Mech E 2653 Exam 2
In the "Big Four" consumable electrode arc welding processes, the depth-to-width ratio is: Low (<1) High (>1) About 1:1
About 1:1
When you have a three-part flame in OAW, you probably have too much: Oxygen Acetylene
Acetylene
Resin or filler material is polymerized to create a bond. Deformation Bonding Adhesive Bonding Brazing & Soldering Fusion Welding Diffusion Bonding
Adhesive Bonding
What distinguished sheet forming from bulk forming? Thickness of the material Type of machinary All of them Lower forces are required
All of them
Which factor induced is used to induce permanent joints in two materials? Metallurgical conditions Pressure Temperature All of them
All of them
Additive Manufacturing is being used for: Manufacture of rapid tooling All of these Direct product manufacture Prototype manufacture
All of these
Ink-jet deposition can build with: Low-melting-point metal All of these Thermoplastic polymer Wax
All of these
Possible types of rapid tooling include: All of these Patterns, molds and cores Jigs, fixtures, templates and gages Die-casting dies
All of these
Prototype products are used to: All of these Provide a visual aid Assess form, fit, and function Evaluate possible concepts
All of these
The "Perfect Metallurgical Bond" requires surfaces that are: All of these Perfectly flat Perfectly aligned Perfectly clean
All of these
The "Perfect Metallurgical Bond" requires surfaces that are: Perfectly clean All of these Perfectly flat Perfectly aligned
All of these
An attractive feature of electron beam melting is: Able to produce fully-dense metal products Can work with high-temperature metals, like tool steels and superalloys All of these are attractive features Can work with reactive metals, like titanium
All of these are attractive features
The molten pool and hot metal of a fusion weld can be "protected" by: Shielding gas A cover slag Any of these A vacuum
Any of these
The forces required for diffusion bonding: Are only what is necessary to establish and maintain firm contact Must be great enough to induce plastic deformation
Are only what is necessary to establish and maintain firm contact
In resistance spot welding, we want the greatest electrical resistance to be: At the interface between the metals being joined At the electrode-workpiece interfaces In the electrodes In the metal being joined
At the interface between the metals being joined
During cold forming, as deformation progresses, the material: Becomes weaker and more ductile Becomes stronger and more brittle Remains unchanged
Becomes stronger and more brittle
During cold forming, as deformation progresses, the material: Becomes weaker and more ductile Remains unchanged Becomes stronger and more brittle
Becomes stronger and more brittle
The applied forces in extrusion are: Tension Compression
Compression
Which operation can you use to bend a round steel bar? Blanking Deep drawing Compression bending V-bending
Compression bending
Additive or direct-digital processing begins with a: Computer file Rigid die or tooling Part patter
Computer file
Low-angle wire drawing dies are often inefficient due to excessive: Contact friction Internal shear
Contact friction
The chemistry (or composition) of the filler metal used for brazing and soldering is ___ that of the materials being joined. The same as Different from
Different from
A solid-state bond is formed by holding materials in contact for long period of time at elevated temperature Adhesive Bonding Brazing & Soldering Deformation Bonding Diffusion Bonding Fusion Welding
Diffusion Bonding
A solid-state bond is formed by holding materials in contact for long period of time at elevated temperature Brazing & Soldering Diffusion Bonding Adhesive Bonding Deformation Bonding Fusion Welding
Diffusion Bonding
A solid-state bond is formed by holding materials in contact for long period of time at elevated temperature Brazing & Soldering Fusion Welding Adhesive Bonding Diffusion Bonding Deformation Bonding
Diffusion Bonding
Has the largest fusion zone area Submerged Arc Welding (SAW) Gas-Metal Arc Welding (GMAW) Shielded Metal Arc Welding (SMAW) Flux-cored Arc Welding (FCAW)
Submerged Arc Welding (SAW)
Since it has the deepest penetration it can join thick pieces of steel in a single welding pass Submerged Arc Welding (SAW) Shielded Metal Arc Welding (SMAW) Flux-cored Arc Welding (FCAW) Gas-Metal Arc Welding (GMAW)
Submerged Arc Welding (SAW)
The arc is buried beneath a layer of flux and is not visible to observers Shielded Metal Arc Welding (SMAW) Submerged Arc Welding (SAW) Flux-cored Arc Welding (FCAW) Gas-Metal Arc Welding (GMAW)
Submerged Arc Welding (SAW)
Adhesive bonding can be used to bond: Only similar materials to one another Virtually anything to anything.
Virtually anything to anything.
