polished and smooth)

what caps the Washington Monument in DC?

an aluminum pyramid because it was so valuable in 1880s.

list three attributes of aluminum:

-one of the most abundant metals on earth
-lightweight
-durable
-corrosion resistant
-conductive

briefly explain the process of precipitation hardening and state an element that is commonly used for precipitation hardening in aluminum:

The supersaturation and subsequent formation of precipitates after heat treatment in low temps results in much greater mechanical properties.

satruating the soultion until it is full of copper/silicon

• cool
  -Silicon is commonly used for hardening aluminum

Why did the price of aluminum drop from $500 a pound to $0.30 a pound?

The discovery of cryolite made it possible to produce aluminum by electrical reduction

what are the five applications of alumnium?

Cans
Foil
Aircraft
Cookware
Bicycles

what is the name of the aluminum manufacturing company that originally had a 100% market share before it was broken up during a court case and decided upon by Justice Learned Hand?

ALCOA

what is cyclic fatigue and how did it affect the shape of airplane windows?

Cyclic fatigue is the repeated application of force below the yield strength which can result in crack propagation and failure.
Aircraft windows had to be rounded to reduce the stress and associated crack propagation associated with pressurization of the cabin.

Precipitation hardening is also known as what and why?

Age hardening, you heat it to a low temperature and allow it to age (precipitates grow)

which of these causes a problem for aluminum in the aircrafts?

cyclic fatigue

Aluminum resists corrosion because:

It forms a protective oxide layer that fits very well

while still a curiosity, what material was fashioned into knives, forks, and spoons for Louis Napoleon in 1848?

Aluminum

why should you never touch aluminum in the factory?

Has a low emissivity making it hard to tell when it's hot.

what is the major hindrance to using pure aluminum for industrial applications?

Very soft and very malleable

What is the Hall-Heroult process?

Mix cryolite and Bauxite and then heat until molten and insert electrodes to reduce aluminum from Al2O3

what is a Volta pile, and what creation was the common household material that first came from this invention?

Volta pile is a battery made from dissimilar metals, it enabled the reduction of sodium which enabled the reduction of aluminum.
-The invention is the electric battery.

in what compound is aluminum naturally found and why does it make it hard to use?

Bauxite (Fe3O4 + Al2O3), which has a very high melting point making electrical reduction very difficult.

aluminum is a very useful metal because of its properties that are similar and different from other metals, and what makes it so useful for aircraft?

Aluminum has higher specific strength than steel. Aircrafts have a strength to weight ratio that is critical to follow. The weight is 1/3 (smaller than steel).

what is the difference between the constant return to scale and economies of scale?

-constant return to scale: means that if one increases the input there is a corresponding increase in output.

-economies of scale: means a savings in cost by increasing production

what effect did success of aluminum have on anti-trust legislation?

The success of aluminum allowed for the creation laws that state there is no such thing as a good monopoly.

what might be the future impact on society if we continue our trend of magnetic memory storage and email use over physical data storage?

May lose information if it is not backed up correctly

give three ways of making paper:

-using fibers from old rags
-mechanical pulping
-chemical pulping

what was the first form of paper?

papyrus

where was papyrus first created and why is it pressed?

Egypt, it was pressed to squeeze out the sugars and increase the strength

what is the difference between primary and secondary storage? give an example of both in a system:

primary storage is the internal working memory of a system (in a computer it would be RAM sticks and cache memory)

secondary storage is an external memory (hard drive or solid state drive (SSD))

what does the phrase "the medium is the message" mean?

The medium influences how the message is perceived (email, paper, call)

why is the yield for mechanically pulped paper so much greater than chemical pulping?

In mechanical pulping the lignin remain behind

briefly describe the difference between hard disc drives and flash memory:

Hard drives are based on magnetic memory store, flash uses transistors to store information.

give three forms of long term digital memory storage:

hard disk drives
solid state drives
CDs

why does mechanically pulped paper yellow?

lignin

list the following four materials used to write information on in the chronological order of their historical development and use:

1. clay tablets
2. papyrus
3. parchment
4. paper

what limited the popularity of papyrus as a form of paper making?

The demand exceeded the supply and there were not enough papyrus plants

how did the invention of the printing press impact the level of education among the masses? explain:

the printing press enabled the production of books which greatly enhanced the transmission of information.

what is Florida's largest crop?

Pine trees, much of it for pulp

what is extracted in the chemical pulping process and what is it used for?

lignin, burned to power the plant

what are some of the adverse effects of the process of chemical pulping used to make paper?

release of hydrogen sulfide which smells, water pollution that must be cleaned up

what are the two main initiatives in the plastic industry attempting to deal with the large volume of plastic materials used in today's society?

Recycling and proper disposal
(Built in decomposition)

what element did Charles Goodyear crosslink early rubber with to reduce its sticky nature?

Sulfur

what is the difference between plastics and polymers?

