Carmen asor 2020

MODULES
in
INDUSTRIAL MATERIALS & PROCESS

Prepared by:
Carmen Asor
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MODULE 1- INTRODUCTION
Lesson 1- PRODUCTION FACILITIES

Introduction

In this age of technology there is a dynamic change of materials that we are using
from hard goods to soft goods. Overtime from stone age, the industry move to
copper age then to iron age. Today as we move to the age of mechanization , and
computer manufacturing, the development of materials is changing fast finding
alternatives to replace traditional materials in the industry.
In the context of production, it is defined as a collection of men , machine tools,
and material-moving systems. Together they accomplish a manufacturing sequences
resulting in a finished product.
In the current age, researchers developed plastics, composite materials and
exotic alloys to replace the traditional materials of metals.
First, as future engineers you must know the basic of manufacturing activities
such as : man, machine, material, methods and money (5M) and production
facilities in an arrangement of a system.

Overview

Industrial Materials- are substances that are used in the manufacture of hard
goods, Example of these are the equipments and machines utilized by an industry.
Industrial Processes- are the activities or the steps and ways on how to
manufacture a certain product.
Manufacturing- the art of crafting a material into finished product.
Production Facility- means a factory, a manufacturing plant or production
plant , usually a building filled with machinery where workers manufacture items or
operate machines under several processes.
Most modern production facility are warehouse-like that contain heavy
equipment used for assembly line production. Large factories are located now in
far-flung area because of some environmental impact of their product, also to find
convenient ways of operation like traffic problems, low cost operation and others
factors that hinders their operation.

You Tube-Mod.4 Lec 10-facility Design Part 1- nptelhrd

Objectives

Upon completion of lesson 1, the learner will be able to:

1. Determine the different layout of production facility.
2. Design an appropriate layout for a particular end-product.
3. Oversee the configuration of equipment, machinery, building structures and
other facilities.

@You tube-Process equipment-CTE Skills.com

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Pre-test

Watch @you tube-1.what is industrial engineering?- The Audiopedia.

2.Beginning Engineers Industrial Engineering- Beginning Engineers
Watch U tube=beginning engineers facilities planning
-beginning engineers

Activities

Answer these questions:

1. Describe the works of an Industrial Engineer?
2. What are the benefits of an employer in hiring an industrial engineer.?
3. Based from the videos , what are the different skills or specialization of an
Industrial Engineer?

Topic Discussions

Duties and Responsibilities of a Production Facilities Engineer

1. Refine operations - In order to maximize efficiency , the facility engineer must
have an in-depth understanding of the a. production schedule b. engineering
specifications c. process flow
2. Analyze material and labor cost- He gathers data and review concerning facility
specifications. He determines the material cost and develop management control
system in labor force.
3. Design a Control Systems and procedures - He should set a quality control
procedures to minimize overall costs.
4. Confer with management on procedures and contracts- He regularly report with
client and management about the process, contract and update them on the status
of the project.

For student’s exercises : Report on the topic above and expound your
understanding on each.

Types of Production:

1. Job type- sometimes called jobbing or one-off production. It involve producing

custom work such as small batch of work in quantities.
2. Batch type.- the products are made as specified groups or amounts within a time
frame. It can go a series of steps in a large manufacturing process
3. Mass production- involves many copies of production, very quickl;y using
assembly line techniques . The partially complete products is send to workers with
an individual step.
4. Continuous production- the items here are produced for the stocks and not for
specific orders.

Exercises: Give an example of a company where the type of production is being

practiced.

Types of facilities
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1. Manufacturing- Here the product is being made or produced. Here the material
undergo a physical or chemical change.
2. Retail facility- it is a stationary source at which the income comes from direct
sales to end-users.

Exercises: Will you mention some Local companies that uses these kind of
facilities.

Production facilities and function:

The goal of the Production is to add value to the product or service which will
create a strong and long lasting customer relationship or association. This goal can
be achieved by healthy and productive association between marketing and
production people.

Types of Layout:

1. Product or Line layout- If all the processing equipment and machines are arranged
according to the sequence of operations of the product, the layout is called product
type layout. In this type of layout, only one product is produced in an operating area.
This product must be standardized and produced in large quantities in order to justify
the product layout.
The raw material is supplied at one end of the line and goes from one operation to
the next quite rapidly with a minimum work in process, storage and material
handling.

