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, metal-
matrix 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