Nickel Alloys and Molding Processes Quiz

A nickel-copper alloy with high strength, toughness, and excellent corrosion resistance. It's used for high-temperature applications where corrosion resistance is crucial.

A nickel-copper alloy with improved strength and hardness compared to Monel, due to the addition of aluminum.

An alloy of Copper, Nickel, and Zinc, known for its hardness, whiteness, and ductility. It's used in both household items and industrial applications.

An iron-nickel alloy with a very low coefficient of thermal expansion, making it ideal for applications sensitive to temperature changes.

A high-nickel, high-chromium alloy used extensively as a resistance wire in electrical appliances like heaters and toasters.

A nickel-chromium alloy known for its exceptional resistance to corrosion, oxidation, and high temperatures.

Malleable iron is a type of cast iron that has been treated to make it less brittle and more malleable.

Carbon content directly influences the hardness and toughness of various metal alloys, including cast iron, wrought iron, and steel. Higher carbon content generally makes the metal harder but less tough.

Alloy steels are often used in machine parts for their improved strength, durability, and resistance to wear and tear.

Malleable cast iron is less brittle and more malleable than gray cast iron due to its different internal structure.

Hot working is done at high temperatures where the material is more malleable, while cold working is done at room temperature, leading to increased hardness and strength.

Alloys of cast iron are used when specific properties are required, such as increased strength, wear resistance, or heat resistance. Alloys can tailor the material's properties to the specific needs of the application.

Nickel, copper, chromium, and molybdenum have distinct effects on cast iron. Nickel increases strength and toughness, copper improves machinability, chromium increases hardness and wear resistance, and molybdenum enhances creep resistance at high temperatures.

Cast steels are preferred over cast iron for applications requiring higher strength, toughness, and more complex shapes.

0.2% carbon steel possesses good strength, ductility, and weldability. It's commonly used in structural applications, machinery parts, and general construction.

A copper-zinc alloy with approximately 70% copper and 30% zinc. It's known for its durability, strength, and machinability.

A tin-based alloy with a low melting point and good wear resistance, used for bearings to reduce friction.

An alloy of copper and aluminum, known for its high strength-to-weight ratio and resistance to corrosion. Used in various industries.

A copper alloy with approximately 92% copper and 8% lead. Used for its excellent machinability and resistance to wear.

A steel with a carbon content less than the eutectoid composition (0.77%). It primarily consists of ferrite and pearlite, making it ductile and malleable.

A steel with a carbon content higher than the eutectoid composition (0.77%). It primarily consists of cementite and pearlite, making it hard and brittle.

A steel with a carbon content of 0.77%. It consists entirely of pearlite, a mixture of ferrite and cementite, offering a balanced combination of strength and ductility.

An iron-carbon alloy with a high carbon content (greater than 2%). It's brittle and hard but lacks ductility.

A steel that has been forged or rolled, giving it greater ductility, toughness, and strength compared to cast iron.

A reservoir at the top of the sprue (in the cope) that receives the stream of molten metal poured from the ladle.

A vertical channel connecting the pouring basin with the runners and gates, directing molten metal into the mold cavity.

Projections on a pattern that create recesses (core seats) in the mold for locating the core.

Made from core sand or other materials, used to create holes or internal features within the casting.

The process of removing the pattern from the mold after the mold has set, ensuring a gap for the molten metal to flow and solidify into the final casting.

A casting method that uses permanent, reusable molds made of high-refractory materials like graphite. These molds are more expensive than sand molds but offer smoother surfaces, increased dimensional accuracy, and higher production rates.

Casting method using expendable or disposable patterns that melt into the final casting, eliminating pattern removal. This is also called the "lost pattern" or "expendable pattern" process.

The metal containers used to hold the molding sand around the pattern. They can be single or multiple, with the most common design being a two-flask system: 'Cope' (upper) and 'Drag' (lower).

A casting process where the pattern is removed from the mold cavity before molten metal is poured.

A casting process where the pattern is not removed from the mold cavity before molten metal is poured. The pattern melts and becomes part of the finished casting.

The section of a foundry responsible for creating and preparing the molds and cores used in casting.

The section of a foundry responsible for melting the raw metal materials into a liquid state for casting.

The section of a foundry responsible for transferring melted metal from the furnace to the molds for casting.

The section of a foundry responsible for removing the solidified casting from the mold.