@You tube-product layout- -Toyota production-Deepak Prakash

Advantage of product layout:

1. lower material handling cost.
2. less work.
3. better utilization of men and machines.
4. less floor is occupied.
5. simplem production control.
6. production time is minimized.

Limitations:
1. no flexibility
2. manufacturing cost increases with a fall in production.
3. If one or two lines are running low, there is a considerable machine idleness.
4. A single machine shutdown,the whole production is shutdown.
5. specialized supervision is essential.

2. Process or functional layout- this kind of layout is useful where low volume of
production is needed. If the product is not standardized, the process layout is more
low desirable, because` it has creator process flexibility than other. This type of
laypout, the machines are not arranged according to the sequence of operations but
are arranged according to the nature or type of operation.This is applicable for non
repetitive jobs.

@ You Tuube-Process layout-Chentaku91

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Advantage
1. less duplication of machines.
2. Better supervision through specialization at various level.
3. flexibility in equipment and man power thus load distribution ois easily controlled.
4. Better utilization of equipment available.
5. breakdown of equipment can be easily handled by transferring work to another
machine.
6. better control of precision process especially where much inspection is required.

Limitations
1. expensive handling of materialws because of long flow lines.
2. production Cycle time is more due to long distance and waiting at various points.
3. Bottle neck occur since more work is in queue.
4. more floor area is required.
5. Counting and more scheduling is more tedious.
6. specialization becomes monotony for workers and once laid out, hard for them to
find another job.

3. Fixed position layout

The least important for today’s industries.The major component remain in a fixed
location, other materials, parts ,tools, machinery, manpower.
The major component or body of the product remain in a fixed position because it is
too heavy. Ex. Boilers, hydraulic, steam turbines and ships.

@You Tube-Formula one fixed Position layout-Ehsan Sabet

Advantages

1. material movement is reduced

2. capital investment is minimized
3. The work is done by operators,, hence continuity of operation is ensured
4. Effective planning and loading. Production is independent.
5. flexible. Allows change in product design, product mix, and volume.

Limitations

1. Highly skilled manpower is required.

2. Movement of machine to production center may be time consuming.
3. complicated fixtures may be required.

@Youtube- noodles factory(proposed facility layout of Elline’s Food Products- Jose

Marwin Evangelista

Assignment;

1. Search on the other types of layout and prepare your materials from You Tube to
be reported on line. Give examples of companies who uses each type of layout.
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References

@You Tube-Admin. Audi’s Mexico Plant Layout

Prachi Juneja-Management study guide.com,20153.
Watch Actual experiences of Facilities engineer: @You tube-A day in the life of a
facilities engineer at Imperial’s Cold Lake Operation.
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INDUSTRIAL MATERIALS & PROCESSES

LEARNING MATERIALS

MODULE 1-INTRODUCTION

LESSON 1- PRODUCTION FACILITIES

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FIXED POSITION LAYOUT

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PRODUCT OR LINE LAYOUT

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MODULE 1- INTRODUCTION
LESSON 2-PROPERTIES OF MATERIALS

Introduction

The design engineer is always limited by the properties of different materials and
its availability. When a material is undergoing a variation in state or in testing
conditions, the material is affected and may not come up with a good quality and
function.
The properties depend on the structure of the atomic, molecular, microscopic and
macroscopic level.The physics of material will be covered by this module.
Physical and chemical properties will be highlighted. For metals , a DIY experiments
might be helpful for you to understand well the properties of different materials in
your home. The virtual experiments can also be viewed in the references provided.

Overview

The material properties are size, shape, density of the particles and their intrinsic
mechanical properties such as modulus, yield stress, fracture toughness,
malleability, ductility. Electrical properties such as conductivity and chemical
properties such as corrosion resistance,plasticity,and density.
The different materials with their respective properties are;
Metals- most of them are strong, hard and shiny and it can be hammered into
different shapes.
Plastics-materials that are made from chemicals and they are not found in nature. It
is manmade.
Glass- is made from sand,soda sh, limestone-melted at very high temp. to form this
new material
Wood- a porous and fibrous structural tissue found in the stems & roots of trees. It is
an organic material, natural composite of cellulose fibers.
Fabrics-origin of this are animals such as wool, silk), mineral (asbestos, glass fiber),
plant(cotton, flax, jute, bamboo) and synthetic(nylon, polester, acrylic, rayon)

Pre-Test

Based from the above descriptions of materials,

Can you mention what are the various function or uses of each kind of materials?
What other materials can you think of to add to these types of materials?

