MATERIALS

MANUFACTURING
GROUP 3

MATERIALS
used to produce the products that make our lives easier, safer and more enjoyable.
Are

MANUFACTURING
Is

the process in which raw materials are transformed into finished goods on a large scale.

MATERIALS USED IN MANUFACTURING

ORGANIC MATERIALS

INORGANIC MATERIALS

Engineering Materials are solid materials that have a solid structure. These are used to give durable products their framework.

Nonengineering Materials (Gases & Liquids) must have a container if they are to be held in a particular shape. FUELS, LUBRICANTS AND WATER

Metallic Materials

 Metals

are the most widely used group of engineering materials. Three-fourths of all natural elements are classified as metals. These materials have desirable mechanical and physical properties. Metallic materials are inorganic, crystal substances. They are generally combined with other materials to produce an alloy.

2 MAJOR CATEGORIES OF METAL

All

ferrous metals (irons and steels) are classified as ironcarbon alloys. Iron is the fundamental ingredient for all ferrous metals while carbon is the most important alloying element in determining the mechanical properties of ferrous metals.

Carbon Steel

High Alloy Steel

Carbon Steel
Are generally classified as:

Low Carbon steel Has less than 0.30 % carbon. It is used for common industrial products such as bolts, nuts, sheet, plates, etc. Medium Carbon Steel Has 0.30 to 0.60 % carbon. It is used in application requiring higher strength than low carbon steel. High Carbon Steel. Has more than 0.60 % carbon. They are coarse materials that can be hardened by heat treatment.

High Alloy Steel

Contain significant alloying elements in addition to carbon. Two common highly alloys are:

Stainless Steel Are characterized primarily by their common resistance, high strength and ductility and high chromium content.

High Speed Steel Mostly highly alloyed tool and die steels and maintain their hardness and a strength at elevating operating temperatures.

- Metals that do not have iron as their principal ingredient

The

most commonly used nonferrous metal Conducts heat well and is fairly chemically inert Commonly used in cookware and food preservation, transformation (aircraft and aerospace application)

THE MOST IMPORTANT FACTORS OF ALUMMINUM

high strength-toweight ratio Resistance to corrosion by many chemicals High thermal and electrical conductivity

Nontoxicity
Reflectivity Appearance Nonmagnetic

Best

conductor of electricity and heat and have good corrosion resistance Tough, ductile material. Can be drawn or hammered easily into new shapes without breaking

PRINCIPAL COPPER ALLOYS

Brass

(alloy of Copper & Zinc)

Earliest alloys developed; used in decorative purposes

Bronze

(alloy of Copper & Tin)

Nickel

Silvers (alloy of Zinc & Silver)

Used as the base metal for silver-plated dinnerware, springs, electrical connectors, and boat parts

OTHER IMPORTANT NONFERROUS METALS

Tin

Soft, malleable material that melts at a fairly low temperature Used as an alloying element and as a coating for steel Heavy, soft, malleable material Used in storage batteries

Lead

Titanium
Discovered in 1791 but was not commercially produced until the 1950s High strength-to-weight ratio

OTHER IMPORTANT NONFERROUS METALS

Beryllium

Steel gray in color; has high strength-to-weight ratio Used in nuclear and x-ray applications

Zirconium
Has god strength and ductility at elevated temperature and good corrosion resistance Used in electronic components and nuclear power reactor

Zinc
Bluish-white in color The fourth most utilized metal after iron, aluminum and copper Used in galvanizing iron and steel sheet and wire, and as a base for casting

organic, non crystalline (without crystal structure) substances.

Are

2 MAJOR PARTS
Natural Polymers

POLYMERIC MATERIALS
Synthetic Polymers

Natural Polymers

FIBER

WOOL & LEATHER

COOTON & FLAX

WOOD (HARDWOODS, SOFTWOODS)

Synthetic Polymers (PLASTIC)

POLYMER

PLASTIC

SYNTHETIC RESIN

Synthetic polymers
and also called as polymers, plastics and synthetic resin.

Plastics
Comes from the greek word plastikos meaning it can be molded and shaped. are composed of polymer molecules and various additives. The smallest repetitive unit in a polymer chain is called mer/monomers.

There are over 25 families of monomers including ethylyne, vinyl chloride, styrene, propylene, acrylic, phenolic, silicon and epoxy. -Plastics are the base for what has been called the "material revolution" -The earliest synthetic (manmade) polymer was a phenol- formaldehyde, a thermoset developed in 1906 and called bakelite (a trade name, after L.H. Bakeland)

MAJOR TYPES OF PLASTIC

THERMOSETS

THERMOPLASTICS

THERMOPLASTICS
- materials that have polymer chains with few cross links - it becomes soft and are easy to form at elevated temperatures and return to their original properties when cooled. -examples are polyolefins polyethylene and polypropylene, polyvinyl chloride, and polystyrene

THERMOSETS
- are obtained by cross linking polymer chains, do not become soft to any significant extent with increasing temperature. Example: handles on a toaster, iron or kettle

Elastomers
- have characteristic ability to undergo large elastic deformations without rupture, soft and have a low elastic modulus. -polymer that extend elastically more than 200% and are capable of full recovery. Example: polyester thermoplastic elastomer, polyurethane and silicone thermosetting elastomers.

Ceramic and Composite Materials

Ceramic Materials

CERAMICS
Refers to both material and product itself. Contains of mostly inorganic and crystalline materials Most rigid and least ductile of all materials Ceramic products are shaped by various casting, forming or pressing techniques Used for dinnerware, sanitary ware, etc.

CERAMICS ARE LARGE FAMILY OF MATERIALS THAT INCLUDE: Clay Cements Plaster and Gypsum Refractories Glass Porcelain Enamel Abrasives

Clays- are fine grain sheetlike structure sediments composed of alumina and silica. Cements- powders that are when mixed with water turns into a solid form. Plaster and Gypsum- hydrated calcium sulfate mineral used in building plaster and wall board

Refractories- ceramics that withstand high temperatures. Glass- ceramics that is predominantly crystalline in structure made from fusing silica. Porcelain enamel- are vitrified ceramic used in chemical and electrical applications Abrasives- used to remove, smooth and polish materials from the workpiece surface.

Composite Materials

COMPOSITE

Macroscopic combinations of two or more distinct materials. Designed to provide properties or behavior so that one material overcome the weakness of another. Contains a structural element (glass fibers, gravel, cellulose) in form of polymeric, metallic, and ceramic materials being used both as fibers and matrix.

Composed of two phases namely: Matrix continuous phase that surrounds the second phase Fibers / Reinforcement discontinuous disperse phase

or

Used for manufacturing hundreds of products including aircraft, automotive and truck bodies, and shower stalls

Examples of composite materials:

Fiber glass most common composite material consisting of resin (matrix) and silicon glass (fiber) Concrete a composite material consisting of cement, gravel, and sand. Wood a natural polymeric composite. The base material is cellulose fibers that are held in place by lignin.

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