Lesson 1

Activity 1
1. Research and discuss the advantages and disadvantages of the different
types of materials.

Metallic Materials
Advantages
 Aluminium: The most abundant metal in the Earth's crust, Aluminum is relatively soft,
durable, lightweight, ductile and malleable metal. It acts as a good thermal and electrical
conductor and is also fairly corrosion resistant. Plus, it is theoretically 100% recyclable
without any loss of its natural qualities and remarkably nontoxic.
 Bronze: Bronze is an alloy consisting mainly of copper but the addition of other metals
(usually tin) produces an alloy much harder than plain copper. Bronze resists corrosion
and metal fatigue better, and conducts heat and electricity, better than most steels.
 Carbon Steel: Carbon steel's main alloying constituent is carbon. Low carbon steel is the
most common and cost effective form. It contains around 0.05–0.320% carbon and is
malleable and ductile. Medium carbon steel contains between 0.30–0.59% carbon and
balances ductility and strength with good wear resistance. High-carbon steel has 0.6–
0.99% carbon content and is exceptionally strong, while ultra-high carbon steel contains
1.0–2.0% carbon and can be tempered to great hardness.
 Nickel: Nickel belongs to the transition metals. It is hard, ductile and considered
corrosion-resistant because of its slow rate of oxidation at room temperature. It also
boasts a high melting point and is magnetic at room temperature.
 Titanium: Titanium is corrosion resistant and has the highest strength-to-density ratio of
any metallic element. Unalloyed it's as strong as some steels but less dense. Its relatively
high melting point (more than 1,650 °C or 3,000 °F) makes it useful as a refractory metal.
It is also paramagnetic and displays fairly low electrical and thermal conductivity.

Disadvantages
 Aluminium: It's not particularly strong and is expensive compared to steel of the same
strength.
 Bronze: Bronzes are generally softer, weaker and more expensive than steel.
  Carbon Steel: Low-carbon steels suffer from yield-point runout and mild steel has a
relatively low tensile strength.
 Nickel: Handling nickel can result in symptoms of dermatitis among sensitized
individuals.
 Titanium: Costly and laborious processes are needed to extract titanium from its various
ores.

Polymeric Materials
Advantages
 Polymers are more resistant to chemicals than their metal counterparts.
 Polymer parts do not require post-treatment finishing efforts, unlike metal.
 Polymer and composite materials are up to ten times lighter than typical metals.
 Polymer materials handle far better than metals in chemically harsh environments.
This increases the lifespan of the aircraft and avoids costly repairs brought about
by corroding metal components
 Polymers are naturally radar absorbent as well as thermally and electrically
insulating.
 In medical Facilities polymer and composite materials are easier to clean and
sterilize than metal.
 Polymer materials allow the oil and gas industry to explore deeper depths than
ever before by offering tool weight reduction without a loss of strength as well as
materials which offer superior sealing.

Disadvantages
 Cannot withstand very high temperature as all plastics melt down very soon as
compared to metals.
 The strength to size ratio of polymer is less while for metals is more.
 Cannot be machined easily and limited speed for machining for it.
 Heat capacity of polymer is very less so cannot be used in heat applications.
 Heavy structure cannot be made by polymer as the structural rigidity is very less.
 The disposal becomes an issue as some polymer cannot be recycled but all metals
can be recycled.
 Ceramic Materials
Advantages
 Harder than conventional structure metals.
 Low coefficient of friction.
 Extremely high melting point.
 Corrosion resistance. 
 Low density.
 Extreme hardness.
 Inexpensive.
 Easily available.
 Glazed ceramic does not stain.
 Most of them have high hardness hence they are used as abrasive powder
and cutting tools
 They have high melting point which makes them excellent refractory material
 They are good thermal insulators this is another reason to use them as refractory
material
 They are high electric resistivity which makes them suitable to be used an
insulator
 They have low mass density which results in lightweight components
 They are generally chemically inert which makes them durable

