Introduction and Prerequisites of Applied Physical Metallurgy - Flashcards (Fill-in-the-Blank)

A set of fill-in-the-blank flashcards covering major topics from AM processes, casting, forging, 3D/4D printing concepts, and case studies.

Material Extrusion (ME) was developed by __ in 1988.

Scott Crump

Powder Bed Fusion (PBF) was developed by __ in 1980.

Dr. Carl Deckard

Vat Photopolymerization was developed by __ in 1984.

Chuck Hull

Binder Jetting (BJ) was introduced by ___ - ___ (MIT) in 1993.

Emanuel Sachs

Material Jetting (MJ) was introduced by ___ in 1995.

Stratasys

Direct Energy Deposition (DED) was invented in the year ___ at Michigan State University.

1980

Sheet Lamination (SL) was developed by __ in 1991.

Michael Feygin

Chuck Hull invents __ (SLA) and co-founds 3D Systems in 1986.

Stereolithography (SLA)

Chuck Hull co-founded __ in 1986.

3D Systems

Sand Casting uses expendable molds made from __.

sand

___-___ ____ Formation, in Sand Casting, uses a reusable pattern made from wood, metal, or plastic pressed into sand.

Pattern-Based Cavity

___ ___ uses a wax pattern coated with a refractory ceramic to form a mold.

Investment Casting

__ __ __ uses a polystyrene foam pattern that evaporates when molten metal is poured.

Lost Foam Casting

Benefits of Die-Casting?

• High-pressure Permanent Mold Process

• High Production Efficiency

• Excellent Dimensional Accuracy and Surface Quality

• Common Materials Used

__-__ __ __ is used for low melting point alloys; the metal is melted inside the machine.

Hot-Chamber Die Casting

__-__ __ __ is used for higher-melting alloys; the metal is melted separately.

Cold Chamber Die Casting

__ __ __ uses reusable molds; an example is die casting.

Permanent Mold Casting

Space Tiles Sintering and Annealing are used to make HRSI tiles from high-purity __.

silica (quartz sand)

__-__ __ is the forging process in which metal is deformed between flat or simple-shaped dies; suitable for large parts.

Open-Die Forging

__-__ __ (Impression-die) is the forging process in which metal is placed in die cavities and takes the shape of the die; suitable for complex shapes.

Closed-Die Forging

__ __ __ __ produces strong ring-shaped components by rolling a pierced round billet.

Seamless Rolled Ring Forging

__ (hot or cold) Forging is performed at room temperature; improves strength and surface finish

Cold

__ Forging (hot or cold) is performed at high temperatures; improves ductility and reduces flow stress.

Hot

__ __ involves a slow squeezing action using hydraulic presses; allows for uniform deformation.

Press Forging

__ __ uses high-energy impact to deform metal quickly; suitable for smaller components.

Hammer Forging

3D printing flow starts with an input file in the form of an __ file.

STL

Typical 3D print speed is __ mm/s.

30-60

__ __ (two words) controls internal solidity.

infill density

Supports are used for overhangs greater than __ degrees.

45

A __ __ (two words) in AM is a virtual model that mirrors a physical product in real time.

digital twin

__-__ __ enables customized production without tooling. Shortens time from design to delivery.

On-Demand Production

4D printing adds the dimension of __; it was introduced by Skylar Tibbits at MIT in 2013.

time

__ __ __ (three words) include Hydrogels, Thermo-responsive, Photo-responsive, Piezoelectric, Electro-responsive, and magneto-responsive materials.

4D Printing materials

MDUSAM (medUSA) stands for __.

Multiple Depot Universal System for Additive Manufacturing