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Test your basic knowledge |
Manufacturing Processes
Start Test
Study First
Subject
:
engineering
Instructions:
Answer 26 questions in 15 minutes.
If you are not ready to take this test, you can
study here
.
Match each statement with the correct term.
Don't refresh. All questions and answers are randomly picked and ordered every time you load a test.
This is a study tool. The 3 wrong answers for each question are randomly chosen from answers to other questions. So, you might find at times the answers obvious, but you will see it re-enforces your understanding as you take the test each time.
1. Re- it is used to quantify flow characteristics. It represents the ratio of the inertia to the viscous forces in fluid flow. Re= vDp/n v= velocity D= diameter of the channel p and n= viscosity and density of the liquid
Reynolds Number
Re Range
Incomplete casting
Solidification Time
2. Or short local solidification times - the structure becomes finer with smaller dendrite arm spacing.
Higher cooling rates (10^4 K/s)
Basic Gravity Casting System
Solidification Time
Fluidity
3. The structures developed are amorphous ('without shape' - or non - crystalline solid is a solid that lacks the long- range order characteristic of a crystal). As the structures develop - the resulting grain sizes influence the properties of the casti
Even higher cooling rates (10^6 to 10^8 K/s)
Flow Characteristics
Gate
Metallic projections
4. Avoid turbulence in gating system - the flow is highly chaotic and can lead to aspiration. Laminar flow is ideal
Basic Steps of Casting
Flow Characteristics
Characteristics of molten metal
Incomplete casting
5. Defects such as folds - laps - scars - adhering sand layers.
Defective surface
Reynolds Number
Incomplete casting
Eutectics
6. Premature solidification - not enough metal poured.
Incomplete casting
Defective surface
Shrinkage
Basic Steps of Casting
7. The law of mass continuity states that - for incompressible liquids and in a system with impermeable walls the rate of flow is constant. Q=Asub1vsub1 = Asub2vsub2 - Q= volume rate of flow (such as m^3/s) - A= cross sectional area of the liquid strea
Higher cooling rates (10^4 K/s)
Basic Steps of Casting
Even higher cooling rates (10^6 to 10^8 K/s)
Mass Continuity
8. The portion of the runner through which the molten metal enters the mold cavity.
Gate
Sprue Design
Mass Continuity
Important considerations in casting operations
9. The heat released or absorbed by a body during a change of state without change of temperature. The term most often refers to a phase transition - such as melting of ice or the boiling of water. Pure metals solidify at constant temperatures - After t
Reynolds Number
Flow Characteristics
Higher cooling rates (10^4 K/s)
Latent Heat
10. Atapered vertical channel through which the molten metal flows downward in the mold.
Basic Steps of Casting
Sprue
Sprue Design
Risers (or feeders)
11. Solidify in similar manner as pure metals; as pure metals freezing range approaches zero - the solidification front moves as a plane without forming a mushy zone. The type of structure developed after solidification depends on the composition of the
Eutectics
Solidification Time
Reynolds Number
Higher cooling rates (10^4 K/s)
12. 1.) Viscosity- varies by temp. 2.) Surface Tension - high surface tension reduces fluidity 3.) Inclusions - can have an adverse effect on fluidity 4.) Mold Design - design - dimensions of the sprue - runners - and risers all affect fluidity. 5.) Heat
Porosity
Sprue Design
Characteristics of molten metal
Gate
13. The width of the mushy zone - in which both liquid and solid phases are present - is described in the terms of a temperature difference - known as the: freezing range = (TL - TS) - which is a time not a temp.
Sprue Design
Mushy Zone
Slow cooling rates (10^2 K/s)
Mass Continuity
14. The higher the Reynolds Number the greater the tendency for turbulent flow to occur. In a gating system Re ranges from 2 -000 to 20 -000. A value of up to 2 -000 represents Laminar flow.
Incomplete casting
Sprue Design
Re Range
Characteristics of molten metal
15. 1. Pouring molten metal into a mold patterned after the part to be manufactured. 2. Allowing it to solidify 3. Removing the part from the mold
Basic Steps of Casting
Characteristics of molten metal
Sprue
Mushy Zone
16. 1.) Contraction of molten metal as it cools prior to solidification. 2.) Contraction of the metal during phase change from liquid to solid (latent heat of fusion). 3.) Contraction of the solidified metal (casting) as its temp. drops to ambient temp.
Even higher cooling rates (10^6 to 10^8 K/s)
Shrinkage
Runners
Slow cooling rates (10^2 K/s)
17. A function of the volume of a casting and it surface area (Chvorinov's rule) = C(volume/surface area)
Solidification Time
Porosity
Risers (or feeders)
Runners
18. The capability of molten metal to fill mold cavaties. Consists of two basic factors: 1.) Characteristics of the molten metal 2.) Casting parameters
Basic Steps of Casting
Re Range
Basic Gravity Casting System
Fluidity
19. The design of a sprue must be tapered from top to bottom as long as the pressures are the same - Asub1/Asub2 = sqrt(hsub2/hsub1)
Fluidity
Mushy Zone
Flow Characteristics
Sprue Design
20. Porous area of a casting caused by shrinkage - or dissolved gases - or both.
Basic Gravity Casting System
Porosity
Re Range
Gate
21. Or long local solidification times result in coarse dendritic structures with large spacing between dendrite arms.
Slow cooling rates (10^2 K/s)
Risers (or feeders)
Mushy Zone
Re Range
22. Serve as reservoirs of molten metal to supply any molten metal necessary to prevent porosity due to shrinkage during solidification.
Risers (or feeders)
Important considerations in casting operations
Higher cooling rates (10^4 K/s)
Sprue
23. Are the channels that carry the molten metal from the sprue into the mold cavity or connect the sprue to the gate.
Even higher cooling rates (10^6 to 10^8 K/s)
Runners
Sprue Design
Solidification Time
24. 1. Pouring basin or cup - where the molten metal is poured. 2. Gating system - molten metal flows through gating system
Slow cooling rates (10^2 K/s)
Higher cooling rates (10^4 K/s)
Characteristics of molten metal
Basic Gravity Casting System
25. 1. Flow of molten metal into the mold cavity 2. Solidification and cooling of the metal in the mold 3. Influence of the type of mold material
Eutectics
Important considerations in casting operations
Fluidity
Basic Gravity Casting System
26. Defects consisting of fins - flash - or projections.
Mushy Zone
Reynolds Number
Sprue Design
Metallic projections