Introduction to Materials Manufacturing and process
EDPT 302
Prof. Yasser Fouad
Winter 2015
EDPT 302: Introduction to Materials Manufacturing and process
Course Objective...
Introduce fundamental concepts in Materials
Science and manufacturing process.
You will learn about:
• material structure
• how structure dictates properties
• how processing can change structure
This course will help you to:
• use materials properly
• realize new design opportunities
with materials
Winter 2015
Lecture
1
Introduction to Materials
Manufacturing and process
1-1
Studying materials
Materials Science Materials Engineering
Relationships between Designing the structure of a
the structures and material to produce a
properties of the predetermined set of properties
materials.
Why do we study materials in an engineering curriculum:
Engineers facing design or production problems are going to be involved
with material selection, which requires basic understanding about the
materials science and engineering.
Civil engineers-structure of a building
Mechanical engineers-design and production of transmission gears
Chemical engineers-an oil refinery component
Electrical engineers-an integrated circuit chip
Environmental engineers-liner for landfilling site
Industrial engineers-product cost including expenses during fabrication
as well as raw material and quality
Winter 2015
The Mars Rovers - Spirit and Opportunity
Spirit and Opportunity are made up of materials such as
* Metals * Ceramics * Composites * Polymers * Semiconductors
Winter 2015
www.nasa.gov
What are Materials?
• Materials may be defined as substance of
which something is composed or made.
• We obtain materials from earth crust and
atmosphere.
• Examples :-
Silicon and Iron constitute 27.72
and 5.00 percentage of weight of
earths crust respectively.
Nitrogen and Oxygen constitute
78.08 and 20.95 percentage of dry
air by volume respectively.
Winter
1-2 2015
Why the Study of Materials is Important?
• Production and processing of materials constitute a
large part of our economy.
• Engineers choose materials to suite design.
• New materials might be needed for some new
applications.
Example :- High temperature resistant materials.
Space station and Mars Rovers should sustain
conditions in space.
* High speed, low temperature, strong but
light.
• Modification of properties might be needed for some
applications.
Example :- Heat treatment to modify properties.
Winter
1-3 2015
Materials Science and Engineering
• Materials science deals with basic knowledge
about the internal structure, properties and
processing of materials.
• Materials engineering deals with the application
of knowledge gained by materials science to
convert materials to products.
Materials Science and
Materials Science Engineering Materials Engineering
Basic Resultant Applied
Knowledge Knowledge Knowledge
of of Structure and of Materials
Materials Properties
Winter
1-4 2015
Types of Materials
• Metallic Materials
Composed of one or more metallic elements.
Example:- Iron, Copper, Aluminum.
Metallic element may combine with
nonmetallic elements.
Example:- Silicon Carbide, Iron Oxide.
Inorganic and have crystalline structure.
Good thermal and electric conductors.
Metals and Alloys
Ferrous Nonferrous
Eg: Steel, Eg:Copper
Cast Iron Aluminum
Winter
1-5 2015
Types of Materials
• Polymeric (Plastic) Materials
Organic giant molecules and mostly
noncrystalline.
Some are mixtures of crystalline and
noncrystalline regions.
Poor conductors of electricity and hence
used as insulators.
Strength and ductility vary greatly.
Low densities and decomposition
temperatures.
Examples :- Poly vinyl Chloride (PVC),
Polyester.
Applications :- Appliances, DVDs, Fabrics
etc.
Winter
1-6 2015
Materials – historical perspective
Materials
drive our
society:
Stone Age
Bronze Age
Iron Age
What Now?
Silicon
Age?
Polymer
Age? 11
Winter 2015
Taxonomy of the kingdom of materials
12
Winter 2015
Types of Materials
• Ceramic Materials
Metallic and nonmetallic elements are chemically
bonded together.
Inorganic but can be either crystalline, noncrystalline
or mixture of both.
High hardness, strength and wear resistance.
Very good insulator. Hence used for furnace lining for
heat treating and melting metals.
Also used in space shuttle to insulate it during exit and
reentry into atmosphere.
Other applications : Abrasives, construction materials,
utensils etc.
Example:- Porcelain, Glass, Silicon nitride.
Winter
1-7 2015
Types of Materials
• Composite Materials
Mixture of two or more materials.
Consists of a filler material and a binding material.
Materials only bond, will not dissolve in each other.
Mainly two types :-
o Fibrous: Fibers in a matrix
o Particulate: Particles in a matrix
o Matrix can be metals, ceramic or polymer
Examples :-
Fiber Glass ( Reinforcing material in a polyester
or epoxy matrix)
Concrete ( Gravels or steel rods reinforced in
cement and sand)
Applications:- Aircraft wings and engine, construction.
