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6.8: Processing techniques

Total questions: 102

Worksheet time: 51mins

Name
Class
Date
1.

What is the purpose of understanding processing techniques?

a)

To improve material aesthetics

b)

To understand how processing techniques affect material properties

c)

To reduce costs

d)

To increase production speed.

2.

By what method can different materials be researched?

a)

By trial and error

b)

By researching different materials

c)

By consulting experts

d)

By using simulation software.

3.

When processing a material, it is possible to alter its ______.

a)

color

b)

properties

c)

weight

d)

size

4.

Material processing is done to modify:

a)

Grain structure

b)

Composition

c)

Both A and B

d)

Neither A nor B

5.

The 'What' of material processing is to understand how processing techniques affect ______.

a)

material color

b)

material properties

c)

material weight

d)

material size

6.

The 'Why' of material processing is to ensure the correct material is ______ for engineering applications.

a)

painted

b)

chosen

c)

weighed

d)

cut

7.

Researching different materials is part of the 'How' in:

a)

Material painting

b)

Material processing

c)

Material weighing

d)

Material cutting

8.

Metal forming is a broad term that encompasses a number of ________ processes.

a)

manufacturing

b)

cooking

c)

painting

d)

cleaning

9.

By researching different materials, one can understand how processing techniques affect material properties. True or False?

a)

True

b)

False

10.

In the context of metal forming, what is the difference between hot rolled and cold rolled processes?

a)

A) Temperature

b)

B) Speed

c)

C) Material

d)

D) Cost

11.

What is metal forging?

a)

A process of cutting metal

b)

A process of shaping metal using compressive forces

c)

A process of melting metal

d)

A process of painting metal.

12.

What is bending in metal forming?

a)

A process using a brake press

b)

A process using a hammer

c)

A process using a saw

d)

A process using a drill

13.

What is the main purpose of the rolling process in metalworking?

a)

To increase the thickness of metal

b)

To reduce the thickness of metal and make it uniform

c)

To change the color of metal

d)

To melt the metal.

14.

Which of the following is true about hot rolling?

a)

It occurs below the recrystallisation temperature

b)

It occurs above the recrystallisation temperature

c)

It does not involve temperature

d)

It is the same as cold rolling.

15.

What is the process called when steel is heated above its recrystallisation temperature and then cooled at room temperature?

a)

A) Annealing

b)

B) Normalisation

c)

C) Tempering

d)

D) Quenching

16.

The hot rolling process enhances the _______ and ductility of steel.

a)

hardness

b)

toughness

c)

brittleness

d)

elasticity

17.

Hot rolled forms can be much larger than cold rolled forms. True or False?

a)

True

b)

False

18.

In the hot rolled steel process, what comes after the 'Hot Rolling' stage?

a)

Slab

b)

Reheating

c)

Black Hot Rolled Steel Coil

d)

Pickling line

19.

What is the final stage in the hot rolled steel process as shown in the diagram?

a)

Reheating

b)

Hot Rolling

c)

Pickling line

d)

Slab

20.

Cold working is done at temperatures ______ the recrystallisation temperature of the metal.

a)

above

b)

below

c)

at

d)

around

21.

What is a dislocation in the context of cold working?

a)

A type of metal

b)

A crystallographic defect in the metal crystal system

c)

A method of heating metals

d)

A process of cooling metals

22.

What is the recovery process in hot working?

a)

No recovery occurs

b)

Recovery occurs simultaneously with deformation

c)

Recovery occurs after deformation

d)

Recovery is not needed.

23.

How are cracks handled in hot working?

a)

A) Cracks propagate

b)

B) Cracks are removed

c)

C) New cracks are formed

d)

D) Cracks are ignored

24.

What is the main difference in temperature between hot working and cold working?

a)

Hot working is performed at temperatures below the recrystallisation temperature

b)

Cold working is performed at temperatures above the recrystallisation temperature

c)

Hot working is performed at temperatures above the recrystallisation temperature

d)

Both are performed at the same temperature.

25.

What is the purpose of understanding how processing techniques affect material properties?

a)

To improve aesthetic appeal

b)

To ensure safety

c)

To choose the correct material for an engineering application

d)

To reduce costs.

26.

In the context of metal processing, what does the stretching process involve?

a)

Heating the metal

b)

Cooling the metal

c)

Stretching and bending the workpiece simultaneously

d)

Painting the metal.

27.