Objectives

1. Determine the various kind of engineering materials, its properties and functions..
2.Applied the DIY experiments in the home on different materials.
3. Determine the actual materials found in the surroundings that greatly affects
our environment.
3. Design and create prototype project using appropriate material based on its
function and properties.
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Topic Discussions

The types of materials and its properties are:

METAL is a material that, when freshly prepared , polished or fractured shows a

lustrous appearance and conducts electricity and heat. They can be hammered into
sheets ( malleable) or can be drawn into wires(ductile). A metal is an element that
readily forms positive ions and has metallic bonds It can be described as a lattice of
positive ions surrounded by a cloud of delocalized electrons.
All metals may be classified as:
1. Ferrous
with Fe content such as cast iron, steel,, various steel alloys.
They come from iron ore. difference between iron and steel is the carbon content.
Properties are too soft and ductile.
Ex.wrought iron,mild steel,stainless steel,tool steel,,plated steel.
If magnet will stick then the material has iron content.
2. Non –ferrous
with no Fe content.
Such as Al,Cu,Pb,Ni,Sn,Ti,Zn.
Precious; Au,Ag,Pt
Rare; Co,Be,Hg,Bi,Tn,Ce Metals in their pure state are luster:

Pre-Test

Rub the surface of an aluminum, Iron ,copper and take note of the shining surface.
Test the hardness by trying to cut them with a knife.
Take one piece of your sample at a time and strike it with a hammer.What do you
observe.
Take an experiment and which of these metals can be form into wires and sheets.
Take a sample of each metal and try to melt or burn it in a lamp or candle.Take
note which burn easily, flame color and the appearance after burning.this is the
reactivity of metals to oxygen.

Physical Properties of metals:

Solid
Hard(except Li,K,Na)
Metallic luster
Malleable(can be beaten into thin sheets)
Ductile(can be drawn into wires)
High melting points (Ga,Ce have low melting point)
High boiling points
Good conductors of heat(best are Ag, Cu.poor conductors are Pb and Hg)called
thermal conductivity.
Good conductors of electricity(best are Ag and Cu)
Sonorus(produce sound when beaten)
Packed together as closely as possible.
Most metals have high density.
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Chemical Properties

Have a tendency to donate electrons

Displace hydrogen gas from dilute acid
React with oxygen to produce basic oxides
React with hydrogen to produce hydrides.

Non Metals:

PLASTICS- usually they are classified by their chemicalstructure, by their

backbone or mother chain. They are also reffered to as polymers.
.The chemical composition of plastics are various elements like carbon, hydrogen,
oxygen, nitrogen, chlorine ans sulfur.
1. Polyethylene Terephthalate(PET)- most widely used in bottling or packaging
because of its Some properties are applicable as fiber, effective moisture barrier,
shatterproof, recyclable…
Meelting point is
2. Polyethylene(PE)- There are two types of this kind of plastic;
a. LDPE(low –density)-this is the plastic bags used in the grocery. It has high
ductility but low tensile strength.
b. HDPE(high-density)- For more strength needed of a plastic, this kind is of-
used, ex. Detergent container, trash bins…
c. UHMW(Ultra high molecular weight)- for medical devices, ex. Artificial hips.

3. Polyvinyl Chloride( PVC)- the most well-known for use in the household and
commercial and construction .Ex. plumbing, electrical insulation…
They are brittle, rigid or flexible(depends on the design), strong.
4. Polypropylene(PP)- They are used for plastic parts of automobile and other
packaging consumer products. It is also used in textiles.
A semi transparent, electrical insulator.
5.Polystyrene (PS)- Used in packaging, termed as “Styrofoam” naturallytransparent.
6. Polyactic Acid (PLA)- This is derived from biomass rather than petroleum. It is
biodegradable much quicker than other plastic ,used in 3D printing.
7. Polycarbonate(PC)- Transparent known for its high impact strength. Used in
greenhouse and riot gear for police.
8. Acrylic(PMMA)- Used in optical devices.extrewmely transparent, scratch
resistance and less damaging to human skin or eye tissue.
9. Acetal(POM)- Very high tensile strengthwith high creep resistance.Used to
bridge thegap between plastic and metals.Strong resistance to heat, abrasion and
chemicals.Low coefficient of friction. Used for gears.1
10. Nylon(PA)- Used for clothing, reinforcement in rubber materiallike car tires. Used
also for ropes and injection molded parts for vehicles and mechanical equipment.
A substitute forlow-strength metals because of its high strength, high temperature
resilience andchemical compatibility.
11. Acrylonitrile Butadiene Styrene(ABS)- Strong resistance to corrosive chemicals
and physical impact.Low melting point, easy to use in injection moldingor 3D
printing. Use in Lego toys.
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RUBBER- a natural product harvested from rubber trees, it is commonly known

