Lab Exercise 5 Demonstration

Rolling Swaging

Common Mill 2 High Rolling Mill Tube Swaging

Roll Positioning System Mill Screw Swaged Diameter
Difference in Height Drought Tolerance
Gripping Mu >= tan(Q) Swaged at elevated T
Angle of Bite tan-1(lambda) due to low ductility

Physical Methods of producing powder particles are PM

Screwdriver blades are the typical example of swaged products
Sintering is done at temperatures melting temperature below
In forging stresses are involved Compressive

is a process in which dia is reduced by forcing it into a confining die Swaging

Shrinkage occurs on of the powder compact at ele temp. Sintering
Forging is a deformation process in which are applied compressive stresses
In rolling process, rollers rotate in directions Opposite
During sintering, small particles coalesce by applying High temperature

In swaging, the inner dia is controlled by using internal mandrels

Sintering of powder at elevated temp leads to of sample shrinkage
If no elastic deformation of rolls, final thickness of metal is same as the roll gap
In swaging process, stresses are involved Compressive

During Rolling, deformation occurs in metal Plastic

PM route significantly the yield losses in manufacturing reduces
Deformation process material is shaped by localized compres. Force forging
In swaging process of tube is changed by applying compr. Stresses shape
Sintering is a process applied to a powder compact in order to impart strengtheat treatment
Lab Exercise 4 Brazing

Brazing usually requires

The Filler rod possesses composition than the base metals.
In brazing, filler melts fil the joint
The strength of joint formed using welding is than that formed using brazing.
During brazing, no melting occurs in

What gases are used for brazing?

During brazing, only the melts.
In Brazing, parts to be joined are heated to a temperature
The most common joint formed by simply placing their ends together without any
special shaping is called
The metal joing processes in which temperature is kept lower than 450 C is called

What is the usual material for filler during brazing?

During brazing, is used to dissolve oxides from the surfaces to be joined.
Melting point of filler metal is than that of metal parts to be joined.
temperature operation in the brazing process enables only mixture of
oxygen-acetylene gases to be used for heating.
Filler rod and base material have

In Brazing, filler metal is drawn into the gap of the joint through
has a low melting point than the parts to be joined.
The strength of joint formed using brazing is than that formed using welding.
High temp. in brazing process is provided by
Brazing is similar to soldering, except for the

Lab Exercise 3 Arc Welding

GMAW Gas metal arc welding

MIG Metal Inert Gas
The full form of SMAW welding is
Mixture of & oxygen is used in gas welding
Maximum flame temperature reached in gas welding is
gases are used to protect the weld area from oxygen, and water vapour.
Consumable electrode used in MIG act as both electrode and

The Full form of GTAW is

Base Metal is shielded in MIG by using
In some welding processes is added to remove the contaminants
Consumable electrode also acts as a material in arc welding.
In gas welding electrode is used.

The Full form of OAW welding is

Max Temp. that can be reached in arc welding is
In GMAW, filler material is added in the form of which is consumable.
Flux in welding also prevents the of the base and filler materials
The flame temp in gas welding can be regulated by changing the

The full form of MAG Welding is

To remove contaminants, additives are added in the interfaces which are known as
In arc welding, electric arc is created b/w an electrode and to melt metals at welding pt.
is a virtreous material formed as a byproduct of arc welding process.
are alloys or unalloyed metals which, when heated,the space between two close fitting parts
liquefy and melt to flow into the space b/w two close fitting parts

Lab Exercise 2 Sheet Metal Forming

Operations involved cutting the metal strip

Combination of tensile and compressive stresses are involved in operation
Shearing stress Is a force that causes layers or parts to slide upon in directions
In bending operation, sheet gets deformed without changed in thickness.
Which of the following are sheet metal working?
Bending and are the two sheet metal working operation
Shearing is equivalent to
Bending is creation of shape from 2-D shape
In the bending of metal, combination of and stresses are involved
For the cutting of the metal strip, stress is applied

During the deformation of the sheet, the material outward is subjected to tensile stress
while the material inside is in the compressive stress.
Shear Stress is defined as the component of stress coplanar with a
For the Stretching of metal strip, stress is involved
operation on metal sheet involves only shear stress.
Units of shear stress can be given as

Which of the following are sheet metal working?

