BJTM 2023

MANUFACTURING
TECHNOLOGY
CHAPTER 2:
FUNDAMENTAL OF MATERIALS
FOR MANUFACTURING

INTRODUCTION
At the end of this lecture, student will be able to:
classify types of engineering materials
elaborate different types of material
properties
explain typical use of materials
explain the method of material selection for
particular manufacturing processes

Materials in Manufacturing

Most engineering materials can be

classified into one of three basic categories:
1.
Metals steel, copper, aluminum
2.
Ceramics clay, alumina, glass (silicon)
3.
Polymers plastic, ABS, polyethylene
Their chemistries are different, their
mechanical and physical properties are
dissimilar
These differences affect the manufacturing
processes that can be used to produce
products
3

4.

In addition to the three basic categories,

there are:
Composites nonhomogeneous mixtures
of the other three basic types rather than
a unique category
example, airplane wings,

Figure 1.3
Venn diagram
of three basic
Material types
plus composites

Metals: The Most

Important Engineering
Materials
Today

They have properties that satisfy a

wide variety of design
requirements
The manufacturing processes by
which they are shaped into
products have been developed and
refined over many years
5

Why Metals Are Important

High stiffness and strength can be alloyed for

high rigidity, strength, and hardness
Toughness capacity to absorb energy better
than other classes of materials
Good electrical conductivity Metals are
conductors
Good thermal conductivity conduct heat
better than ceramics or polymers
Cost the price of steel is very competitive
with other engineering materials
6

Starting Forms of Metals

used in Manufacturing
Processes

Cast metal - starting form is a casting

Wrought metal - the metal has been
worked or can be worked after
casting
Powdered metal - starting form is
very small powders for conversion
into parts using powder metallurgy
techniques
7

Classification of Metals

Ferrous those based on iron

Nonferrous all other metals

Steels
Cast irons
Aluminum, magnesium, copper, nickel,
titanium, zinc, lead, tin, molybdenum,
tungsten, gold, silver, platinum, and others

Superalloys
8

Steel
An alloy of iron containing from 0.02% and 2.11%
carbon by weight
It is the carbon content that turns iron into steel
Often includes other alloying elements:
manganese, chromium, nickel, and molybdenum
Steel alloys can be grouped into four categories:
1.
2.
3.
4.

Plain carbon steels

Low alloy steels
Stainless steels
Tool steels

Stainless Steel
(SS)
Highly alloyed steels designed for corrosion
resistance
Principal alloying element is chromium, usually
greater than 15%
Cr forms a thin impervious oxide film that
protects surface from corrosion
Nickel (Ni) is another alloying ingredient in certain
SS to increase corrosion protection
Carbon is used to strengthen and harden SS, but
high C content reduces corrosion protection since
chromium carbide forms to reduce available free
Cr
10

The Light Non Ferrous

Metals:
Aluminum
and
Magnesium

Aluminum and magnesium are

light metals

They are often specified in

engineering applications for this
feature

Both elements are abundant on

earth, aluminum on land and
magnesium in the sea
11

Tungsten

Properties: highest melting point among

metals, one of the densest, also the stiffest
(highest modulus of elasticity) and hardest of
all pure metals
Applications typically characterized by high
operating temperatures: filament wire in
incandescent light bulbs, parts for rocket and
jet engines, and electrodes for arc welding
Also widely used as an element in tool steels,
heat resistant alloys, and tungsten carbide

12

Ceramics
A compound containing metallic (or semi-metallic)
and nonmetallic elements. Typical nonmetallic
elements are oxygen, nitrogen, and carbon

For processing purposes, ceramics divide into:

1. Crystalline ceramics includes:

Traditional ceramics, such as clay

(hydrous aluminum silicates)

Modern ceramics, such as alumina (Al2O3)

2. Glasses mostly based on silica (SiO2)

13

Polymers
A compound formed of repeating structural units
called mers, whose atoms share electrons to
form very large molecules

Three categories:
1.
Thermoplastic polymers - can be subjected to
multiple heating and cooling cycles without
altering their molecular structure
2.
Thermosetting polymers - molecules
chemically transform (cure) into a rigid
structure upon cooling from a heated plastic
condition
3. Elastomers - exhibit significant elastic
behavior, i.e. rubber

