MEGASTRUCTURES STEEL

47 min
 Materials Technology
Classification of Materials
 Classification of Materials

Materials used in the design and

manufacture of products

Plastics
Wood
Composites
Ceramics
Metals
Fabrics Linen,
Layers
Balsacotton,
Tungsten
Steel,of nylon,
aluminium Kevlar
polycarbonate,
carbide
Acrylic model bit
woodlens tool
aluminium & acrylic
Classification of Materials (Plastics)

Plastics can be further classified as;

Thermoplastic
Thermoset
Elastomers

Thermoplastics Thermosets Elastomers

Acrylics Epoxy resins Rubbers
Nylons Phenolic Silicones
PVC Polyesters
Phenol
Urea Polyurethanes
formaldehyde
formaldehyde
PVC Polyethylene
gutters
Polyethylene
Rubber
 Classification of Materials (Wood)
Wood can be further categorised as;
Hardwood
Softwood
Manufactured board Beech
Ash
Oak
Mahogany
Chipboard
Plywood
Cedar with Veneer

Hardwood Softwood Manufactured

Board
Oak Pine Plywood
Ash Cedar Blockboard
Beech Fir MDF
Sycamore Spruce Melamine
board
Classification of Materials (Composites)

A composite is a combination of two or more

chemically distinct materials whose physical
characteristics are superior to its constituents
acting independently.
Because of their high strength/stiffness to weight
ratio they are widely used in the;
Aerospace industry
Offshore structures
Boats
Sporting goods
Classification of Materials (Composites)

Examples of composites include;

Reinforced Plastics
Ceramic-matrix
Metal-Matrix
Laminates

Carbon
Outer Cylinder
Thrust
Combustion
reinforced
Kevlar,
skin
Cylinder
Glass
panels linings
chamber
taffeta
plastic
reinforced
chamber
linings
& for
polyester
fuselage
of rocket
plastic
jet
A380
sails
engine
hull
 Classification of Materials (Ceramics)

Ceramics are compounds of metallic and

non-metallic elements, examples include;

Oxides (alumina insulation and

abrasives, zirconia dies for metal
extrusion and abrasives)
Carbides (tungsten-carbide tools)
Nitrides (cubic boron nitride, 2nd in
hardness to diamond)
 Classification of Materials (Metals)

Metals can be further classified as Ferrous &

Non-Ferrous, some examples include;

Ferrous High
Stainless
Brass
Copper
Aluminium
Speed steel Non-Ferrous
Steel

Steels Aluminium

Stainless Steels Copper

High Speed Steels Brass

Cast Irons Titanium

BBC Technical Studies Non-ferrous M
etals and Alloys 24min
Classification of Materials (Fabrics)

Fabrics can be further classified as natural

and synthetic

Natural Synthetic

Cotton Nylon

Canvas Polyester

Materials used
Cotton in Colourful
Canvas space
T-shirt
Polyester suits
(design
Polyester
deck
marine include
&
chair
nylon print
kite
rope- aluminized Mylar, neoprene
projects)
spinnaker
less
coated nylon,stretch
dacron,
thanurethane
nylon- coated nylon,
resists UV lighttricot and spandex.
The outer layer is a blend of Gortex, Kevlar and Nomex
Engineering Materials
 Classification of Materials
(Smart Materials)
A smart material can be described as a
material that has a useful response to
external influences or stimuli.
There are many examples of smart materials in everyday
use that are not modern developments they include;
Metal springs
Light bulbs self regulate because as
The filament temperature increases
their resistance rises
Ancient civilisations have long used
porous ceramics for self regulating cooling
Wine Cooler
 Classification of Materials
(Smart Materials)
Other more modern examples of smart
materials include;
Shape memory polymers and alloys
Heat shrink
Smart Wire tubing and packaging
Automatic actuators open/close greenhouse windows
Smart Linklinear,
Actuators, Silicone
angular and rotary
Thermostats for heating control
Anthromorphic actuation
Allows rotary motion human
between like
shafts uprobotic
to 360motion
0
Smart Fluids
Motion control
Piezoelectric gel CD tray opening/closing, camera lenses
Materials
Ferro fluids earthquake dampers in buildings, hard disks
Chameleon Colours
Sensors, musical cards, motors, actuators, clocks
Car paints, printing inks, packaging
 Classification of Materials
(Smart Materials)
Other more modern examples of smart
materials include;
Polymorph

This is a unique polymer that

fuses in hot water and can then
be moulded to any form. When
solid it has similar properties to
nylon

Used to make the

moulds for the
vacuum formed seat
and fuel tank of this
motorcycle project
 Classification of Materials
(Smart Materials)
Other more modern examples of smart
materials include;
Thermo-colour Sheet

This is a self adhesive

sheet whose colour
changes according to the
temperature. Used for
thermometers, heat
warning patches and
novelty advertising of Inactivated
Finger
Sheet changes
placed
Sheet
oncolour
sheetaccording to temp
products
 Classification of Materials
(Smart Materials)
Other more modern examples of smart
materials include;
Phosphorescent Sheet

