1/What are some possible objectives of surface engineering processes?

Answer : Manufacture as a joined structure composed of several pieces is favored when the product needs to be large, composed of several parts with different properties or have a complex shape. 2/What are some of the factor that should be considered when selecting a surfacemodification process? Answer : Consolidatin processes are those in which different material bodies are joined to produce the part or product. Examples of csolidation processes are welding of relatively large pieces together to form a part, powder metallurgy with the sintering of particles together add additive rapid prototyping techniques such as inkjet and 3-D printing. 3/How are the surface and its integrity altered by the process of metalcutting? Answer : Welding is the permanent joinung od two material bodies by coalescence produced by temperatur, pressure and metallurgical conditions. 4/Tow surfaces can have the same microinch roughness but the different in appearance.Explain! Answer : The ideal metallurgical bond requires : (1) perfectly smooth, flat or matching surfaces, (2) clean surfaces, free from oxides, absorbed gases , grease, and other contaminants, (3) metals with no internal impurities, and (4) two metals that are both single crystals with identical crystallographic structure and orientation. 5/What limits the resolution of a stylus-type surface-measuring device in finding profiles? Answer : Surface roughness is overcome either by force, causing plastic deformation of the asperities, or by melting the two surfaces so that fusion occours . In solid state welding, contaminated layers are removed by mechanical or chemical cleaning prior to welding or by causing sufficient metal to flow along the interface so that they are squeezed out of the weld. In fusion welding, the contaminants are removed by fluxing agents. Welding in a vacuum also serves to remove cataminants.

6/What is the general relationship betweed surface roughness and tolerance? Between tolerance and cost to produce the surface and/or tolerance? Answer : When high temperatures are used in welding, the metals may be adversely affected by the surrounding environment . If actual meling occurs, serious modification of the metal may result. The metallurgical structure and properties of the metal can also be adversely affected by the heating and cooling cycle of the weld process. 7/What are some of the sources of foreign material on the surface of manufactured product? Answer : Thermal cutting is the separation of a piece of material into two pieces by the imposition of localized thermal energy such as with a flame, electric arc , laser beam, lectron beam or the impingement of an oxygen stream into a hot material . 8/What are some the common abrasive media used in blasting or abrasive cleaning operations? Answer : Some common weld defects are cracks, cavities, inclusions, incomplete fusion between the weld and base materials, incomplete penetration of the weld into the materials to be joined, unacceptable weld shape, surface defects due to arc strikes, blemishes due to spatter, metallurgical changes that are detrimental to product performance and warping and distortion. 9/What types of quanlities and part sizes are most altractive for barrel finishing operation? Answer : The four basic types of fusion welds are bead welds, groove welds, fillet welds, and plug welds, as illustrated in Figure 35-3 . 10/Describe why there might be an optimum fill level in barrel finishing. How might you find the optimum rolational speed? Answer : Fillet welds are used for tee, lap , and corner joints . These configurations are shown in Figure 35.6 . 11/Describe the primary differences between barrel finishing and vibratory finishing?

Answer : The cost of making a weld is a affected by the required edge preparation, the amount of weld metal that must be deposited, the type of process and equipment that must be used, and the speed and ease with which the welding can be accomplished. 12/What are some of the possible functions of the compounds that are used in abrasive finishing operations? Answer : When two pieces are welded together, they become one piece. Cracks in one segment can then cross the weld and continue propagation throughout the structure . Alson, one sefment constrains the other, so that properties such as fracture resistance and ductility can change appreciably . 13/How is electropolishing different from electroplating? Answer : the notch ductility characteristics of metal can change markedly with a change in the size of the piece . While a small piece, such as a Charpy impact specimen, exhibits ductile behavior and good energy absorption down to low temperature, a large structure of the same metal exhibits brittle behavior at higher temperature . Because of the added forbidden, resulting in a product with reduced fracture resistance, reduced ductility, and an elevatre ductile-to-brittle transition temperature. 14/What are some of the mechanisms of alkaline cleaning, and what types of soils can be removed? Answer : Excessive rigidity in a welded structure can restric the materials ability to redistribute stresses, and thereby avoid failure . Structures and joints should be designed to have some flexibility. 15/ What types of surface contaminants cannot be removed by solvent cleaning? Answer : In a fusion weld, a poll of molten metal is created, contained, and solidified within a metal mold formed by the segments being welded . This is actually a casting in a metal mold and has all of the structural and property features of such a casting.

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