Describe with sketch the surface treatment process used to built-up worn out metal components of automotive engines.

Describe with sketch the surface treatment process used to built-up worn out metal components of automotive engines.
by

1 Answer

Answer :

Metal spraying is to build-up worn out metal components of automotive engines.

image 


Metal Spraying of metalizing literally means to treat with or coat with a metal or metallic compound. Metalizing as a process normally includes the preparation of base material, the spraying on the metal and finally finishing the surface by grinding. Basically there are two types of equipment are used for metal spraying. One is the metallic gun which consists of a gas torch with a hole in centre of the tip for the wire, a small air turbine and gears to feed in the wire through the tip into the flame as fast as it melts and an air cap around the torch tip and nozzle which supplies a blast of air to atomise the molten metal and deposit it on the prepared surface. In other method powered metal is fed from container through rubber hose to spray-gun and out through the centre of flame, similar to the wire gun. In this case metal is already in atomized form and hence air needed is sufficient to deposit the molten metal on the surface being coated. The metallic-gun using metal in the wire form is commonly used. The wire is fed to spray gun at a definite rate melted by an oxyacetylene flame, and then blown on the surface being coated, by compressed air. A sectional view of metal spraying gun is shown in fig.  

by

Related questions

Define forgeability and give any four forgeable materials used to produce automotive components.

Description : Define forgeability and give any four forgeable materials used to produce automotive components.

Last Answer : Forgeability Forgeability can be defined as the tolerance of a metal or alloy for deformation without failure. OR Forgeability is defined as the ability of a metal to change size and shape when ... Columbium alloys 10) Tantalum alloys 11) Molybdenum alloys 12) Tungsten alloys 13) Beryllium.

Describe Abrasive blast cleaning process with neat sketch.

Description : Describe Abrasive blast cleaning process with neat sketch.

Last Answer : Abrasive Blast Cleaning (Blasting): This method is widely used for removing all classes of scale and rust from forgings, castings, weldments, and heat treated parts. Depending on the finish ... and other material are removed, providing an excellent surface for bonding final finishes.

Explain the shielded metal arc welding (SMAW) processes with neat sketch. State its two advantages and disadvantages.

Description : Explain the shielded metal arc welding (SMAW) processes with neat sketch. State its two advantages and disadvantages.

Last Answer : Working  : Shielded metal arc welding uses a metallic consumable electrode of a proper composition for generating arc between itself and the parent work piece. The molten electrode metal fills the weld ... . 2. Weld may contain slag inclusions 3. Fumes make difficult the process control.

Explain with neat sketch method of welding used in manufacturing sheet metal roofs and doors of automobiles.

Description : Explain with neat sketch method of welding used in manufacturing sheet metal roofs and doors of automobiles. 

Last Answer : Method of Welding Used in Manufacturing Sheet Metal Roofs and doors of automobiles: MIG Welding: Gas-metal-arc welding is a gas shielded metal arc welding process which uses the high ... mixtures) which will not combine with metal. Carbon dioxide is most commonly used as it inexpensive.

Sketch and describe the following press operations: 1. Punching 2. Shearing and 3. Trimming

Description : Sketch and describe the following press operations: 1. Punching 2. Shearing and 3. Trimming

Last Answer : (i) Punching : In punching operation, a hole is the desired result. The size of hole is determined by the size of punch and clearance is allowed on the die. The figure shows the ... still hot for maximum efficiency; therefore it is usually incorporated into the larger production process.

Describe with neat sketch: (i) Spot Welding (ii)Seam Welding

Description : Describe with neat sketch: (i) Spot Welding (ii)Seam Welding

Last Answer : (i) Spot Welding: Spot welding is employed to join overlapping strips, sheets or plates of metal at small areas .The pieces are assembled between two electrodes, which must possess high electrical & ... used to conserve the electrodes and cool the work rapidly to speed up the operation.   

