Manufacturing Processes #2

1.       Which one of the following statements is wrong regardin HAZ?

• Material in this region is heated, but remains below melting temp.

• Retains chemical composition of base metal, but microstructures (and properties) are altered.

• Single crystal grain morphology is produced at/near the joint.

• Effects are usually negative, and is often the location of weld failures.

2. Which of the following statements regarding the "Oxyfuel gas welding (OFW)" process is wrong?

• Same flame can be used to cut metal parts.

• Sometimes a filler metal and flux are added.

• is a family of fusion welding processes.

• Cheap, and slow but has a small HAZ.

3. 3. Which one of the following statements is correct?

• Ultrasonic Metal Welding: Metal parts held together under pressure and vibrated normal to each other at joined surfaces (welding head moves up and down vertically).

• Diffusion Welding (DFW): Metals coalesce by fusion of metal between each part, held together with pressure & heat.

• Solid-State Welding:

  Joining processes that rely on pressure with or without applied heat, but no melting occurs.

• Friction Stir Lap Welding is when two pieces of metal are placed end-to-end without overlap and then welded along the joint.

4. Uncommon Process in 3D printing:

• Stereolithography (SLA)

• Fused Deposition Modeling (FDM)

• Friction Surfacing (FS)

• Inkjet Binder

5. Which one of the following techniques is not a Solid-State process?

• Resistance Welding

• Lateral Friction Surfacing (LFS)

• MELD Technique

• Selective Laser Sintering (SLS)

6. In ........ process, after washing, parts are sintered in a furnace at approximately 85% of the metal’s melting point, burning away any waxy polymer binder and fusing the metal powder into a solid metal part ready for use.

• Fused Deposition Modeling (FDM)

• Directed Energy Deposition (DOD)

• Atomic Diffusion Additive Manufacturing (ADAM)

• Selective Laser Melting (SLM)

7. .............., also known as spark machining, is a non-traditional machining process that uses sparks to remove material from a workpiece, enabling the creation of complex shapes and intricate details in conductive materials.

• Laser Beam Machining (LBM)

• Electrical Discharge Machining (EDM)

• Plasma Arc Cutting (PAC)

• Ultrasonic Machining

8. ................. in sheet metal forming is a cold-forming process that joins sheet metal layers by folding or interlocking their edges to create strong, often leak-proof joints

• Clinching

• Seaming

• Diffusion Welding

• Casting

9. In oxyfuel gas welding, if the oxygen is insufficient for full combustion, the flame is known as a ................ (having excess acetylene) or ................. flame.

• neutral; oxidizing

• reducing; oxidizing

• reducing; carburizing

• neutral; carburizing

10. Which of the following statements comparing lateral friction surfacing (LFS) with conventional friction surfacing (FS) is incorrect?

• FS typically produces more flash.

• LFS uses a consumable tool that rotates and plunges vertically into the substrate.

• LFS generally has lower process temperature than FS.

• FS generally creates thicker coatings compared to LFS.