Materials Fabrication.

MDP 472
◼ Dr. Ramadan EL-Gamsy
◼ Associate professor
◼ Design &production Engineering Dept.
◼ E- mail elgamsy_ramadan@eng.asu.edu.eg
◼ Mobile : 01005066892.
 Materials Fabrications

◼ 40% final Exam.

◼ 25% Mid Terms.
◼ 5% Class work.
◼ 5% attendance.
◼ 15% project.
◼ 10 Quiz
 Course out line

◼ 1- Introduction
◼ 2- Phase diagram
◼ 3- Iron Carbon Diagram
◼ 4- Heat Treatment
◼ 5- Tools Heat treatment
◼ 6- Gear Heat treatment
Introduction

◼ Physical properties.
◼ Mechanical properties.
◼ Families of materials.
◼ Materials Behaviors.
◼ Product function interdependence
 Material properties

◼ Physical properties
quantities that characterize the
behavior of a material in response to
physical phenomena other than mechanical forces
…(e.g. such as heat, electricity, radiation)

Mechanical properties ◼

quantities that characterize the

behavior of a material in response to
external, or applied forces
Definition

Notes – Physical Properties

I. Physical Properties – descriptions of matter that
can be observed without changing it into a new
substance.
Back to Our Notes

Notes – Physical Properties

I. Physical Properties – descriptions of matter that can
be observed without changing it into a new substance.
A. Density – describes how compact the matter
is in a substance. A bowling ball is more
dense than a beach ball.
 Density
Gold - 19300 kg/m3

Uranium - 19100 kg/m3

Lead - 11340 kg/m3

Steel - 7800 kg/m3

Aluminum - 2700 kg/m3

Copper - 8100 kg/m3

Write it!

Notes – Physical Properties

I. Physical Properties – descriptions of matter that can
be observed without changing it into a new substance.
A. Density – describes how compact the matter
is in a substance. A bowling ball is more
dense than a beach ball.
B. Color – describes how light reflects off a
substance.
Get it on your paper!

Notes – Physical Properties

I. Physical Properties – descriptions of matter that can
be observed without changing it into a new substance.
A. Density – describes how compact the matter
is in a substance. A bowling ball is more
dense than a beach ball.
B. Color – describes how light reflects off a
substance.
C. Luster – describes how shiny a substance is.
A diamond has higher luster than wood.
CONDUCTIVITY

Some substances allow forms of energy,

such as heat, sound, and electricity, to flow
through them very easily.

These substances are very useful for things

like:
the best conductor
Material Conductivity
silver 63 x 106 S/m (1/ohm)

copper
59.6 x 106 S/m (1/ohm)
gold
45.2 x 106 S/m (1/ohm)
aluminium
37.8 x 106 S/m (1/ohm)
the best insulator
Material Specific resistance
polyethylene tereph thalate (PET) 1020 ohm

glass 1014 ohm

rubber 1013 ohm

 MALLEABILITY

What do these substances have in common?

If you said that they can be pounded with a mallet or hammer or fist
or forehead into new shapes easily, then you’re right!
H. Malleability – describes how easily a substance can be formed into
new shapes. Opposite of “brittle.”
 MELTING & FREEZING POINT

At what temperature does an ice cube melt into water?

At what temperature does liquid water freeze into ice?

SAME ANSWER! 320 F or 00 Celsius.

This is a property of water…that 00 Celsius is a magical temperature
for this particular substance. Above this temperature it stays liquid,
but below it, it freezes to solid. NOTICE that it is still just a physical
property because the water changes, but not into any new substance!