Enlist any four operations carried out in forging process and explain fullering with neat sketch.

Description : Enlist any four operations carried out in forging process and explain fullering with neat sketch.

Last Answer : Operations carried out in forging process:  a) Upsetting b) Drawing Down c) Setting down d) Welding e) Bending f) Cutting g) Punching Fullering: In ... sledge hammer. The force is applied on the top fuller which results in decreasing the cross section at that point.

Explain the resistance spot welding process with neat sketch. State its two advantage and disadvantage.

Description : Explain the resistance spot welding process with neat sketch. State its two advantage and disadvantage. 

Last Answer : Resistance Spot welding: Spot welding is employed to join overlapping strips, sheets or plates of metal at small areas .The pieces are assembled between two electrodes, which must possess high electrical & thermal ... for making the RSW a success. 4. The thick jobs are not easy to weld. 

Explain seam welding process with the help of neat sketch.

Description : Explain seam welding process with the help of neat sketch.

Last Answer : Seam Welding is a Resistance Welding (RW) process used for producing continuous joint of overlapping sheets by passing them between two rotating electrode wheels. Heat generated by the electric current flowing through ... the electrodes and cool the work rapidly to speed up the operation.    

Explain buffing process with neat sketch.

Description : Explain buffing process with neat sketch. 

Last Answer : Buffing process :- Buffing is used to give a much higher, lustrous, reflective finish that cannot be obtained by polishing. The buffing process consists in applying very fine ... sporting items, tools, store fixtures, commercial and residential hardware and household utensils and appliances. 

(i) Compare Open Die Forging and Close Die Forging. (ii) Explain with neat sketch process of Drop Forging.

Description : (i) Compare Open Die Forging and Close Die Forging. (ii) Explain with neat sketch process of Drop Forging.

Last Answer : (i) Difference between Open Die and Close Die Forging: (ii)Drop Forging  Drop forging is carried out by using drop hammers. They are board or gravity hammer, air lift hammer and power drop ... of upper and lower dies. The ram is fastened to the lower end of vertical hard wood board.

Explain TIG (GTAW) welding process with neat sketch.

Description : Explain TIG (GTAW) welding process with neat sketch.

Last Answer : Tungsten Inert Gas Arc Welding (TIG, GTAW): It is a welding process, in which heat is generated by an electric arc struck between a nonconsumable tungsten electrode and the work piece. The weld pool is ... produces a high quality weld of most of metals. Flux is not used in the process.  

Explain with sketch construction and application of progressive die.

Description : Explain with sketch construction and application of progressive die.

Last Answer : OR Construction A progressive die consists of the following parts.: 1. Stop 2. Sheet metal 3. Pilot 4. Blanking punch 5. Ram 6. Piercing punch 7. Stripper Plate 8. Die ... such as automotive, electronics and appliances. Example car brake caliper, washer, lid of a beverage can etc.

Draw neat labeled sketch of ply press.

Description : Draw neat labeled sketch of ply press.

Last Answer : sketch of ply press

Explain drop forging with neat sketch.

Description : Explain drop forging with neat sketch. 

Last Answer : Drop Forging Process: Drop forging is carried out by using drop hammers. They are board or gravity hammer, air lift hammer and power drop hammer. Anvil of drop forging hammer is attached to the frame ... [5] This energy will be delivered to the metal work-piece to produce plastic deformation.  

What is interpolation? State its types. Explain linear interpolation with neat sketch

Description : What is interpolation? State its types. Explain linear interpolation with neat sketch

Last Answer : Definition : When the feed rates of individual axis are not constant and they vary continuously through the move it is called interpolation. Following are the types of interpolation: 1. G00- Rapid Traverse 2. ... to clear the job for loading /Unloading N9 M02 EOB  Programme End.  

Name the types of dies used in press work. Explain any one with neat sketch.

Description : Name the types of dies used in press work. Explain any one with neat sketch.

