chapter 3 engineering material

8/19/2019 Chapter 3 Engineering Material

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ENGINEERINGMATERIALS

DR JAMIL BIN ABD. BASER

FAKULTI OF TECH. EDU. AND VOCATIONAL

UTHM


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OBJECTIVES

At the end of this chapter,students should be able to: List and differentiate between various types of

ferrous and non-ferrous metals and non-metallic

materials. Identify some uses of ferrous and non-ferrous

metals and non-metallic materials.

List and define the mechanical properties of

metals Explain the uses and advantages of every

material based on its mechanical properties.


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ENGINEERING

MATERIALS

METALLIC

MATERIALS

NON-METALLIC

MATERIALS

FERROUS

METALS

NON-FERROUS

METALS

NATURALMATERIALS

MAN-MADEMATERIALS

PURE METAL

EX: IRON

ALLOY METAL

EX: STEEL

PURE METAL

EX:ALUMINIUM,

COPPER, TIN

ALLOY META

EX: ALUMINIUM

ALLOY


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FERROUS METALS

Ferrous metals are those of which iron is

the main constituent.

Ferrous metals are produced in largerquantities than any other metal type.


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FERROUS METAL

CASTIRON STEEL


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STEEL

ALLOYSTEEL

CARBONSTEEL

STAINLESS

STEEL

HIGHSPEEDSTEEL

LOWCARBONSTEEL

SOFTSTEEL

MEDIUMCARBONSTEEL

HIGHCARBONSTEEL


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Stainless Steels

Contain steel added with18% chromium and 8%nickel

Properties: highly resistantto corrosion (rusting) invariety of environments,high strength andtoughness

Typical applications:automotive exhaustcomponents, valves,combustion chambers,cutlery, surgical tools


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High-speed Steel

Contain steel added withtungsten, chromium, vanadiumand molybdenum

Properties: brittle but can

maintain hardness at a hightemperature. Can be heattreated to improve theirmechanical properties

Typical applications: cuttingedge for drilling machine and

lathe machine


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Low-carbon Steel Contain less than 0.15%

carbon Properties: soft but have

outstanding ductility andtoughness, machinable,weldable

Typical applications:automobile bodycomponents, structuralshape (I-beam, channel),sheets that are use in

pipelines, bridges and tincans


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Medium-carbon steel

Contain 0.3% to 0.7% carbon

Properties: high strength and wearresistance compared to low-carbon steels

but less ductile and tough

Typical applications: railway wheels andtracks, gears, crankshafts, chisels, hammers


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Example of medium carbon steel


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High-carbon Steel Contain 0.7% to 1.4% carbon.

Properties: the hardest, strongest and yet least ductileof the carbon steels.

Typical applications: utilized as cutting tools and diesfor forming and shaping materials-knives, razors,hacksaw blades, springs and high-strength wire


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Examples of high carbon steel


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CAST

IRON

GREY

CASTIRON

WHITE

CASTIRON

WROUGHTIRON


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Cast Iron

Generically, cast irons are a class of ferrousalloys with carbon contents above 2.14%.

They are easily melted and amenable to

casting. Furthermore, some cast irons are verybrittle, and casting is the most convenientfabrication technique.

The most common cast iron types are:

I. Grey cast irons

II. White cast irons

III. Malleable cast irons


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Grey Cast Iron

Contain 1.7% to 4.5% carbon

Properties: weak and brittle in tension, strong and

ductile under compressive loads.

Typical applications: diesel engine castings,

pressure-containing parts such as valve and

pump bodies, pinions, gears


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Examples of grey cast iron


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White Cast Iron

Contain 2% to 3.5%carbon

Properties: very hard andhave a high compressionstrength, high degree ofductility and almostunmachinable

Typical applications:

limited to applications thatnecessitate a very hardand wear resistancesurface such as rollers inrolling mills

RAILWAYS


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Wrought (Malleable Cast) Iron

Malleable cast irons are

quenched white cast irons

Properties: more ductile,

machinable, highertension strength.

Typical applications:connecting rods,

transmission gears, pipe

fittings and valve parts for

railroad, marine


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NON-FERROUSMETALS

ALUMINIUM

COPPER

BRASS

TIN

•Non-ferrous

metal hasno iron

element.


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Aluminium

Properties:

I. high electrical and thermal conductivities

II. A resistance to corrosion include in theambient atmosphere

III. Easily formed by virtue of high ductility

IV. Machinable, malleable, light

V. White metallic in colour

VI. Low melting temperature (650oC)


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Copper

Properties:

I. Highly resistance to corrosion in diverseenvironments, seawater and some industrial

chemicalsII. Soft, ductile

III. high electrical and thermal conductivities

IV. Can be formed by cold and hot works

V. Yellow-red in colour

VI. Melting temperature (1083oC)


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Typical Applications Of Copper

Electrical wire

Automotive radiator cores Welding and soldering rods


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Typical Applications Of Brass Costume jewelry

cartridge casings

musical instruments electronic packaging

coins

jewelryBrass Pipe connectors


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TIN

Properties:

-Soft, ductile

-Does not corrode

-Not easily tarnished even in humidconditions

-Easy to forge

-Melting point temperature of 2320 C

-Silvery white


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Typical Applications of Tin

Tin Jewel

Tin plateAluminium


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MECHANICAL

PROPERTIES OF METAL

HARDNESS ROBUSTNESS

FORGEABILITY

STRENGTH

DUCTILITY ELASTICITY

BRITTLENESS


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HARDNESSHardness means the ability of metal to

withstand penetration by other objects. For

example, it is not easily scratched, nicked or

punctured


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STRENGTHStrength is the ability of metal to support a

load or force without changing its shape


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BRITTLENESSBrittleness is a metal property that easily

breaks or cracks when impacted or

hammered.


