IE 121E – Industrial

Materials and Processes

Lecture

INTRODUCTION TO
MATERIALS AND
PROCESSES
 Everyone in this class
is an “A” student
until you prove yourself
otherwise.
Why do you need to
take this course?
Why do you need to
take this course?

A company must
produce products
in an optimal way
to compete in
today’s global
marketplace.
Why do you need to
take this course?

A knowledge of the basic

manufacturing processes is
essential for a successful
engineer in today’s global
marketplace.
What do engineers do?

Research
Design Products

Manufacture Products

Manage Departments
and Companies
What is a manufacturing process?

Manufacturing processes
alter a material’s properties
in a controlled manner
to produce components
of products.
 WHAT IS
MANUFACTURING?
• Transformed from various raw materials
and assembled into the shapes
• Manufacturing: - PROCESSES OF
CONVERTING RAW MATERIALS INTO
PRODUCTS.
• Encompasses of
– the design of the product – selection of
raw materials, and – sequence of processes.
• Country level of manufacturing directly
related with economic health
Why study Manufacturing?

• Manufacturing is the core to

economic activity!
• As a designer: understand the
limitations available – Tolerances
– Production rates
– Economic issues
 Design Issues

• Designer must consider:

– What processes are available/relevant for
the product?
– What tolerances can be achieved, and are
these sufficient?
– Are there any design features that need to
be incorporated (eg webbing, round edges, etc)?
– Can the expected production rate be met?
– How will the product be assembled?
Types of Processes

1. Material removal

2. Deform or shape material

through heat or pressure

3. Join two or more materials

 Remove Material

1. Sawing
2. Drilling
3. Milling
4. Turning (Lathe)
5. Abrasive finishing
Deform/Shape Material

1. Casting
2. Rolling/Forging
3. Extrusion/Drawing
4. Sheet metal forming
5. Powder metal processes
 Join Two or More
Materials

1. Welding
2. Brazing
3. Soldering
4. Adhesive bonding
5. Fastening
 Math/Manufacturing

In calculus there is usually only one

correct answer to a problem.

In manufacturing there are usually

many ways to make a part, some
ways are better than others
 Manufacturing
In manufacturing there are usually many
ways to make a part, some ways are
better than others.

Factors that must be considered.

Cost Quality
Safety Equipment
Quantity
available
 Manufacturing

A company must produce products in

an optimal way to compete in
today’s global marketplace.

On all tests and quiz questions

you are expected to give an
optimal answer to a question, not
just an answer that will work.
Example

How can you

sharpen a
wooden
pencil?
 Example

How can you sharpen a

wooden pencil?
Knife or other sharp object
Sand or abrasion
Toy pencil sharpener
Hand pencil sharpener
Electric pencil sharpener
Automated pencil sharpener
How to decide the material with the
properties required ??

• Use the “right material for the right job”

• It is impossible to remember the large
number of engineering materials.
• More than a thousand types of steel alone
, each with a specific composition, thermal
and mechanical history.
• So, it is better to study the key factors that
determine the properties of a material.
Classification of Engineering
Materials
 Properties of Materials

• Mechanical properties: strength, toughness,

ductility, hardness, elasticity, fatigue, and creep
• Physical properties: density, thermal expansion,
conductivity, specific heat, melting point, and
electrical and magnetic properties
• Chemical properties: oxidation, corrosion,
toxicity, and flammability
• Manufacturing properties: castability, formability,
machinability, weldability, and hardenability
by heat treatment.
Engineering Materials
 Metals
Ferrous metals
 metals and alloys containing a high proportion of
the element iron.
 strongest materials available and are used for
applications where high strength is required at
relatively low cost and where weight is not of
primary importance.
 Iron based that are good conductor of heat and
electricity
 As an example of ferrous metals such as : bridge
building, the structure of large buildings, railway
lines, locomotives and rolling stock and the bodies
and highly stressed engine parts of road vehicles.
Classification of ferrous
metals
 Non – ferrous metals
 Low strength and high resistance to corrosion
 The pure metals are rarely used as structural
materials as they lack mechanical strength.
 special properties such as corrosion resistance,
electrical conductivity and thermal conductivity.
Copper and aluminum are used as electrical
conductors and, together with sheet zinc and
sheet lead, are use as roofing materials.
 They are mainly used with other metals to
improve their strength.
Non – metallic materials
(synthetic materials)
These are non – metallic materials that do
not exist in nature, although they are
manufactured from natural substances
such as oil, coal and clay.
 Plastics
- Polymeric materials that are formed into a
variety of three-dimensional shapes; large
molecules (bulky) ; molecules are not
compact (low density) ; polymers are
flexible.

a. Thermoplastics – polymers that soften and

flow upon heating and become hard again
when cooled.
b. Thermosets – three dimensional,
chemically resistant networks, cannot be
melted.
Composite materials
(composites )
- These are materials made up from, or
composed of, a combination of different
materials to take overall advantage of their
different properties.
- Fiber glass sheet (made of glass fibers and
polymers) & concrete (made of cement and
aggregate); ex. (combination of strength and
flexibility)
 Ceramics

• Normally insulators
• Hard and brittle
• defined as inorganic non metallic solid
• Ex. Clay products (bricks,pots)
Non – metallic materials
(natural materials)
Rubber :This is used for hydraulic and compressed air hoses
and oil seals. Naturally occurring latex is too soft for most
engineering uses but it is used widely for vehicle tyres when it
is compounded with carbon black.

Glass : This is a hardwearing, abrasion-resistant material with

excellent weathering properties. It is used for electrical
insulators, laboratory equipment, optical components in
measuring instruments etaand, in the form of fibers, is used to
reinforce plastics.

Emery : This is a widely used abrasive and is a naturally

occurring aluminum oxide. Nowadays it is produced
synthetically to maintain uniform quality and performance.
Non – metallic materials
(natural materials)
Diamonds: These can be used for cutting tools for operation at
high speeds for metal finishing where surface finish is greater
importance. For example, internal combustion engine pistons
and bearings. They are also used for dressing grinding
wheels.

Oils : Used as bearing lubricants, cutting fluids and fuels.

Silicon : This is used as an alloying element and also for the

manufacture of semiconductor devices.
 Factors affecting
materials properties
• Heat treatment - This is the controlled
heating and cooling of metals to change their
properties to improve their performance or to
facilitate processing.
• Processing - Hot and cold working process
will be referred to understand what is meant
by terms hot and cold working as applied to
metals.
• Environmental reactions - Resting of steel,
Dezincification of brass,Degradation of plastic
 Structure
• Sub atomic – electrons and nuclei (protons
and neutrons)
• Atomic – organization of atoms or
molecules
• Microscopic – groups of atoms that are
normally agglomerated together
• Macroscopic – viewable with the un-aided
eye
The Materials Selection Process

1. Pick Application Determine required

Properties
Properties: mechanical, electrical, thermal,
magnetic, optical, deteriorative.
2. Properties Identify candidate
Material(s)
Material: structure, composition.
3. Material Identify required Processing
Processing: changes structureand overall
shape ex: casting, sintering, vapor
deposition, doping forming, joining,
annealing.