Last Answer : The various types dies used in press work are: 1. Types of dies according to operations performed (i) Shearing (ii) Bending (iii) Drawing (iv) Squeezing 2. Types of ... giving output. These dies are simple in construction and can manufacture by conventional machining processes.     

Explain forming and punching operation with neat sketch.

Description : Explain forming and punching operation with neat sketch.

Last Answer : Forming: Forming processes are particular manufacturing processes which make use of suitable stresses (like compression, tension, shear or combined stresses) to cause plastic deformation of the materials to produce ... metal from being lifted along with the punch 3 after punching operation.   

Explain Closed loop and Open loop system with sketch.

Description : Explain Closed loop and Open loop system with sketch. 

Last Answer : Closed Loop System: [1] The name indicates that the closed loop control system has a loop that is closed as shown in figure. [2] A feedback device is used for this purpose. This makes ... system is generally used in point-to-point systems where the accuracy requirements are not critical. 

Explain with neat sketch pilots and its types.

Description : Explain with neat sketch pilots and its types.

Last Answer : The pilot illustrated in Fig. enables the correct location of the blank when it is fed by mechanical means. The pilot enters into the previously pierced hole and moves the blank to the correct ... enter previous punched holes in the strips some distance away from the blanking punch    

With neat sketch explain MIG welding

Description : With neat sketch explain MIG welding

Last Answer : MIG Welding: Gas-metal-arc welding is a gas shielded metal arc welding process which uses the high heat of an electric arc between a continuously fed, consumable electrode wire and the material to be ... which will not combine with metal. Carbon dioxide is most commonly used as it inexpensive.

Sketch and label different types of gas welding flames. Also give application of any one flame.

Description : Sketch and label different types of gas welding flames. Also give application of any one flame.

Last Answer : 1) Neutral Flame: - A neutral flame is obtained when equal amounts of oxygen and acetylene are mixed and burnt in a torch.   Applications: - stainless steel, cast iron, copper ,mild ... when acetylene is supplied more than oxygen.   Applications:-high carbon steel, nonferrous alloy 

Explain electrolytic cleaning with neat sketch.

Description : Explain electrolytic cleaning with neat sketch.

Last Answer : Electrolytic Cleaning: This is effective as final cleaning process for removing oil and grease from machined surface when extreme cleanliness is required. It is almost always used for final cleaning of steel parts ... should be low or excessive foaming with danger of explosion may result.

Draw a neat sketch of progressive die.

Description : Draw a neat sketch of progressive die. 

Last Answer : progressive die

Explain the importance of pressure pads in a die with neat sketch.

Description : Explain the importance of pressure pads in a die with neat sketch.

Last Answer : Importance of Pressure pad:  It is used for drawing operation for maintaining flat surface of the cup. A pressure pad presses against the material during L bending or U bending, and is used for ... . There is also the purpose of stripping off the material from the punch after forming.

Explain fly press with neat sketch.

Description : Explain fly press with neat sketch.

Last Answer : Fly Press : [1] It is simplest type of all presses, called as hand press / ball press/single side fly press. [2] It consists of robust cast iron frame. Top portion of frame forms the nut ... adjusted with help of Stop Collar / Arrestor. Advance type of fly press is double side Press. 

Explain simple die with neat sketch

Description : Explain simple die with neat sketch

Last Answer : Simple Die: Simple die or single action dies perform single operation for each stroke of the press slide. The operation may be cutting or forming operation such as blanking, punching, piercing etc. ... are simple in construction and can manufacture by conventional machining processes.    

Explain closed die forging with neat sketch

Description : Explain closed die forging with neat sketch

Last Answer : Impression die & Closed die forging process: Closed Die forging is also known as impression die forging. Close die forging process consist of specially prepared dies to manufacturing forged parts in large ... of accuracy. Complex shaped parts can be easily forged by this forging process.  

