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