Minggu-3 Manufacturing Processes

Teknologi Manuaktur
(TPS-1116A)
Tatap Maya-3 Minggu ke-3

Selasa, 16 Maret 2021
Jam 13.00-15.30
Prodi Teknologi Pengolahan Sawit (D-3)

INSTITUT TEKNOLOGI SAINS BANDUNG
(ITSB) 2021
Materi Minggu ke-3
Reviu Pembahasan
Material in Manufacturing
(Metals, Ceramics, Polymers &
Composite)
4 (Four) Types of
Engineering Materials
1. Metals
2. Ceramics
3. Polymers
4. Composites
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Bagian 3a Metals
(1)Ferrous Metals and Alloys:
Production, General Properties, and
Applications
Blast Furnace
Figure 5.1 Schematic illustration of a blast furnace.
Electric Furnaces
Figure 5.2 Schematic illustrations of types of electric furnaces:

(a) direct arc, (b) indirect arc, and (c) induction.
Basic-oxygen Process
Figure 5.3 Schematic illustration showing (a) charging, (b) melting,

and (c) pouring of molten iron in a basic-oxygen process.
Casting
Figure 5.4 (a) The

continuous-casting
process for steel.
Typically, the solidified
metal descends at a
speed of 25 mm/s (1
in./s). Note that the
platform is about 20m
(65ft.) above ground
level. Source:
Metalcaster’s
Reference and Guide,
American
Foundrymen’s Society.
(b) Continuous strip
casting of nonferrous
metal strip. Source:
Courtesy of Hazelett.
Carbon and Alloy Steel Applications
Mechanical Properties of Carbon and Alloy Steels
AISI Designation of Steel
Properties and Applications of Annealed Stainless Steels
Tool and Die Steels
Tool and Die Steel Traits
Tool and Die
Materials
(2)Nonferrous Metals and Alloys:
Production, General Properties, and
Applications
Cost of Wrought Metals and Plastics vs. Carbon Steel
Nonferrous Metals and Alloys
Jet Engine Cross-Section
Figure 6.1 Cross-section of a jet engine (PW2037) showing various components and the
alloys used in manufacturing them. Source: Courtesy of United Aircraft Pratt & Whitney.
Aluminum Alloy Properties
Aluminum Alloy Properties and Applications
The All Aluminum Audi A8
Figure 6.2 (a) The Audi A8

automobile which has an all-
aluminum body structure.
(b) The aluminum body
structure, showing various
components made by
extrusion, sheet forming, and
casting processes. Source:
Courtesy of ALCOA, Inc.
Wrought Magnesium Alloys:
Properties and Forms
Wrought Copper and Brasses:
Properties and Applications
Wrought Bronzes: Properties and Applications
Nickel Alloy Properties and Applications
Nickel-Based Superalloy Properties and Applications
Wrought Titanium Alloy Properties and Applications
Bagian 3b Polymers
Polymers: Structure, General
Properties and Applications
Mechanical Properties of Engineering Plastics
Figure 7.1 Outline of the topics described
Structure of Polymer Molecules
Figure 7.2 Basic structure of polymer

molecules: (a) ethylene molecule; (b)
polyethylene, a linear chain of many
ethylene molecule; and (c) molecular
structure of various polymers. These
are examples of the basic building
blocks for plastics.
Polymerization
Figure 7.3 Examples of polymerization. (a) Condensation polymerization of nylon 6,6

and (b) addition polymerization of polyethylene molecules from ethylene mers.
The Effect of Molecular Weight and Degree of
Polymerization on Polymers
Figure 7.4 Effect of molecular

weight and degree of
polymerization on the strength and
viscosity of polymers.
Polymer Chains
Figure 7.5 Schematic illustration of polymer chains. (a) Linear structure – thermoplastics
such as acrylics, nylons, polyethylene, and polyvinyl chloride have linear structures. (b)
Branched structure, such as in polyethylene. (c) Cross-linked structure – many rubbers or
elastomers have this structure, and the vulcanization of rubber produces this structure. (d)
Network structure, which is basically highly cross-linked – examples are thermosetting
plastics, such as expoxies and phenolics.
Behavior of Polymers
Figure 7.6 Behavior of polymers as a function of temperature and (a) degree of

