Metal profiles can be formed by i) extrusion from billets,  by  ii) cutting,  bending sheet metal followed by seam welding or by  iii) rolling from blooms.

Aluminum profiles as shown below are usually made by 

SHS, CHS, RHS  profiles as shown below are usually made by 

External threads on bolt can be formed by cutting them on a lathe or using a die, or rolled in a cold forming process. Which of the statements below is correct.

For each of the statements below,  decide which process they are better associated with.

1) The amount of deformation possible is limited by the ductility of the material.

2) The process leaves the part in a work hardened state with elevated yield and ultimate strength but reduced ductility. 

3) The crystal grain sized are smaller in the finished product and could be aligned in certain directions, thus resulting in superior mechanical properties compared to other forming processes.  

4) Annealing can be done after forming to either increase ductility or prepare the part for another round of forming operations. 

5)  While forming, the workpiece is soft and malleable and there is no limit to the amount of deformation that can be done. 

Which are the following statements are correctly associated with automotive sheet metal stamping.

What are the motivations for heating the metal to above the recrystallization temperature before working to shape it?

For the following statements, indicate if they better describe open or closed dies forging.

1) Parting line and draft angles are required.

2) To fabricate a part, usually many different dies could be used to progressively shape the workpiece.  

3) Parts are designed to reduce the amount the metal needs to flow vertically upwards into the die cavity to reduce wear on the die.  

4) More suitable for automation and larger production runs. 

During the lab last week, the biggest challenge to metal casting experienced by most teams is:

The basic Solidworks operation

If that surface with a draft angle is not a functional surface, I would

If that surface with a draft angle is a functional surface, I would

Match the following processes in the right order/sequence for Investment Casting

Match the correct description for the following processes respectively: