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Файл:Materials Processing Technology Part 2. Coursebook
.pdf
adjective
considerable
distinct
typical
relative
initial
literal
adverb
considerably
distinctly
typically
relatively
initially
literally
adjective > noun
noun > adjective
verb > noun
dense > density
metal > metallic
resist > resistance,
resistivity
tense > …
structure > …
conduct > …
elastic > …
metallurgy > …
load > …
tough > …
compression > …
apply > …
ductile > …
cycle > …
reduce > …
soft > …
powder > …
grow > …
similar > …
effect > …
expand > …
malleable > …
result > …
melt > …
rigid > …
industry > …
classify > …
electric > …
austenite > …
perform > …
permeable > …
ion > …
deteriorate > …
soluble > …
engineer > …
appreciate > …
susceptible > …
magnet > …
predominate > …
solid > …
pair > …
process > …
thick > …
molecule > …
refine > …
synthetic > …
environment > …
anneal > …
=========================================================
_____1 Form a noun or an adjective from the following words by adding the
correct suffix.
11
____ 2 Complete the following sentences by adding a word derived from the
word given.
1. In the mid 1960s, a new group of materials, called advanced (a) _______
(engineer) composite materials, began to emerge. Advanced composite materials
utilize a (b) ________(combine) of resins and fibers. The fibers provide the high
(c) ________ (stiff), while the surrounding polymer resin matrix holds the
structure together. The fundamental design concept of composites is that the bulk
phase (d) _______ (accept) the load over a large surface area, and (e) _________
(transfer) it to the (f) _________ (reinforce) material. There are numerous matrix
materials and as many fiber types, which can be (g) ________(combine) in
countless ways to produce the desired properties. These materials were first (h)
_________(develop) for use in the aerospace industry because for certain (i)
__________ (apply) they have a (g) ________(high) strength-to-weight ratio than
metals. This means metal parts can (k) ________ (replace) with lighter weight
parts (l) ________ (manufacture) from advanced composites. Generally,
composites are (m) ________(resist) to fatigue damage and harsh environments,
and are (n) _________ (repair).
____3 Complete the following sentences with the adjective and adverb
in brackets. Use each word once only.
1. Cold working the metal __________ doubles its strength.
(approximate/approximately)
2. __________ pure aluminum has a tensile strength of about 13,000 psi.
3. This strong, hard, lightweight alloy of aluminum is _______ used in aircraft
construction. (wide/widely)
4. A polymeric solid can be thought of as a material that contains many
__________ bonded parts which themselves are bonded together to form a solid.
(chemical/chemically)
5. Since polymerization is __________ accomplished by heating the raw
materials and bringing them together, this group is called thermosetting polymers
or plastics. (initial /initially)
6. Such chains form joint structures and rings, and may fold back and forth to
take on a _______ crystalline structure. (partial/partially)
7. Metallic fillers in plastics can make them _________ conductive or give them
magnetic properties. (thermal/thermally)
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8. Generally the term composite is applied to materials that are created by
STUDY SKILL Compound nouns & Compound adjectives
A compound noun can be formed by putting two nouns together. These are
written:
as two words, e.g. radio waves, heat treatment
as one word, e.g. microwave, gearbox
with a hyphen, e.g. data-processing, steel-making
A compound adjective can be made with:
a noun + adjective, e.g. computer literate, wear-resistant
an adjective + present /past participle, e.g. fine-grained
an adverb + present /past participle, e.g. well-known, partially-filled
an adjective + noun, e.g. stainless steel, cast iron
___________ bonding two or more materials together.
(mechanical/mechanically)
9. Many synthetic fibers have been developed (a)__________to replace natural
fibers, because synthetics often behave more (b)_________ and are
(c)_________more uniform in size.
(a. special/specially; b. predictable/predictably; c. usual/usually)
10. If the composite is designed and fabricated _________, it combines the
strength of the reinforcement with the toughness of the matrix. (correct/correctly)
11. Properties that describe how a substance changes into a _________ different
substance are called chemical properties. (complete/completely)
12. The yield strength is the strength in which a material first deforms
_________. (plastic/plastically)
_____ 4 Match the nouns to form compound nouns. There may be more than
one possible combination. Use a dictionary to find out how to write them.
1 □ information a dish
2 □ steel b treatment
3 □ heat c machine
4 □ fax d making
5 □ word e relief
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6 □ cable f processor
high-speed man-made strain-hardened water-based
bullet-proof
service life steady-state fatigue life load-bearing
metal-rolling
7 □ satellite g technology
8 □ stress h television
____5 Complete the sentences. Use a compound adjective or a compound
noun from the box.
1. Process annealing is a heat treatment used to soften and increase the ductility
of a previously _________metal.
2. The engineering plastics are now challenging the domains traditionally held
by metals: truly _________, structural parts.