as the latex . There are types of latex origin;; synthetic-artificially done or
manmade.
POLYMER –made up of large molecule of many repeated smaller units called
monomers.
ELASTOMERS- has an elastic properties as in rubber.ex. silicone rubber
GLASS- an inorganic material , usually transparent or transluscent, non
crystalline, amorphous solid.
WOOD- a porous, and fibrous structural tissue found in stems and roots of trees.
It is an organic material.Strong in tension, resists compression. There are 3 types;
softwoods, hardwoods and engineered wood.
FABRICS-known as thetextile.made from many materials from different sources
such as animal( wool, silk), plant (cotton, bamboo), mineral(asbestos,glass fiber),
synthetic(nylon, polyester).These mentioned sources are natural,There are fibres
that are made from petroleum.

Activity:

In your household, find some items of different materials mentioned in our

discussion. Identify it and give its properties and function.

Exercise

Set up an electric circuit and place the metal in between the A and B. Does the
bulb glow?

Assignment

Watch the videos provided in the references

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References

You Tube 1. Year 1- Materials & their properties

2. material properties 101- Real Engineering
3. physical properties of metals & non metals-Don’t Memorize
At Google- Material Properties- Springer (2020)
Pascoe, K.J.M.A.,springer.com
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INDUSTRIAL MATERIALS & PROCESSES

LEARNING MATERIALS

MODULE 1-INTRODUCTION

LESSON 2- PROPERTIES OF MATERIALS

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PLATINUM
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MODULE 2- METALS

LESSON 3- PROPERTIES& USES OF COMMON ENGINEERING METALS

Introduction

In the science of engineering materials, the art of making metals and alloys is
called metallurgy, an important applied science to the design engineer in order to
have a clear understanding of the properties and uses of metals & its alloys.
The metals are considered as the most widely used materials in the industry as
for the design of consumer products, equipment components and for construction
products.

Approximately 91 of the 118 elements of the periodic table are metals,The

physical properties are shown in the table like density and mass. The unique
properties they posses like a good conductor of electricity and heat, malleability,
ductility and high density have contributed to a diverse range of applications.
Most of the metals are present in the earth as compound such as oxides and
sulphides.
There are types of metals:
noble- generally unreactive ex. Ag, Pt, Au & Pa.;
alkali metals-very reactive with low melting points & soft ex. K, Na; alkaline earth
metals—less reactive, higher melting points and harder ex. Ca, Mg, Ba; Transition
metals- diverse properties ex. Al, Ga, Sn,Ta, Pb,Bi

Overview

Metal is a material that, when freshly prepared , polished or fractured shows a

lustrous appearance and conducts electricity and heat. They can be hammered into
sheets ( malleable) or can be drawn into wires(ductile). A metal is an element that
readily forms positive ions and has metallic bonds It can be described as a lattice of
positive ions surrounded by a cloud of delocalized electrons.
All metals may be classified as:
1. Ferrous
 with Fe content such as cast iron, steel,, various steel alloys.
 They come from iron ore. difference between iron and steel is the carbon content.
 Properties are too soft and ductile.
 Ex.wrought iron,mild steel,stainless steel,tool steel,,plated steel.
 If magnet will stick then the material has iron content.
2.Non –ferrous
 with no Fe content.
 Such as Al,Cu,Pb,Ni,Sn,Ti,Zn.
 Precious; Au,Ag,Pt
 Rare; Co,Be,Hg,Bi,Tn,Ce

Objectives
Upon completion of lesson 3, the learner will be able to:
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1. Determine the chemical properties and physical properties of metals.

2. Use the eutectic chart to process an alloy.

3. Determine the uses of common metals.
4. Determine the different methods of fabricating a metal.
.
Pre-test
In the periodic table, a diagonal line drawn from Boron (B) to Polonium(Po)
separates the metal from the non metals.
Most elements on this line are metalloids, sometimes called semi-metals, elements
to the left are metals, elements to the upper right are non metals.

