ENME382 HW 1 Solutions

1.1 Select one or more of the following modern items or devices and conduct an internet
search in order to determine what specific material(s) is (are) used and what specific
properties this (these) material(s) possess(es) in order for the device/ item to function
properly. Finally, write a short essay in which you report your findings.

Cell phone/digital camera batteries

Cell phone displays
Solar cells
Wind turbine blades
Fuel cells
Automobile engine blocks (other than cast iron)
Automobile bodies (other than steel alloys)

m
Space telescope mirrors

er as
Military body armor

co
Sports equipment

eH w
Soccer balls

o.
Basketballs
Ski poles
rs e
ou urc
Ski boots
Snowboards
Surfboards
o

Golf clubs
Golf balls
aC s
vi y re

Kayaks
Lightweight bicycle frames

Examples of Minimally Adequate Answers (50%)

ed d

These answers have not included sources, meaning that they would actually get 0% and a
ar stu

referral to the office of student conduct.

 The item I chose was surfboards. Surfboards are made from polyurethane or polystyrene
foam, covered with layers of fiberglass cloth, and polyester or epoxy resin. The
sh is

polyurethane/polystyrene foam has a low density, which allows the surfboard to be light and
Th

buoyant. The fiberglass is hard, which allows the board to support the surfer without
breaking. The resin acts as a sealant, to allow for the board to be durable, waterproof, and to
protect any painted designs.

 First generation solar cells (aka conventional/traditional cells) are made of crystalline silicon
(c-Si) (also known as “solar grade silicon”). This is because solar cells are used as
photodetectors that detect light (or other electromagnetic radiation). Because crystalline
silicon is a semiconducting material, it can sense the light that allows solar panels to absorb
energy from the sun.

https://www.coursehero.com/file/18784049/HW1-solutions-ENMA-300-ENME-382/
  Wind turbine blades are typically made from glass-fiber or carbon-fiber reinforced plastics.
Both materials are strong and light. Their strength makes them a suitable choice for a wind
turbine which will be subjected to high speed winds and the resulting forces. Since they are
both light, it won’t take a huge amount of wind or force to move the blades. This means the
blades will turn more easily, and the wind turbines will be able to effectively and efficiently
use the wind to generate power.

 Wind turbine blades should be made from low weight materials (to enable higher rotation
speed), have high strength to withstand load cycles (due to gravitational forces) and be easily
processed. Wind turbine blades can be made of low density materials such as aluminum or
composites. These materials provide several features for the device such as low weight, high
fatigue resistance and fracture toughness to withstand cyclic loading, and low manufacturing
cost.

m
Examples of Good Answers (100%)

er as
These answers have not included sources, meaning that they would actually get 0% and a

co
referral to the office of student conduct.

eH w
o.
 Aluminium-alloy cylinder blocks are widely used in the automobile industry for internal
rs e
combustion engines. Although traditionally made out of cast iron, aluminum alloys are
ou urc
superior in terms of weight reduction for a similar sized engine. Although they are softer
than steel or cast iron, cylinder liners and surface hardening techniques like nitriding are used
to improve surface wear characteristics. Further, aluminium alloys possess higher heat
o

transfer capabilities, making engine cooling much easier, resulting in secondary weight
aC s

reduction.
vi y re

However, aluminium-alloys also have higher coefficients of thermal expansion, meaning the
relative fit of the piston rings within the cylinder based on the temperature changes more as
compared to an iron cylinder block. These challenges are not of significance in smaller
ed d

engines, but require specially designed piston rings and oil control rings to ensure pressure
ar stu

loss to the crank case is minimal in engines with a larger bore radius.

