Chapter 1 – History of Metallurgy 1.

During the Bronze Age, __c___ was made into decorative items due
to its resistance to tarnishing.

a. Bronze

b. Copper

c. Gold

d. Tin

. The matter remaining once a metal has been separated from its ore is known as __b___.

a. Bloom

b. Slag

c. Wootz steel

d. Ingot

Cast iron ingots are also known as __c___ iron.

a. Puddle

b. Bog

c. Pig

d. Wrought

Which of the following is a disadvantage of the open-hearth furnace?

a. It produced a lower grade of steel than the Bessemer converter.

b. It took eight hours to produce one heat of steel.

c. It immediately increased the cost of steel.

d. It was prone to explosions.

Answer is b

What is the difference between smelting and alloying?

• Smelting is the process of heating up the ore to extract the metal in it while alloying is the
process of combining metals

Describe the process used to produce wrought iron

• Wrought iron was produced by heating the iron ore with charcoal and limestone that then
formed into a spongey mass of iron and thick slag, the spongey iron was then reheated and
hammered multiple times while also folding it over, stringers of iron called bloom was created.
. How did the invention of the Bessemer converter influence the development of an industrialized
society?

• It was able to produce steel in less than an hour, removed many impurities and all carbon in the
melt of pig iron and made the cost of steel drop heavily

Explain how the conception of electric generators created the need for high-purity copper and
simultaneously made it commercially possible.

• High purity copper was needed for electrical applications, in a time where electricity was finding
its way into building the electric generator was used to refine the copper used for this electrical
purpose and drove up the need for electric generators since they could purify the copper.

List three advantages that a basic oxygen furnace (BOF) has over an open hearth furnaces.

• Much faster, 20mins to produce a heat of steel compared to 8hrs

• Metal quality was equal or even greater when compared to the open hearth
• Building a BOF was much less expensive to build than a open hearth furnace

Nearly every kind of manufacturing today is affected by the behavior of metals. How does this affect the
need for a study of metallurgy?

• Because manufacturing today relies on metals to produce goods and those manufacturers want
the best metal they could get that’s right for the job needed and is as cheap as possible to
purchase. So the need for people who are professionals in metallurgy is driven up since they are
the ones who can figure that out and/or find the problems with metals that manufacturers
purchase or produce to fix that problem, or to even better the manufacturers process making it
better and cheaper.

Chapter 2

1. ___b__ are responsible for the properties seen in metal.

a. Alloys

b. Microstructure

c. Ores

d. Elements
A(n) __b___ is a substance comprised of either two or more metals or one metal and one or more
nonmetals mixed together while melted.

a. Ore

b. Alloy

c. Microstructure

d. Property

All metals whose major component is iron are classified as __a___.

a. Ferrous

b. Nonferrous

c. Alloys

d. Microstructures

A(n) __c___ heats a piece of metal using high-frequency energy.

a. Furnace

b. Hydraulic pump

c. Induction coil

d. Electric heater

Why is it important to understand the cause-and-effect relationship between processes and a metal’s
microstructure?

• Because certain processes create a unique structure in the metals microstructure that a
different process might not create but that isn't visible to the naked eye

Explain why metallurgical knowledge is beneficial to someone in an occupation other than direct
production.

• Because it can help someone fix or modify a metal part of a machine to fit their specific needs

Why is every step in a production process essential?

• Because aluminum that is use in for example radiator cooling fins has different performance
requirements than aluminum cooling fins used In blood coolers. So the aluminum used in blood
coolers can't have any defects in it while radiator fins won't perform worse If there are defects
in the aluminum.
Explain why a spectrum of professionals is necessary to implement new and improved products and
processes.

• To be able to make a superior product than the one before or a faster more cost effective
process that retains the quality needed for the metal

Why is it critical for a company to look for ways to improve processes on a continual basis?

• Because it can save the company from spending more money to increase the size of a metal part
of a machine, instead they can add a process to that specific metal parts manufacturing process
to reenforce its strength instead of spending more money on buying more metal to physically
make the part bigger and stronger and reengineering the machine which would be much more
expensive.

. Provide an example of when metallurgical knowledge can be used to solve an industrial problem (see
Chapter 2.2).

• Tractor axle shaft, instead of changing the diameter of the axle shaft or change in alloy used by
a tractor which would be expensive to do, simply by dropping the heating temperature by a bit
added enough strength to the axle shaft to satisfy the design requirements.