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engineering
materials science engineering

Questions and Answers of Materials Science Engineering

What is a match plate and how does it aid molding?
How is a cope-and-drag pattern different from a matchplate pattern? When might this be attractive?
Figure CS-14 presents a cut-away sketch of the moveable and fixed jaw pieces of a heavy-duty vise that might see use in vocational schools, factories and machine shops. The vise is intended to have a
What are some of the major disadvantages of the expendable-mold casting processes?
How does low-pressure permanent mold casting differ from the traditional gravity-pour process?
What are some of the attractive features of the low-pressure permanent mold process?
What are some additional advantages of vacuum permanent mold casting over the low-pressure process?
Contrast the feeding pressures on the molten metal in low-pressure permanent molding and die casting.
Contrast the materials used to make dies for gravity permanent mold casting and die casting. Why is there a notable difference?
Why might the pressure on the molten metal vary during the die casting cycle?
For what types of materials would a hot-chamber die-casting machine be appropriate?
What metals are routinely cast with cold-chamber die-casting machines?
How does the air in the mold cavity escape in the die-casting process?
Are risers employed in die casting? Can sand cores be used?
What are some possible limitations of multiple-use molds?
What are some of the advantages of the heated-manifold direct-injection die casting of zinc?
When might low quantities be justified for the die-casting process?
Describe the squeeze-casting process.
What is a thixotropic material? How does it provide an attractive alternative to squeeze casting?
What are some of the attractive features of semisolid casting?
Contrast the structure and properties of the outer and inner surfaces of a centrifugal casting.
What is the difference between semicentrifugal casting and centrifuging?
What are some of the factors that influence the selection of a furnace type or melt procedure in a casting operation?
In cupola-melting operations, why are many of the chemistry control operations performed in the ladle, via ladle metallurgy?
What are some of the ways that the melting rate of a cupola can be increased?
What are some of the attractive features of arc furnaces in foundry applications?
Why are channel induction furnaces attractive for metal-holding applications where molten metal must be held at a specified temperature for long periods of time?
What are the primary functions of a pouring operation?
What are some of the typical cleaning and finishing operations that are performed on castings?
What are some common ways to remove cores from castings? To remove runners, gates, and risers?
How might defective castings be repaired to permit successful use in their intended applications?
Describe some of the process advantages of permanent mold casting.
What are some of the ways that industrial robots can be employed in metal-casting operations?
Describe some of the features that affect the cost of a cast product. Why might the cost vary significantly with the quantity to be produced?
Why might low production runs be unattractive for permanent mold casting?
What features affect the life of a permanent mold?
How is venting provided in the permanent mold process?
The item depicted in Figure CS-15 is the baseplate of a high-quality household steam iron. It is rated for operation at up to 1200 watts and is designed to provide both steady steam and burst of
What type of product would be considered to be a prospect for powder metallurgy manufacture?
Why is powder metallurgy a key process in producing products from amorphous or rapidly solidified powders?
Why is flow rate an important powder characterization property?
What is apparent density, and how is it related to the final density of a P/M product?
What is green strength, and why is it important to the manufacture of high-quality P/M products?
How might the use of a graphite lubricant be fundamentally different from the use of wax or stearates?
What types of composite materials can be produced through powder metallurgy?
What are some of the objectives of the compacting operation?
What limits the cross-sectional area of most P/M parts to several square inches or less?
What were some of the earliest powder metallurgy products?
Describe the movement of powder particles during compaction. What feature is responsible for the fact that powder does not flow and transmit pressure like a liquid?
For what conditions might a double-action pressing be more attractive than compaction with a single moving punch?
How is the final density of a P/M product typically reported?
Describe the four common classes of conventional powder metallurgy products.
What is isostatic compaction? For what product shapes might it be preferred?
What is the benefit of warm compaction?
What are some of the ways that the binder can be removed from metal injection molded parts?
Describe the ideal geometry for a metal injection molded product.
For what types of parts is P/M injection molding an attractive manufacturing process?
What are the three stages associated with most P/M sintering operations?
Why is it necessary to raise the temperature of P/M compacts slowly to the temperature of sintering?
Why is a protective atmosphere required during sintering?
What are some of the attractive properties of hot isostatic pressed products?
What are some of the major limitations of the HIP process?
What is the attractive feature of the sinter-HIP and pressure-assisted sintering processes?
Which metal family currently dominates the powder metallurgy market?
Describe the spray forming process, and the unique feature that enables production of high-density, fine grain size products.
Why can we not use the original compaction tooling to perform repressing?
What is the major difference between repressing and P/M forging?
What is the difference between impregnation and infiltration? How are they similar?
What role does product density play when determining how to heat treat, machine, or surface treat a powder metallurgy product?
What advice would you want to give to a person who is planning to convert the manufacture of a component from die casting to powder metallurgy?
What are some P/M products that have been intentionally de-signed to use the porosity or permeability features of the process?
Give an example of a product where two or more materials are mixed to produce a composite P/M product with a unique set of properties.
Why is finish machining such an expensive component in parts manufacture?
Describe some of the materials that can be made into P/M parts that could not be used for processes such as casting and forming.
Why is P/M not attractive for parts with low production quantities?
What features of the P/M process often compensate for the higher cost of the starting material?
How might you respond to the criticism that P/M parts have inferior strength?
What is the most common method of producing metal powders?
What are some of the other techniques that can be employed to produce particulate material?
Which of the powder manufacturing processes are likely to be restricted to the production of elemental (unalloyed) metal particles?
When specifying the starting material for casting processes, the primary variables are chemistry and purity. Any structure of the starting material will be erased by the melting. For forming
In conventional powder metallurgy manufacture, the material is compacted with applied pressure at room temperature and then sintered by elevated temperature at atmospheric pressure. With P/M hot
The component pictured in Figure CS-16 is the impeller of a water pump used by a major automotive manufacturer. The outer diameter of the component is 2.75 in. and the total height of the six curved
What is plasticity?
Why is it important to be able to predict the forces or powers required to perform specific forming processes?
Why is it important to know and control the thermal history of a metal as it undergoes deformation?
Why is it often difficult to determine the specific relationships between independent and dependent variables?
What features limit the value of laboratory experiments in modeling metalforming processes?
What features have contributed to the expanded use of process modeling?
What are some of the uses or applications of process models?
What are some of the general assets of the metal deformation processes? Some general liabilities?
What type of information about the material being deformed may be particularly significant to a metalforming engineer?
Why is friction such an important parameter in metalworking operations?
What are several ways in which the friction conditions during metalworking differ from the friction conditions found in most mechanical equipment?
According to modern friction theory, frictional resistance can be attributed to what two physical phenomena?
Discuss the significance of wear in metalforming: wear on the workpiece and wear on the tooling.
Lubricants are often selected for properties in addition to their ability to reduce friction. What are some of these additional properties?
If the temperature of a material is increased, what changes in properties might occur that would promote the ease of deformation?
Define the various regimes of cold working, warm working, and hot working in terms of the melting point of the material being formed.
What are some of the attractive manufacturing and metallurgical features of hot-working processes?

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