In the process of sintering, the material is squeezed together under high temperature and pressure to increase its properties. Which property is improved by this process?

a)

A) Thermal conductivity

b)

B) Electrical conductivity

c)

C) Material strength

d)

D) All of the above.

28.

Thermoplastic powder coating becomes ______ when heated.

a)

Hard and brittle

b)

Liquid and very soft

c)

Solid and rigid

d)

Sticky and elastic

29.

Why is thermoset powder coating suitable for high heat areas?

a)

It melts easily

b)

It forms chemical bonds

c)

It is flexible

d)

It is cost-effective.

30.

Which of the following is NOT a type of mould design mentioned in the casting process?

a)

Expendable mould

b)

Permanent mould

c)

Composite mould

d)

Temporary mould

31.

Name a suitable process for the fabrication of this joint.

a)

Brazing

b)

Welding

c)

Soldering

d)

Epoxy resin

32.

Name a suitable process for the manufacture of this kitchen sink.

a)

Die casting

b)

Milling

c)

Spinning

d)

Press forming

33.

Name a suitable process for the manufacture of this car wheel.

a)

Die casting

b)

Milling

c)

Spinning

d)

Press forming

34.

Name the joining/filling method shown.

a)

Epoxy Resin

b)

Brazing

c)

Soldering

d)

Welding

35.

Name a suitable process for the manufacture of this component.

a)

Die casting

b)

Milling

c)

Spinning

d)

Press forming

36.

Name a suitable process for the manufacture of these components.

a)

Die casting

b)

Milling

c)

Spinning

d)

Press forming

37.

Name a suitable process for the manufacture of these components.

a)

Sand casting

b)

Sintering

c)

Drop Forging

d)

Deep drawing

38.

Name a suitable process for the manufacture of these components.

a)

Sand casting

b)

Sintered

c)

Forged

d)

Deep drawing

39.

Name a suitable process for the manufacture of this component.

a)

Sand casting

b)

sintering

c)

Spinning

d)

Press forming

40.

Name a suitable process for the manufacture of these components.

a)

Cupping

b)

CNC Router

c)

Spinning

d)

CNC Lathe

41.

Name a suitable process for the fabrication of this car door panel.

a)

Press forming

b)

die casting

c)

Drop forging

d)

Cold forming

42.

Name a suitable process for the fabrication of this joint.

a)

Brazing

b)

Welding

c)

Epoxy Resin

d)

Soldering

43.

Name a suitable process for the manufacture of these components.

a)

Piercing

b)

Cupping

c)

Drop Forging

d)

Deep drawing

44.

Name a suitable process for the manufacture of this component.

a)

Piercing

b)

Cupping

c)

Drop Forging

d)

Investment Casting

45.

Name a suitable process for the fabrication of this tag.

a)

Press forming

b)

Punching

c)

Drop forging

d)

Cold forming

46.

Name a suitable process for the fabrication of this joint.

a)

Epoxy Resin

b)

Brazing

c)

Soldering

d)

Welding

47.

Name a suitable process for this letter rack.

a)

Drop forging

b)

De-bossing

c)

Cold forming

d)

Press forming

48.

What aspect of a material is altered during material processing?

a)

Its location

b)

Its properties

c)

Its ownership

d)

Its price

49.

Which component is often modified in material processing?

a)

Temperature

b)

Grain structure

c)

Color

d)

Volume

50.

Which of the following is a key difference between hot rolling and cold rolling?

a)

The color of the metal

b)

The temperature at which the process is performed

c)

The type of metal used

d)

The speed of the rollers

51.

At what temperature is hot working performed?

a)

Below the recrystallisation temperature

b)

Above the recrystallisation temperature

c)

At room temperature

d)

At freezing temperature

52.

What is the recovery process like in cold working?

a)

Rapid recovery

b)

No significant recovery

c)

Complete recovery

d)

Partial recovery

53.

What happens to cracks in cold working?

a)

Cracks are sealed

b)

Cracks propagate and new cracks form

c)

Cracks disappear

d)

Cracks remain unchanged

54.

In the stretching process, how does the deformation of the sheet occur?

a)

Through axial strain

b)

Through radial strain

c)

Through torsional strain

d)

Through compressive strain

55.

What happens to the atoms in the material during sintering?

a)

They evaporate

b)

They melt

c)

They diffuse across particle boundaries and fuse together

d)

They condense

56.

What is the key difference between sintering and melting?

a)

Sintering involves liquefaction

b)

Sintering forms a solid without melting

c)

Melting uses pressure

d)

Melting forms a gas

57.