M. Melting & Freezing Point – describes the temperature at which a

solid turns liquid or vice versa.
Chemical properties
◼ corrosion resistance - a material's ability to resist
deterioration caused by exposure to an environment
Mechanical properties
◼ tensile strength – measures the force required to
pull something such as rope,wire or a structural
beam to the point where it breaks

◼ ductility – a measure of how much strain a material

can take before rupturing
◼ malleability – the pproperty of a material that can
be worked or hammered or shaped without breaking

◼ brittleness –breaking or shattering of a material

when subjected to stress (when force is applied to it)
◼ elasticity – the property of a material that returns to
its original shape after stress (e.g. external forces)
that made it deform or distort is removed

◼ plasticity - the deformation of a material

undergoing non-reversible changes of shape in
response to applied forces
Mechanical properties
◼ toughness – the ability of a material to absorb
energy and plastically deform without fracturing

◼ hardness – the property of being rigid and resistant

to pressure; not easily scratched
Mechanical properties
◼ machinability – the property of a material that can
be shaped by Metal cutting processes.

◼ Formability- the property of a material that can

be shaped by forming processes.
Mechanical properties
◼ Weld ability – the property of a material that can
be shaped by Metal welding.

◼ Castability- the property of a material that can be

shaped by casting process.
 Mechanical properties
F
stress
 =F/A
A
ductile ?
L L + L
S ut

Sy

brittle
elastic plastic
y f L + L
strain =  =
L

stiffness ? E=

Strength = stress at failure = (failure)
Mechanical properties
 Fundamental properties

Characteristic Behavior Property Units

Strength strong, weak ultimate strength MPa (ksi)
Elastic strength elastic then plastic yield strength MPa (ksi)
Stiffness flexible, rigid modulus of elasticity MPa (Mpsi)
% elongation,
Ductility draws, forms easily dimensionless
% area reduction
Hardness resists surface Brinell No. MPa (ksi)
indentation
Corrosion resistance resists chemicals, galvanic series activity
oxidation number
 Fundamental properties

Characteristic Behavior Property Units

Fatigue resistance endures many load cycles endurance limit MPa (Mpsi)
thermal
Conductivity conductivity
conducts, insulates 1/ohm
(heat, electric) electrical
conductivity
Creep resistance time dependent creep strength MPa (ksi)
stretching
Impact resistance shock, impact loads Charpy energy N-m, (ft-lbs)
Density (mass) mass density kg/m3, (slugs/ft3)
heavy, light
Density (weight) weight density N/m3, (lbs/ft3)
Temperature tolerance softens, or melts easily melting point degrees C, F
Which properties do the following materials
possess?
Material Properties
aluminium
rubber
ceramics
steel
copper
lead
nylon
cast iron
wood
Which properties do the following materials
possess?
Material Properties
aluminium lightness ; strength
Rubber elasticity ; insulation
Ceramics thermal resistivity
Steel strength
copper conductivity ; corrosion resistance
lead high density; ductility
nylon strength ; toughness
cast iron damping capacity
wood insulation ; environmental friendly
Find application for the following engineering
materials:
Material Application
aluminium
rubber
ceramics
steel
copper
lead
nylon
cast iron
wood
Find application for the following engineering
materials:
Material Application
aluminium foil; aircraft; window frame
rubber tyres,; seal; gasket
ceramics furnace; brick
steel section; pipe
copper pipe; cables
lead storage battery; radiation protection ;
bullets
nylon rope; clothing
cast iron engine block; valves
wood furniture; deck
the strongest material
Material Tensile Strength
carbon nanotubes 62000 MPa
(theoretical300000 MPa)

carbon fibre 5650 MPa

glass fibre 4700 MPa

spider web 1000 MPa

high-strength steel 1200 MPa

 Material families / sub-families

Materials

Metals Plastics Ceramics Composites Family

(Ashby)

Ferrous Thermoplastics

Non-ferrous Thermosets Sub-family

Elastomers
Property profiles by family
Material sub-families / classes

Materials

Metals
Family

Ferrous
Sub-family

Cast iron
Carbon steel
Alloy steel Classes
Stainless steel
Metals

Metals

Ferrous Non-ferrous
cast iron aluminum
carbon steel brass
alloy steel bronze
stainless steel copper
lead
magnesium
nickel
tin
titanium
tungsten
zinc
 Natural and
Polymers synthetic rubbers

Polymers

Thermoplastics Thermosets Elastomers

ABS alkyd butyl

acetal epoxy fluorocarbon
acrylic melamine neoprene
nylon phenolic nitrile
polycarbonate polyester polysulfide
polyethylene urethane rubber
polypropylene silicone
polystyrene
vinyl
Ceramics

Ceramics
alumina
beryllia
diamond
magnesia
silicon carbide
silicon nitride
zirconia
Composites

Composites
carbon fiber
ceramic
matrix
glass fiber
Kevlar
metal
matrix
 Most Commonly Used Materials
The following 25 materials are the most commonly used
materials in the design of mechanical products; in themselves
they represent the broad range of other materials.

