Materials

Properties of Materials
Mechanical Properties: strength, toughness, ductility,
hardness, elasticity, fatigue, creep.

Behavior Under Loading: tension, compression, bending,

torsion, shear.

Physical Properties: density, specific heat, thermal expansion,

thermal conductivity, melting point, electrical and magnetic
properties.

Chemical Properties: oxidation, corrosion, degradation,

toxicity, flammability.

Types of Materials
Ferrous Metals: iron and steel.
Nonferrous Metals and Alloys: aluminum,
magnesium, copper, nickel, titanium, superalloys,
beryllium, zirconium, low-melting alloys, precious metals.

Plastics: thermoplastics, thermosets, elastomers.

Ceramics: glass, graphite, diamond.
Composite materials: reinforced plastics, metalmatrix and ceramic-matrix composites, honeycomb
structures.

Ferrous Metals: Applications

Structural: building structures, concrete reinforcement
Automotive: chassis, engine parts, drive train, body
parts
Marine: ship hulls, structure, engines
Defense: tanks, weapons
Consumer Products: appliances, recreational vehicles,
toys, utensils and tools

Nonferrous Metals: Applications

Architectural: aluminum windows and doors
Automotive: aluminum engine blocks, copper
wiring, mag wheels
Marine: brass/bronze fittings, bearings, propellers
Defense: brass shell casings
Consumer Products: electrical wiring, utensils,
jewelry, electronics

Plastics (Polymers)
Compared to metals, plastics have lower density,
strength, elastic modulus, and thermal and
electrical conductivity, and a higher coefficient of
thermal expansion
The design of plastic parts should include
considerations of their low strength and stiffness,
and high thermal expansion and low resistance to
temperature.

Plastics: Applications
Architectural: electrical and thermal insulation, weather
seals, carpets, wall coverings, paint
Aerospace: electrical and thermal insulation, instrument
panels,upholstery, seals
Automotive: body panels, instrument panels, upholstery,
electrical and thermal insulation, seals, hoses, tires
Consumer Products: toys, sporting goods, appliances, tools,
utensils, clothing, shoes, packaging

Manufacturing
The Process of Converting Raw
Materials Into Products

Manufacturing a Product:
General Considerations
Material Selection
Processing Methods
Final Shape and Appearance
Dimensional and Surface Finish
Economics of Tooling
Design Requirements
Safety and Environmental Concerns

Choosing Methods of Production

Use a Selection Chart

Manufacturing Processes for Metals

Casting: expendable mold and permanent mold.
Forming and Shaping: rolling, forging, extrusion, drawing, sheet
forming, powder metallurgy, molding

Machining: turning, boring, drilling, milling, planing, shaping,

broaching, grinding, ultrasonic machining, chemical machining, electrical
discharge machining (EDM), electrochemical machining, high-energy
beam machining

Joining: welding, brazing, soldering, diffusion bonding, adhesive

bonding, mechanical joining

Finishing: honing, lapping, polishing, burnishing, deburring, surface

treating, coating, plating

Casting Processes
Introduction of molten metal into a mold cavity; upon
solidification, metal conforms to the shape of the cavity.

Die Casting

Sand Casting

Forming and Shaping Processes

Bulk deformation processes that induce shape changes
by plastic deformation under forces applied by tools
and dies.

Forging
Extrusion

Machining Processes
Material removal from a work piece: cutting, grinding,
nontraditional machining processes.

Milling

Lathe Machine

NC Machine Tool and Controller

NC Punch Press Machine

Manufacturing Processes
for Plastics
Plastics are shipped to manufacturing plants as
pellets or powders and are melted just before the
shaping process. Polymers melt at relatively low
temperatures and are easy to handle.
Plastics can be molded and formed, as well as
machined and joined, into many shapes with
relative ease.

Injection Molding of Plastics

Selective Laser Sintering System

Courtesy of the University of Texas