Plastics= polymer + additives
Polymers are typically viewed as the pure chemical

cellulose nitrate was a polymer made from reacting cellulose with nitric acid. what was the biggest drawback to using this for billiard balls?

It explodes near a flame

Vinyl polymers often have different side groups on the C-C chain to change their properties. Give two examples of vinyl polymers and the element or side group

Examples of Vinyl Polymers:
PVC: Cl
Polyethylene: H
Polypropylene: CH3
Polystyrene: Benzene ring
Teflon: F

what can you do to polyethylene to help it crystallize?

Stretch it

what are the three strategies of advertising and marketing?

selling the need
hard sell - persuasion
Endorsement, or science

what are two examples of natural polymers?

Silk, bitumen, rubber

what is the most commonly-produced plastic?

polyethylene

what are the two affordances of plastics?

flexible, transparent, colorful, washable

what are two benefits of thermoplastics?

can be melted and recycled

what is the difference between thermosets and thermoplastics? name some advantage for each:

Thermosets cannot be melted but thermoplastics can

Thermosets can be made more durable and stand up to wear and temperature better.

Thermoplastics can be more easily molded and recycled

Advancements in thermosets include the development of sustainable and bio-based materials, while progress in thermoplastics involves high-performance engineering polymers, additive manufacturing applications, and a focus on recyclability and sustainability.

give three properties of plastics:

low density, low hardness, easy to manufacture, corrosion resistant, inexpensive

polyethylene can have a range of properties from floor wax to bullet proof vests. what is changing between these different products?

molecular weight or chain length

what were some of the issues with the first rubber made from Heeve trees?

very soft and sticky

what property of carbon changes as it chain gets longer?

it becomes stronger, tensile strength goes up

why was side branching a problem with polyethylene and what was done to solve it?

had to make consistant product, added a catalyst

explain why silicon has become the preferred semiconductor over the years and where one would look to find silicon in nature?

abundant and forms oxide, sand

why would it be better to use MoS2 for transistors instead of graphene?

it has a bandgap which is critical for the fabrication of a transistor

what does it mean to "dope" a material?

add an impurity to chemically alter its electrical properties

what does Moore's law refer to?

the doubling of the number of transistors per chip every two years

what is myopia and why has it increased in correlation with the increase in semiconductors?

nearsightedness from staring at computer screens

give three properties of the semiconductor silicon:

high melting point, electrically insulating (if pure), reflects light/shiny, brittle

list four things enabled by semiconductors:

the cloud, YouTube, cell phones, computer, texting, fantasy football, the internet

what is experience design? give an example:

the practice of designing products with a focus placed on the quality of the user experience (A camera)

explain the concept of "delegation" and list two examples of how humans may delegate or have delegated materials in society:

assigning a duty to a material (navigation, calculations, reminders, etc.)

described what is meant when it is said that silicon has a bandgap:

energy must be supplied to the material in order to create free carriers that enable electrical conduction

when it comes to processing silicon, what the biggest challenge faced when trying to make larger wafers?

growing defect free boules (cylindrical single crystals of silicon)

what is the difference between a conductor and a semiconductor?

semiconductors electrical properties can vary widely based on doping, conductors electrical properties do not vary as significantly

per Moore's law, the number of transistors on a silicon chip will double every year since their invention. list a couple of benefits that could result from having fast processors be widely available:

virtual reality, faster rendering, AI, smaller/easier to wear electronics

besides information storage, what is another application of semiconductors?

LED lights, power electronic for electric brushless motors for energy efficiency, digital imaging with phone camera

what is an allotrope?

different crystalline forms of the same element

what are examples of carbon allotropes?

graphite, diamond, graphene

why is graphene not a good semiconductor for electronics?

it doesn't have a bandgap

can diamond be used for electronics? where?

yes, for high temperature applications

what are steps that can be taken to mitigate CO2 in the atmosphere?

reduce production, sequestration, reduce usage

why does CO2 production go up with GDP?

as societies becomes wealthier, the citizens want to own more stuff, they become more mobile and their carbon footprint increases

in sequestration, what is the ideal end product for the CO2?

turn it back into rock (limestone)

what did Alan Savory discover works to reduce desertification and lead to great carbon capture?

Holistic Management- animal grazing that create microclimates that trap carbon and lead to more fertile land

what form of low carbon footprint energy is easily in the greatest supply?

SOLAR

give a promising example of an application of graphene or graphene oxide

desalination, biomedical, flexible electronics. Biosensors with epitaxial graphene on silicone carbine that are capable of selective binding with antibodies.

why are diamond electronics not popular today?

very expensive and difficult to grow the materials

what is a possible benefit for you as an engineer to be aware of creative destruction?

being aware of who is being displaced means you could retrain them for your company, gain from their experience, gain from their contacts, etc.

what do you have to do to cast iron to make steel?

remove carbon

what did Andrew Carnegie do to become a price maker, not a price taker?

increased his market share and employed vertical integration