Industrial Materials

and Processes
ENGR. BINGO B. CUETO, MSIEM,PIE
Industrial Engineering, LPUL
Fundamentals of Industrial Materials and Processes
Learning Objectives
1. Describe the course of Industrial Materials and Processes as a scientific discipline
2. Understand and appreciate the challenges and complexities involved in the design
and construction of a product (all major classes of materials)
3. Introduce the broad spectrum of manufacturing processes to individual who will
be involved in the design and manufacture of finished products
4. Provide a good theoretical background and a sound practical knowledge to the
engineering students
5. Be aware of the following terms for better understanding of the scope of the study
Introduction
All of us live in a world of dynamic change, and materials are no exception.
The advancement of civilization has historically depended on the
improvement of materials to work with.
Over time, they moved from the materials Stone Age into the newer Copper
(Bronze) and Iron Ages.
Today’s competitive manufacturing era of high industrial development and
research, is being called the age of mechanization, automation and computer
integrated manufacturing.
Introduction
Manufacturing is the backbone of any industrialized nation.
Since products require materials, engineers should be knowledgeable about the internal
structure and properties of materials so that they can choose the most suitable ones for each
application and develop the best processing methods.
PRODUCTS AND
MANUFACTURING
Design Materials Selection Process Selection

Manufacture Inspection Feedback

Product Creation Cycle

MANUFACTURING
Is the economic term for making goods and services available to
satisfy human wants.

It implies creating value by applying useful mental and physical labor.

GOODS AND SERVICES
Goods
- are material things that we buy to satisfy our wants,
needs or desires.

Services
- are nonmaterial things that we buy to satisfy our wants,
needs or desires.
PRODUCTS AND
MANUFACTURING
Design Materials Selection Process Selection

Manufacture Inspection Feedback

Product Creation Cycle

Industrial Materials
History of Materials
Even our history has been defined by the materials we use…
• The stone age
• The copper age
• The bronze age
• The iron age
• The current age is that of plastics, composite materials, and exotic alloys
What would be a good material name for today?
History of Materials
• Man has been studying materials since before leaving the cave.
• Due to lack of communication, early man spent hundreds of
millennia experimenting with stone tools.
• The first metal tools appeared perhaps only six thousand years ago.
• The discovery of “Iceman” in the Alps in 1991 gave significant
information on early Copper age. He was carrying a copper axe.
• It is dated at about 5300 years, when the first pyramids were built.
History of Materials
• As our knowledge of materials grows, so does the sophistication
of our tools.
• The more sophisticated our tools, the more sophisticated our
accomplishments.
Since the earliest days of the evolution of mankind, the main
distinguishing features between human beings and other mammals
has been the ability to use and develop materials to satisfy their
human requirements.

Nowadays we use many types of materials, fashioned in many

different ways, to satisfy our requirements for housing, furniture,
clothes, transportations, entertainment, medical care, defense and
all the other trappings of a modern civilized society.
What are Materials?

Our clothes are made of materials, our homes are made of materials
- mostly manufactured. Glass windows, vinyl siding, metal
silverware, ceramic dishes…

Most things are made from many different kinds of materials.

Kinds of Materials
Kinds of Materials
Metals: are materials that are normally combinations of "metallic
elements". Metals usually are good conductors of heat and
electricity. Also, they are quite strong but malleable and tend to
have a lustrous look when polished.

Ceramics: are generally compounds between metallic and

nonmetallic elements. Typically they are insulating and resistant to
high temperatures and harsh environments. (MSECRC, 2006)
Kinds of Materials
Plastics: (or polymers) are generally organic compounds based
upon carbon and hydrogen. They are very large molecular
structures. Usually they are low density and are not stable at high
temperatures.

Semiconductors: have electrical properties intermediate between

metallic conductors and ceramic insulators. Also, the electrical
properties are strongly dependent upon small amounts of
impurities. (MSECRC, 2006)
Kinds of Materials
Composites: consist of more than one material type. Fiberglass, a
combination of glass and a polymer, is an example. Concrete and
plywood are other familiar composites. Many new combinations
include ceramic fibers in metal or polymer matrix. (MSECRC, 2006)

Glass: it is a mixture of number of metallic silicate, one of which is

usually that of an alkali metal. most important fact about glass is it
is amorphous, transparent or translucent.
Kinds of Materials
Wood: is a hard, fibrous tissue found in many plants. It has been
used for hundreds of thousands of years for both fuel and as a
construction material. It is an organic material, a
natural composite of cellulose fibers (which are strong in tension)
embedded in a matrix of lignin which resists compression.
Manufacturing Process
Manufacturing Process
A sequence of operations and processes designed to create a specific
product.
The process of turning materials into a product

©iStockphoto.com ©iStockphoto.com ©iStockphoto.com

Machine or Machine Tool
A specific piece of equipment designed to accomplish specific
processes.

Examples:
spot welder, milling machine, lathe, drill press, drop
hammer, die caster, grinder, etc.
Basic Manufacturing
Processes
• Casting, Foundry or Molding
• Forming or Metalworking
• Machining or Material Removal
• Heat Treating
• Joining and Assembly
• Surface Treatment or Finishing
Casting, Foundry or Molding Processes
In one step raw materials are transformed into a desirable shape
Parts require finishing processes
Excess material is recyclable

©iStockphoto.com
Basic Casting Process
• A mold is created – A cavity that holds the molten material in a
desired shape until it is solidified
• Material is heated to a specified temperature
• Molten material is poured into a mold cavity
• Molten material solidifies into the shape of the cavity
• Casting or mold is removed
• Casting is cleaned, finished, and inspected
Forming and Metalworking Processes
Utilizes material that has been cast
Modify the shape, size, and physical properties of the material
Hot and cold forming

©iStockphoto.com ©iStockphoto.com
Machining Processes
Controlled removal of material from a part to create a specific
shape or surface finish
Cutting element is used
Movement must exist between the part and cutting element

©iStockphoto.com
Heat Treating Processes
Controlled heating and cooling of a material to alter its
properties while maintaining its shape
Properties include: Strength, toughness, machinability, wear
resistance, and corrosion resistance
90% of heat treating is preformed
on steel and other ferrous metals
Joining and Assembly
Processes
Most products consist of multiple parts that are
assembled to form a finished product.
Typical assembly processes include: Mechanical
fastening; soldering and brazing, welding; adhesive
bonding
Surface Finishing
A broad range of industrial processes that alter the surface of a
manufactured item to achieve a certain property