production technology-2016 مبادءئ هندسة انتاج و ورش

1. rialsEngineering Mate2CH.
Engineering
Materials
metallic
ferrous
Pig
iron
Cast
iron
Wrought
iron
steel
non-
ferrous
copper
brass
bronze
aluminum
duralumin
nikel
lead
titanium
babbit
non-metallic
Organic
(polymers)
Thermoplasts Thermosets
inorganic
(ceramics)
composite
They are the materials which
contain metallic elements as a main
constituent
Characterized by:
1-crystalline structure
2-high reflectivity
3-good conductor of heat &electricity
4-strength &ability to flow before
fracturing
The metals which the iron (Fe)is
the main constituent. Its name
derived from the latin word ferum
which means iron.
_All ferrous metals are alloys
mainly of Fe &carbon.
_ferrous metals are classified
according to the percentage of iron.
Material which composed of 2 or more distinct
phases, one of them is a matrix surrounding
fibers or particles of the other….-Prop.:-
1-Some form of bonding at the interface bet.
Them.
2-designed to provide a combination of desired
prop. That isn’t exhibited by either material on
its own.
3-one of the materials has distinct advantage
examples:- concrete, car tires
They are metals which doesn’t contain iron.
Porp.:-
1- used as structural materials.
2-have poor mechanical properties So,they are used in
the form of alloys except copper, aluminum, nickel can
be used pure or alloyed.
3-weaker &softer than ferrous metal
4-resist corrosion & have attractive colors

2. Ferrous Materials
SteelWrought ironCast ironPig IronP.O.C
Fe+ up to 2%Carbon & several elements
_Types of steel are classified according to their carbon content
pig iron refined in
the puddling
furnace,
Ferrous metal has the same
constituents Of pig iron
&produced by the further
refinement of pig iron in
cupola furnace.
Ferrous metal obtained
by smelting iron ore in
the blast furnace with
the aid of coal and
fluxes.
Definition
_As the carbon content increase the strength &hardness
increase but ductility decrease.
have ferrite content
about 99.9%contains 2-5% carbon
92-97% Fe +high percentage
of carbon in addition to small
amounts of Si, Mn, P,S
percentage
1-Plain carbon steel:-
a)mild
steel:0.06-
0.25%
Carbon
_weak, soft,
&ductile&
has
considerable
strength
&ductility,so,
it can be
easily cold or
hot worked
&machined
b)Medium carbon steel:
0.35- 0.65% Carbon
c)high carbon steel:
0.65- 1.5% carbon
_low melting pt.&
fluidity inc. in the liq.
State so, it can be
casted
_Hard, strong, brittle
&little ductility
&malleability.
_used in: cutting tools
subjected to impact
such as chisels, dies&
wood working
tools…also the tools
subjected to high
abrasive action like
scribers, punches, files,
vice jaws, cold
chisels……
_used in:
cheap rivets,
pipes, wires,
angels, car
bodies, bolts,
screws, nuts
_used in: engineering
components requiring high
strength& moderate
hardness like tool holders,
axles, gears, &railways
rails
2-Alloy steels:-
plain carbon steels their mech. Prop. Improved by adding
alloying elements..most of them are Cr 4-22%, Cu,Ni 0-
26%,Mn, molybdenum, silicon
_HSS(high speed steel) has the ability to keep its hardness
up to 500-600°C so they used in producing cutting tools
working at moderate speeds by adding 18%tungsten, 4%Cr,
1% V to high carbon steels (0.7%)
1-soft& strong in
tension
2-tough &resistant
to atmospheric
corrosion bec. It is
covered by with a
protective oxide
layer.
3-can't be heated to
a liquid State bec. It
has v. low carbon
content but it
becomes pasty.
4-it isn't casted but
at red heat it is very
soft & welds readily
by hammering
making it an ideal
metal for forge work.
5-easily cold worked
by rolling, twisted
&bending
1-presented as free graphite
when cools slowly & has a
grey appearance when it
fractures.
2-acts as a lubricant during
machining operations.
3-brittle, can't be forged
4-weak in tension but
strong under compression
5-easy to machine
6-the amount of carbon
gives great fluidity to the
molten cast iron.
7-the resulting casting is
extremely hard &brittle bec.
the carbon no longer
presents as free graphite
but combines with the metal
forming Fe carbide
8-white cast Fe: v. difficult
to be machined it has white
appearance when it
fractures…it is used in
rolls, balls in mills
1-brittle and week
bec.it includes large
amount of carbon
&impurities.
2-never used as
structural material but
used only to produce
other ferrous metals
-Properties(Kinds)
used for: making
chains & crane
hooks
intricate shapes like tool
machines, beds & engine
bodies
_it is the base of
production of all ferrous
metals.
uses

