Manufacturing Processes Exam 1

true

A binary phase diagram is a phase diagram indicating the phases of two metallic elements as a function of composition and temperature at atmospheric pressure: (a) true or (b) false?

foundry

A factory that performs casting processes is called which of the following (one best answer): (a) casting plant, (b) foundry, (c) ingot-making plant, (d) metal working plant or (e) molding plant?

actual processing time, inspection time, and work handling time

A typical production cycle time consists of which of the following elements (three best answers): (a) actual processing time, (b) inspection time, (c) rest breaks for the worker, (d) time to withdraw starting materials from storage, (e) tool fabrication time, (f) tool handling time, and (g) work handling time?

true

Annealing consists of heating a metal to a suitable temperature, holding at that temperature for a certain time, and then slowly cooling: (a) true or (b) false?

austenite

As temperature is increased to slightly above 912C (1674F), pure iron transforms into which one of the following phases ;(a) austenite, (b) cementite, (c) delta, or (d) ferrite?

true

Casting is a process in which molten metal flows into a mold where it solidifies in the shape of the mold cavity; the term casting also applies to the part that is made by this process: (a) true or (b) false?

extrusion and forging

Deformation processes include which of the following (two correct answers): (a) casting, (b) drilling, (c) extrusion, (d) forging, (e) milling, (f) painting, and (g) sintering?

cast iron and steel

Ferrous metals include which of the following (two correct answers): (a) aluminum, (b) cast iron, (c) copper, (d) gold, and (e) steel?

true

Hardenability refers to the relative capacity of a steel to be hardened by transformation to martensite: (a) true or (b) false?

resistance to permanent indention

Hardness is best defined as which one of the following: (a) energy absorbed by a material when an object strikes its surface, (b) resistance to bending, (c) resistance to permanent indention, or (d) resistance to scratching?

molybdenum and tungsten

High-speed steels are used in cutting tools for machining. Which of the following alloying elements are used in the highest proportion in high-speed steel (two correct answers): (a) carbon, (b) manganese, (c) molybdenum, (d) nickel, (e) tungsten, and (f) vanadium?

product layout

High-volume production of assembled products is most closely associated with which one of the following layout types: (a) cellular layout, (b) fixed position layout, (c) process layout, or (d) product layout?

elastic region

Hooke's Law defines which one of the following regions of the stress strain relationship for engineering materials: (a) elastic region, (b) plastic region, or (c) neither?

engineering strain

If engineering strain and true strain were measured simultaneously during a tensile test, which would have the higher value: (a) engineering strain or (b) true strain?

true stress

If engineering stress and true stress were measured simultaneously during a tensile test, which would have the higher value: (a) engineering stress or (b) true stress?

greater than

In a sand-casting mold, the V/A ratio of the riser should be (a) equal to, (b) greater than, or (c) smaller than the V/A ratio of the casting itself?

channel in the mold leading from the downsprue

In casting processes, a runner is which one of the following: (a) channel in the mold leading from the downsprue to the main mold cavity, (b) worker who moves the molten metal to the mold, or (c) vertical channel into which molten metal is poured into the mold?

box which holds the cope and drag

In casting, a flask is which one of the following: (a) beverage bottle for workers who perform casting, (b) box which holds the cope and drag, (c) container for holding liquid metal, or (d) metal which extrudes between the mold halves?

solidus

In the heating of most metal alloys, melting begins at a certain temperature and concludes at a higher temperature. In these cases, which of the following temperatures marks the beginning of melting? (a) liquidus (b) maximus (c) solidus (d) spartacus

A phase consisting of an iron-carbon solution whose composition is the same as the austenite from which it was derived

Martensite can best be defined as which one of the following? (a) a mixture of ferrite and carbide phases obtained by rapid cooling of austenite (b) a mixture of ferrite and carbide phases obtained by slow cooling of austenite (c) a phase consisting of an iron-carbon solution whose composition is the same as the austenite from which it was derived (d) a solution of cementite in ferrite obtained by rapid cooling of austenite

external chills

Metal inserts in the walls of a sand mold cavity designed to remove heat from the molten metal more rapidly than the surrounding sand are called which one of the following: (a) external chills, (b) internal chills, (c) pipes, or (d) sprues?

primary industry

Mining is classified in which one of the following industry categories: (a) agricultural industry, (b) manufacturing industry, (c) primary industry, (d) secondary industry, (e) service industry, or (f) tertiary industry?

