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MANUFACTURING
TECHNOLOGY
CHAPTER 2:
FUNDAMENTAL OF MATERIALS
FOR MANUFACTURING
INTRODUCTION
At the end of this lecture, student will be able to:
classify types of engineering materials
elaborate different types of material
properties
explain typical use of materials
explain the method of material selection for
particular manufacturing processes
Materials in Manufacturing
4.
Figure 1.3
Venn diagram
of three basic
Material types
plus composites
Classification of Metals
Steels
Cast irons
Aluminum, magnesium, copper, nickel,
titanium, zinc, lead, tin, molybdenum,
tungsten, gold, silver, platinum, and others
Superalloys
8
Steel
An alloy of iron containing from 0.02% and 2.11%
carbon by weight
It is the carbon content that turns iron into steel
Often includes other alloying elements:
manganese, chromium, nickel, and molybdenum
Steel alloys can be grouped into four categories:
1.
2.
3.
4.
Stainless Steel
(SS)
Highly alloyed steels designed for corrosion
resistance
Principal alloying element is chromium, usually
greater than 15%
Cr forms a thin impervious oxide film that
protects surface from corrosion
Nickel (Ni) is another alloying ingredient in certain
SS to increase corrosion protection
Carbon is used to strengthen and harden SS, but
high C content reduces corrosion protection since
chromium carbide forms to reduce available free
Cr
10
Tungsten
12
Ceramics
A compound containing metallic (or semi-metallic)
and nonmetallic elements. Typical nonmetallic
elements are oxygen, nitrogen, and carbon
13
Polymers
A compound formed of repeating structural units
called mers, whose atoms share electrons to
form very large molecules
Three categories:
1.
Thermoplastic polymers - can be subjected to
multiple heating and cooling cycles without
altering their molecular structure
2.
Thermosetting polymers - molecules
chemically transform (cure) into a rigid
structure upon cooling from a heated plastic
condition
3. Elastomers - exhibit significant elastic
behavior, i.e. rubber
14
SOME OF IMPORTANT
THERMOPLASTICS
Composites
A material consisting of two or more phases
that are processed separately and then
bonded together to achieve properties
superior to its constituents
A phase = a homogeneous mass of
material, such as grains of identical unit cell
structure in a solid metal
Usual structure consists of particles or fibers
of one phase mixed in a second phase
Properties depend on components, physical
shapes of components, and the way they
are combined to form the final material
16
Properties of
materials
Metal
Ceramic
Polymer
Very low
density
Medium to
Very high
high melting melting
point
point
Low melting
point
Ductile
Brittle
Ductile and
brittle types
Electrical
conductor
Electrical
insulator
Electrical
insulator
Thermal
conductor
Thermal
insulator
Thermal
insulator
May be
transparent
17
Typical use
Metals such
Industrial machineries such as mould, tools and
as steels and part of machinery; automotive components etc
NFM (Non
Ferrous Metals)
Polymers
such as TP
Ceramics
Composites
18
Material selection
19
22
23
24
Property requirement:
Manufacturing concern:
Material availability
Material cost
Etc.
27
Compatibility charts of
materials and processes
Y Can be used
0 Can be used but has difficulty
Blank Not recommended
Material
Iron
Stee
l
Aluminu
m
Coppe
r
Process
Sand
Casting
Die
Casting
Investmen
t Casting
Powder
Metallurgy
0
Y
28
29