3. The super-material known as Kevlar is a _______ polymer.
4. Kevlar is used in __________ vests, and underwater cables that are 20 times
stronger than steel.
5. Powders more often than not cost more than __________.
6. Power stations depend on hydrogen cooling their _________ turbine
generators.
7. ___________ paints and vinyl records are made with the help of acetylene,
which has many applications.
8. The mechanical properties of metals determine the range of usefulness of a
material and establish the _________ that can be expected.
9. The constant creep rate is called the minimum creep rate or _________ creep
rate since it is the slowest creep rate during the test.
10. Since fatigue cracks generally initiate at a surface, the surface condition of the
component being loaded will have an effect on its __________.
1 strain-hardened 6 high-speed
2 load-bearing 7 water-based
3 man-made 8 service life
4 bullet-proof 9 steady-state
5 metal-rolling 10 fatigue life
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STUDY SKILL Using a dictionary
Use an English-English dictionary to read the definition(s) and
look at the example sentences. These will help you use the
words correctly.
Affect vs. Effect
Affect and effect are often confused.
affect
v
means to cause some result or change in; influence: an
important decision that will affect the company’s future
effect n means a result or condition produced by a cause;
something that happens when one thing acts on another: The
advertising campaign didn’t have much effect on sales.
COMPARE affect and effect. 1. Affect is the usual verb and
effect is the usual noun: Government policy will not affect (v)
us /will not have any effect (n) on us. 2. Affect means ‘to
change’: Nicotine adversely affects the functioning of the heart
and arteries.
Effect used as a verb is very formal and means “to bring about,
usually according to one’s wishes”: He was able to effect
certain changes in government policy.
A dictionary entry will also help you use a word by giving any
prepositions which collocate, e.g. have an effect on, which
means to cause a particular kind of change in something or
someone:
The advertising campaign didn’t have much effect on sales.
(from Longman Dictionary of English Language and
Culture, 1992 )
______6 Choose the correct word in bold.
electrical, magnetic and optical properties.
of the material’s electrons will be (c) effected / affected.
cadmium and tin increase hardness in heat treatable alloys.
1. The atomic structure (a) affects /effects the chemical, physical, thermal,
2. The inclusion of manganese (b) affects /effects the properties of steel.
3. When a material is placed within a magnetic field, the magnetic forces
4. Cobalt and nickel (d) effect/affect strength and workability, while
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5. The annealing temperature is typically a relatively low one, such that (e)
Preparing a presentation
An oral presentation can be more difficult to
understand than a text. It is usually better to give a
presentation from notes than reading aloud from a
text.
►Introduce the subject and the structure of the talk at
the
beginning.
►Speak clearly.
►Explain, rephrase, and clarify new or difficult
terms.
►Write notes to remind you of the main points.
►Write key phrases to each section and the summary
affects /effects resulting from cold working treatment are not (f) affected
/effected.
6. Iron, manganese, nickel, and molybdenum are also added to aluminum
with various beneficial (g) affects / effects.
7. The microstructure and macrostructure generally have a large (h) affect /
effect on mechanical properties.
8. Creep in service is usually (i) affected /effected by changing conditions
of loading.
9. Stress concentration, corrosion, temperature, overload, metallurgical
structure, and residual stresses can (j) effect /affect the propensity for fatigue.
10. Since fatigue cracks generally initiate at a surface, the surface condition
of the component will have an (k) effect /affect on its fatigue life.
11. Scientists are investigating the ways in which the oceans (l)
effect/affect the climate.
12. The rise in gas prices is likely (m) to affect /effect the cost of
electricity.
a affects e effects i affected m affect
b affects f affected j affect
c affected g effects k effect
d affect h effect l affect
SPEAKING
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of your
presentation.
►Practice your presentation at home. Time yourself
and make
sure it is the right length.
____1 Give a 5-10 minute presentation to the members of your group.
Possible topics are as follows:
a) Polymers;
b) Composite materials:
c) Ceramic engineering.
To find information on the topic “Polymers”, go to the following websites:
- LiveScience at https://www.livescience.com/60682-polymers.html;
- ThoughtCo at https://www.thoughtco.com/what-is-a-polymer-820536;
- ThoughtCo at https://www.thoughtco.com/what-are-examples-of-polymers-
604299.
To find information for the presentation on the topic “Composite materials”, go
to the following websites:
-Encyclopedia Britannica at https://www.britannica.com/technology/compositematerial;
-New World Encyclopedia at
http://www.newworldencyclopedia.org/entry/Composite_material;
- BrainKart at https://www.brainkart.com/article/Composite-materials-andTypes-of-Composites_3670/.
To find information for the presentation on the topic “Ceramic engineering”, go
to the following websites:
- New World Encyclopedia at
http://www.newworldencyclopedia.org/entry/Ceramic_engineering;
- The American Ceramic Society at https://ceramics.org/.