true

Most hardness tests involve pressing a hard object into the surface of a test specimen and measuring the resulting indention or its effect: (a) true or (b) false?

brine

Of the following quenching media, which one produces the most rapid cooling rate: (a) air, (b) brine, (c) oil , or (d) pure water?

pressing and sintering

Particulate processing of metals and ceramics involves which two of the following steps: (a) adhesive bonding, (b) deformation, (c) forging, (d) material removal, (e) melting, (f) pressing, and (g) sintering?

capital goods

Products purchased by companies to produce products or provide services are called which one of the following: (a) assembled products, (b) capital goods, (c) consumer goods, (d) final products, or (e) manufactured products?

expendable mold

Sand casting is which of the following types of casting process: (a) expendable mold or (b) permanent mold?

contraction during the phase change from liquid to solid

Solidification shrinkage in casting is defined as which one of the following: (a) liquid contraction during cooling prior to solidification, (b) liquid contraction during cooling and solidification, (c) contraction during the phase change from liquid to solid, or (d) thermal contraction of the solidified casting during cooling to room temperature?

strain hardening

The flow curve describes the property of metals known as which one of the following: (a) ductility, (b) engineering strain, (c) fracture stress, (d) strain hardening, or (e) tensile strength?

core

The internal surfaces of a casting are determined during the casting process by means of which one of the following: (a) core, (b) gating system, (c) parting line, (d) pattern, or (e) sprue?

Young's modulus

The modulus of elasticity is also known as which one of the following: (a) elastic limit, (b) strain hardening exponent, (c) strength coefficient, or (d) Young's modulus?

over sized

The pattern that determines the geometry of the casting in expendable mold processes is usually made (a) over sized, (b) the same size, (c) undersized relative to the dimensions of the casting?

false

The plastic region of the stress strain curve for a metal is characterized by a proportional relationship between stress and strain: (a) true or (b) false?

a non proportional relationship between stress and strain

The plastic region of the stress-strain curve for a metal is characterized by ________________. (a) a non proportional relationship between stress and strain (b) an inverse relationship between stress and strain (c) an additive relationship between stress and strain (d) an S-curve

torsion test

The shear strength of a metal is commonly determined in which one of the following tests: (a) bending test, (b) compression test, (c) flexure test, (d) tensile test, or (e) torsion test?

increases

The strength and hardness of steel increases as carbon content (a) increases or (b) decreases?

true

The term plant capacity refers to the maximum rate of production that a factory can achieve under assumed labor manning levels, hours of operation per week, and other operating conditions: (a) true or (b) false?

rubber

The term vulcanization is associated with which one of the following: (a) adhesives, (b) bronze, (c) fire, (d) rubber, or (e) wood?

Indicates how cooling rate affects the transformation of austenite into various possible phases

The time-temperature-transformation curve (TTT curve) for steel can best be described by which one of the following? (a) Indicates how annealing is used to achieve a given desired microstructure (b) Indicates how cooling rate affects the transformation of austenite into various possible phases (c) Indicates how martensite is gradually transformed into tempered martensite as a function of time (d) Indicates how various phases are obtained during heating as a function of time and temperature?

tempering

The treatment in which the brittleness of martensite is reduced is called which one of the following: (a) aging, (b) annealing, (c) austenitizing, (d) normalizing, (e) quenching, or (f) tempering?

cope

The upper half of a sand-casting mold is called which one of the following: (a) cope, (b) drag, (c) flask, or (d) pattern?

time between pouring and complete solidification

Total solidification time is defined as which one of the following: (a) time between pouring and complete solidification, (b) time between pouring and cooling to room temperature, (c) time between solidification and cooling to room temperature, or (d) time to give up the heat of fusion?

it increases erosion of the mold surfaces

Turbulence during pouring of the molten metal is undesirable for which of the following reasons? (a) it causes discoloration of the mold surfaces (b) it dissolves the binder used to hold together the sand mold (c) it increases erosion of the mold surfaces (d) it increases the mold filling time

chromium and nickel

Which of the following alloying elements are most commonly associated with stainless steel (two best answers): (a) chromium, (b) manganese, (c) molybdenum, (d) nickel, and (e) tungsten?