Explain honing with neat sketch

Description : Explain honing with neat sketch 

Last Answer : Honing Process (micro finishing process): To correct hole geometry in component, honing is used as a micro finishing process. Honing is an abrading process used mainly for finishing round holes by means ... operation of this process, to flush away small chips and to keep temperatures uniform. 

Explain axes identification of CNC machine with neat sketch

Description : Explain axes identification of CNC machine with neat sketch

Last Answer : The first axis to be identified is the Z axis. This is then followed by the X and Y axes respectively. Z axis and motion: Location: The Z axis motion is either along the spindle axis or ... which advance right-hand screws in the positive X, Y and Z directions respectively. 

With neat sketch explain the working principle of CNC machines.

Description : With neat sketch explain the working principle of CNC machines. 

Last Answer : Working Principle of CNC machine:- A CNC machine also has a tape reader or any other input media for entry of the part program. CNC uses the part program in a different manner though there is ... to the reference. These two signals are compared and necessary action is controlled.   Or  

Explain the working principle of resistance welding with neat sketch.

Description : Explain the working principle of resistance welding with neat sketch. 

Last Answer : Resistance Welding Process: 1.Resistance Spot welding:  Spot welding is employed to join overlapping strips, sheets or plates of metal at small areas. The pieces are assembled between two ... welding small parts. Butt Welding provides joining with no loss of the welded materials.  

Draw neat sketch showing various parts of die set.

Description : Draw neat sketch showing various parts of die set. 

Last Answer : Answer: 1. Stop 2.Sheet metal 3.Pilot 4.Blanking punch 5.Ram 6.Piercing punch 7.Stripper 8.die Fig. Progressive Die OR

With neat sketch explain the features of oxidizing flame and carburizing flame.

Description : With neat sketch explain the features of oxidizing flame and carburizing flame.

Last Answer : Oxidizing Flame: An oxidizing flame is one in which there is an excess of oxygen. The flame has two zones- the smaller inner cone which has purplish tinge, the outer cone or envelop.   Carburizing ... defined inner cone 2) An intermediate cone of whitish colour. 3) Bluish outer cone   

Explain the working principle of MIG welding with neat sketch.

Description : Explain the working principle of MIG welding with neat sketch.

Last Answer : MIG Welding: Gas-metal-arc welding is a gas shielded metal arc welding process which uses the high heat of an electric arc between a continuously fed, consumable electrode wire and the material to be ... will not combine with metal. Carbon dioxide is most commonly used as it inexpensive.

Draw neat sketch of compound die, showing various parts of it.

Description : Draw neat sketch of compound die, showing various parts of it.

Last Answer : Answer:

Draw the neat sketch of fly press. Give the functions of important parts of it.

Description : Draw the neat sketch of fly press. Give the functions of important parts of it. 

Last Answer : Answer: OR Functions of important parts of Fly Press. 1. Ram : This is main operating part of the press which works directly during processing of a workpiece. Ram ... : A die is a specialized tool used in manufacturing industries to cut or shape material mostly using a press 

Explain press forging with neat sketch.

Description : Explain press forging with neat sketch. 

Last Answer : Press Forging: In press forging, impression dies are used in which partd are made by plastically deforming a metal blank into die avities by slow squeezing action. The forging pressure builds up from the ... they are generally employed for non-ferrous alloys weighting from upto about 135 N. 

Sketch and explain a progressive die used to make washer.

Description : Sketch and explain a progressive die used to make washer.

Last Answer : Progressive Die: In a progressive die two or more operations are performed simultaneously at two or more stations with each press stroke by mounting separate sets of dies and punch. The metal is progressed ... locate it while the blanking punch descend and shear the plate to form a washer.  

Explain Blanking operation on press with neat sketch.

Description : Explain Blanking operation on press with neat sketch.

