TEKNOLOGI BAHAN (exam)

CLASSIFICATION OF MATERIALS
METAL
⁃ composed of two or more elements, at least one of which is metallic
Ferrous
1. Steel
⁃ plain carbon steel
⁃ low alloy steel
⁃ stainless steel
⁃ tool steel
2. Cast iron
⁃ gray cast iron
⁃ white cast iron
⁃ ductile iron
⁃ malleable iron
Non Ferrous
Al,Ti,Zn,Mg,Copper

POLYMER
1. Thermoplastics
2. Thermosetting
3. Elastomer
CERAMIC
1. Glass
2. Graphite
3. Diamond
4. Carbide
COMPOSITE
1. Metal-matrix composite
2. Ceramic-matrix composite
3. Polymer-matrix composite
METALS
⁃ Metal (from Greek : mine,quarry, metal) is a material (element,compound or
alloy) that is typically hard when in solid state, shiny and has good electrical and thermal
conductivity
⁃ Can be hammered or pressed permanently out of shape without breaking
⁃ able to melted and ductile (drawn out into thin wire)
⁃ some of that appear in both metallic and non-metallic forms

FERROUS METAL
⁃ metal that consist of Iron (Fe) element
⁃ can be group into steel and cast iron
⁃ little resistance to corrosion

STEEL
1. Plain Carbon Steel
⁃ high carbon steel
⁃ medium carbon steel
⁃ low carbon steel
⁃ cast iron

2. Low Alloy Steel

3. Stainless Steel
⁃ Austenitic
⁃ Ferritic
⁃ Martensitic

4. Tool Steel
⁃ High speed steel
⁃ Hot working
⁃ Mold steel
FERROUS

1. Iron & Steel

⁃ pure iron is soft and ductile but when carbon added they known as carbon steel

2. Cast Iron
⁃ contains 2%-4% of carbon
⁃ very hard and brittle
⁃ strong under compression

3. Stainless Steel
⁃ Hard and tough
⁃ corrosion resistance

4. Low Carbon Steel (plate,railroad)

⁃ ductile
⁃ malleable
⁃ easy to machine

5. Medium Carbon Steel (engine part)

⁃ more hardness and toughess

6. High Carbon Steel (spring,blade,gear)

⁃ high hardness and toughess

PURE METALS AND ALLOYS

Pure Metal that are not mixed with any other material
⁃ Iron (Fe)
⁃ Copper (Cu)
⁃ Zinc (Zn)

Alloys are mixture of two or more metals that formed together to create new metal
Type of metals

Ferrous
contains iron

Non Ferrous
does not contain iron

IRON AND STEEL

Stainless Steel
⁃ steel alloyed with chromium 18%, nickel 8%, magnesium 8%
⁃ hard and tough
⁃ corrosion resistance

High Speed Steel

⁃ Medium carbon steel alloyed with tungsten, chromium, vanadium
⁃ very hard
⁃ resistance to frictional heat even high temp
⁃ using for drills, machine cutting

Heat Treatment
process to alter the characteristics of metals by heating and cooling
⁃ heat the metal to the correct temp
⁃ keep at that temp for the required time (soaking)
⁃ cool it with the desired shape

Types of heat treatment:

Annealing
⁃ heating and can be shaped
Normalizing
⁃ refine the grain due to work hardening
Hardening
⁃ to increase the hardness of steel by adding carbon
Tempering
⁃ to reduce the hardness of steel workpiece
Case Hardening (Carburizing)
⁃ used mild steel to give a hard skin

Extraction of Iron
found in iron oxide in the earth

3 primary iron ores : magnetite,hematite,tacnite

Iron is extract using blast furnace

Steps of extraction:
⁃ ores is washed, crushed and mixed with limestone and coke
⁃ the mixture fed into the furnace and melted
⁃ coke: (carbon) is used to convert the iron oxides to iron
⁃ limestone helps to seperate the dust from the metal
⁃ they are then seperated
⁃ refine iron using basic oxygen furnace and the electric arc furnace to produce
steel

CAST IRON
White
⁃ less carbon and silicon than white
hard and good wear resistance
uses : rolling & crunching equipment

Ductile Iron
⁃ stronger and more ductile and hence
Grey Cast Iron
⁃ more carbon and silicon than white
good compressive and strenght
uses : machine base, furnace doors

Malleable Iron
⁃ high toughness and absorb impact force

NON FERROUS METAL

⁃ not contain iron
⁃ used in production of tools or materials that lightweight,conduct electric and
stainless

Types of non ferrous metal :