The section of a foundry responsible for cleaning and finishing the casting after removal from the mold.

Titanium alloys are incredibly strong due to heat treatment, incredibly lightweight, and exceptionally resistant to corrosion.

These metals are designed to withstand extreme temperatures and are very difficult to melt. Notable examples include Tungsten, Molybdenum, and Niobium.

Tungsten is widely used in the form of wire in incandescent light bulbs.

Nuclear applications demand metals with exceptional resistance to harsh conditions due to intense radiation and high temperatures.

It is the most important metal used in nuclear engineering. Its isotope U235 is the core fuel for nuclear reactors.

Thorium is a naturally occurring metal that can be used as a nuclear fuel.

Stellite is a cobalt-based alloy with high proportions of chromium and tungsten, providing exceptional hardness, resistance to wear and abrasion, and non-magnetic properties.

Stellite is mainly used in cutting tools, as it can withstand high temperatures and abrasion during operations on cast iron, malleable iron, and some steels.

Stellite's high cost often leads to the use of steel tools with Stellite tips welded onto them, providing the necessary hardness at the cutting edge.

Stellite coatings applied through welding are used for surface protection against wear and abrasion on critical items like oil-well pits and cement-mill grinding rigs.

Wood is a light-weight material used in machine components where moderate shock loading is required and a non-metallic bearing material is desirable, for example, circuit breaker operating rods.

Glass, once considered brittle, has undergone significant advances in its mechanical properties and is now considered for design problems.

Non-metallic materials like wood, glass, rubber, leather, carbon, and plastics are also used in machine components, each offering specific properties.

The coefficient of friction between dry metals is generally between 0.15 and 0.24, with an average of 0.18, indicating a moderate level of friction.

Stellite materials can be welded, cast, forged, or hard-surfaced, with each process affecting its mechanical properties.

Plastics that undergo no chemical change when heated. They can be softened and reshaped repeatedly.

Plastics that undergo a permanent chemical change when heated. They cannot be softened or reshaped once cured.

A type of plastic that is nonflammable, has good dielectric strength, and is often used in machine guards, tool handles, and electrical insulation.

The tendency of plastics to deform continuously under a constant load, especially at higher temperatures.

The tendency of some plastics to become brittle and less flexible over time, especially when exposed to sunlight or heat.

The process of heating a thermoplastic material to a viscous or liquid state so that it can be molded into a desired shape.

A type of plastic that is used in various products, including electrical insulation, machine guards, and toys. It's known for its toughness and moldability.

The trade name for a type of thermosetting plastic that is used in electronics, construction, and other applications. It's known for its durability and heat resistance.

The trade name for a type of thermosetting plastic that is used in various applications, including electrical insulation and laminates. It's known for its high strength and resistance to moisture.

The trade name for a type of thermosetting plastic that is used in various applications, including electrical insulation, automotive parts, and consumer products. It's known for its durability and resistance to heat.

This molding process involves baking the sand mixture, increasing its strength and dimensional accuracy compared to green sand molds. This leads to smoother surfaces and better casting integrity.

These molds utilize a specialized sand mixture containing resin and a catalyst. The sand is reactive and rapidly hardens, providing high tensile strength and dimensional accuracy. This method allows for complex shapes, reduced mold weight, and a faster production rate.

This casting process uses a specific type of sand core (a core made of dry sand) to create internal cavities within the casting. Due to the core's strength, it can withstand the pouring process without collapsing.

Moulds that harden at room temperature without baking; they use resins like furfuryl alcohols, urea, and formaldehyde.

Cores are baked at 175-230°C for 4-24 hours, depending on their size and the type of sand used.

Sand moulds that use chemical binders to achieve greater strength, resulting in better dimensional accuracy but at a higher cost.

These moulds combine different materials for optimal strength, accuracy, and surface finish while reducing costs and time in casting.

The most economical mould type made from sand, water, and a binder. It's versatile and fast but less accurate than dry sand moulds.

This moulding process utilizes assemblies of baked sand cores to form moulds; it's suitable for large and complex casting shapes.

A crucial step in the casting process where molten metal is poured into the prepared mould cavity.

The process of removing the finished casting from the mould.

The final stage in casting where blemishes and imperfections are removed from the casting.

Metal alloys, such as cast iron, are used extensively due to their unique properties like hardness, strength, and wear resistance.