This is a sheet that absorbs

light energy and re-emits it
as white light for up to eight
hours. Used extensively for
emergency lighting in the
event of a power cut
 Classification of Materials
(Smart Materials)
Other more modern examples of smart
materials include;
Magnetic Sheet

This is a flat polymer

magnetic sheet as used in
fridge magnets. Also
available in thin A4 sheets
that can be printed on
 Classification of Materials
(Smart Materials)
Other more modern examples of smart
materials include;
Rigid PVC Foam Plastic

This is a new generation of

sheet material used widely
for signs and exhibitions.
Thermoforms very well. It
is widely used for plug and
yoke mouldings
 Classification of Materials
(Smart Materials)
Other more modern examples of smart
materials include;
Lenticular Sheet

This sheet is about 1mm

thick but gives the illusion
that it is nearer to 6mm
thick. An object placed on
the sheet appears to sink
below the surface

The camera lens does not capture the effect

 Classification of Materials
(Smart Materials)
Other more modern examples of smart
materials include;
Anodised Effect Card

This is almost impossible to

tell from the real thing.
Ideal for project mock-ups.
It is relatively cheap and
cuts easily with a scissors
or craft knife
 Classification of Materials
(Smart Materials)
Other more modern examples of smart
materials include;
Galvanised Effect Card

This is almost identical to

the real thing. Ideal for
project mock-ups. It is
relatively cheap and cuts
easily with a scissors or
craft knife. Used for
packaging of top branded
goods
 Classification of Materials
(Smart Materials)
Other more modern examples of smart
materials include;
Quantum Tunnelling Composite (QTC)
A QTC in its normal state is a perfect insulator
When compressed it becomes a perfect conductor
If only lightly compressed its conductivity is proportional to the
pressure applied
How does it work?
In normal physics an electron cannot pass through an insulation
barrier.
In Quantum physics theory a wave of electrons can pass through an
insulator this is what is happening!
 Classification of Materials
(Smart Materials)
Other more modern examples of smart
materials include;
Quantum Tunnelling Composite (QTC)
Battery
LED

QTC Pill
 Classification of Materials
(Smart Materials)
Other more modern examples of smart
materials include;
Quantum Tunnelling Composite (QTC)

Firm
Before
Light pressure
pressure
Pressure being
is applied
being applied
applied
A Typical Colour Code (while purchasing materials)

Carbon Steel
CARBON STEEL
C.D. 1018 NO COLOR /////

H.R. 1018 GREEN

C.D. 12L14 BLACK / WHITE

C.D. 1045 WHITE

H.R. 1045 ORANGE / BLACK

A-36 PLATE NO COLOR /////

Non Ferrous
NON-FERROUS

6061 ALUMINUM BLUE

360 BRASS RED

932 BRONZE GREEN

954 BRONZE YELLOW

110 COPPER WHITE

CL II COPPER ORANGE
For others: please visit the different standards or attached word file
CL III COPPER BROWN
Material Properties
Knowledge of material properties

Application
Design of components
Material protection (from corrosion,
damage, etc.)
Material properties

1. Physical properties
2. Mechanical properties
3. Chemical properties
Physical properties

Colour light wave length

Specific heat the heat required to raise

the temperature of one gram of a
substance by one degree centigrade (J/kg
K)
Physical properties

Density mass per unit volume expressed

in such units as kg/cm 3

Thermal conductivity rate at which heat

flows through a given material (W/m K)
Physical properties

Melting point a temperature at which a

solid begins to liquify

Electrical conductivity a measure of how

strongly a material opposes the flow of
electric current (m)
Coefficient of thermal expansion degree
of expansion divided by the change in
temperature (m/C)
http://www-materials.eng.cam.ac.uk
Mechanical properties
Tensile strength measures the force
required to pull something such as
rope,wire or a structural beam to the point
where it breaks

Ductility a measure of how much strain a

material can take before rupturing
Malleability the property of a material that
can be worked or hammered or shaped
without breaking

Brittleness breaking or shattering of a

material when subjected to stress (when
force is applied to it)
Elasticity the property of a material that
returns to its original shape after stress
(e.g. external forces) that made it deform
or distort is removed

Plasticity - the deformation of a material

undergoing non-reversible changes of
shape in response to applied forces
Mechanical properties

Toughness the ability of a material to

absorb energy and plastically deform
without fracturing

Hardness the property of being rigid and

resistant to pressure; not easily scratched
http://www-materials.eng.cam.ac.uk
http://www-materials.eng.cam.ac.uk
http://www-materials.eng.cam.ac.uk
Mechanical properties

Machinability the property of a material

that can be shaped by hammering,
pressing, rolling
Chemical properties

Corrosion resistance - a material's ability

to resist deterioration caused by exposure
to an environment
Which properties do the following
materials possess?

Material Properties
aluminium
rubber
ceramics
steel
copper
lead
nylon
cast iron
wood
Which properties do the following
materials possess?

