HW3 Solution - Homework 3 (due Mar.11) 1. Describe the four...

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Homework 3 (due Mar.11) 1. Describe the four basic families of shape production processes. Ans: Casting Processes Material removal processes Deformation processes Consolidation processes Casting is when molten material is poured into a mold and hardened. Material removal is when material is cut away from a larger object. Deformation is when the object is shaped by applying forces to it. Consolidating involves combining materials by methods such as welding and soldering. 2. Describe the six steps of metal casting. Ans: Mold cavity is produced having the desired shape and size of the part Melting process Pouring technique Solidification process Mold removal Cleaning, finishing and inspection operations 3. Describe the difference between expandable mold and permanent mold. What are they generally made of respectively? Ans: Expendable mold process uses an expendable mold which must be destroyed to remove casting while permanent mold processes uses a permanent mold which can be used many times to produce many casting. Usually, expendable mold is made of sand plaster and similar materials plus binders. And permanent mold is made of metal or ceramic refractory material. 4. Explain why directional solidification is very important for casting. Ans: In order to minimize damaging effects of shrinkage, it is desirable for regions of the casting most distant from the liquid metal supply to freeze first and
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for solidification to progress from these remote regions toward the riser. 5. Describe the difference between casting of pure metal and binary alloy, in term of casting microstructure and chemical composition. Ans: Grain structure in a casting of a pure metal shows randomly oriented grains of small size near the mold wall and large columnar grains oriented toward the center of the casting. While for an alloy casting, there is a segregation of alloying components in center of casting. In terms of chemical composition, casting of binary alloy is not uniform in composition from the surface to the center. 6.
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This note was uploaded on 01/19/2012 for the course IE 230 taught by Professor Xangi during the Spring '08 term at Purdue University-West Lafayette.

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HW3 Solution - Homework 3 (due Mar.11) 1. Describe the four...

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