1. Tin (Sn)
⁃ chemical element belongs to carbon
⁃ soft, silvery white metal
⁃ to coat food container and solder material
⁃ Bronze : Copper + Tin (Alloy)

2. Aluminium (Al)
⁃ silvery white metal
⁃ light, durable and functional
⁃ easy to cast
⁃ good electric conductor
⁃ ductile and can malleable
⁃ window, door frame

3. Copper (Cu)
⁃ soft
⁃ ductile and can malleable
⁃ good electric conductor
⁃ electric cable, pipe
4. Brass
⁃ alloy of cooper and zinc
⁃ varying mechanical, electrical stuff

5. Gold
⁃ good electric conductor
⁃ not toxic
⁃ stainless
JOINING AND ASSEMBLY PROCESS

JOINING
⁃ Welding
⁃ Brazing
⁃ Soldering
⁃ Adhesive bonding
⁃ Mechanical Fastening
WELDING
⁃ heating them with suitable temperature
⁃ uses for making permanent joints
⁃ cars body, tanks

Types:
Plastic Welding / Pressure Welding
⁃ heated to a plastic state and forced together by external pressure
⁃ Resistance Welding

Fusion Welding / Non-Pressure Welding

⁃ heated to a molten state and allowed to solidify
⁃ Gas Welding, Arc Welding

Classification of Welding process :

1. Arc Welding
⁃ using electrodes
⁃ electric arc used to produce heat energy and the base metal is heated
Advantage
⁃ most efficient ways to join metal
⁃ lowest cost
⁃ joins all commercial metals
⁃ design flexibility
Disadvantage
 ⁃ Manually applied
⁃ high energy, causing danger
⁃ hard to detect at joints

2. Resistance Welding
⁃ electric resistance generates to the flow of current and create heat energy
between 2 contacting surface

3. Gas Welding
⁃ heated is generates by gas of oxygen.
⁃ used to melt base and filler material

4. Solid State Welding

⁃ joining done by pressure only or a combination of heat and pressure

BRAZING
⁃ joined using just the filler materials heat is raised to its melting temp
⁃ filler has a low melting temp than component that you are joining

SOLDERING
⁃ use primarily tin-lead as filler material
⁃ main use for electronics parts (circuit board)
⁃ same techniq as brazing by wave soldering

ADHESIVE BONDING

Natural Adhesives
⁃ made from natural ingerdients
⁃ animal,vegetable based
⁃ some of natural adhesive can be :
⁃ strong
⁃ flexible
⁃ waterproof
 ⁃ soluble in water
⁃ transparent
⁃ enviroment friendly and no chemical used.
⁃ used in furniture and architectur restoration project

Elastomer Adhesive
⁃ based on natural rubbers
⁃ flexible bonds in plastic and rubber

Thermoplastic Adhesive
⁃ fusible, soluble but with poor heat and creep resistance

Thermoset Adhesive
⁃ high strength
⁃ resistant to heat and cold

Toughened Adhesives
⁃ have small rubber-like particle dispersed trought glassy matrix
⁃ high resistance to crack

MECHANICAL BONDING

Screw Fasteners
⁃ non permanent method of joining materials
⁃ type of screw :
⁃ woodscrews
⁃ round head slotted
⁃ tapping screw
⁃ furniture screw
⁃ knockdown fittings
⁃ bolts
⁃ nuts & washers
⁃ pop rivets
POLYMERS

⁃ polymers is a large molecule, composed of many repeated subunits

⁃ all of polymers materials today are synthetic (exception is natural rubber)
⁃ made by solidification processes
⁃ grouped into plastic (thermoplastic, thermosetting and rubber elastomer)

Characteristics Polymers
⁃ resistent to chemicals
⁃ can be both thermal and electrical insulators
⁃ light in weight
⁃ limitless range of shape and colours

Advantage
⁃ cheap to make
⁃ many uses bcs of diff properties
⁃ some polymers can be recycle, melted down and can saves natural resources
⁃ if polymers are used instead of wood, fewer tress will have to be cut down

Disadvantage
⁃ people dont like to live near the polymers industrial works
⁃ people thinks plastic products looks cheaped compared to natural materials
⁃ give off toxic fumes when they burn
⁃ landfill sites are ugly

Group of polymers:

Thermoplastic
⁃ solid material at room temp but become liquid when heating up to hundred deg
temp
⁃ can recycle when heating
Type of thermoplastic
⁃ Polysteryne (container)
⁃ Polypropylene (plastic chair)
⁃ High density polythene (plastic bottles)