To produce a significant change in cross-sectional area using the extrusion process: We can use a single die We will need multiple dies and multiple passes
We can use a single die
To produce a significant change in cross-sectional area using the wire drawing process: We will need multiple dies and multiple passes We can use a single die
We will need multiple dies and multiple passes
A simple tooling method for obtaining multiple operations such a piercing and blanking while getting a finished part from each press stroke is a progressive die an average die a turret press a compound die
a turret press
This process is also called TIG welding for Tungsten Inert Gas Gas Tungsten Arc Welding (GTAW) Electron Beam Welding (EBW) Oxyacetylene Welding (OAW) Resistance Spot Welding (RSW) Laser Welding (LBW) Plasma Arc Welding (PAW)
Gas Tungsten Arc Welding (GTAW)
This process is also called TIG welding for Tungsten Inert Gas Resistance Spot Welding (RSW) Plasma Arc Welding (PAW) Laser Welding (LBW) Oxyacetylene Welding (OAW) Electron Beam Welding (EBW) Gas Tungsten Arc Welding (GTAW)
Gas Tungsten Arc Welding (GTAW)
If we are producing a large part that requires a considerable amount of deformation, we would prefer to do the forming process at a ___ temperature. Low High
High
Resistance spot welding has a ___ rate of heat input. High Low Medium
High
In all metal forming processes, the applied stresses must be ___ than the yield strength of the material. Higher Lower
Higher
In the "Big Four" consumable electrode arc welding processes, the rate of heat input is: Medium High Low
Medium
Because it is limited to the lowest currents, it has the slowest deposition rate and shallowest penetration Gas-Metal Arc Welding (GMAW) Flux-cored Arc Welding (FCAW) Submerged Arc Welding (SAW) Shielded Metal Arc Welding (SMAW)
Shielded Metal Arc Welding (SMAW)
Finite length "stick" electrodes are used Shielded Metal Arc Welding (SMAW) Gas-Metal Arc Welding (GMAW) Submerged Arc Welding (SAW) Flux-cored Arc Welding (FCAW
Shielded Metal Arc Welding (SMAW)
Finite length "stick" electrodes are used Submerged Arc Welding (SAW) Shielded Metal Arc Welding (SMAW) Flux-cored Arc Welding (FCAW) Gas-Metal Arc Welding (GMAW)
Shielded Metal Arc Welding (SMAW)
Requires the least expensive equipment Submerged Arc Welding (SAW) Shielded Metal Arc Welding (SMAW) Gas-Metal Arc Welding (GMAW) Flux-cored Arc Welding (FCAW)
Shielded Metal Arc Welding (SMAW)
The flux is a coating on the outside of the electrode Shielded Metal Arc Welding (SMAW) Gas-Metal Arc Welding (GMAW) Submerged Arc Welding (SAW) Flux-cored Arc Welding (FCAW)
Shielded Metal Arc Welding (SMAW)
The Fused Deposition Modeling process bears similarity to: A hot-melt glue gun A ink-jet printer
A hot-melt glue gun
In the 3-D Printing process, the scanning ink-jet is depositing: A liquid binder that joins the powder particles Molten build material
A liquid binder that joins the powder particles
In stereolithography, a layer is cured by ___. In the solid ground curing process, the layer is cured by ____. A scanning UV laser ; A single shot of UV light A single shot of UV light ; A scanning UV laser
A scanning UV laser ; A single shot of UV light
Because a fusion weld is actually a mini-casting, one might expect the possibility of: Both of these Gas porosity Shrinkage
Both of these
Because a fusion weld is actually a mini-casting, one might expect the possibility of: Shrinkage Both of these Gas porosity
Both of these
Direct Metal Deposition and Laser-Engineered Net Shaping both use: A stream of powder particles A laser Both of these
Both of these
Brazing can be used to join: Both similar and dissimilar materials, even metals to ceramics Only similar or identical materials
Both similar and dissimilar materials, even metals to ceramics
Capillary action draws melted filler metal into the joint. The materials being joined do not melt. Brazing & Soldering Adhesive Bonding Fusion Welding Deformation Bonding Diffusion Bonding
Brazing & Soldering
The primary difference between brazing and soldering is: Soldering is performed at higher temperatures than brazing Brazing is performed at higher temperatures than soldering
Brazing is performed at higher temperatures than soldering
Additive manufacturing builds parts: By joining block segments Building layer-by-layer
Building layer-by-layer
The forging process that produces complex shaped parts to near-net shape is: Closed-die forging Open-die forging
Closed-die forging
Foil is most likely rolled on this type of mill: 4-high Cluster 3-high 2-high
Cluster
Foil is most likely rolled on this type of mill: Cluster 4-high 3-high 2-high
Cluster