Winter
1-8 2015
Types of Materials
• Electronic Materials
Not Major by volume but very
important.
Silicon is a common electronic
material.
Its electrical characteristics are
changed by adding impurities.
Examples:- Silicon chips, transistors
Applications :- Computers, Integrated
Circuits, Satellites etc.
Winter
1-9 2015
Competition Among Materials
• Materials compete with each
other to exist in new market Example:-
Aluminum
1600
Iron
1400 Plastic
• Over a period of time usage 1200
Steel
of different materials changes
1000
lb/Car
depending on cost and
800
performance.
600
400
• New, cheaper or better 200
materials replace the old 0
materials when there is a 1985 1992 1997
Model Year
breakthrough in technology
Figure 1.14
Predictions and use of
materials in US automobiles.
Winter
1-10 2015 After J.G. Simon, Adv. Mat. & Proc., 133:63(1988) and new data
Future Trends
• Metallic Materials
Production follows economy closely.
Alloys may be improved by better chemistry and
process control.
New aerospace alloys being constantly
researched.
o Aim: To improve temperature and corrosion
resistance.
o Example: Nickel based high temperature super
alloys.
New processing techniques are investigated.
o Aim: To improve product life and fatigue
properties.
o Example: Isothermal forging, Powder metallurgy.
Metals for biomedical applications
Winter
1-11 2015
Future Trends
• Polymeric (Plastic Materials)
Fastest growing basic material (9%
per year).
After 1995 growth rate decreased
due to saturation.
Different polymeric materials can
be blend together to produce new
plastic alloys.
Search for new plastic continues.
Winter
1-12 2015
Future Trends
• Ceramic Materials
New family of engineering ceramics are produced
last decade
New materials and applications are constantly
found.
Now used in Auto and Biomedical applications.
Processing of ceramics is expensive.
Easily damaged as they are highly brittle.
Better processing techniques and high-impact
ceramics are to be found.
Winter
1-13 2015
Future Trends
• Composite Materials
Fiber reinforced plastics are primary
products.
On an average 3% annual growth from
1981 to 1987.
Annual growth rate of 5% is predicted
for new composites such as Fiberglass-
Epoxy and Graphite-Epoxy
combinations.
Commercial aircrafts are expected to
use more and more composite materials.
Winter
1-14 2015
Future Trends
• Electronic Materials
Use of electronic materials such as silicon
increased rapidly from 1970.
Electronic materials are expected to play
vital role in “Factories of Future”.
Use of computers and robots will increase
resulting in extensive growth in use of
electronic materials.
Aluminum for interconnections in
integrated circuits might be replaced by
copper resulting in better conductivity.
Winter
1-15 2015
Future Trends
• Smart Materials : Change their properties by
sensing external stimulus.
Shape memory alloys: Strained material reverts
back to its original shape above a critical
temperature.
Used in heart valves and to expand arteries.
Piezoelectric materials: Produce electric field when
exposed to force and vice versa.
Used in actuators and vibration reducers.
Winter 2015
MEMS and Nanomaterials
• MEMS: Microelectromechanical systems.
Miniature devices
Micro-pumps, sensors
• Nanomaterials: Characteristic length < 100 nm
Examples: ceramics powder and grain size < 100
nm
Nanomaterials are harder and stronger than bulk
materials.
Have biocompatible characteristics ( as in
Zirconia)
Transistors and diodes are developed on a
nanowire.
Winter 2015
Case Study – Material Selection
• Problem: Select suitable material for bicycle
frame and fork.
Carbon fiber
Steel and Aluminum Ti and Mg
Wood Reinforced
alloys alloys alloys
plastic
Low cost but Light and Very light and Light, moderately Slightly better
Heavy. Less strong. But strong. No Strong. Corrosion Than Al
Corrosion Cannot be corrosion. Resistance. alloys. But much
resistance shaped Very expensive expensive expensive
Cost important? Select steel
Properties important? Select CFRP
Winter 2015
Materials in an Automotive Engine
Figure I.1 Section of an automotive engine - the Duratec
V-6 - showing various components and the materials used
in making them. Source: Courtesy of Ford Motor
Winter 2015Company. Illustration by David Kimball.
Components in Products
• Some products are a single components
(nail, bolt, fork, coat hanger, etc.)
• Some products are assemblies of many
components (ball point pens, automobiles,
washing machines, etc.)
• All components are manufactured.