14

SOME OF IMPORTANT
THERMOPLASTICS

Important Commercial Thermoplastics are:

Acetals: Automotive door handles, appliance
hard ware and machinery components.
Acrylics: Tail light lenses of automobiles,
optical
instruments, aircraft windows.
(Excellent
transparency)
ABS: Components for automobiles, pipes and
fittings.
Polycarbonate: PC used as safety helmets,
housing
for business machines
Polyesters: PE, used as fibers in apparels, blow
molded containers.
Polyethylene: PET, used to produce bottles, pipes
and hard wares.,
15

Composites
A material consisting of two or more phases
that are processed separately and then
bonded together to achieve properties
superior to its constituents
A phase = a homogeneous mass of
material, such as grains of identical unit cell
structure in a solid metal
Usual structure consists of particles or fibers
of one phase mixed in a second phase
Properties depend on components, physical
shapes of components, and the way they
are combined to form the final material
16

Properties of
materials
Metal
Ceramic

Polymer

High density Low density

Very low
density

Medium to
Very high
high melting melting
point
point

Low melting
point

Ductile

Brittle

Ductile and
brittle types

Electrical
conductor

Electrical
insulator

Electrical
insulator

Thermal
conductor

Thermal
insulator

Thermal
insulator

Opaque (not May be

transparent) transparent

May be
transparent

17

Typical use of materials

Types of
material

Typical use

Metals such
Industrial machineries such as mould, tools and
as steels and part of machinery; automotive components etc
NFM (Non
Ferrous Metals)

Polymers
such as TP

Consumer products casing such as television,

computers, etc; containers such as bottles,
rubber products

Ceramics

Structural parts such as bricks, tiles, etc;

cooking wear, glass products etc.

Composites

High technology products such as airplanes

components, air jet components, etc

18

Material selection

The interdependence of materials and the

manufacturing process must also be
recognized.
A change in material may require a change in
the process.
Improvements in processes will often lead to
re-evaluation of the materials being processed.
Improper processing of a well-chosen material
may result in defective product.

19

Procedure for material

selection

Selection of an appropriate material

and its subsequent process is a
complex process.
Usually, a manufactured product
follows a sequence of activities:
Design Material Selection
Process Selection Production
Evaluation Redesign (if necessary)
Several methods have been developed
for material selection
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Procedure for material

selection

Case history method:

Evaluating what has been done in
the past or
What is currently being done by the
competitor.
Duplication or modification of the
materials and method of
manufacture
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Procedure for material

selection

Modification of existing product:

The objective is to reduce cost, improve
quality or overcome a problem or defect
Ex: A customer may request the same
product but require capability of
operating at high temperature.
Development of entirely new product

22

Procedure for material

selection

The first step in material selection

process is to define the needs/
requirement of the product.
There are three major needs of a product:
Shape and geometry
Property requirements
Manufacturing concerns

23

Procedure for material

selection

Shape and geometry:

What is the relative size of the
component?
How complex is the shape?
How many dimensions must be
specified? How precise?
Etc.

24

Procedure for material

selection

Property requirement:

How much strength?

Are there any electrical requirements?
Are there any optical requirements?
Are there any surface treatment/
process needed?
What will be the effect of temperature
of the product?
Is there any preferred color?
Etc.
25

Procedure for material

selection

Manufacturing concern:

How many components are to be

produced? At what rate?
What is the level of quality?
Are there any assembly or disassembly
required?
What are the largest and smallest
thickness?
Etc
26

Other factors to consider

Material availability

The material must be ready in

the required size, quantity or
shaped

Material cost
Etc.
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Compatibility charts of
materials and processes
Y Can be used
0 Can be used but has difficulty
Blank Not recommended
Material
Iron

Stee
l

Aluminu
m

Coppe
r

Process
Sand
Casting
Die
Casting
Investmen
t Casting
Powder
Metallurgy

Nicke Zinc Refractor

l
y Metals
Y

0
Y

28

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