Which of the following processes does NOT produce a product with constant cross-section shape? Wire drawing Deep drawing Rolling Extrusion
Deep Drawing
Less weld distortion occurs when the fusion zone is: Deep and narrow Shallow and wide
Deep and narrow
The most desirable fusion zone profile would be: Deep and narrow Shallow and wide Deep and wide
Deep and narrow
Which operation can you use to make a kitchen metallic sink? Extrusion Deep drawing Spinning Roll bending
Deep drawing
Materials are squeezed together under pressure, resulting in plastic deformation and the creation of uncontaminated surfaces Deformation Bonding Brazing & Soldering Adhesive Bonding Fusion Welding Diffusion Bonding
Deformation Bonding
When the forces of deformation are compressive, the deformation should be performed: Cold Hot Either hot or cold is acceptable
Either hot or cold is acceptable
The flux is on the inside of a tubular consumable metal electrode Flux-cored Arc Welding (FCAW) Shielded Metal Arc Welding (SMAW) Gas-Metal Arc Welding (GMAW) Submerged Arc Welding (SAW)
Flux-cored Arc Welding (FCAW)
A unique characteristic of a good bond is a wavy interface between the two base metals Explosive welding Ultrasonic welding Inertia welding Roll bonding Friction welding Cold indentation welding
Explosive welding
Which operation can you use to produce gutters and downspouts? Extrusion Deep drawing V-bending Roll forming
Extrusion
Heat affected zone is a desirable region during welding True False
False
Direct-digital manufacturing can only be used to produce parts from plastics and polymeric materials. True False
Fasle
A high rate of heat input is usually desirable in welding. Which of the following characteristics are associated with a high rate of heat input? Slow cooling of the weld Fast cooling of the weld
Fast cooling of the weld
The flux is on the inside of a tubular consumable metal electrode Shielded Metal Arc Welding (SMAW) Submerged Arc Welding (SAW) Flux-cored Arc Welding (FCAW) Gas-Metal Arc Welding (GMAW)
Flux-cored Arc Welding (FCAW)
Of the two rotational welding processes, this one produces the larger HAZ Roll bonding Inertia welding Cold indentation welding Ultrasonic welding Friction welding Explosive welding
Friction welding
Of the two rotational welding processes, this one produces the larger HAZ Ultrasonic welding Friction welding Roll bonding Explosive welding Inertia welding Cold indentation welding
Friction welding
Portions of the material being joined melts and flows as liquid (along with possible filler metal) to fill the joint Adhesive Bonding Deformation Bonding Fusion Welding Diffusion Bonding Brazing & Soldering
Fusion Welding
Portions of the material being joined melts and flows as liquid (along with possible filler metal) to fill the joint Brazing & Soldering Diffusion Bonding Fusion Welding Adhesive Bonding Deformation Bonding
Fusion Welding
Portions of the material being joined melts and flows as liquid (along with possible filler metal) to fill the joint Diffusion Bonding Adhesive Bonding Brazing & Soldering Deformation Bonding Fusion Welding
Fusion Welding
Since the joint material is a mix of the two materials being joined plus possible filler material, all compositions must be similar. Deformation Bonding Diffusion Bonding Adhesive Bonding Brazing & Soldering Fusion Welding
Fusion Welding
The portion of a weldment that melts during the joining process is called the: Unaffected base metal Fusion zone Heat-affected zone
Fusion zone
When helium gas is used for shielding, this process has been called "Heliarc" welding Plasma Arc Welding (PAW) Electron Beam Welding (EBW) Oxyacetylene Welding (OAW) Gas Tungsten Arc Welding (GTAW) Laser Welding (LBW) Resistance Spot Welding (RSW)
Gas Tungsten Arc Welding (GTAW)
No slag forms, so slag removal is not required Shielded Metal Arc Welding (SMAW) Gas-Metal Arc Welding (GMAW) Flux-cored Arc Welding (FCAW) Submerged Arc Welding (SAW)
Gas-Metal Arc Welding (GMAW)
The widest variety of both ferrous and nonferrous metals can be welded Submerged Arc Welding (SAW) Flux-cored Arc Welding (FCAW) Shielded Metal Arc Welding (SMAW) Gas-Metal Arc Welding (GMAW)
Gas-Metal Arc Welding (GMAW)
The widest variety of both ferrous and nonferrous metals can be welded Submerged Arc Welding (SAW) Gas-Metal Arc Welding (GMAW) Shielded Metal Arc Welding (SMAW) Flux-cored Arc Welding (FCAW)
Gas-Metal Arc Welding (GMAW)
The maximum strength of a brazed joint is: Equal to the strength of the filler metal About half the strength of the filler material Greater than the strength of the filler metal (based on lap joint design)
Greater than the strength of the filler metal (based on lap joint design)
To minimize cracking, it is best if the materials being welded: Are highly restrained Have little restraint