Material Properties
aluminium lightness ; strength
rubber elasticity ; insulation
ceramics thermal resistivity
steel strength
copper conductivity ; corrosion resistance
lead high density; ductility
nylon strength ; toughness
cast iron damping capacity
wood insulation ; environmental friendliness
Find application for the following
engineering materials:

Material Application
aluminium
rubber
ceramics
steel
copper
lead
nylon
cast iron
wood
Find application for the following
engineering materials:

Material Application
aluminium foil; aircraft; window frame
rubber tyres,; seal; gasket
ceramics furnace; brick
steel section; pipe
copper pipe; cables
lead storage battery; radiation protection
ballast; bullets
nylon rope; clothing
cast iron engine block; valves
wood furniture; deck
Material with greatest density

gold - 19300 kg/m3

uranium - 19100 kg/m3

lead - 11340 kg/m3

steel - 7800 kg/m3

The strongest material

Material Tensile Strength UTS (Ultimate Tensile

Strength)
carbon nanotubes 62000 MPa (theoretical 48000 kNm/kg
300000 MPa)

carbon fibre 5650 MPa 3200 kNm/kg

glass fibre 4700 MPa 1340 kNm/kg

spider web 1000 MPa 900 kNm/kg

high-strength steel 1200 MPa 154 kNm/kg

The best conductor

Material Conductivity
Silver 63 x 106 S/m (1/ohm)

Copper
59.6 x 106 S/m (1/ohm)

Gold
45.2 x 106 S/m (1/ohm)

Aluminium
37.8 x 106 S/m (1/ohm)
The best insulator

Material Specific resistance

Polyethylene terephthalate (PET) 1020 ohm

Glass 1014 ohm

Rubber 1013 ohm

Processes
Forming - a manufacturing process
where metal is shaped by plastic
deformation under great pressure into
high strength parts.

Casting pouring or injecting molten metal

into a mold containing a cavity with the
desired shape
 PRINCIPLES OF CONVENTIONAL MATERIAL
PROCESSING
LOW PLASTIC ZONE

DUCTILE FALURE
MATERIAL

MACHININGNG
DUCTILE
MATERIAL
ELASTIC
ZONE

PLASTIC ZONE FALURE

S
T FORMING MACHINING

R
E Tensile Residual Stress
S
S Decreases Surface
Properties
Compressive Residual Stress STRAIN
Improves Surface Properties
RAW
MATERIAL
TO FINISHED
PRODUCT
C
A
R COMPONENT-1
S
A M
T
W A
COMPONENT-2 I C
N H
M G I
COMPONENT-3 N JOINING
A S
I
F N &
T P E F
COMPONENT-4 O C G ASSEMBL
R O
O Y
E IR N
R
M
R MM D I
COMPONENT-5 AI A N
I R G
R Y
Y
N
A COMPONENT-6 G
L

MANUFACTURING PROCESSES IN
SEQUENCE
 A PRODUCTION CYCLE

ENGG. FINISHED
MATERIAL PRODUCT

HANDLING - 1 HANDLING ( n+1)

Production
PROCESS - n
Cycle Time = T

I=n I=n+1 HANDLING ( n 1)

HANDLING - 2
T = Tpi + Thi
I=1 I=1

PROCESS - 2 PROCESS - i

HANDLING ( i 1)
 ENERGY FORM FOR MATERIAL DEFORMATION

MECHANICAL DEPORMATION
ELECTRICAL

OPTICAL D = K En T
CHEMICAL
RAW MATERIAL
Where,
K is a Constant depends
MICROWAVE MAGNETIC
on,
Material property
NUCLEAR Energy coupling
E is the energy supply

COMPONENT
n depends on coupling
energy
and
T is the time of interaction
EQUIVAENCE BETWEEN MACHINING & ENERGY BEAM
PROCESSING
ENERGY
LOSS
DEFORMED
TOOL SURFACE
(MACHINED)

WORK
Solution approach
Micro Mechanics
CUTTING
VELOCITY
Micro Energy
CONVETIONAL Transfer
UNCONVETIONAL

ENERGY
SOURCE
REFLECTION REFLECTION Deformation, D = K En T
Where, K = material constant
E = the supply energy
n = coupling coefficient
WORK
DEFORMATION
TRANSMITION
ENERGY COUPLING COEFFICIENT
 SHAPING OF COMPONENTS

FORMING JOINING MACHINING GMP

UNCONVENTIONAL
(Generative Mfg Processes)
CONVENTIONAL MATERIAL ADDITION or
IN LIQUID STATE CREATION TYPE PROCESS
UNCONVENTIONAL
IN SOLID STATE BY MATERIAL
CONVERSION

BY MATERIAL
MICRO MACHINING
ROLLING ADDITION
CASTING or JOINING

FORGING
LIQUID TO SOLID IN LAYERS

EXTRUSION POWDER TO SOLID IN PARTICLES/

LINES
For further knowledge, please list
en to NPTEL video on
Engineering Materials