Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 1 IE 251 Manufacturing matesrial l Instructor: Dr. Mohamed Ali Eissa Saleh s Room: ………….... 2A 128/1 s Phone: ………… l Grading s Midterm #1: ………..……….....…… 20% s Midterm #2: ………. ……………….. 20% s Midterm #3: ………. …………………20% s Final Exam:. ……...………………… 40%

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 2 Visual Materials... Texts l Manufacturing Processes for Engineering Materials, 5 th ed. S. Kalpakjian and S. Schmid, Upper saddle River, Nj: Printice Hill (2008) References l Engineering Materials 1: An introduction to their properties and applications - M. Ashby & D.Jones l Engineering Materials 2: An introduction to microstructures, processing & design - M. R. Ashby & D. R. H. Jones

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 3 l Introduction to the structure, processing, properties and performance of Manufacturing materials s metals, polymers, glasses, ceramics and composites l Case studies covering... s selection of materials s component design s analysis of component failures IE 251 Manufacturing matesrial

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 4 1. Engineering materials and their properties Key points l Enormous range of engineering materials s Types of material properties s Range of properties within and among materials classes s Development of new materials and their impact on design l Failure to select suitable materials can lead to failure of engineering structures and systems s Some failures can be quite spectacular m Liberty ships m Comet (1st commercial jetliner) m Space Shuttle Challenger

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 5 There are more than 50,000 commercially available materials with which an engineer may choose to design Table 1.2 l Metals and alloys s Steel, aluminum, etc. l Polymers s Polyethylene, polystyrene, nylon, epoxies, etc. l Ceramics and glasses s Alumina, silica, silicon carbide, etc. l Composite materials s Fiberglass, carbon fiber reinforced polymers, etc. l Natural materials s Wood, leather, silk, bone How to Choose?

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 6 The Possible Combinations of Composite Materials are Virtually Unlimited (Fig. 1.1) Composites Polymers Ceramics, Glasses Metals, Alloys Steel cord tires cermets Filled polymers

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 7 The Three P’s Successful Commercial Products Price PerformanceProducibility

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 8 We Make Decisions Regarding Material Selection Based on Material Properties l Economic l Mechanical l Physical and Chemical l Electrical, magnetic, optical l Manufacturing l Aesthetics l Price, availablity, recyclability, etc. l Modulus, yield strength, tensile strength, etc. l Density, reactivity (oxidation & corrosion), thermal expansion, melting temp., etc. l Resistivity, dielectric constant, optical absorption, etc. l Forming, joining, finishing, etc. l Color, touch, texture, etc.

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 9 Screwdriver Aesthetics Economic Mechanical Physical and Chemical Electrical Magnetic optical Manufacturing

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 10 Jet Engine Fan Blades (complex Ni base alloys) Conventional Directionally Cast Single Crystal High Temperature Strength (creep) Oxidation Resistance

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 11 Microelectronic Devices are Complex Composite Structures

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 12 In Considering Materials for a Given Application, The Desired Attributes of the Entire Engineering System Must Be Considered System Design Attributive economic, aesthetic Collective compatibility, fabricability, assembly Intrinsic strength, ductility, etc.