In conclusion, aluminium-alloys provide similar performance with lesser weight penalties,

when compared at the automobile level.
sh is
Th

 Automobile bodies have traditionally been manufactured using steels, owing to their
abundance and ease (and low cost) of manufacturing processes such as welding, stamping
etc. However, modern technologies have focused on weight reduction while still improving
safety of passengers (and more recently, even pedestrians). With advancing carbon fiber and
polymer structures, CFRP and multi-material bodies have found their way into prototypes.
Carbon fiber is sometimes used exclusively in exotic (and thus, expensive) cars and also in
racing and motorsport. These provide very high performance characteristics at a fraction of
the weight penalty. The manufacturing methods such as lay-up etc. provide opportunities for
exploring different body configurations like the monocoque – where the chassis and the rest
of the body act as stress members, providing further opportunities for weight reduction.

https://www.coursehero.com/file/18784049/HW1-solutions-ENMA-300-ENME-382/
 However, the high cost and relative complexity of manufacturing have led to minimal use.
Further, predictability of failure is more difficult as these structures tend to behave like brittle
materials, and show little or no signs of impending yield or failure. Also, damage to these
structures does not allow room for repair. Usually, the entire part needs to be replaced.
Although techniques to simulate their response and predict failure is improving, they are
usually the choice for any vehicle where high performance is desired.

Multi-material bodies allow for design optimization at multiple levels with opportunities to
reduce costs and environmental impact, while providing an opportunity for using recycled
materials.

Example Excellent Answer (120%)

 The item selected for studying is the lightweight bicycle frame. In fact, several different

m
materials can be used for bicycle frame featuring lightweight, and there is no consensus on

er as
which one is the best. This short essay will discuss the most common materials used for this

co
purpose and their properties.

eH w
o.
Lightweight bicycles generally require that the frame material has low density, while
rs e
achieving high strength and durability. Steel was the most conventional material for bicycle
ou urc
frames decades ago. It is nowhere near ideal for lightweight bikes, since the density of
various types of steels usually ranges between 7,750 and 8,050 kg/m3 [1]. This is nearly
twice as heavy as the common lightweight materials to be discussed below.
o
aC s

The first material common for lightweight bicycles is aluminum. Since its introduction as a
vi y re

material bicycle frame material about 30 years ago, aluminum is now the most common
material, thanks to its low density and stiffness, as well as affordability [2]. With the density
only 1/3 of the steel, the aluminum results in significantly lighter frames. Besides, the
stiffness is also lower, leading to improved machinability compared with steel [3]. However,
ed d

lower strength is a problem for pure aluminum, so an aluminum alloy is generally used, of
ar stu

which the 6000 series aluminum alloy is a common choice because of the excellent
machinability and decent strength. While the 7000 series aluminum alloy is stronger, it is
much harder and therefore the machinability is poor [4]. In order to achieve enough strength,
however, the tubes have to be made in larger diameter compared with steel, which reduces
sh is

the advantage of lower density.

Th

Titanium is a potentially good choice for lightweight bicycle frames due to its combination of
strength and low weight. The stiffness and density (about 4.43g/cm3) of titanium alloys are
about half of those of steel. An additional desirable characteristic of titanium is its resistance
to corrosion. The family of titanium alloys offers a wide spectrum of strength and
combinations of strength and fracture toughness [5]. Today, most titanium bicycle frames
use the 3Al/2.5V alloy (3% aluminum/2.5% vanadium). Nevertheless, titanium frames are
expensive to make not only due to the high material costs of titanium, but due to the welding
of titanium tubes being demanding [2].

https://www.coursehero.com/file/18784049/HW1-solutions-ENMA-300-ENME-382/
 Carbon fiber is becoming the most preferred lightweight bicycle frame material. It is known
for both its low weight and its ultra-high strength, stiffness, and durability. Carbon fiber
consists of non-metallic graphite fiber cloth that is layered together with a high strength
epoxy resin to form a matrix, which arranges the individual fibers to form a strong structure.
The fatigue life of carbon fiber is almost infinite, unlike its metal counterparts [6]. Another
unique feature of carbon fiber composites is that they can be molded and tuned to orient the
strength wherever necessary. Therefore, it is almost ideal for high performance lightweight
bikes due to its customizability in strength orientation. Although carbon fiber is expensive, it
is still the most popular lightweight material for performance and racing bicycles nowadays.

