Metals

Question 1

What are the three common metals?

Answer 1

• Ferrous
• Non-ferrous
• Alloys

Question 2

Name some Ferrous metals

Answer 2

• Cast iron
• Steels
• Mild steel
• Medium carbon steel
• High carbon steel

Question 3

Name some non-ferrous metals

Answer 3

• Aluminium
• Copper
• Lead
• Tin
• Zinc

Question 4

Name some Alloys

Answer 4

• Brass
• Bronze
• Stainless steel

Question 5

What does Ferrous metal mean?

Answer 5

Metals which contain iron

Question 6

What does Non-Ferrous metal mean?

Answer 6

Metals which do not contain iron

Question 7

What does Ferrous alloy mean?

Answer 7

A mixture of two or more metals but at least one metal is iron

Question 8

What does Non-Ferrous alloy mean?

Answer 8

A mixture of two or more metals which do not contain iron.

Question 9

Name some common metals

Answer 9

• Iron
• Copper
• Aluminium
• Lead
• Tin
• Zinc

Question 10

What is pig iron?

Answer 10

Iron which has just come out of the blast furnace and is not at a high enough quality yet.

Question 11

How is pig iron converted?

Answer 11

By adding carbon into its structure, this is done in a oxygen furnace.

Question 12

Where is mild steel usually used in?

Answer 12

• Nuts
• Bolts
• Washers

Question 13

Where is medium carbon steel usually used in?

Answer 13

• Springs

- Garden tools

Question 14

Where is high carbon steel usually used in?

Answer 14

• Hand tools
• Dot punchers
• Chisels

Question 15

Where is cast iron usually used in?

Answer 15

• Machine parts
• Brake discs
• Engines

Question 16

What is aluminium use in?

Answer 16

-Kitchenware e.g. saucepans

Question 17

What is Copper used in?

Answer 17

• Electrical contacts
• Domestic pipes for heating and water
• Electrical cables

Question 18

What is Gold used in?

Answer 18

• Jewelry

- SIM cards

Question 19

What is lead used in?

Answer 19

-Brickwork

Question 20

What are the benefits of alloying?

Answer 20

• Changes the melting point
• Changes the colour
• Increases strength, hardness and ductility
• Enhances resistance to corrosion
• Changes electrical/thermal properties
• Improves flow properties

Question 21

What does oxidation mean?

Answer 21

when a material comes in contact with oxygen the result is an oxide layer is formed over the surface of the metal. this acts as protection.

Question 22

What is work hardening?

Answer 22

The name given to the effects of processing e.g. rolling, bending or hammering a material while it is cold.

Question 23

What are the common heat treatments?

Answer 23

• Annealing
• Hardening
• Tempering
• Normalising

Question 24

What is annealing?

Answer 24

heating up metal so that you can easily work with it

Question 25

What is hardening?

Answer 25

heating the metal to cherry red followed by rapid cooling

Question 26

What is tempering?

Answer 26

removing any brittleness that may be present in the hardening material.

Question 27

What is welding?

Answer 27

The term given to joining materials together by heat fusing the components together

Question 28

What is finishing?

Answer 28

the removal of blemishes or blurs in a material

Question 29

What is press forming?

Answer 29

Press forming is carried out at room temperature and it is when metals are press and cut into shapes

Question 30

What is embossing?

Answer 30

similar to press forming but is used to make decorative features which are punched into metals.

Question 31

What is sand casting?

Answer 31

this is where you use sand as molds and fill it with molten metal.

Question 32

What are the advantages of using sand casting?

Answer 32

- Complex 3D shapes - Can produce hollow sections - Good for small runs - Automated processes are good for the long run

Question 33

What are the disadvantages of sand casting?

Answer 33

- Poor surface finishing - Not accurate as die casting - Low rate of out put only good for small runs

Question 34

What is die casting?

Answer 34

melting metal and pouring it into a mold

Question 35

What is a Flux?

Answer 35

A chemical used to Prevent oxidation of the material at the joint areas

Question 36

What is sintering?

Answer 36

process where materials are crushed into powder and compacted into a die which will give the product its final shape.

Question 37

What is forging?

Answer 37

It can be carried out by hand or machine, forging is done while the metal is hot as it requires less energy to achieve the result. you hammer the metal into place.