Disadvantages
 Dimensional tolerances difficult to control during processing.
 Weak in tension.
 Poor shock resistance.
 Can crack when hit with heavy items
 They are brittle in nature
 They have almost zero ductility
 They have poor tensile strength
 The show a wide range in the variation of strength, even for the identical
specimens
 They are difficult to shape and machine
 Composite Materials
Advantages
 Design Flexibility: They be molded into the most intricate components and can be made a
wide range of densities and chemical formulations to have precise performance
properties.
 Low cost per cubic inch: When comparing costs based on volume, thermoset composites
have lower material costs than traditional materials such as wood, engineered
thermoplastics and metals.
 Lower material costs: Because thermoset composites can be precisely molded, there is
little waste and therefore significantly lower overall material costs than metals products.
 Improved productivity: Industrial Designers and Engineers are able to reduce assembly
costs by combining several previously assembles parts into a single component. In
addition, composites do not usually require additional machining, thereby reducing work-
in- process and time to market.
 A higher performance for a given weight leads to fuel savings. Excellent strength to
weight and stiffness to weight ratios can be achieved by composite material.
 This is usually expressed as strength divided by density and stiffness modulus) divided
by density
 it is easier to achieve smooth aerodynamic profiles for drag reduction. Complex double-
curvature part with a smooth surface finish can be made in one manufacturing operation
 Laminate pattern and ply buildup in a part can be tailored to give the required mechanical
properties in various directions.

Disadvantages
 Specialized manufacturing process required
 High-quality mold needed.
 CARBON FIBRE
 Only available in black
 Cannot be easily repaired as structure loses integrity
 Cannot be easily recycled
 Heavier
 Requires appropriate finishes to seal surface fibers
 Swells and breaks when waterlogged
  Warps or expands if not sealed
 Contains urea-formaldehyde which may cause eye and lung irritation when cutting and
sanding
 Dulls blades more quickly than many woods

Electronic Materials
Advantages
Disadvantages

Biomaterials
Advantages
Metallic Biomaterials
 High strength
 Fatigue resistance
 Wear resistance
 Easy fabrication
 Easy to sterilize
 Shape Memory
Polymeric Biomaterials
 Easy to make complicated items
 Tailorable physical and mechanical properties
 Surface modification
 Immobilize cell
 Biodegradable
Bioceramic
 High compression strength
 Wear and corrosion resistance
 Can be highly polished
 Bioactive/inert
Biocomposites
  Strong while being lightweight
 Have low density and also are resistant to corrosion

Disadvantages
Metallic Biomaterials
 High modulus
 Corrosion
 Metal ion sensitivity and toxicity
 Metallic looking
Polymeric Biomaterials
 Leachable compounds
 Absorb water, proteins etc.
 Surface contamination
 Wear and breakdown
 Biodegradation
 Difficult to sterilize
Bioceramic
 High modulus (mismatched with bone)
 Low strength in tension
 Low fracture toughness
 Difficult to fabricate
Biocomposites
 High cost involved in manufacture of composites
 Shape cannot be changed easily
https://www.slideshare.net/mobile/Bedar1988/composite-materials-
1#:~:text=16.&text=1.5%20Advantages%20and%20Disadvantages%20of,fewer%20detail
%20parts%20and%20fasteners.