In summary, a number of materials are available for lightweight bicycle frames. Each of
them has unique properties that enable them to stand out.

References

m
[1] Elert, Glenn. "Density of Steel". Retrieved 04/23/2009.

er as
[2] “Which frame material is the best?”, http://bigshark.com/articles/which-frame-material-

co
is-the-best-pg531.htm. Retrieved 08/24/2016.

eH w
[3] Wikipedia “Aluminum”, https://en.wikipedia.org/wiki/Aluminium. Retrieved

o.
08/24/2016.
rs e
[4] Wikipedia “Aluminum Alloy”, https://en.wikipedia.org/wiki/Aluminium_alloy.
ou urc
Retrieved 08/24/2016.
[5] http://www.rtiintl.com/Titanium/RTI-Titanium-Alloy-Guide.pdf. Retrieved 08/24/2016.
[6] http://cyclingtips.com/2015/08/what-is-the-lifespan-of-a-carbon-frame/. Retrieved
o

08/24/2016.
aC s
vi y re

1.2 List three items (in addition to those shown in Figure 1.9) made from metals or their
alloys. For each item, note the specific metal or alloy used and at least one characteristic
that makes it the material of choice.
ed d
ar stu

Kitchen Appliances Some made from stainless steel. Stainless steel is an alloy of iron, low
levels of carbon, and chromium. The chromium gives the steel resistance to iron rust.

Solder Usually an alloy of tin and lead. Chosen because it has a low melting point.
sh is
Th

Solder It can be made of 50% tin and 50% lead. Low melting point of the tin-lead alloy
makes processing and soldering possible at relatively low temperatures (lower than the pieces
it is intended to join).

Jewelry sometimes sterling silver. Sterling silver is an alloy of mostly pure silver, with
some amount of copper. This is chosen, even over pure silver, because it is stronger due to
the copper, but is still ductile. It also has a lower cost than precious metals.

Jewelry It can be made of a silver alloy called sterling silver: 92.5% pure silver and 7.5%
another material usually copper. Silver is very soft and therefore easy to be processed in
different shapes.

https://www.coursehero.com/file/18784049/HW1-solutions-ENMA-300-ENME-382/
 Cast-iron skillets Made of cast-iron (surprise, surprise) because it distributes heat evenly and
retains heat well.

Pots Many pots are made from stainless steel because it’s non-reactive (meaning you can
cook any kind of food in it), heavy, durable, and dishwasher safe.

Bridges Often made of steel because it’s cheap and durable.

Sewing needle, shower head, and doorknob. All of these materials are very stiff and are
resistant to fracturing. They all also have a lustrous appearance when polished. I also tested
attaching a magnet to each of these items, and the magnet stuck to all three.

Zipper It can be made of brass, which is an alloy of copper and zinc. Its color is very similar

m
to gold, but much cheaper.

er as
co
eH w
1.3 List three items (in addition to those shown in Figure 1.10) made from ceramic

o.
materials. For each item, note the specific ceramic used and at least one characteristic that
rs e
makes it the material of choice.
ou urc
Spark Plugs Various types, sometimes alumina silicate. Electrical insulator.
o

Dentistry Various types, sometimes porcelain. They are insoluble and are hard which gives
them good durability.
aC s
vi y re

Aerospace industry Various types, sometimes aluminum oxide or zirconium oxide.

Electrical and thermal insulation, durability, and good strength to density ratios.
ed d

Ceramic vase, toilet tank lid, and hourglass. All materials are relatively stiff but are not
ar stu

ductile and fracture easily.

Electrical insulator Ceramic made from alumina and porcelain, electrical insulating.
sh is

Electrical insulators Can be made from alumina (aluminum oxide). It is a poor conductor
Th

even if a very high voltage is applied)

Space shuttle tiles Can be made of heat resistant materials such as silica (silicon dioxide).
The source of heat is the friction with the Earth’s atmosphere.