Have little restraint
The region of a weldment that is not melted, but has been heated above some critical temperature that causes a change in the structure and/or properties of the material is called the: Fusion zone Unaffected base metal Heat-affected zone
Heat-affected zone
The hottest arc would be obtained with this shielding gas. Carbon dioxide Helium Argon
Helium
If we are producing a large part that requires a considerable amount of deformation, we would prefer to do the forming process at a ___ temperature. High Low
High
What is the difference between piercing and blanking? type of cut: straight or rounded edges Different presses In blanking, the remaining sheet is the workpiece In blanking, the workpiece is punched out of the sheet
In blanking, the workpiece is punched out of the sheet
The form of extrusion that has the best mechanical efficiency, since it eliminates billet-chamber friction, is: Direct extrusion Indirect (or back-) extrusion
Indirect (or back-) extrusion
The form of extrusion that has the best mechanical efficiency, since it eliminates billet-chamber friction, is: Indirect (or back-) extrusion Direct extrusion
Indirect (or back-) extrusion
Because a heavy spinning flywheel is used as the energy source in this process, very reproducible welds result Ultrasonic welding Roll bonding Explosive welding Inertia welding Cold indentation welding Friction welding
Inertia welding
Solid sheets of material are bonded in: Direct Metal Deposition Laminated-object Manufacturing
Laminated-object Manufacturing
In brazing or soldering, the strength of the filler metal is ___ the strength of the material being joined. Less than The same as Greater than
Less than
Metal deformation processes can be used to shape: All materials Only ductile materials Metals and ceramics
Only ductile materials
Metal deformation processes can be used to shape: Metals and ceramics All materials Only ductile materials
Only ductile materials
The deformation bonding processes can be used to join: All metals and ceramics Only ductile metals All metals
Only ductile metals
Compared to fusion welding, in brazing and soldering operations: Both melt Only the parent material being joined melts Only the filler melts
Only the filler melts
Compared to fusion welding, in brazing and soldering operations: Only the parent material being joined melts Only the filler melts Both melt
Only the filler melts
The blacksmith's hammer and anvil is actually a crude form of: Closed-die forging Open-die forging
Open-die forging
The blacksmith's hammer and anvil is actually a crude form of: Open-die forging Closed-die forging
Open-die forging
Which of the following is a common concern during welding Overlap Misrun Runout Hot spot
Overlap
It's the most portable of all welding techniques Laser Welding (LBW) Electron Beam Welding (EBW) Oxyacetylene Welding (OAW) Plasma Arc Welding (PAW) Resistance Spot Welding (RSW) Gas Tungsten Arc Welding (GTAW)
Oxyacetylene Welding (OAW)
In the stereolithography process, the build material is: Photocurable polymer Metal powder Molten plastic
Photocurable polymer
A "keyhole" can be produced, assuring complete penetration with minimum distortion Laser Welding (LBW) Resistance Spot Welding (RSW) Oxyacetylene Welding (OAW) Plasma Arc Welding (PAW) Electron Beam Welding (EBW) Gas Tungsten Arc Welding (GTAW)
Plasma Arc Welding (PAW
A "keyhole" can be produced, assuring complete penetration with minimum distortion Laser Welding (LBW) Plasma Arc Welding (PAW) Electron Beam Welding (EBW) Gas Tungsten Arc Welding (GTAW) Resistance Spot Welding (RSW) Oxyacetylene Welding (OAW)
Plasma Arc Welding (PAW)
Backup rolls are used to: Keep the width constant Produce uniform thickness Eliminate friction
Produce uniform thickness
Crowning of rolls is done to: Keep the width constant Eliminate friction Produce uniform thickness
Produce uniform thickness
Crowning of rolls is done to: Keep the width constant Produce uniform thickness Eliminate friction
Produce uniform thickness
In the selective laser sintering process, the unfused powder: Remains in place to serve as a support Is vacuumed away between each layer
Remains in place to serve as a support
During hot forming, the strength of the material: Decreases Remains unchanged Increases
Remains unchanged
During hot forming, the strength of the material: Increases Decreases Remains unchanged
Remains unchanged
The primary role of the flux in brazing or soldering is to: Reduce the melting temperature of the material being joined Remove oxides and other impurities (i.e. clean the base metal surfaces) Reduce the melting temperature of the filler metal
Remove oxides and other impurities (i.e. clean the base metal surfaces)