Which of the following is a common application of sintering?

a)

Making paper

b)

Producing metal parts

c)

Growing plants

d)

Baking bread

58.

Which of the following is NOT a property increased by sintering?

a)

Thermal conductivity

b)

Electrical conductivity

c)

Material strength

d)

Porosity

59.

What is the primary purpose of sintering?

a)

To increase the weight of the material

b)

To impart strength and integrity to the material

c)

To change the color of the material

d)

To reduce the size of the material

60.

During the sintering process, what must be kept below the melting point of the constituent materials?

a)

Pressure

b)

Volume

c)

Temperature

d)

Density

61.

What is the third type of mould used in casting?

a)

Composite mould

b)

Flexible mould

c)

Temporary mould

d)

Reusable mould

62.

What is the main advantage of using a permanent mould in casting?

a)

Lower cost per casting

b)

Higher production speed

c)

Greater flexibility in design

d)

Easier to modify

63.

What is the primary purpose of using a lubricant in metal forming processes?

a)

To increase friction

b)

To reduce tool wear

c)

To change the color of the metal

d)

To increase the temperature

64.

What is amorphous in crystal structure?

a)
Amorphous materials have a well-defined crystal lattice.
b)
Amorphous structures are always solid and rigid.
c)
Amorphous materials exhibit perfect long-range order.
d)
Amorphous materials lack long-range order in their atomic structure.
65.

What is the final shape of the product made with deep drawing?

a)
Flat, rectangular shape
b)
Irregular, fragmented shape
c)
Hollow, cylindrical, or conical shape
d)
Solid, spherical shape
66.

Why is acrylic used in engineering?

a)
Acrylic is used for its high density and weight.
b)
Acrylic is primarily used for its electrical conductivity.
c)
Acrylic is chosen for its ability to withstand extreme temperatures.
d)
Acrylic is used in engineering for its lightweight, durability, optical clarity, and ease of fabrication.
67.

What is powder coating?

a)
Powder coating is a dry finishing process that uses a powder to create a protective and decorative layer on surfaces.
b)
Powder coating is a type of metal alloy used in construction.
c)
Powder coating is a method of applying wallpaper.
d)
Powder coating is a liquid painting technique.
68.

What is the process of forming a solid mass of material through heat and pressure without melting to the point of liquefaction?

a)

Rolling

b)

Sintering

c)

Bending

d)

Casting

69.

Which metal forming process is used to produce components with long lengths or for large production runs?

a)

Bending

b)

Roll forming

c)

Deep drawing

d)

Injection moulding

70.

What is the temperature range for hot working in metal processing?

a)

Below the recrystallisation temperature

b)

At the melting point of the metal

c)

Above the recrystallisation temperature

d)

At room temperature

71.

Which metal forming process involves stretching and bending the workpiece simultaneously over a die to form complex or large contoured parts?

a)

Sintering

b)

Stretching

c)

Rolling

d)

Casting

72.

What is the purpose of sintering in materials processing?

a)

To increase the melting point of the material

b)

To reduce the strength of the material

c)

To impart strength and integrity to the material

d)

To make the material more brittle

73.

Which type of powder coating forms chemical bonds once cured, making it impossible to recycle?

a)

Polyethyelene powder coating

b)

Thermoplastic powder coating

c)

Thermoset powder coating

d)

Acrylic powder coating

74.

What is the most common type of expendable mould casting that generally uses permanent patterns to create the mould?

a)

Die casting

b)

Gravity casting

c)

Investment casting

d)

Sand casting

75.

Which material is known for its strength, impact resistance, and corrosion resistance in injection moulding?

a)

Acrylic (PMMA)

b)

Polyethyelene (PE)

c)

Acrylonitrile butadiene styrene (ABS)

d)

Polycarbonate (PC)

76.

What is the process of melting plastic pellets at pressure into a mould cavity to produce the final product?

a)

Rolling

b)

Sintering

c)

Bending

d)

Injection moulding

77.

What is the key difference between hot working and cold working in metal processing?

a)

The type of metal used

b)

The temperature range used

c)

The size of the finished product

d)

The presence of internal and residual stresses

78.

What is the process of heating a metal to a temperature below its melting point and then cooling it slowly?

a)

Quenching

b)

Tempering

c)

Annealing

d)

Hardening

79.

Which plastic is most commonly used in injection moulding due to its easy flow and low cost?

a)

Polyvinyl Chloride (PVC)

b)

Polystyrene (PS)

c)

Polypropylene (PP)

d)

Polycarbonate (PC)

80.