compression, tensile, and shear

Which of the following are the three basic types of static stresses to which a material can be subjected (three correct answers): (a) compression, (b) hardness, (c) reduction in area, (d) shear, (e) tensile, (f) true stress, and (f) yield?

increase hardness, reduce brittleness, and relieve stresses

Which of the following are the usual objectives of heat treatment (three best answers): (a) increase hardness, (b) increase melting temperature, (c) increase recrystallization temperature, (d) reduce brittleness, (e) reduce density, and (f) relieve stresses?

to reduce brittleness and to relieve stresses

Which of the following are typical reasons to anneal a metal (two correct answers): (a) to heat the metal for hot working, (b) to increase strength and hardness, (c) to reduce brittleness, (d) to reduce ductility, and (e) to relieve stresses?

medium quantity production and setup time between batches is a disadvantage

Which of the following features and terms are associated with batch production: (a) cellular manufacturing, (b) mass production, (c) medium quantity production, (d) production equipment is dedicated to one product, and (e) setup time between batches is a disadvantage?

beverages, power utilities, and publishing

Which of the following industries are classified as secondary industries (three correct answers): (a) beverages, (b) financial services, (c) fishing, (d) power utilities, (e) publishing, and (f) transportation?

publishing, power utilities, beverages, and aerospace

Which of the following industries are classified as secondary industries? (a) financial services, transportation, entertainment, and real estate (b) fishing, mining, livestock, and petroleum (c) transportation, aerospace, livestock, and publishing (d) publishing, power utilities, beverages, aerospace

gray cast iron

Which of the following is the most important cast iron commercially: (a) ductile cast iron, (b) gray cast iron, (c) malleable iron, or (d) white cast iron?

copper

Which of the following metals is noted for its good electrical conductivity (one best answer): (a) copper, (b) gold, (c) iron, (d) nickel, or (e) tungsten?

grinding, milling, and turning

Which of the following operations are classified as material removal processes (three correct answers): (a) anodizing, (b) brazing, (c) forging, (d) grinding, (e) milling, (f) sintering, and (g) turning?

casting and molding

Which of the following processes start with a material that is in a fluid or semi fluid state and solidifies the material in a cavity (two correct answers): (a) casting (for molten metal), (b) forging, (c) machining, (d) molding (for hot polymer), (e) pressing, and (f) turning?

high electrical resistivity

Which of the following properties or characteristics do not apply to metals: (a) good thermal conductivity, (b) high strength, (c) high electrical resistivity, and (d) high stiffness?

elastic and strain hardening

Which of the following types of stress-strain relationship best describes the behavior of most metals at room temperature? (a) elastic and perfectly plastic (b) elastic and strain hardening (c) perfectly elastic (d) none of the above

carbon

Which one of the following elements is the most important alloying ingredient in steel: (a) carbon, (b) chromium, (c) nickel, (d) molybdenum, or (e) vanadium?

ceramic

Which one of the following engineering materials is defined as a compound containing metallic (or semi-metallic) and nonmetallic elements: (a) ceramic, (b) composite, (c) metal, or (d) polymer?

press

Which one of the following is a type of machine used to perform extrusion: (a) forge hammer, (b) milling machine, (c) rolling mill, (d) press, or (e) torch?

zinc

Which one of the following is not a common alloying ingredient in steel: (a) chromium, (b) manganese, (c) nickel, (d) vanadium, (e) zinc?

the maximum load divided by the original area of the specimen

Which one of the following is the correct definition of ultimate tensile strength, as derived from the results of a tensile test on a metal specimen: (a) the stress encountered when the stress strain curve transforms from elastic to plastic behavior, (b) the maximum load divided by the final area of the specimen, (c) the maximum load divided by the original area of the specimen, or (d) the stress observed when the specimen finally fails?

diamond

Which one of the following materials has the highest modulus of elasticity: (a) aluminum, (b) diamond, (c) steel, (d) titanium, or (e) tungsten?

magnesium

Which one of the following metals has the lowest density: (a) aluminum, (b) magnesium, (c) manganese, (d) tin, (e) titanium, or (f) zinc?

tin

Which one of the following metals has the lowest melting point: (a) aluminum, (b) lead, (c) magnesium, (d) tin, or (e) zinc?

carburizing

Which one of the following surface-hardening treatments is the most common: (a) boronizing, (b) carbonitriding, (c) carburizing, (d) chromizing, (e) nitriding?