You should choose one of the topics to prepare a short presentation, summarizing
the main points and, if necessary, using additional resources provided by the
above mentioned sites.
17
Unit 2
drawing forging open-die forging closed-die forging
sheet metal forming
bending roll forming spinning deep drawing
stretch forming
shielded metal arc welding gas metal arc welding submerged arc
welding
flux-cored arc welding laser beam welding electron beam welding
Metalworking and Welding
Metalworking is the process of working with metals to create individual
parts, assemblies, or large scale structures. It is a science, art, hobby, industry and
trade.
Metalworking has evolved from the discovery of smelting various ores,
producing malleable and ductile metal useful for tools and adornments. Modern
metalworking processes, though diverse and specialized, can be categorized as
forming, cutting or joining processes.
The term covers a wide range of work from large ships and bridges to precise
engine parts and delicate jewelry.
Metal fabrication is the creation of metal structures by cutting, bending,
and assembling processes.
Metalworking processes:
Welding is a fabrication process that joins materials, usually metals or
thermoplastics, by causing coalescence. It is often done by melting the
workpieces and adding a filler material to form a pool of molten material that
cools to become a strong joint. Sometimes, the weld is produced through the use
of pressure, with or without heat. By contrast, soldering and brazing involve
melting a lower-melting-point material between the workpieces to form a bond
between them, without melting the workpieces.
A variety of energy sources can be used for welding, including a gas flame,
an electric arc, a laser, an electron beam, friction, and ultrasound.
Welding techniques:
READING Metalworking processes
→ Read Study Skill
___1 Read the texts from Unit 2 of the Textbook.
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___2 Survey the texts from Section 5 and underline the information which
answers the questions.
1) What are the characteristics of forging as a manufacturing process?
2) How is forging classified depending on the temperature at which it is
performed?
3) What is the difference between the processes of open-die forging and closeddie forging?
4) What is the correspondence between the terms ‘closed-die forging’ and ‘
impression-die forging’?
5) What are the main types of sheet metal forging processes?
_____ 3 Survey the texts from Section 7 and underline the information
which answers the questions.
1) What is the most widely used method of welding?
2) What should be provided to create the arc in electric arc welding?
3) What type of welding process employs the reaction between a fuel gas and
oxygen?
4) What are the advantages of rightward welding over the leftward welding
technique?
5) What role plays the direction of current in the arc welding process?
6) What is the most common type of arc welding?
7) What makes submerged arc welding a highly productive welding process?
8) What type of welding employs the electrical resistance of material?
9) What is the main characteristic of plasma arc welding?
______4 Survey the texts from Section 7.6 and underline the information
which answers the questions.
1) What are unique advantages of laser beam welding?
2) What are the differences between laser beam welding and arc welding
processes?
3) What are mechanical properties of laser-welded joints?
4) What are peculiar properties of laser beam welding compared to electron
beam welding?
5) Who started the laser age?
6) What are the unique characteristics of laser light?
7) What does the acronym ‘laser’ stand for?
8) What are the most common features of all lasers?
9) How is laser action produced?
10) What are two commonly used types of lasers?
11) What conditions are necessary to perform electron beam welding?
19
VOCABULARY DEVELOPMENT
die shaping friction sheet metal
bend
roller die tool wear rotating
workpiece
welding
uses heat to form the weld which is generated by the
electrical resistance of material combined with the time
and the force applied to hold the materials
electric arc welding
a process in which the arc is struck beneath a covering
layer of a granular flux
gas welding
uses a non-consumable electrode made of tungsten
rightward welding
a process that melts and joins metals by heating them
with a constricted arc established between a tungsten
electrode and the metals
arc welding
uses a welding power supply to create an electric arc
between an electrode and the base material
_____1 Complete the following sentences with the words from the box.
Consult paragraphs 5.1 and 5.2 for correct choice of the words.
1) Drawing consists of pulling metal through a ________.
2) In open-die forging a hammer strikes and deforms the _________, which is
placed on a stationary anvil.
3) Closed-die forging is the ________ of hot metal within the walls of two dies.
4) Sheet metal forming processes are those in which force is applied to a
________ to modify its geometry.
5) Bending is a metal forming process in which force is applied to a piece of
sheet metal, causing it to ________ at an angle and form the desired shape.
6) In the roll forming process the sheet metal stock is fed through a series of roll
stations, each having a roller, referred to as a _________.
7) The roller dies are lubricated to reduce ________ between the die and the
sheet, thus reducing the ________.
8) Spinning is a metal forming process used to form _________ parts by rotating
a piece of sheet metal.
_____ 2 Study sections 7.1 – 7.5 and match the following words and phrases
with their definitions and characteristics.
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