ME 2653 Exam 2

The applied forces in wire drawing are: A: Tension B: Compression

A: Tension

To produce thin sheet (such as foil), we need to use ___ diameter contact rolls. A: Large B: Small

B: Small

In the stereolithography process, the build material is: A: Metal powder B: Molten plastic C: Photocurable polymer D: Thermoplastic filament

C: Photocurable polymer

In stereolithography, a layer is cured by ___. A: An infrared laser B: A single shot of UV light C: Temperature D: A scanning UV laser

D: A scanning UV laser

Which factor induced is used to induce permanent joints in two materials? A: Pressure B: Metallurgical conditions C: Temperature D: All of them

D: All of them

Additive or direct-digital processing begins with a: A: Rigid die or tooling B: Any of these C: Part pattern D: Computer file

D: Computer file

These two processes use non-melting tungsten electrodes. A: GTAW & OAW B: GTAW & EBW C: OAW & EBW D: GTAW & PAW

D: GTAW & PAW

When helium gas is used for shielding, this process has been called "Heliarc" welding A: Oxyacetylene Welding (OAW) B: Laser Welding (LBW) C: Resistance Spot Welding (RSW) D: Gas Tungsten Arc Welding (GTAW) E: Electron Beam Welding (EBW) F: Plasma Arc Welding (PAW)

D: Gas Tungsten Arc Welding (GTAW)

No slag forms, so slag removal is not required A: Gas-Metal Arc Welding (GMAW) B: Shielded Metal Arc Welding (SMAW) C: Submerged Arc Welding (SAW) D: Flux-cored Arc Welding (FCAW)

A: Gas-Metal Arc Welding (GMAW)

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: A: Heat-affected zone B: Unaffected base metal C: Fusion zone

A: Heat-affected zone

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. A: High B: Low

A: High

In all metal forming processes, the applied stresses must be ___ than the yield strength of the material. A: Higher B: Lower

A: Higher

The form of extrusion that has the best mechanical efficiency, since it eliminates billet-chamber friction, is: A: Indirect (or back-) extrusion B: Direct Extrusion

A: Indirect (or back-) extrusion

Which of the following is it not a proper use of welding A: Melt B: Repair C: Hardfacing D: Joining

A: Melt

Metal deformation processes can be used to shape: A: Only ductile materials B: Metals and ceramics C: All materials

A: Only ductile materials

Which of the following is a common concern during welding A: Overlap B: Runout C: Misrun D: Hot spot

A: Overlap

Backup rolls are used to: A: Produce uniform thickness B: Eliminate friction C: Keep width constant

A: Produce uniform thickness

In the selective laser sintering process, the unfused powder: A: Remains in place to serve as support B: Any of these C: Protects the material of heat-affected zones D: Is vacuumed away between each layer

A: Remains in place to serve as support

The primary role of the flux in brazing or soldering is to: A: Remove oxides and other impurities B: Reduce the melting temperature of the material being joined C: Reduce the melting temperature of the filler metal

A: Remove oxides and other impurities

If a material exhibits speed sensitivity, as speed increases, it will become: A: Stronger and more brittle B: Weaker and more ductile

A: Stronger and more brittle

Since it has the deepest penetration it can join thick pieces of steel in a single welding pass A: Submerged Arc Welding (SAW) B: Shielded Metal Arc Welding (SMAW) C: Flux-cored Arc Welding (FCAW) D: Gas-Metal Arc Welding (GMAW)

A: Submerged Arc Welding (SAW)

The arc is buried beneath a layer of flux and is not visible to observers A: Submerged arc welding (SAW) B: Gas-metal arc welding (GMAW) C: Shielding metal arc welding (SMAW) D: Flux-cored arc welding (FCAW)

A: Submerged arc welding (SAW)

The applied forces in wire drawing are: A: Tension B: Compressions

A: Tension

Arc length is defined as the distance from the: A: Tip of the electrode to the surface of the workpiece B: Top of the workpiece to the bottom of the fusion zone

A: Tip of the electrode to the surface of the workpiece

Penetration is defined as the distance from the: A: Top of the workpiece to the bottom of the fusion zone B: Tip of the electrode to the surface of the workpiece

A: Top of the workpiece to the bottom of the fusion zone

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. A: True B: False

A: True

The thickness of a rolled sheet or plate can be made more uniform by all BUT: A: Use smaller diameter rolls B: Use back-up rolls C: Apply front and back tensions D: Crowing the rolls

A: Use smaller diameter rolls

To produce a significant change in cross-sectional area using the wire drawing process: A: We will need multiple dies and multiple passes B: We can use a single die

A: We will need multiple dies and multiple passes

Resin or filler material is polymerized to create a bond. A: Brazing and Soldering B: Adhesive Bonding C: Deformation Bonding D: Diffusion Bonding E: Fusion Welding