Metal
Stainless steel, gold, cobalt-chromium alloy and nickel-titanium alloy are the most commonly
metals used as biomaterials. Applications include bone and joint replacements, dental implants
and pacemaker cases. The main advantages of metals are that they are strong and are resistant
to fatigue degradation. They have shape memory and can be sterilized easily before use. The
main disadvantage is that metal can corrode due to chemical reaction with the body enzymes
and acids. It also can cause metal ion toxicity in the body.
Polymer
Polymers include collagen, nylon and silicones. They are used in tissue repair, heart valves and
breast implants. Polymers are widely used as they can be manufactured to adapt to their use.
They are easy to manufacture and modify. They are also biodegradable, which is both an
advantage and a disadvantage. Due to the intensive interaction with the body, they can leach,
leading to wear and tear. They also can absorb important nutrients and water from the blood.
Ceramics
Alumina, zirconia and pyrolitic carbon are some of the ceramics used as biomaterials in
applications such as orthopedic and dental implants. The main advantage is that they are strong
and chemically inert. They have high compressive strength, which is necessary for bone
implants. Some ceramic materials are also biodegradable. Difficulty in manufacturing forms
the main disadvantage. They also can minimize bone ingrowth. Sometimes, implants can
loosen over time and become dislodged.
Composites
Composites include bioglass-ceramic, allograft and xenograft. They are used in tissue
engineering and joint replacements. Because composites are made from two or more materials,
the final product combines the properties of all the materials used. The main advantage of
composites is that they are strong while being lightweight. They have  low density and also are
resistant to corrosion. The high cost involved in the manufacture of composites is a
disadvantage. In addition, their shape cannot be changed easily.
https://sciencing.com/uses-pvc-plastic-6292581.html

Advantages of Metal Fabrication

Like plastic fabrication, metal fabrication depends largely on the family and grade of metal used
in production. Some of the more commonly fabricated metals include steel, magnesium, iron,
aluminum, copper, and nickel, each with their own various grades. Metals generally provide the
following advantages over plastic fabrication:
Heat resistance: Metals typically have a higher melting-point and are less likely to degrade under
elevated temperatures.
Improved strength: Metal grades tend to be stronger, harder, and more durable than their plastic
counterparts.
Versatility: Metal can be fabricated through a wider range of processes, including casting, deep
drawing, welding, forging, soldering, and chipping.
Cost-effectiveness: Metal is usually a cost efficient option, particularly in high-volume or long-
term production runs.
Disadvantages of Metal Fabrication
Despite offering numerous benefits, metal is not ideal for every application. Some of the
disadvantages of metal fabrication include:
Secondary operations: Metal fabrication is more likely to require post-fabrication processes, such
as finishing, painting, and deburring, which can be time-consuming or costly.
Design limitations: The viscosity and molten flow behavior of some metals are not suited for
crafting highly complex geometries or shapes.
High start-up fees: metal tooling costs are typically more expensive than comparable plastic
fabrication tooling
https://www.thomasnet.com/articles/custom-manufacturing-fabricating/disadvantages-and-
advantages-of-plastic-over-metal-fabrication/

Pros
Stiff per mass
Strong per mass
Cheap, for a metal
Abundant
Recyclable
Magnetic (can be con)
Amazingly tunable (heat treat, alloy, cold work..)
Displays endurance limit behavior for infinite fatigue life.
Very manufacturable. Extrude, forge, cast, machine, roll, press, stamp, coin, draw, deep draw,
3D print, weld, braze,many others
Most studied metal, vast data available for empirical calculations, like fatigue life, or rules of
thumb.
Cons
For non-stainless alloys, rusts readily in air/moisture. Rust is lower density than base alloy,
causing expansion, causing flaking causing mechanical failure
Dense, heavy.
Hard. Makes hobby/diy work more difficult
Magnetic (can be pro)
Infinite choices in composition and heat treating can lead time analysis paralysis
For a staggering number of applications, steel is over Engineering the component. For instance, a
tool box doesn't need the strength or rigidity if steel, but would love to be lighter. This is why so
many light duty tool boxes are now plastic.
Sparks. In certain environments, you can't risk a spark, and so steel is the wrong choice. This is
why tool catalogs will have brass mallets sold as “non sparking”
To make steel usable, often requires a secondary plating/paonting/coating to prevent rust. Think
chrome plated hand tools. Or painted hand rails.
You can't make shapes quite as intricate as injection molding so to get to the same basics shape,
often you stamp and weld. More steps is usually more expensive. (see point 6 about why this
could matter

https://www.processindustryforum.com/article/advantages-disadvantages-metals-commonly-
used-manufacturing
\