Last Answer : Blanking Operation:  1. It is the operation of cutting of flat sheet to the desired shape.  2. The metal punched out (i.e. blank) is the required product & the plate with hole left on ... is governed by size of die and the clearance left on the punch.  Fig. shows blanking operation

Explain drawing operation on press with neat sketch.

Description : Explain drawing operation on press with neat sketch.

Last Answer : Drawing Operation:  1. The drawing is the operation of production of cup shaped parts from flat sheet metal blanks by bending and plastic flow of the metal.  2. The blank is placed on die ... , clearance between punch and die is greater. The drawing operation is illustrated in Fig. 

Explain construction and working of Combination Die with neat sketch.

Description : Explain construction and working of Combination Die with neat sketch.

Last Answer : Combination Die: In this both cutting and non-cutting operations are performed at one station of the press in every stroke of the ram. Figure shows a combination of blanking and drawing die.In this ... as blank holder when the drawing punch descends and draws the blank into the desired shape.

Draw simple labeled sketch showing forging sequence for manufacturing Crank Shaft.

Description : Draw simple labeled sketch showing forging sequence for manufacturing Crank Shaft.

Last Answer : Forging Sequence for Manufacturing Crank Shaft: [1] Stock is redistributed and size is increased at certain place and reduced at other place by roll forging. [2] After preliminary roll forging, ... Then the finished part is then trimmed in blanking die to remove excess metal or flash.   

Explain metal spraying process and give two applications.

Description : Explain metal spraying process and give two applications.

Last Answer : Metal praying of metalizing literally means to treat with or coat with a metal or metallic compound. Metalizing as a process normally includes the preparation of base material, the spraying on ... Its other applications are in having decorative films, reflecting surfaces and special metal forms. 

List the materials used in press work for automobile components parts with example.

Description : List the materials used in press work for automobile components parts with example.

Last Answer : Materials used in press work: 1) Aluminium, 2) Copper, 3) Brass, 4) Mild Steel, 5) Galvanized iron (G.I) sheets, 6) Duralumin, 7) Y-alloys, 8) Naval Brass, 9) Cartridge Brass, ... 8) Carburettor bodies 9) Valves 10) Combustion Chamber 11) Cylinder heads , blocks,  12) Gear box cases

What are the factors considered while selecting the components for machining on CNC machines?

Description : What are the factors considered while selecting the components for machining on CNC machines?

Last Answer : Following are the factors to be considered in selecting components of CNC machines? 1. High precision and repeatability. 2. Reliability. 3. Efficiency -To meet the requirement of high precision. ... should be such that removal of swarf is easy and the chips do not fall on the slideways.

List the components of NC machines.

Description : List the components of NC machines.

Last Answer : Components of NC Machines: 1. Program input device  2. Memory storage 3. Microprocessor 4. Machine control Unit (MCU) 5. Drive system 6. Machine Tool 7. Feedback system 8. Programmable logic controller (PLC) 9. Machine control panel 10. Operator control panel 11. Tape Reader

Enlist any four forging components.

Description : Enlist any four forging components.

Last Answer : Forging Components:  1. Connecting rod  2. Crankshaft  3. Camshaft  4. Alloy wheel  5. Drive shafts  6. Clutch hubs  7. Universal joints  8. Hand Tools

State different methods by which forged components can be made.

Description : State different methods by which forged components can be made. 

Last Answer : Answer: Different types of forging method - I. Open die forging: a) Hand forging b) Power forging: i. Hammer forging ii. Press forging II. Close die forging: a) Drop forging b) Press forging c) Machine forging OR

Enlist four press components used in automobiles.

Description : Enlist four press components used in automobiles. 

Last Answer : The various Pressed Products used in Automobiles are: 1) Gears 2) Crank Shafts 3) Automobile panels 4) Wires 5) Frames and Chassis 6) Connecting Rods 7) Springs 8) Carburetor bodies 9) Valves 10) Combustion Chamber 11) Cylinder heads & blocks 12) Gear box cases etc.