metals quiz

Ferrous metals properties

• contain iron

• Magnetic

• Durable and strong

• More likely to rust

Ferrous metals

Irons and steel

Non ferrous metals properties

• don’t contain iron

• Lighter and malleable

• More expensive

• High corrosion resistance

Non ferrous metals

copper, aluminum,lead, zinc

Alloy

Mixture of metals with 1+ elements in it

Alloy properties

• Greater hardness

• Greater strength

• More lightness

• More durability

Additive processes

Typically building up layers of material

Minimal waste

High initial cost

Subtractive process

Cuts away at metal

High waste produced

Cheaper

CNC

Casting

Poured metal

Forming

Deforming metal into shapes

Machining

Subtractive manufacturing

Joining

Assembling from parts

Surface finishes

• electroplating

• Blasting

• Powder coating

• Painting

• Galvanizing

• Anodizing

Die Casting

process where molten metal is injected and forced by pressure into reusable steel molds (die), the cooled and ejected to create complex 3D metal parts

materials: non-ferrous

melting point of ferrous metals is too high

examples: automotive wheels, traffic lights, kitchen pots

Metal stamping

process used to form shallow sheets and bend profiles in sheet metal;metal sheet is put down and machine slams down on it stamping it into shape. trimming is common. very quick. washing machine, vehicle door, engine mounting

materials: carbon steel, stainless steel, aluminum, magnesium, titanium, copper, brass, zinc

examples: door linings, trim, electronic housing, appliances, tools, cutlery, washing machine enclosures; external and internal features

Tube and Section Bending

the process of deforming a tube to create curvature without visible joinery. mandrel bending, ring rolling

examples: coffee table, electrical hosing, architectural beams

Low Volume, High Cost

investment casting, sandcasting, lost wax casting, electroforming, forging, welding, panel beating, metal spinning, subtractive manufacturing

High Volume, Low Cost

metal stamping, roll forming, deep drawing, die casting, metal injection molding, swaging, tube and section bending, metal extrusion, hydroforming

Add Tolerance

machine it to get to a point of exactly the size you want, add precision

Ring Rolling

tube or sheet is passed between 3 rollers

Mandrel Bending

tube is loaded over the mandrel and clamped onto die, tube is drawn onto the rotating die as it spins, pressure clamp travels with the tube to keep a wrinkle free bend, clamp releases tub

Die

Tool used to cut or bend metal in desired shape