B: Adhesive Bonding

Because a fusion weld is actually a mini-casting, one might expect the possibility of: A: Shrinkage B: Both of these C: Gas porosity

B: Both of these

Direct Metal Deposition and Laser-Engineered Net Shaping both use: A: A laser B: Both of these C: A stream of powder particles

B: Both of these

Brazing can be used to join: A: Only similar or identical materials B: Both similar and dissimilar materials, even metals to ceramics

B: Both similar and dissimilar materials, even metals to ceramics

The forging process that produces complex shaped parts to near-net shape is: A: Open-die forging B: Closed-die forging

B: Closed-die forging

Low-angle wire drawing dies are often inefficient due to excessive: A: Internal shear B: Contact friction

B: Contact friction

Less weld distortion occurs when the fusion zone is: A: Shallow and wide B: Deep and narrow

B: Deep and narrow

Brazing and soldering can be used to join: A: Only similar metals B: Dissimilar metals and even dissimilar materials

B: Dissimilar metals and even dissimilar materials

When the forces of deformation are compressive, the deformation should be performed: A: Hot B: Either hot or cold is acceptable C: Cold

B: Either hot or cold is acceptable

Direct-digital manufacturing can only be used to produce parts from plastics and polymeric materials. A: True B: False

B: False

Heat affected zone is a desirable region during welding A: True B: False

B: False

Only a shielding gas is used for protection A: Flux-cored Arc Welding (FCAW) B: Gas-Metal Arc Welding (GMAW) C: Submerged Arc Welding (SAW) D: Shielded Metal Arc Welding (SMAW)

B: Gas-Metal Arc Welding (GMAW)

No slag forms, so slag removal is not required A: Flux-cored arc welding (FCAW) B: Gas-metal arc welding (GMAW) C: Shielded metal arc welding (SMAW) D: Submerged arc welding (SAW)

B: Gas-metal arc welding (GMAW)

The maximum strength of a brazed joint is: A: Equal to the strength of the filler metal B: Greater than the strength of the filler metal C: About half the strength of the filler metal

B: Greater than the strength of the filler metal

In all metal forming processes, the applied stresses must be ___ than the yield strength of the material. A: Lower B: Higher

B: Higher

What is the difference between piercing and blanking? A: Different presses B: In blanking, the workpiece is punched out of the sheet C: Type of cut: straight or rounded edges D: In blanking, the remaining sheet is the workpiece

B: In blanking, the workpiece is punched out of the sheet

Solid sheets of material are bonded in: A: Direct metal deposition B: Laminated-object manufacturing C: Stereolithography D: Selective laser sintering

B: Laminated-object manufacturing

In the "Big Four" consumable electrode arc welding processes, the rate of heat input is: A: Low B: Medium C: High

B: Medium

Diffusion bonding can be used to join (check the reference book before answer): A: only ceramics B: Most combinations of metals and/or ceramics C: Only similar metals D: Only metals, but metals can be dissimilar

B: Most combinations of metals and/or ceramics

Resistance welding is: A: Good for joining thick plates because of the high rate of heat input B: Normally used to join thin sheets to one another C: An excellent process for joining ceramic materials to one another

B: Normally used for joining thin sheets to one another

The blacksmith's hammer and anvil is actually a crude form of: A: Closed-die forging B: Open-die forging

B: Open-die forging

This type of metal transfer is generally preferred when welding thin material: A: Spray B: Short-circuit C: Globular

B: Short-circuit

The quick freezing of the fusion zone usually results in the creation of: A: Weak metal B: Strong metal

B: Strong Metal

If the hold-down pressure is too high in deep drawing, we will likely produce: A: Wrinkling of the side wall B: Tearing

B: Tearing

What is the neutral axis in bending? A: The location where the material is at both compression and tension B: The location where the material is at neither compression or tension C: The location where the material is at tension D: The location where the material is at compression

B: The location where the material is at neither compression or tension

To produce a significant change in cross-sectional area using the extrusion process: A: We will need multiple dies and multiple passes B: We can use a single die

B: We can use a single die

The Fused Deposition Modeling process bears similarity to: A: An ink-jet printer B: A hot-melt glue gun

B: a hot-melt glue gun

A simple tooling method for obtaining multiple operations such a piercing and blanking while getting a finished part from each press stroke is A: a progressive die B: a turret press C: a compound die D: an average die

B: a turret press

Which operation can you use to produce gutters and downspouts? A: V-bending B: Roll forming C: Slitting D: Deep drawing

B: roll forming

A solid-state bond is formed by holding materials in contact for long period of time at elevated temperature A: Adhesive bonding B: Deformation bonding C: Fusion welding D: Brazing and soldering E: Diffusion bonding