Steel and Cast Iron

1. 1020 (plain carbon steel, hot-rolled or cold-drawn)

2. 1040 (plain carbon steel, hot-rolled or cold-drawn)
3. 4140 (heat-treated alloy steel, chromium-molybdenum)
4. 4340 (heat-treated alloy steel, nickel-chromium-molybdenum)
5. S30400 (stainless steel)
6. S316 (stainless steel)
7. O1 (tool steel)
8. ASTM20-60 (gray cast iron)

40
 Properties of Most Commonly Used
Materials

Ultimate
Strength
in tension

Ken Youssefi SJSU, ME dept. 41

 Properties of Most Commonly used
Materials

Yield
strength

Ken Youssefi SJSU, ME dept. 42

 Materials

Fatigue
endurance
limit (strength
under cyclic
loading)

Ken Youssefi SJSU, ME dept. 43

 Properties of Most Commonly used
Materials

Density

Ken Youssefi SJSU, ME dept. 44

Cost of Most Commonly used Materials

Ken Youssefi SJSU, ME dept. 45

Metals and Alloys

Properties and Applications

 Ferrous alloys

◼ Plain carbon steels

◼ Alloy steels
◼ Stainless steels
◼ Cast irons
 Low-carbon steels

◼ Contain less than 0.25%C

◼ Not very responsive to heat treatments
◼ soft, weak, tough and ductile
◼ Machinable, weldable, not expensive
◼ YS~275 MPa, TS~415-550MPa, 25% el.
High strength low alloy steels
(HSLA steels)
◼ Contain alloying elements such as Cu, V, Ni, Mo in
combined concentrations of >10 wt%
◼ Stronger than plain low-C steels
◼ Ductile, formable and machinable
 Medium-carbon steels

◼ Contain 0.25-0.60 wt.% carbon

◼ Can be heat-treated but only in thin sections
◼ Stronger than low-C steels but less ductile and less tough
◼ Good wear resistance
◼ Railway wheels & tracks, gears
 High carbon steels

◼ 0.60 -1.4 wt.% C

◼ Hardest, strongest, least ductile of all steels
◼ Almost always used in tempered condition
◼ Especially wear resistant
◼ Form hard and wear resistant carbides with alloying elements
◼ Used in cutting tools, dies, knives, razors, springs and high
strength wires
 Stainless steels

◼ Highly resistant to corrosion in many environments

◼ Predominant alloying element is at least 11% Chromium
◼ Corrosion resistance may be enhanced by Ni and Mo additions
◼ 4 classes: ferritic, austenitic, martensitic and precipitation-
hardening
◼ Used at high temperatures (upto ~ 1000 C) and severe
environments
◼ Gas turbines, steam boilers, aircraft, missiles
 Cast irons

◼ Theoretically contains > 2.14 wt.% carbon

◼ Usually contains between 3.0-4.5 wt.% C, hence very
brittle
◼ Also 1-3 wt.% silicon
◼ Since they become liquid easily between 1150 C and
1300 C, they can be easily cast
◼ Inexpensive
◼ Machinable, wear resistant
◼ 4 types: gray cast iron, nodular cast iron, white cast
iron, malleable cast iron
Interdependence - compatibility

Material
Properties

Manufacturing compatible
Processes materials & processes
Interdependence - capability

capable processes
for the geometry

Manufacturing Product
Processes Geometry
Product function is interdependent

Material
Properties

Product
Function

Manufacturing Product
Processes Geometry