Which metal forming process involves compressing a metal piece between two rollers?

a)

Rolling

b)

Forging

c)

Extrusion

d)

Deep drawing

81.

What is the process of shaping metal by deforming it with a hammer or by using a press?

a)

Forging

b)

Rolling

c)

Extrusion

d)

Sintering

82.

What is the process of forcing a metal through a die to reduce its cross section or change its shape?

a)

Forging

b)

Rolling

c)

Extrusion

d)

Sintering

83.

What is the process of heating a metal to a high temperature and then cooling it rapidly to increase its hardness?

a)

Quenching

b)

Tempering

c)

Annealing

d)

Hardening

84.

What is the process of shaping a metal into a thin, flat piece by placing it between two rollers?

a)

Forging

b)

Rolling

c)

Extrusion

d)

Sintering

85.

What is the process of creating a hollow object by expanding a hot metal against the interior surface of a mould?

a)

Blow moulding

b)

Injection moulding

c)

Extrusion

d)

Forging

86.

What is the process of heating a metal to a high temperature and then cooling it slowly to relieve internal stresses?

a)

Quenching

b)

Tempering

c)

Annealing

d)

Hardening

87.

What is the process of shaping a metal into a cylindrical shape by rotating it against a cutting tool?

a)

Forging

b)

Rolling

c)

Turning

d)

Sintering

88.

Which plastic is known for its transparency and excellent resistance to UV radiation in injection moulding?

a)

Acrylic (PMMA)

b)

Polyethyelene (PE)

c)

Acrylonitrile butadiene styrene (ABS)

d)

Polycarbonate (PC)

89.

What is the process of heating a metal to a high temperature and then cooling it rapidly to increase its toughness?

a)

Quenching

b)

Tempering

c)

Annealing

d)

Hardening

90.

What is the process of shaping a metal into a hollow cylindrical shape by forcing it through a die?

a)

Forging

b)

Rolling

c)

Extrusion

d)

Tubing

91.

Which plastic is known for its high impact strength and flexibility in injection moulding?

a)

Polyvinyl Chloride (PVC)

b)

Polystyrene (PS)

c)

Polypropylene (PP)

d)

Polyethylene (PE)

92.

What is the process of heating a metal to a high temperature and then cooling it slowly to increase its ductility?

a)

Quenching

b)

Tempering

c)

Annealing

d)

Hardening

93.

What is the process of shaping a metal into a thin wire by pulling it through a die?

a)

Forging

b)

Rolling

c)

Extrusion

d)

Drawing

94.

Which plastic is known for its high heat resistance and strength in injection moulding?

a)

Polyvinyl Chloride (PVC)

b)

Polystyrene (PS)

c)

Polypropylene (PP)

d)

Polysulfone (PSU)

95.

What is the process of heating a metal to a high temperature and then cooling it rapidly to increase its wear resistance?

a)

Quenching

b)

Tempering

c)

Annealing

d)

Hardening

96.

What is the process of heating a metal to a high temperature and then cooling it rapidly to increase its tensile strength?

a)

Quenching

b)

Tempering

c)

Annealing

d)

Hardening

97.

Which plastic is known for its high chemical resistance and toughness in injection moulding?

a)

Polyvinyl Chloride (PVC)

b)

Polystyrene (PS)

c)

Polypropylene (PP)

d)

Polyethylene (PE)

98.

What is the process of shaping a metal into a flat sheet by compressing it between two rollers?

a)

Forging

b)

Rolling

c)

Extrusion

d)

Sheeting

99.

What is the process of heating a metal to a high temperature and then cooling it slowly to increase its malleability?

a)

Quenching

b)

Tempering

c)

Annealing

d)

Hardening

100.

Which plastic is known for its high transparency and excellent weather resistance in injection moulding?

a)

Polyvinyl Chloride (PVC)

b)

Polystyrene (PS)

c)

Polypropylene (PP)

d)

Polymethyl Methacrylate (PMMA)

101.

What is the process of shaping a metal into a desired shape by heating it to a high temperature and then hammering or pressing?

a)

Forging

b)

Rolling

c)

Extrusion

d)

Sheeting

102.

Which plastic is known for its high heat resistance and strength in injection moulding?

a)

Polyvinyl Chloride (PVC)

b)

Polystyrene (PS)

c)

Polypropylene (PP)

d)

Polycarbonate (PC)

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