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Material Fabrication Machining Forming Welding Heat Treatment
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Material Fabrication Machining Forming Welding Heat Treatment
Material Fabrication Machining Forming Welding Heat Treatment
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1
Question
What are the four material fabrication characteristics listed?
Answer
Machinability, Formability, Weldability, Castability
2
Question
What are typical indicators of good machinability?
Answer
Low cutting forces, easy chip formation, good surface finish, longer tool life
3
Question
Name one method to evaluate machinability.
Answer
Tool life for a given surface-foot speed and tool geometry (cubic-inch removal rate)
4
Question
What is the general purpose of a machinability rating table like Table 1?
Answer
Quantify machinability of different steels and metals for tooling selection
5
Question
What is the meaning of the abbreviations Sfpm and Feed/ipr in the table context?
Answer
Surface feet per minute and feed per inch by revolution
6
Question
How does sulfur in steel affect machinability according to the notes?
Answer
Forms manganese sulfide inclusions that increase cutting efficiency and reduce chip formation difficulty
7
Question
Which stainless steel section is noted to generally have poor machinability?
Answer
300 series austenitic stainless steel
8
Question
What type of cutting tool is recommended for ferritic stainless steels according to the notes?
Answer
Hard tools with good wear resistance and stiffness
9
Question
What does lead do in tin-doped, low-shear steels?
Answer
Acts as a solid lubricant due to low shear strength
10
Question
What is the role of calcium oxide-containing layers in calcium oxide steel?
Answer
Reduce secondary shear zone, lower friction and wear at high temperatures
11
Question
Which stainless steel series typically machines poorly?
Answer
Austenitic (300 series)
12
Question
What characterizes martensitic (400 series) stainless steels for machining?
Answer
Hard, bulky shapes; require hard tool materials and high crater wear resistance
13
Question
How does pretreatment (hardening) affect stainless steel machinability?
Answer
Increases hardness and roughness, demanding harder tooling and abrasion resistance
14
Question
What is commonly claimed about boron’s effect on steel machinability?
Answer
Boron effect can be ignored
15
Question
How does aluminum machining behavior compare to steel machining?
Answer
Aluminum is usually easy to machine with high cutting speeds and favorable tool angles
16
Question
Define formability in metallurgical terms given in the notes.
Answer
Ability to form material via rolling and bending; influenced by ductility and grain size
17
Question
What are key factors controlling weldability?
Answer
Thermal conductivity, boiling point, surface condition, and thermal expansion
18
Question
Which materials are shown on the provided mechanical properties graph description?
Answer
SAE 1340 steel, nickel-alloy steel, 17-7PH stainless, 18-8 stainless, Ti-6Al-4V, N-155 alloy, 2024-T81 aluminum, mild steel, magnesium
19
Question
Which metal is described as very easy to machine and allows high cutting speeds with high rake and relief angles?
Answer
Aluminum
20
Question
What is Formability in materials science?
Answer
Ability to be formed by rolling or bending
21
Question
What are the four determinants of weldability listed?
Answer
Thermal conductivity, boiling point, surface condition, thermal expansion
22
Question
In the image description, which material curves are included in the stress-strain graphs?
Answer
SAE 1340 steel, Nickel-alloy steel, 17-7PH stainless, 18-8 stainless, Ti-6Al-4V, N-155, 2024-T3 aluminum, mild steel, magnesium
23
Question
What is the y-axis described as in the stress-strain graph?
Answer
Stress (S) in psi x 10^3 and MPa on secondary axis
24
Question
What two broad mechanical property charts are described in the later section (image and table)?
Answer
Specific strength vs. temperature; table of mechanical properties for various metals
25
Question
What property does the table indicate for mild steel's yield strength?
Answer
50 MPa
26
Question
What is the purpose of heat treatment in metals?
Answer
To alter physical/mechanical properties by heating and cooling
27
Question
What happens during annealing in heat treatment?
Answer
Softens metal, relieves stresses, improves ductility
28
Question
What is hardening in heat treatment?
Answer
Increasing hardness through rapid cooling or quenching
29
Question
Why is controlled heating rate important in heat treatment?
Answer
Prevents thermal shock and ensures uniform temperature
30
Question
What is the yield strength in materials science?
Answer
Stress at which material begins to deform plastically