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

“The Process of Converting Raw Materials Into Products” 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