Activity:
 Metals in their pure state are luster: Rub the surface of an aluminum, Iron ,copper
and take note of the shining surface.
 Test the hardness by trying to cut them with a knife.
 Take one piece of your sample at a time and strike it with a hammer.What do you
observe.
 Take an experiment and which of these metals can be form into wires and sheets.
 Take a sample of each metal and try to melt or burn it in a lamp or candle.Take
note which burn easily, flame color and the appearance after burning.
 Set up an electric circuit and place the metal in between the A and B. Does the
bulb glow?

Topic Discussion
Physical Properties of metals:
 Solid
 Hard(except Li,K,Na)
 Metallic luster
 Malleable(can be beaten into thin sheets)
 Ductile(can be drawn into wires)
 High melting points (Ga,Ce have low melting point)
 High boiling points
 Good conductors of heat(best are Ag, Cu.poor conductors are Pb and Hg)called
thermal conductivity.
 Good conductors of electricity(best are Ag and Cu)
 Sonorus(produce sound when beaten)
 Packed together as closely as possible.
 Most metals have high density- density are shown in the periodic table.

Chemical Properties

 Have a tendency to donate electrons (REDOX reaction)

 Displace hydrogen gas from dilute acid
 React with oxygen to produce basic oxides
 React with hydrogen to produce hydrides.

Common uses of metals:

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1. gold- best filling for cavities and crown and other orthodontic application because
of its ductility.other uses are for electronics,computers,medals, jewelries.
2. silver- for jewelries and tablewares,also used as reflector in mirror, electrical
contacts and batteries.
3. aluminum- because of its silvery-white metal.it is soft and malleable.used in cans,
utensils, window frames,
4. titanium- considered as the strongest metal on earth used for alloys.used in
aerospace where lightweight strength and ability to withstand temperature and
pressure.
5. zinc- used as alloys such as brass, and aluminum solder, also for paints and
pharmaceuticals.

6. . Shiny metals like copper,silver, and gold are often used for decorative arts and
jewelries and coins.
2. Strong metals like iron & metyal alloys Such as stainless steel are used for
constructions, build structures1, ships, and vehicles.
6. Mercury used inthermometr to check the temperature,

PROCESSES OF METALS AND ALLOYS

The eutectic temperature- is the lowest possible melting temperature over all of
the mixture ratios for the involved components.

The chart applicable for alloy processing

 The coordinates in the phase diagram defining a eutectic point are the: percentage
ratio(atomic/molecular ratio axis) and the eutectic temperature(on the temperature
axis)

How to use the eutectic diagram.

Two-component eutectic systems

The figure shows the two-component diagram. The components are A and B, the
phases are: a). pure crystal A b) pure crystal B c) liquid with A & B compositions .

Plotted in the x axis at the bottom of the diagram (in percentage composition) . The
temperature is plotted in the y axis.

The diagram ;
Composition x will be all liquid above the temp. T 1 , at T1 crystals of A begin to form.
Lowering of temp. ,more crystal A is formed.,so more liquid B is enriched.

As the temperature is lowered, the liquid composition is will changed from point 1 to
point 2 to point 3.and finally to T E (Eutectic point)

At temp. between T1 to TE , two phases will be present. 1 ) liquid 2) crystal A

At TE , 1) crystal B begin to form 2) crystal A 3) crystal B 4) liquid.
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The temperature must remain at TE until one of the phases disappear.

Result is:
 liquid crystallizes completely
 pure A & pure B remain
 the proportion will be at that original mixture of 80% A and 20 % B.

In abbreviated form:

T > T1 all liquid

T1 - TE liquid + A
@ TE liquid + A + B

T < TE all solid

The Process:
Metallic raw materials are processed through fabrication :
1. cutting 2. Folding 3. Welding 4. Machining 5. Punching 6. Shearing 7. Stamping 8.
casting

Assignment:

Name other types of metal and alloy that you know and their uses and properties.
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References:
You tube –uses of metals=gold, copper, aluminum, steel/properties of matter by
fuse school=global education-

You Tube-Metal Displacement Reaction –WACE Chem.

You tube- Making a titanium axe- timothy Dyck
You tube-eutectic alloys and age hardening dental scholar
You Tube-Eutectic of Ag and Cu
The first lesson of welding-learn to run a straight bead-Weld.com
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LEARNING MATERIALS

MODULE 2-METALS

LESSON 3- PROPERTIES & USES OF COMMON ENGINEERING METALS

Carmen asor 2020