Grinding materials These are abrasive resistant materials such as silicon carbide (SiC),
which have very high hardness and can be used for polishing and sanding various surfaces.

Optical fiber Glass (silica), immune to electromagnetic interference.

Cement ground Cement, high hardness and stiffness, high strength.

https://www.coursehero.com/file/18784049/HW1-solutions-ENMA-300-ENME-382/
 Piston rings Low sliding friction, high wear resistance.
Zirconia (Ref - http://www.certechinc.com/zirconia-rings/)

Insulators and refractory materials Low thermal conductivity. b. Alumina (aluminium

oxide) – high melting point.

Silicon Carbide – brake discs Used due to their high wear resistance and high melting point.
Low thermal expansion.

Silicon Carbide – manufacturing products and abrasives Called “carborundum”. Used due
to their superior hardness and wear resistance

m
1.4 List three items (in addition to those shown in Figure 1.11) made from polymeric

er as
materials. For each item, note the specific polymer used and at least one characteristic that

co
makes it the material of choice.

eH w
o.
Plastic bags Polyethylene. Low rigidity, high ductility.
rs e
ou urc
Ropes Polypropylene. Low density, tough and flexible.

Water pipes Polychloroethene. Good insulator, low cost.

o

Rubber band, phone case, and Styrofoam. All of these materials are not very stiff and can all
aC s
vi y re

be easily broken. In addition to this, they would all melt pretty easily if I were to put them on
the stovetop. I also know that Styrofoam is also known as polystyrene, which is clearly a
polymer based on its name.
ed d

CD and DVD Polycarbonate: strong (hardness) and transparent.

ar stu

Paint Polyurethane: low odor and low toxicity.

Food wraps Polyvinyl chloride: permeability to water vapor and oxygen transmission.
sh is
Th

1.5 Classify each of the following materials as to whether it is a metal, ceramic, or polymer.
Justify each choice: (a) brass; (b) magnesium oxide (MgO); (c) Plexiglas®; (d)
polychloroprene; (e) boron car- bide (B4C); and (f) cast iron.

Example minimal answer (50%)

a. Metal
b. Ceramic
c. Ceramic
d. Polymer
e. Ceramic

https://www.coursehero.com/file/18784049/HW1-solutions-ENMA-300-ENME-382/
 f. Metal

Example better answers (100%)

a) Brass is a metal. It is stiff and does not fracture easily. I also know that it is an alloy
between zinc and copper which are both metals.
b) Magnesium oxide (MgO) is a ceramic. Ceramics are compounds between metals and
nonmetals. Magnesium is a metal while oxygen is a nonmetal.
c) Plexiglas is a polymer. The molecular name of Plexiglas is polymethyl methacrylate.
Just based on this name I know it is a polymer because it is made up of a long chain of
methyl methacrylate.
d) Polychloroprene is also a polymer. Again, I can tell because of the name.
e) Boron carbide (B4C) is a ceramic. I know this because it is a compound between a metal
(boron) and a nonmetal (carbon).

m
f) Cast iron is a metal. It is an iron carbon alloy, and is also relatively brittle.

er as
co
a) brass is a metal alloy (combination of two metals)

eH w
b) magnesium oxide (MgO) is a ceramic ( it is an oxide compound between metallic and

o.
nonmetallic elements)
rs e
c) Plexiglass® is a polymer (poly(methyl methacrylate) has a chain-like structure with a
ou urc
backbone of carbon atoms)
d) polychropropene is a polymer (it has a chain-like structure with a backbone of carbon
atoms)
o

e) boron carbide is a ceramic (compound between metallic and nonmetallic elements)

f) cast iron is a metal alloy (it is made of iron (metal) and carbon (nonmetallic) elements.
aC s
vi y re
ed d
ar stu
sh is
Th

https://www.coursehero.com/file/18784049/HW1-solutions-ENMA-300-ENME-382/

Powered by TCPDF (www.tcpdf.org)