PEMP

EMM2512

Introduction to Materials and

Manufacturing Processes

Module Leader
Dr. N S Mahesh

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Session Objectives
• At the end of the session delegates should have
understood
– Overview of materials and manufacturing
– Importance of Microstructure, Properties, Processing
and Performance
• Example
– Introduction to design and manufacturing processes

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EMM2512

Engineering Materials and

Manufacturing Technology

Materials Science Manufacturing

and Engineering Engineering

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EMM2512

Atomic Structure and The Structure of Imperfections in Solids

Interatomic Bonding Crystalline Solids

Materials Science and

Engineering Phase Diagrams

Mechanical Properties Advanced Composites Dislocations and

of Metals Strengthening Mechanisms

Structure and
Polymer Structures
Properties of Ceramics

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EMM2512

Metal-Casting Processes Manufacturing in a

competitive environment

Forming and
Shaping Processes
Rolling
Forging
Manufacturing Engineering Extrusion
Drawing
and Technology Sheet-metal forming
Processing of
powder metals,
ceramics, glass etc
Material removal Forming and
processes shaping plastics
Joining processes Cutting RPT
Abrasive machining
Advanced machining
processes
Surface technology Manufacturing management

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EMM2512

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.

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EMM2512

Materials Science Tetrahedron

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EMM2512

Multiple Length Scales

Critical in Engineering
In Askeland and Phule’s book, from J. Allison and W. Donlon (Ford Motor Company)
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Materials Teaching

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Classification of Engineering Materials

Metallics Metals
Alloys
Intermetallic
compounds

Polymerics Composites Ceramics

Plastics
Glasses
Rubber
Porcelain
Elastomers
Semiconductors
Textile
Stoneware
leather
Cement

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EMM2512

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.

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EMM2512

Properties of Materials (cont.)

Environmental Aspects

Composition Recycling
Production

Resource depletion Waste

Energy
Effluents

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Controlling :- Processing - Structure - Properties –

Performance of materials
• Realistically engineering materials: Trade-off
between
– properties (what do we need or want?)
– deterioration (how long will it last?)
– cost (what’s the biggest bang for the buck?)
– resources depletion (how to find new reserves,
develop new environmentally-friendly materials,
and increase recycling)

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EMM2512

Key Relationships
• PropertiesMicrostructure Processing
• Microstructure : Structure as observed under the
optical microscope. Magnification by about 1500
times.
• Substructure: Structure observed under electron
microscope . Magnification upto 1,00,000 is
possible.
• Crystal structure : tells us the details of the atomic
arrangement within the crystal.

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EMM2512

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EMM2512

TYPES OF ENGINEERING MATERIALS

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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

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EMM2512

Why study Manufacturing?

• Manufacturing is the core to economic
activity!
• As a designer: understand the limitations
available
– Tolerances
– Production rates
– Economic issues

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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?

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EMM2512

Design Steps

(a) Chart showing various

steps involved in designing
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 a product may
range from a few months to
many years.

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(b) Chart showing general

product flow, from
market analysis to selling
the product, and
depicting concurrent
engineering.

Concurrent engineering or
simultaneous engineering

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Summary
• Interrelationship between processing,
microstructure, properties and performance with
example have been illustrated
• Design steps and issues have been discussed
• Significance of materials and manufacturing
used in critical engineering environment have
been emphasized

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