This process does not require any form of external "protection", since the weld location is fully isolated from any undesirable environment Electron Beam Welding (EBW) Gas Tungsten Arc Welding (GTAW) Resistance Spot Welding (RSW) Plasma Arc Welding (PAW) Laser Welding (LBW) Oxyacetylene Welding (OAW)
Resistance Spot Welding (RSW)
If the hold-down pressure is too high in deep drawing, we will likely produce: Tearing Wrinkling of the side wall
Tearing
The product is a layered sheet or plate material, like the "sandwich" stock for US quarters Cold indentation welding Roll bonding Friction welding Explosive welding Ultrasonic welding Inertia welding
Roll bonding
An example of a process where tool-workpiece friction is helpful during the process is: Deep drawing Extrusion Rolling Forging
Rolling
Wire drawing and deep drawing are almost always performed at ___ temperature. Elevated Room
Room
This process is NOT continuous -- (frequently interrupted to change electrodes) Flux-cored Arc Welding (FCAW) Shielded Metal Arc Welding (SMAW) Submerged Arc Welding (SAW) Gas-Metal Arc Welding (GMAW)
Shielded Metal Arc Welding (SMAW)
To minimize hydrogen (moisture) pick-up, special electrode storage may be required Flux-cored Arc Welding (FCAW) Shielded Metal Arc Welding (SMAW) Gas-Metal Arc Welding (GMAW) Submerged Arc Welding (SAW)
Shielded Metal Arc Welding (SMAW)
To produce thin sheet (such as foil), we need to use ___ diameter contact rolls. Large Small
Small
The quick freezing of the fusion zone usually results in the creation of: Weak metal Strong metal
Strong metal
If a material exhibits speed sensitivity, as speed increases, it will become: Stronger and more brittle Weaker and more ductile
Stronger and more brittle
Has the highest welding currents of the consumable electrode processes Submerged Arc Welding (SAW) Shielded Metal Arc Welding (SMAW) Flux-cored Arc Welding (FCAW) Gas-Metal Arc Welding (GMAW)
Submerged Arc Welding (SAW)
The applied forces in wire drawing are: Tension Compression
Tesnion
What is the neutral axis in bending? The location where the material is at both compression and tension The location where the material is at neither compression nor tension The location where the material is at tension The location where the material is at compression
The location where the material is at neither compression nor tension
Because of the low rate of heat input, oxyacetylene welding is best suited to the joining of: Al and Cu Thick steel Thin steel All of these
Thin steel
Arc length is defined as the distance from the: Tip of the electrode to the surface of the workpiece Top of the workpiece to the bottom of the fusion zone
Tip of the electrode to the surface of the workpiece
Arc length is defined as the distance from the: Top of the workpiece to the bottom of the fusion zone Tip of the electrode to the surface of the workpiece
Tip of the electrode to the surface of the workpiece
What measures can be employed to improve the quality of a shared edge? To use a bigger clearance To apply pressure to hold the sheet during cutting To use other material To use a different die
To apply pressure to hold the sheet during cutting
Penetration is defined as the distance from the: Tip of the electrode to the surface of the workpiece Top of the workpiece to the bottom of the fusion zone
Top of the workpiece to the bottom of the fusion zone
Penetration is defined as the distance from the: Top of the workpiece to the bottom of the fusion zone Tip of the electrode to the surface of the workpiece
Top of the workpiece to the bottom of the fusion zone
Brazing requires higher temperatures than soldering. True False
True
Direct-digital manufacture is attractive for small-quantity production or even one-of-a-kind products. True False
True
Hollow investment casting patterns collapse inward when melted, eliminating the possibility of ceramic shell or mold cracking. True False
True
With direct-digital manufacturing it is easy to make a change in a part after the design has been set or multi-part production run has been started. True False
True
A high-frequency oscillation is used to break up surface contaminants and bond thin sheets of metal Ultrasonic welding Explosive welding Friction welding Cold indentation welding Inertia welding Roll bonding
Ultrasonic welding
The thickness of a rolled sheet or plate can be made more uniform by all BUT: Crowning the rolls Apply front and back tensions Use back-up rolls Use smaller diameter rolls
Use smaller diameter rolls
During sharing, shared edges generally shows different regions: one smooth and other rough. The rough part is due to: the plastic deformation the punch surface the high temperature the inter-granular fracture
the punch surface