Deformation of a material substance in which parallel internal surfaces slide past one
another is known as
is a tool which is forced through the workpiece to create a hole via shearing.
is a forming operation in which a sheet metal is subjected to bending stress thereby a flat
straight sheet is made into a curved sheet.
Sheet metal working involves in the thickness of the metal sheet.

Lab Exercise 1 Mold Making & Casting

State T or F with Reasoning

Casting can't be used to make product with irregular shapes. F

Casting can be done not only on metals but also on polymers, ceramics and glasses. T

Wax can be used to make molds. T

Gating system act as a reservoir for molten metal. F
Pouring rate of molten metal inside the mold is irrelevant. F

Casting is used to make the product only with regular shapes. F

Casting can be done only with metals. F
Sand Casting is an example of expendable mold. T
Riser is used to pour the molten metal into the mold. F
Temperature of molten metal while pouring inside the mold is irrelevant. F

Vents in the mold allow the escape of

Binder used in the sand casting are
For the successful casting, pouring temperature of the molten metal should be
is the last step of casting.
is used in the casting to produce internal cavities.

Sand Casting comes under the classification of mold casting.

For the successful casting, pouring rate of the molten metal should be
is the first step of casting.
leads to shrinkage of metal inside the mold.
serves as reservoir to supply molten metal necessary to prevent
shrinkage during solidification.
 Powder Mettalurgy

Mandrels Unique Material Tungsten Carbide (WC) bonded with cobalt

0.5-15mm PM Press & Sinter Powder Blending (Pulverisation)
0.05-0.5 mm Die Compaction
Tungsten & Sintering
Molybdenum Optional Coining

swaged products

Compressive

compressive stresses

High temperature

the roll gap

Compressive

heat treatment
Brass

lower

Very different composition for welding, but similar for brazing.

Capilliary action
Filler material
weaker
oxy-acetylene
use of high temperature
 Shielded Metal Arc Welding
Acetylene
3500 C
Shielding i.e Inert
Filler

Gas-Tungsten Arc Welding

Shielding Gases
Fluxing agents
Filler
Consumable

Oxy Acetylene Welding

5500 C
Wire Electrode
Oxidation
gas composition

Metal Active Gas

Fluxing Agents
metals at welding pt. the base material
Slag
wo close fitting parts Filler Metals

Cutting
Bending
Opposite
Plastically
Rolling Extrusion Forging Bending Wire Drawing
 Shearing
Cutting
3-D
Tensile Compressive
Shear

tensile stress Bending

Material Cross-Section
Tensile
Cutting
N/m^2, Pascal

Rolling Extrusion Shearing Bending

Shearing
Punch
ss thereby a flat Bending

No Change

Casting can be used to make product with regular and irregular shapes.
Casting process is primarily used for shaping metallic materials; although it can be adopted for shaping other materials such as

Riser acts as a reservoir while gating system deliver the molten metal from outside the mold into the mold cavity.
If high - Turbulance can occur
If low - Solidification can occur

Also used to make parts that contains irregular curved surface.

Can also be done with ceramics, polymerics & glassy materials.
The mold can't be used again
Cadle is used to pour the molten metal into the mold. Gatting system serves to compensate the shrinkage in the casting materi
It is relevant. Temp. of molten metal while pouring inside the mold is less than the mold.

Gases, Moisture
clay, molasses, oil, resin
more than the melting pt. of metal.
Removal and finishing of casting material after complete soldification.
Core

Expendable
neither too fast nor too slow.
Mold Making
Solidification
Riser
shaping other materials such as ceramic, polymeric and glassy materials.

to the mold cavity.

e shrinkage in the casting material during solidification