• Manufacturing means, literally, “Made by
Hand”.
Winter 2015
History of Manufacturing (until 1700)
Winter 2015
History of Manufacturing (1700-1960)
Winter 2015
History of Manufacturing (1960-2000s)
Winter 2015
Materials Selection for Paper Clips
Questions for consideration:
• What material properties are required?
• What manufacturing attributes are
required?
• Would the material and processing
strategy change if the desired quantity
was 10,000 vs. 1 million per day?
Figure I.2 Examples of the wide variety of materials and
geometries for paper clips.
Winter 2015
Manufacture of Light Bulbs
Figure I.3a Components of a Figure I.3b Manufacturing
common incandescent light steps in making an
bulb. Source: Courtesy of incandescent light bulb.
General Electric Company. Source: Courtesy of General
Electric Company.
Winter 2015
Product Design Process
Figure I.4 (a) Chart showing the
various steps involved in design
and manufacturing a product.
Depending on the complexity of
the product and the type of
materials used, the time span
between the original concept and
the marketing of the product may
range from a few months to
many years.
(b) Chart showing general
product flow in concurrent
engineering, from market
analysis to selling the product.
Source: After S. Pugh, Total
Design. Addison-Wesley, 1991.
Winter 2015
Redesign of Parts
Figure I.5 Redesign of parts to facilitate assembly. Source: Reprinted
from G. Boothroyd and P. Dewhurst, Product Design for Assembly,
1989. Courtesy of Marcel Dekker, Inc.
Winter 2015
Manufacturing Characteristics of Alloys
Winter 2015
Baseball Bat Cross-sections
Figure I.6 Cross-sections of
baseball bats made of
aluminum (top portion) and
composite material (bottom
portion).
Winter 2015
Manufacturing Processes: Casting
Figure I.7a Schematic illustration of various casting processes
Winter 2015
Manufacturing Processes: Forming and Shaping
Extrusion
Figure I.7b Schematic illustration of various bulk deformation processes
Winter 2015
Manufacturing Processes: Forming and Shaping
Figure I.7c Schematic illustration of various sheet metal forming processes
Winter 2015
Manufacturing Processes: Forming and Shaping
Figure I.7d Schematic illustration of various polymer processing methods
Winter 2015
Manufacturing Processes: Machining
Figure 1.7e Schematic illustrations of various machining and finishing processes.
Winter 2015
Manufacturing Processes: Joining
Figure I.7f Schematic illustration of various joining processes
Winter 2015
Laser Cutting
Figure I.8 Cutting sheet metal with a
laser beam. Source: Courtesy of
Rofin-Sinar, Inc. and Manufacturing
Engineering Magazine, Society of
Manufacturing Engineers
Winter 2015
Hip Replacement
Figure 1.9 Components of a total hip replacement. Source: Courtesy of Zimmer, Inc.
Winter 2015
Manufacturing of Hip Replacement
Figure 1.10 (a) Manufacturing steps in the production of a roll-formed and machined
total hip replacement stem; (b) Manufacturing steps in the production of a forged stem.
Hip stems can also be produced by investment casting, metal injection molding, insert
injection molding, and assorted other processes. Source: Courtesy of Zimmer, Inc.
Winter 2015
Microscopic Components
Figure I.11 (a) Microscopic gears with dust mite. Source: Courtesy Sandia
National Laboratory; (b) A movable micromirror component of a light sensor.
Source: Courtesy of Richard Mueller, University of California at Berkeley.
Winter 2015
Salt and Pepper Shakers
Figure I.12 A salt and pepper mill set. The two
metal pieces (at the bottom) for the pepper mill
are made by powder-metallurgy techniques.
Source: Reproduced with permission from
Success Stories on P/M Parts, Metal Powder
Industries Federation, Princeton, NJ, 1998.
Winter 2015
Automated welding of automobiles
Figure I.13 Automated spot
welding of automobile bodies in
a mass production line. Source:
Courtesy of Ford Motor
Company.
Winter 2015
Application of CAD/CAM to make sunglasses mold
Figure I.14 Machining a mold
cavity for making sunglasses.
(a) Computer model of the sunglass
as designed and viewed on the
monitor.
(b) Machine the die cavity using a
computer numerical-control milling
machine
(c) Final product. Source:
Courtesy of Mastercam/CNC
Software, Inc.
Winter 2015
SUMMARY
Course Goals:
• Use the right material for the job.
• Understand the relation between properties,
structure, and processing.
• Manufacturing and production systems
Classification of manufacturing processes.
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Winter 2015