crystallinity and (b) cross-linking. The combined elastic and viscous behavior of
polymers is known as viscoelasticity.
Microstructure of Polymethylmethacrylate Cement
Figure 7.7 Schematic illustration of the microstructure of

polymethylmethacrylate cement used in dental and mental applications.
Amorphous and Crystalline Regions in a Polymer
Figure 7.8 Amorphous and crystalline regions in a polymer. The crystalline

region (crystallite) has an orderly arrangement of molecules. The higher
the crystallinity, the harder, stiffer, and less ductile the polymer.
Volume of Polymers as a Function of Temperature
Figure 7.9 Specific volume of

polymers as a function of
temperature. Amorphous polymers,
such as acrylic and polycarbonate,
have a glass-transition temperature,
Tg, but do not have a specific
melting point, Tm. Partly crystalline
polymers, such as polyethylene and
nylons, contract sharply while
passing through their melting
temperatures during cooling.
Glass-Transition and Melting Temperatures of Polymers
Types of Plastics
Figure 7.10 General terminology describing the behavior of three types of plastics. PTFE
(polytetrafluoroethylene) has Teflon as its trade name. Source: After R.L.E. Brown
Effect of Temperature on the Stress-strain Curve
for Cellulose Acetate
Figure 7.11 Effect of temperature on the stress-strain curve for cellulose acetate, a
thermoplastic. Note the large drop in strength and the large increase in ductility with a
relatively small increase in temperature. Source: After T.S. Carswell and H.K. Nason.
Effect of Temperature on Plastic Impact Strength
Figure 7.12 Effect of

temperature on the impact
strength of various plastics.
Small changes in temperature
can have a significant effect
on impact strength. Source:
After P.C. Powell
Load-Elongation Curve and Tensile-Test Specimen
Figure 7.13 (a) Load-elongation curve for polycarbonate, a thermoplastic. Source:

Courtesy of R. P. Kambour and R. E. Robertson. (b) High-density polyethylene tensile-test
specimen, showing uniform elongation (the long, narrow region in the specimen).
Plastic Product Recommendations
Thermoplastic Polymer Trade Names
Load-Elongation Curve for Rubbers
Figure 7.14 Typical load-elongation

curve for rubbers. The clockwise
loop, indicating the loading and the
unloading paths, displays the
hysteresis loss. Hysteresis gives
rubbers the capacity to dissipate
energy, damp vibration, and absorb
shock loading, as is necessary in
automobile ties and in vibration
dampers placed under machinery.
Bagian 3c Ceramics
Ceramics, Graphite, and Diamond:
Structure, General Properties, and
Applications
Ceramic Components
Figure 8.1 A variety of ceramic components. (a) High-strength alumina for high-
temperature applications. (b) Gas-turbine rotors made of silicon nitride. Source:
Courtesy of Wesgo Div., GTE.
Ceramic Types and Characteristics
Properties of Ceramics
Tensile strength : UTS = UTS oenP

Elastic modulus : E  E o 11.9P  0.9P 2 
Thermal conductivity : k  k o 1 P 
Ceramic Bearing and Races
Figure 8.2 A selection of ceramic bearings and races. Source: Courtesy of Timken, Inc.
Graphite Components and Electrodes
Figure 8.3 (a) Various engineering components made of graphite. Source:

Courtesy of Poco Graphite, Inc., a Unocal Co. (b) Examples of graphite electrodes
for electrical discharge machining. Source: Courtesy of Unicor, Inc.
CERAMICS
Definition of Ceramics:
Ceramic powders have characteristics that are in
many ways different from metals and polymers,
differences stems from the different bonding
typical of them
Lets see the type of bonding that plays an
important role on the characteristics of ceramics:
CERAMICS
Covalent bonds: are formed by electrons

shared between adjacent atoms. These are
very strong bonds. The high bond strength
reflects in
•high melting point
•High strength
•hardness coupled with brittleness
•thermal expansion is often low
•electrical resistance is high
Properties of Ceramics
(a)Mechanical Properties:
1. Ceramics are not only brittle but often have microcracks in
them.
2. Because of their sensivity to cracks, ceramics are often
used in compressive loading and compressive strength,
hardness and hot hardness are then specified.
3. The high hardness of ceramics also makes them
indispensable in many applications where wear resistance
are important.
4. Cracks or defects in ceramics can have sharp radii which
cause large stress concentrations, reduce fracture
strength, and makes ceramics vulnerable to fatigue failure
Cont’
(b)Pyhsical Properties
1. Their thermal expansion is lower than that of metals
2. The electrical properties of ceramics range from good
conductors through semiconductors and insulators
3. Some ceramics exhibit piezoelectricity
1. Thus a crystal subjected to mechanical loading generates
a potential difference and can be used as a force
transducer.
2. In the reverse mode, a potential difference is applied to
the crystal causes a dimensional change which can be
exploited in ultrasonic transducers and force generators
Cont’
4. Ceramics can be formulated to provide the full

range of optical properties.
5. Single crystals of ionically bonded ceramics are
usually transparent whereas covalently bonded
ceramics may range from transparent to opaque
Cont’
(c)Chemical Properties
1. A great advantage of ceramics is that they are
often resistant to chemical attack by gases, liquids
and even high temperature melts
2. Combines with their remarkable high strength, this
makes them ideal for such applications as
temperature-resistant furnace linings
(refractories), insulators, and even mechanical
components, such as turbine disks, turbine blades
and various components of internal combustion
engines.
Applications:
• Clay-based ceramics
Some products are made of natural products
• Vitrified whiteware for bathroom fixtures
• Dry-pressed floor tiles, lathe-turned electrical
porcelains
• Semivitrified tableware and hard porcelains
• Refractories
• Like refractory metals, refractory ceramics are
noted for their resistance to high temperature
• Mortar and furnace hearths are made of
refractory granules bonded with a cement
Cont’
• Carbides, nitrides, borides, and silicides

• Carbides
• These ceramics are noted for their
hardness
• Carbides have the highest melting point of
all substances
• Rocket nozzles and sandblast nozzles
• One of the most important abrasive for
grinding
• Used in wear-resistant bodies and body
armor
Cont’
• Nitrides
• Have only slightly lower melting point than
carbides
• The cubic form (CBN- Cubic boron nitride)
has a structure to that of diamond and is
after diamond the hardest material, suitable
for metal cutting
Cont’
• Carbides, nitrides, borides, and silicides

• Silicon nitride
• Has a good thermal conductivity, low
expansion and high hot strength, making it
the prime candidate for ceramic engine
components, turbine disks, and rocket
nozzles
• Borides
• Have high melting point, strengths and
oxidation resistance and are used as
turbine blades, rocket nozzles, and
combustion chamber liners
Cont’
• Carbon
• Diamond
• Natural diamonds are used in wear-
resistant applications such as wire-drawing
dies, cutting tools, and grinding wheels
• Man-made diamond outperforms natural
diamond in many applications
Bagian 3d Composites
Composite Materials:
Structure, General Properties and
Applications
Boeing 757-200
Figure 9.1 Application of advanced composite materials in Boeing 757-200

commercial aircraft. Source: Courtesy of Boeing Commercial Airplane Company.
Methods of Reinforcing Plastics
Figure 9.2 Schematic illustration of methods of reinforcing plastics (matrix) with (a)
particles, (b) short or long fibers or flakes, and (c) continuous fibers. The laminate
structures shown in (d) can be produced from layers of continuous fibers or sandwich
structures using a foam or honeycomb core (see also Fig. 16.50).
Characteristics of Composite Materials
Tensile Strength and Modulus for Fibers in Plastic
Figure 9.3 Specific tensile strength (tensile strength-to-density ratio) and specific
tensile modulus (modulus of elasticity-to-density ratio) for various fibers used in
reinforced plastics. Note the wide range of specific strengths and stiffnesses available.
Properties of Reinforcing Fibers
Cross-sections of Fiber-reinforced Materials
Figure 9.4 (a) Cross-section of a tennis racket, showing graphite and aramid (Kevlar)
reinforcing fibers. Source: Courtesy of J. Dvorak, Mercury Marine Corporation and F. Garret,
Wilson Sporting Goods Co. (b) Cross-section of boron fiber-reinforced composite material
Effect of Fiber Type on Properties of Fiber-reinforced Nylon
Figure 9.5 The

effect of type of
fiber on various
properties of fiber-
reinforced nylon
(6,6). Source:
Courtesy of NASA.
Fracture Surfaces of Fiber-reinforced Epoxy Composites
(a) (b)
Figure 9.6 (a) Fracture surface of a glass fiber-reinforced epoxy composite. The fibers
are 10μm (400μin.) in diameter and have random orientation. (b) Fracture surface of a
graphite fiber-reinforced epoxy composite. The fibers, 9 μm to 11μm in diameter, are in
bundles and are all aligned in the same direction. Source: Courtesy of L.J. Broutman
Mechanical Properties of Reinforced Plastics
Load fraction of fibers :

Pf Af E f

Pm Am E m
Elastic modulus of composite :

E c  xE f  1 x E m
Figure 9.7 The tensile strength of glass-reinforced

polyester as a function of fiber content and
fiber
direction in the matrix.
Composite Sailboard Cross-section
Figure 9.8 Cross-section of a composite sailboard, an example of advanced

materials construction. Source: K. Easterline, Tomorrow’s Materials (2nd ed.),
p. 133. Institute of Metals, 1990.
Metal-Matrix Composite Materials and Applications
Metal Matrix Automotive Brake Caliper
Figure 9.11 Aluminum-matrix composite

brake caliper using nanocrystallyne
alumina fiber reinforcement. Source:
Courtesy of 3M Corp.

Minggu-3 Manufacturing Processes

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Minggu-3 Manufacturing Processes

Uploaded by

Copyright:

Available Formats

Teknologi Manuaktur

Tatap Maya-3 Minggu ke-3

Prodi Teknologi Pengolahan Sawit (D-3)

Figure 5.1 Schematic illustration of a blast furnace.

Figure 5.2 Schematic illustrations of types of electric furnaces:

Figure 5.3 Schematic illustration showing (a) charging, (b) melting,

Figure 5.4 (a) The

Figure 6.2 (a) The Audi A8

Figure 7.2 Basic structure of polymer

Figure 7.3 Examples of polymerization. (a) Condensation polymerization of nylon 6,6

Figure 7.4 Effect of molecular

Figure 7.6 Behavior of polymers as a function of temperature and (a) degree of

Figure 7.7 Schematic illustration of the microstructure of

Figure 7.8 Amorphous and crystalline regions in a polymer. The crystalline

Figure 7.9 Specific volume of

Figure 7.12 Effect of

Figure 7.13 (a) Load-elongation curve for polycarbonate, a thermoplastic. Source:

Figure 7.14 Typical load-elongation

Tensile strength : UTS = UTS oenP

Figure 8.3 (a) Various engineering components made of graphite. Source:

Covalent bonds: are formed by electrons

4. Ceramics can be formulated to provide the full

• Carbides, nitrides, borides, and silicides

• Carbides, nitrides, borides, and silicides

Figure 9.1 Application of advanced composite materials in Boeing 757-200

Figure 9.5 The

Load fraction of fibers :

Elastic modulus of composite :

Figure 9.7 The tensile strength of glass-reinforced

Figure 9.8 Cross-section of a composite sailboard, an example of advanced

Figure 9.11 Aluminum-matrix composite

You might also like