Advantages
⁃ suits many diff type bcs og high strength and lightweight
⁃ low processing cost
⁃ easy and quickly to manufacture in high volumes
Disadvantages
⁃ easy to melt rahter than metal
⁃ some types of low-quality thermoplastic melt when exposed to uv light (sun)
⁃ victim of creep, the material weakens when exposed to long-term loading

Thermoset
⁃ cannot be reheated or reformed once heated
⁃ difficult to recycle

Advantages
⁃ tensile and flexural strength
⁃ corrosion resistance
⁃ cost effective
⁃ design flexibility
Disadvantage
⁃ cannot be recycle
⁃ cannot be reshaped
⁃ more difficult to surface finish

Elastomer
⁃ polymers that capable of large elastic deformation
⁃ can withstand extension up to 500% and still can return to their original shape
⁃ popular term is rubber
⁃ 2 category (natural rubber and synthetic rubber)
 ⁃ O-Rings, Molded Rubber, Gaskets

Advantages
⁃ recycable like plastic
⁃ better durability
⁃ simpler processing
⁃ can be easily coloured by most types of dyes
Disavantage
⁃ much expensive
⁃ can be easily distorted
⁃ low thermal stability
CERAMICS
⁃ organic compound consisting of metal (semimetal) and one or more non metal
⁃ high hardness, good electrical and thermal conductor, chemical stability
⁃ high melting temperature
⁃ traditional ceramic (silica)
⁃ new ceramic (combination of carbide and glasses)

Advantages
⁃ harder than conventional structure metals
⁃ low coefficient of friction (geseran rendah)
⁃ extremely high melting point
⁃ corrosion ressistance
⁃ low density
⁃ easily available
⁃ Low cost

Disadvantage
⁃ dimensional tolerance difficult to control during processing
⁃ weak in tension
⁃ poor shock resistance
⁃ easily crack when hit with heavy things

Classification of Ceramics
1. Silicates ceramics
⁃ silicates having a compositions of silicon and oxygen
⁃ main types of silicates ceramic are
⁃ alumo silicates
⁃ magnesium silicates

2. Oxide ceramics
⁃ include alumina,zirconia,silica and other metal oxide-based
⁃ these are non metallic compound
⁃ oxide ceramic posses the following :
 ⁃ high melting points
⁃ low wear resistance
⁃ extensive collection of electrical
⁃ available with variety of special features such as glazed and protective coatings
seal porosity
⁃ used in wide range of application, chemical, radiofrequency, microwave and
metal processing

3. Non-oxide ceramics
⁃ enable to overcome the extreme wear and corrosion problems even at high
temp and several thermal shock condition
⁃ application in diff spheres such as oil and gas, valves, seals, rotating parts,
metal forming tooling etc.

4. Glass Ceramics
⁃ a polycrystalline materials that are made from glass base
⁃ share many common characteristics with both glass and ceramics
⁃ posses an amorphous phase and more than one crystalline phase
⁃ produced by controlled crystallization procedure.

Application of ceramics
⁃ ceramic cookware (non-stick pan)
⁃ dental ceramics (poreclain dental restorations)
COMPOSITES
⁃ a microscopic mixture of two or more diff materials
⁃ when combined, produce a material with diff character from the individual
components
⁃ the individual components remain seperate within the finished structure
⁃ new materials which are stronger, lighter or less expensive compared to
traditional materials

Advantages
⁃ lightweight, strong
⁃ corrosion and chemical resistance
⁃ excellent elastic properties
⁃ regains shape after bending till certain limit

Disadvantages
⁃ complicated time consuming process
⁃ repair procedure is complex
⁃ compressive strength not dependable

Type of composites
1. Metal-Matrix composites (MMCs)
⁃ mixture of ceramics and metals such as cement carbids, aluminum reinforced
by strong, high stiffness fibers

2. Ceramic-Matrix composites (CMCs)

⁃ least common category
⁃ aluminium oxide and silicon carbide that can be imbedded with fiber for
improved properties
⁃ for high temp app

3. Polymer-Matrix composites (PMCs)

⁃ thermosetting resin are the most widely used polymer.
⁃ Epoxy and polymer mixed with fiber reinforcement, and phenolic is mixed with
powder.
⁃ Thermoplastic molding compounds are often reinforced using powder
Application of composites
⁃ importance for modeen analysis and improved performanced
⁃ such as :
⁃ bullet proof
⁃ aircrafts
⁃ automobile parts
⁃ sports kits

Composites Process
⁃ Hand lay-up (manual process)
⁃ Vacuum Bagging
⁃ Compression Molding
⁃ Liquid resin molding
⁃ Resin transfer molding
⁃ Pultrusion
⁃ Filament winding
⁃ Injection Molding
⁃ Thermoplastics processing
⁃ Automated tape laying