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ROBUSTNESSRobustness is the ability to maintain strength

even after it has undergone permanent

change in shape. This is the opposite of

brittleness.


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FORGEABILITYThis is the ability of metal to be shaped using

forging or hammering method.


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ELASTICITYElasticity is the ability of metal to regain its

original condition after undergoing a change

in shape.


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DUCTILITYDuctility is the ability of metal to be stretched

without snapping or breaking even in taut

condition.


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Rubber

A linear elastomer material with the ability to

restore itself completely to the original size and

shape after its load is released.

Vulcanization process (adding of 30% sulphur tohot rubber before reheating at a certain

temperature) must be carried out to increase the

strength of natural rubber.

Eg: tyres, shoes and pipes manufacturing


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Rubber Product

Rubber Cord

Rubber gasket

Rubber Mould


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WOOD

Important in construction sector, furniture and

paper manufacturing.

Drying process must be carried out so that the

wood becomes stronger, more resilient and lesslikely to break, shrink or warp.

Wood must also be cured to avoid attacked by

moss, pests and protected from uncertain weatherconditions


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GLASS

Used as ornaments, bottles, windows and

lenses.

In the manufacturing industry –

transparent,stained and opaque flat glass are used

widely.

Fiberglass – widely used in making boats,

cars and fishing rods


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POLYMER

Definition:

A huge molecule builtof small molecules

called monomer Examples of

polymer:

a) Plastic

b) Rubber c) Adhesives


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PROPERTIES OF MOST PLASTIC

Good insulator of electricity and heat

Does not rust

Resist chemical reaction

Light

Easy to mould into various shape Easy to tint

Has a low moisture absorption property

Less brittle compared to glass

Commendable strength and rigidity

Durable for certain types of plastics Burns easily

Plastic Product


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Plastic Product

monitor frame kettle Diskette box

Plastic bags Plastic product byinjection mould 3 pin socket


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MOLECULAR BONDINGSTRUCTURES

THERMOPLASTIC THERMOSETTING PLASTIC


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THERMOPLASTIC THERMOSETTING

PLASTIC

Soften when heated and

harden when cooled-

processes that are totally

reversible and may be

repeated

Become permanently

hard when heat is applied

and do not soften upon

subsequent heating

Durable and soft Harder and tougher than

thermoplastic, quite brittle

Melt at a lowtemperature, 93oC

Melt at a hightemperature, 260oC


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NAME OF PLASTIC PROPERTIES USAGE

1. Polythene

chemical name:

Polythene

There are two grades:

1. Low density polythene

Durable and flexible,

good chemical

resistance, goodinsulator of electricity

and soft.

2. High density polythene

Hard and fairly chemicalresistant

Plastic bottle and

toy, bag and plastic

sheet, insulator for

telecommunication

cable.

Water tank, pipe,

machine part such

as gear wheel.

THERMOPLASTIC


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2. Polyvinyl chloride

(PVC)

chemical name:

Polychlorethane

3. Polystyrene

chemical name:

Polyphenylethene

Hard, rigid and robust atroom temperature, light,

good acid and alkaline

resistant

Hard and rigid

Raincoat, musicalrecord, electric

wire coating, water

tank, pipe.

Food container,

film, plastic fork

and spoon, toy

THERMOPLASTIC


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4. Acrylate

chemical name:

Polymethyl

methylpropenoate

Hard, rigid,transparent, easy to

machine, a good

insulator of electricity

resists various acid

and weather.

Lens, clocksurface, aircraft

windows,

perspec

THERMOPLASTIC


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1. Polyester resin

chemical name:

Unsaturated

polyester resin

Good insulator ofelectricity and heat, rigid,

hard but brittle,

waterproof and resists

ultra violet rays.

If mixed with glass, it will

be a glass reinforced

plastic, i.e. a strong

material.

Yacht, corrugatedsheet, furniture

THERMOSETTING PLASTIC


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2. Ureaformaldehyde

chemical name:

Urea methanol

3. Melamine

Formaldehyde

chemical name:Melamine methanol

Rigid, hard, strong butbrittle, a good insulator of

heat.

Rigid, hard and strong.

Low resistance to

chemicals, highresistance to stains.

Domesticequipment.

Adhesive for wood.

Dining set, formica.

THERMOPLASTIC


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CONCRETE PROPERTIES

High compression strength

Durable

Watertight Can be cast into various shapes

Fairly low tensile strength


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Concrete


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TYPICAL APPLICATIONS OFCONCRETE

Roads/ highways

dams

building structuresWATER TANK

HOUSING

STRUCTURES

BRIDGE


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CERAMICS

Ceramics is a material that contains metalatoms, which is bonded to non-metal atoms

such as oxygen.

Most widely used ceramic oxide is alumina

(aluminium oxide –

Al2O3)

Ceramic breaks easily, is not ductile and

has fairly low tensile strength.


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TYPICAL APPLICATIONS OFCERAMIC

PROPERTIES USAGE

Hard and has high compression

strength

Cutting tools and abrasive, wear

and corrosion resistant

componentsHeat resistance Refractory, fire clay bricks in

furnace construction

Electric insulator Insulators, dielectric in capacitor

Chemical resistance Dental surgery, biology materials

(to replace human bone)


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CERAMICS


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THE END

chapter 3 engineering material

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