ME 3503

Materials and Manufacturing Processes

Tanzila Younas
Email: tanzila@szabist.edu.pk

ME 3503
Materials and Manufacturing Processes

Materials
Processing

Manufacturing
Technology

Microstructures of metals

Casting process

Defects in metals, dislocations

Conventional Machining process

Plastic flow, grain boundaries

Non-conventional machining process

Forming of Metals

Joining process

Phase diagrams (Heat treatment)

Polymers & ceramics microstructure

Week
1

Session Topics

Assessment

i.
Introduction to course, Properties of materials in general
ii. Casting (Disposable : Sand and investment casting)
Casting ( Permanent : Slush, Pressure, Die, Centrifugal, Continuous)
i.
A brief on microstructure, defects, dislocations, grain boundaries &
recrystallization
ii. Forming processes (cold, warm and hot working)
i.
Metal Alloys, Phase diagrams
ii. Heat treatment
i.
Quiz 1
ii.
Powder Metallurgy
i.
Ceramics & Polymers (micro structure and their processing)
Mid term exam
Composites (ceramic matrix, metal matrix)
Fundamentals of joining, Intro to welding, Fusion & Solid-state Welding

N/A

10

i.
ii.

Quiz 2

11

Traditional Machining
i.
Fundamentals of Machining
ii. Producing round shapes
i.
Quiz 3
ii. Machining (Milling, Planing, Shaping, Broaching and Sawing

N/A

Abrasive machining and finishing processes

Non-traditional Machining
Chemical, Electromechanical (ECM) , Mechanical (WJC, AWC, AJM, AFM) ,
Thermal (EDM, LBM, PAC)
Revision Lecture
Final Exam

N/A
N/A

2
3
4
5
6
7
8
9

12
13
14
15
16

Quiz 2
Brazing soldering, Mechanical Fastening

N/A
N/A
N/A
Quiz 1
N/A
N/A
N/A

Quiz 3

N/A

Assessement

Three quizzes - 4 marks each

Two assignments 5 marks each
Project 8 marks
Mid term exam - 25 marks
Final exam - 45 marks

Books
Materials and Processes in Manufacturing by E.P Degarmo, Prentice Hall,
Latest Edition.
Fundamentals of Modern Manufacturing, Mikel P. Groover, 4th Edition,
Weily,2014.
Engineering Materials 2 : An Introduction to Microstructures, Processing
and Design, Michael F. Ashby and David R. H. Jones
Elements of material science and engineering , Van Vlack, 5th Edition,
Addison Wesley,2012.
Materials Science for Engineers, James F. Shackelford, 8th Edition,
Pearson ,2012.
Engineering with Polymers, P. C. Powell, Chapman and Hall, Stanley
Thornes, 5th Edition, ,2012

Materials selection
Material requirements based on the operating conditions:
Mechanical characteristics strength, fracture and impact resistance,
fatigue
Physical characteristics density, appearance
Service environment - Operating temperature, corrosive environment

Materials selection is an integral part of the design process

What is manufacturing?

Raw
Materials

End
Products
Manufacturing

Manufacturing is the process of converting raw materials into products; it

encompasses the design and manufacturing of goods using various production
methods and techniques.

STRUCTURE
Classification of solids on the basis of the arrangement of atoms or molecules.
CRYSTALLINE SOLIDS:
Highly ordered three dimensional arrangement of particles.
Sharp melting points.
Examples of crystalline engineering materials : metals, alloys, ceramics (alumina,
crystalline silicon dioxide), diamond
AMORPHOUS SOLIDS:
Particles are randomly arranged in three dimension.
Melt over a wide range of temperature.
Examples of amorphous materials : glasses and polymers.

Mechanical properties of materials

Tensile strength

Mechanical properties of materials

Elastic limit (Yield strength)
The maximum stress that can be applied to a material without causing
permanent deformation.

Offset yield strength /Proof stress

The stress that will cause a specified small, permanent extension of a
tensile test piece. Normally 0.1% or 0.2% strain.
It is used to define the yield strength of the materials which don`t
have a well defined yield point.

Ultimate Yield strength (UTS)

The maximum stress that a material can withstand while being
stretched or pulled before necking.

Mechanical properties of materials

Modulus of Elasticity
It is a measure of the stiffness of an elastic material and is
defined as the ratio of the linear stress to the linear strain.
Compressive strength
The maximum compressive stress that can be applied to a material
without fracturing it.

Hardness
Ability to withstand surface indentation.
Methods of measuring hardness :Brinell hardness test, Rockwell
test, Vickers hardness test..

Ductility
Ability of a material to be drawn out longitudinally to a reduced
section without fracture under the action of a tensile force.

Mechanical properties of materials

Toughness
Toughness is the work per unit volume required to fracture a
material. It is the ability of a material to absorb energy and
plastically deform without fracturing.

Mechanical properties of materials

Fracture Toughness
Fracture toughness is a property which is the measure of the
material`s resistance to brittle fracture.
In the linear elastic fracture mechanics, fracture toughness of
a material is determined from the stress intensity factor at
which the crack begins to propagate.
Fatigue
Structural failure which results from either the cyclic repetition
of a particular loading cycle or entirely random variations in
stress.

Mechanical properties of materials

Fatigue Limit/ Endurance Limit

The stress below which the material will not fail regardless of
the number of load cycles.

Mechanical properties of materials

Creep
Failure caused by long term exposure of the material under load to
elevated temperatures.
Even if the applied stress is much lower than the yield strength, the
component elongates continuously with time until rupture, if
exposed to elevated temperatures.

Creep curve for a single specimen at a fixed temperature