E: Diffusion bonding

It's the most portable of all welding techniques A: Gas Tungsten Arc Welding (GTAW) B: Laser Welding (LBW) C: Resistance Spot Welding (RSW) D: Plasma Arc Welding (PAW) E: Oxyacetylene Welding (OAW) F: Electron Beam Welding (EBW)

E: Oxyacetylene Welding (OAW)

An attractive feature of electron beam melting is: A: All of these B: Can work with high-temperature metals, like tools steels or superalloys C: Can work with reactive metals, like titanium D: Able to produce fully-dense metal products

A: all of these

The blacksmith's hammer and anvil is actually a crude form of: A: Open-die forging B: Closed-die forging

A: open-die forging

Backup rolls are used to: A: Produce uniform thickness B: Eliminate friction C: Keep constant wideth

A: produce uniform thickness

To produce thin sheet (such as foil), we need to use ___ diameter contact rolls. A: Small B: large

A: small

Direct-digital manufacture is attractive for small-quantity production or even one-of-a-kind products. A: True B: False

A: true

The joint clearance (at the temperature of the braze) should be on the order of ___ to obtain a high strength joint in brazing or soldering. A: 0.003 in B: 0.3 in C: 0.03 in

A: 0.003 in

What distinguished sheet forming from bulk forming? A: All of them B: Thickness of material C: Type of machinery D: Lower forces are required

A: All of them

The "Perfect Metallurgical Bond" requires surfaces that are: A: All of these B: Perfectly Flat C: Perfectly Aligned D: Perfectly clean

A: All of these

The molten pool and hot metal of a fusion weld can be "protected" by: A: Any of these B: A cover slag C: A vacuum D: Shielding gas

A: Any of these

Because a fusion weld is actually a mini-casting, one might expect the possibility of: A: Both of these B: Gas porosity C: Shrinkage

A: Both of these

The forging process that produces complex shaped parts to near-net shape is: A: Closed-die forging B: Open-die forging

A: Closed-die forging

A noticeable dent or impression is produced at the location where two pieces of sheet are being joined A: Cold indentation welding B: Inertia welding C: Friction welding D: Ultrasonic welding E: Roll bonding F: Explosive welding

A: Cold indentation welding

The applied forces in extrusion are: A: Compression B: Tension

A: Compression

The most desirable fusion zone profile would be: A: Deep and narrow B: Shallow and wide C: Deep and wide

A: Deep and narrow

Which of the following processes does NOT produce a product with constant cross-section shape? A: Deep drawing B: Extrusion C: Wire drawing D: Rolling

A: Deep drawing

The chemistry (or composition) of the filler metal used for brazing and soldering is ___ that of the materials being joined. A: Different form B: Same as

A: Different from

A unique characteristic of a good bond is a wavy interface between the two base metals A: Explosive welding B: Roll bonding C: Ultrasonic welding D: Friction welding E: Cold indentation welding F: Inertia welding

A: Explosive welding

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? A: Fast cooling weld B: Slow cooling weld

A: Fast cooling weld

In the 3-D Printing process, the scanning ink-jet is depositing: A: Any of the options are true B: a molten thermoplastic filament C: A liquid binder that joins the powder particles D: Molten build material

C: A liquid binder that joins the powder particles

In the "Big Four" consumable electrode arc welding processes, the depth-to-width ratio is: A: Low (<1) B: High (>1) C: About 1:1

C: About 1:1

Which factor induced is used to induce permanent joints in two materials? A: Pressure B: Temperature C: All of them D: Metallurgical conditions

C: All of them

The heat source for fusion welding can be: A: Gas combustion B: An electric arc C: Any of the above D: A laser beam

C: Any of the above

During cold forming, as deformation progresses, the material: A: Remains unchanged B: Becomes weaker and more ductile C: Becomes stronger and more brittle

C: Becomes stronger and more brittle

Foil is most likely rolled on this type of mill: A: 4-high B: 2-high C: Cluster D: 3-high

C: Cluster

Which operation can you use to bend a round steel bar (check reference book before answer)? A: Blanking B: Deep drawing C: Compression Bending D: V-bending

C: Compression Bending

Which operation can you use to make a kitchen metallic sink? A: Extrusion B: Roll Bending C: Deep drawing D: Spinning

C: Deep drawing

Of the two rotational welding processes, this one produces the larger HAZ A: Explosive welding B: Inertia welding C: Friction welding D: Roll bonding E: Cold indentation welding F: Ultrasonic welding

C: Friction welding

Portions of the material being joined melts and flows as liquid (along with possible filler metal) to fill the joint A: Diffusion Bonding B: Brazing and soldering C: Fusion Welding D: Adhesive Bonding E: Deformation Bonding

C: Fusion Welding

The portion of a weldment that melts during the joining process is called the: A: Unaffected base metal B: Heat-affected zone C: Fusion Zone

C: Fusion Zone

Is sometimes referred to as MIG (metal inert gas) welding A: Shielded Metal Arc Welding (SMAW) B: Flux-cored Arc Welding (FCAW) C: Gas-Metal Arc Welding (GMAW) D: Submerged Arc Welding (SAW)

C: Gas-Metal Arc Welding (GMAW)

The deformation bonding processes can be used to join (check the reference book before answer): A: All metals and ceramics B: All metals C: Only ductile metals

C: Only ductile metals

A "keyhole" can be produced, assuring complete penetration with minimum distortion A: Electron beam welding (EBW) B: Oxyacetylene welding (OAW) C: Plasma arc welding (PAW) D: Gas tungsten arc welding (GTAW) E: Laser welding (LBW) F: Resistance spot welding (RSW)

C: Plasma arc welding (PAW)

Crowning of rolls is done to: A: Keep width constant B: Eliminate friction C: Produce uniform thickness

C: Produce uniform thickness

During hot forming, the strength of the material: A: Decreases B: Increases C: Remains unchanged

C: Remains unchanged

An example of a process where tool-workpiece friction is helpful during the process is: A: Deep drawing B: Forging C: Rolling D: Extrusion

C: Rolling

It is not considered a consolidation process: A: Arc Welding B: Adhesive Bonding C: Sand Casting D: Powder Metallurgy

C: Sand Casting

It is not considered a consolidation process: A: Powder metallurgy B: Arc welding C: Sand casting D: adhesive bonding

C: Sand casting

During sharing, shared edges generally shows different regions: one smooth and other rough. The rough part is due to (check the reference book before answer): A: The plastic deformation B: The punch surface C: The inter-granular fracture D: The high temperature

C: The inter-granular fracture

Possible types of rapid tooling include: A: Jigs, fixtures, templates, and gages B: Patterns, molds or cores C: All of these D: Die-casting dies

C: all of these

Additive manufacturing builds parts: A: Using glue B: By joining block segments C: building layer-by-layer D: by diffusional bonding

C: building layer-by-layer

In brazing or soldering, the strength of the filler metal is ___ the strength of the material being joined. A: The same as B: Greater than C: Less than

C: less than

During hot forming, the strength of the material: A: Decreases B: increases C: remains unchanged

C: remains unchanged

Additive Manufacturing is being used for: A: Direct product manufacture B: Manufacture of rapid tooling C: Prototype manufature D: All of these

D: All of these

Materials are squeezed together under pressure, resulting in plastic deformation and the creation of uncontaminated surfaces A: Adhesive bonding B: Diffusion bonding C: Brazing and Soldering D: Deformation Bonding E: Fusion welding

D: Deformation Bonding

Diffusion bonding can be used to join (check the reference book before answer): A: Only ceramics B: Only metals, but the metals can be dissimilar C: Only similar metals D: Most combinations of metals and/or ceramics

D: Most combinations of metals and/or ceramics

This process does not require any form of external "protection", since the weld location is fully isolated from any undesirable environment A: Laser welding (LBW) B: Gas tungsten arc welding (GTAW) C: Electron beam welding (EBW) D: Resistance spot welding (RSW) E: Oxyacetylene welding (OAW) F: Plasma arc welding (PAW)

D: Resistance spot welding (RSW)

Wire drawing and deep drawing are almost always performed at ___ temperature. A: Elevated B: Freezing C: Recrystallization D: Room

D: Room

What measures can be employed to improve the quality of a shared edge (check the reference book before answer)? A: To use a different die B: To use a bigger clearance C: To use other material D: To apply pressure to hold the sheet during cutting

D: To apply pressure to hold the sheet during cutting

Ink-jet deposition can build with: A: Thermoplastic polymer B: Low-melting-point metal C: Wax D: All of these

D: all of these

Prototype products are used to: A: Evaluate possible concepts B: Assess form, fit, and function C: Provide visual aid D: All of these

D: all of these

The most desirable fusion zone profile would be: A: Shallow and wide B: deep and wide C: Deep and narrow

Deep and Narrow

The electrode comes into direct contact with the workpiece, and some degree of force is applied A: Gas tungsten arc welding (GTAW) B: Electron Beam welding (EBW) C: Laser welding (LBW) D: Plasma arc welding (PAW) E: Oxyacetylene welding (OAW) F: Resistance Spot Welding (RSW)

F: Resistance Spot Welding (RSW)

A noticeable dent or impression is produced at the location where two pieces of sheet are being joined A: Friction welding B: Roll bonding C: Ultrasonic welding D: Inertia welding E: Explosive welding F: Explosive welding G: Cold indentation welding

G: Cold indentation welding