Week 11: Mass Production 2 (30 Flashcards)

1. Q: What is die casting?

A: A process of injecting molten metal into a steel mold under high pressure.

2. Q: What are the two main types of die casting?

A: Cold chamber and hot chamber.

3. Q: What metals are used in hot chamber die casting?

A: Low-melting-point metals like zinc.

4. Q: Why is cold chamber die casting used for aluminum?

A: Aluminum’s high melting point requires an unheated chamber to prevent tool damage.

5. Q: What is the purpose of ejector pins in die casting?

A: To push the molded part out of the mold after solidification.

6. Q: What is a sprue in die casting?

A: The entry point for molten metal into the mold.

7. Q: What is the role of runners in molds?

A: Channels that distribute molten metal to various parts of the mold.

8. Q: Why are sliders used in die casting molds?

A: To create undercuts or complex geometries.

9. Q: What is the Giga Press?

A: A massive die casting machine used by Tesla for large parts.

10. Q: How does draft angle affect die casting?

A: Ensures parts can be ejected without damaging the mold.

11. Q: Name three metals commonly used in die casting.

A: Zinc, aluminum, magnesium.

12. Q: What is powder coating?

A: A durable, eco-friendly coating applied as a powder and cured with heat.

13. Q: What are the benefits of powder coating?

A: Scratch resistance, VOC-free, variety of finishes.

14. Q: What is PVD coating?

A: Physical vapor deposition creates thin, durable layers on parts.

15. Q: What is anodizing used for?

A: Improving aluminum’s corrosion resistance and surface finish.

16. Q: Why is porosity a concern in die casting?

A: It weakens parts and can lead to functional failures.

17. Q: What is vacuum impregnation?

A: A process to seal porosity in cast parts, making them watertight.

18. Q: What are the advantages of using zinc in die casting?

A: Low melting point, durability, corrosion resistance.

19. Q: Why is aluminum used in automotive applications?

A: Lightweight, strong, good thermal properties.

20. Q: How does magnesium compare to aluminum in die casting?

A: Magnesium is lighter but offers lower strength.

21. Q: What are the key steps in the die casting process?

A: Molten metal injection, cooling, ejection, trimming.

22. Q: Why is surface finishing important?

A: Improves aesthetics, corrosion resistance, and durability.

23. Q: What is the function of gates in die casting molds?

A: Control metal flow into the mold cavities.

24. Q: How are ejector pin marks managed?

A: By specifying placement in the design process.

25. Q: What are the benefits of clearcoats in automotive painting?

A: Protects paint layers and controls gloss levels.

26. Q: Name three materials used for powder coating.

A: Epoxy, polyester, urethane.

27. Q: What is deep drawing?

A: Shaping sheet metal by drawing it into a die using a punch.

28. Q: What is the main use of stamping in manufacturing?

A: Producing automotive body parts.

29. Q: What is spinning, and where is it applied?

A: Forming metal using a lathe; used for round, complex shapes like cookware.

30. Q: What is slide forming?

A: A process for creating small, intricate metal parts using a series of punches.