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1.

Briefly explain the material selection considerations while tailoring MMC.

Composite materials:

Metallic materials - predominantly: metallic bond, crystalline structure, good conductivity, ductile, chemically unstable.

Non-metallic materials - predominantly: unipolar and dipolar bonds, amorphous structure, poor conductivity, high temperature ductile, chemically stable

Ceramic materials - predominantly: amorphous or crystalline structure, poor conductivity, non-ductile, chemically stable.

  • 2. Which are the MMC reinforcements’ shapes?

Dispersion hardened and particle composites Layer composites (laminates) Fiber composites Infiltration composites

  • 3. Name several requirements imposed upon the MMC’ reinforcements.

low density

mechanically compatibility (a thermal expansion coefficient which is low but adapted to the matrix)

chemical compatibility

thermal stability

high Young’s modulus

high compression and tensile strength1

economic efficiency

  • 4. Name several applications of MMC. Expand one of the reasons for which was the MMC selected.

Automotive applications brake discs Lotus Elise disc temperature: T max 380°C, Car weight: <700 kg.

Cylinder blocks and pistons - local reinforcement for wear and creep resistance.

Railway applications - Brake discs weight of 74 kg (-38% vs. cast iron), and a total weight saving >10 tons (192 discs)

  • 5. Do you consider a larger market expansion regarding the MMC application?

Yes, especially considering the market growth by more than 50% in the electronics domain, together with the other growth in the transportation, aerospace, industrial, etc. domains.

  • 6. Sintering followed but a deformation procedure is called …? Can you underline few differences among the particular procedures?

Hot pressing fabrication of MMC - sintering under a unidirectional pressure applied by a hot press.

Hot isostatic extrusion fabrication of MMC - sintering under a pressure applied from multiple directions through a liquid or gaseous medium surrounding the compacted part and at elevated temperature.

Hot powder extrusion fabrication of MMC - sintering under a pressure applied by an extruder at elevated temperature.

  • 7. What is the impact of economy of scale and the economy of scope on the automotive manufacturing process?

A better understanding of the manufacturing environment due to switch from the economy of scale to an economy of scope to accommodate new demands from emerging markets, mainly in Brazil, Russia, India, and China or the BRIC countries

  • 8. List three challenges that have impacted the automotive industry in the past decade.

Automotive designers and engineers have to understand the current manufacturing infrastructure available, understanding design characteristics and the overall cost.

Designers should be aware that the vehicle design complexity in terms of number of parts and intricate shapes results in additional manufacturing steps.

New manufacturing and design strategies should be implemented and explored to lessen complications in the manufacturing process.

  • 9. Fill in the boxes to draw a complete painting booth layout (see fig.)

9. Fill in the boxes to draw a complete painting booth layout (see fig.)
9. Fill in the boxes to draw a complete painting booth layout (see fig.)