3. Non-ferrous materials
P.O.C
Aluminum & its alloys Copper-brass alloys lead nickel titanium
properties
*according to the volume of
production aluminum keeps
the 1st place among the non-
ferrous metals.
-ProP.:-1- light (its weight is
1/3 the weight of steel)
2-soft & ductile
Copper is next to Al in its use
-Prop.:- 1- pure copper (99%)
has high electrical & thermal
conductivity.
1-It is the heaviest
common metal
2-very soft
3-weak in tension
4-highly malleable
Contains 97.5-99.5% Ni,
0.6-1% Co
1-high corrosion
resistance.
2-ferromagnetic
1-High melting point(1725°C)
2-high strength
3-low specific weight
4-very good corrosion
resistance.
color -white colorBluish -Blue colorgray
Produced in the form of thin
sheets, wires, tubes or solid
selections.
Can be rolled into sheets
or tubes but can't be
drawn into wires
Uses
Its alloys used in:
1-means of transport
2-foodstuff industry (foils,
kitchen utensils, food
cotainers)
3-building engineering due to
it corrosion resistance.
1-electrical conductors &
cables.
Constituent in making
bronzes fusible alloys &
soft solders &radiation
shielding
1-surface protection of
metals.
2-chemical & food stuff
industry
3-steam seals, coins,
resistance thermometers
High speed aircraft
components
alloys
Duralumin: one of the most
important Al alloys..consists
of:95% Al, 4% Cu, 0.5%Mg,
0.5% Mn..
Also it has the advantage of
Al& steel strength so it is used
in aircraft industry
Brass: it consists of Cu &
39-45%Zn..used in cartridge
cases, radiators& sealing
rings.
If copper is alloyed with other
elements its often called
bronze..some alloys are
specified like tin bronze,
phosphor bronze
Monel alloy contains
30% Cu,
has heat& corrosion
resistance metals &
good mechanical
properties…used in
making chemical
apparatuses, medical
instruments
Can be alloyed with Cr, Al,
Fe, Ni& other certain
elements.
These alloys applied as heat
resistance materials in place
of Al alloys& steels to
reduce the weight of the
construction as in rockets.

4. Organic non-metallic
materials(polymers)(plastics)
It is the material which composed mainly or wholly of carbon compounds
P.O.C Thermoplastics (Thermo-
softening)
Thermosets (thermos-
hardening)
Inorganic non-metals (ceramics)
definition Materials can be shaped & reshaped by
the application of heat &pressure as
long as the heat doesn't cause damage.
Materials that undergo chemical
change by subjecting to heat
&pressure after which they can't be
changed by further heat or pressure
(can't be reshaped)
Ceramics: Products made from inorganic materials which
contain metallic or non-metallic elements
properties
1-don’t melt but flow at a suitable
temperature & pressure
2-suitable for injection moulding
&extrusion
3-behave like glass when blown
4-can be shaped by pressure an
vacuum technique
1-they gain rigidity before the applied
pressure & heat is removed
1-hard, brittle
2-tend to be more resistant than other metals
3-plastics to high temperatures &to serve enviroments
examples bottles Melamine, formaldehyde, bakelite MgO magnesia (ionically bonded), silicon carbide SiC
(covalently bonded), floor tiles, bricks, electrical insulators,
spark plugs, concrete, glass, clay, stone
Mention the factors of selecting materials.
1-the ability to stand up to service conditions
2-the suitability for the process used to manufacture it
3-the material cost & availability

5. Classifications of properties
(physical, chemical, thermal, electrical& magnetic, optical, Mechanical )
Mechanical
property
definition
Elasticity The ability of material to restore its original shape or volume at once when the external force is removed
Ductility The ability of the material to be drawn into wires by a tensile force… the ductile material must be strong & plastic
Ex. Copper aluminum, mild steel, nickel, zinc, tin &lead
Hardness It has a wide variety of meaning from them. The resistance to wear, penetration, scratching& machining, Also; it is the ability of the
metal to cut another metals.
It is very important in making cutting tools
Strength The ability of the material to resist fracture or yielding when subjecting to external load
Brittlness The opposite of ductility or it means that property of breaking the material with little permanent elongation or distortion ..it is also
associated with hardness So, the brittle materials can't be forged
Ex. Cast iron
Toughness It is the opposite of brittles OR the ability of the material to resist fracture due to high impact loads like sudden shocks
The toughness decreases by heating
Ex. Hammer head
Malleability Special case of ductility that permits material to be rolled or hammered into thin sheets or different shape without fracturing..
Heat may be used to make material more malleable
There is little difference bet. Malleability & ductility for example Lead is malleable bec. It can be shaped by hammering but not ductile
bec. It isn’t strong enough to be drawn into wires
Fusibility The ability of a material to become easily liquid when heated
Conductivity The ability of material to conduct heat or electricity