EM-226 Materials and

Manufacturing Processes

Instructor: Dr. Khurram Kamal

 Course Outline
Engineering Materials
Desired Engineering Properties
Concept of Structure
Metals and Alloys
Phase Diagrams
Ceramics
Polymers
Composites
Semiconductors
Materials Characterization
Scanning Probe Microscopy
Non-Destructive Testing
Material Selection
Failure Analysis
Manufacturing Processes
Manufacturing Systems
Foundry Practice and Modern Casting
Machining Processes
Welding
Brazing and Soldering
Non-traditional Manufacturing Processes
Heat Treatment
Electronic Fabrication
Rapid Prototyping
 Recommended Books
Elements of Material Science and Engineering by
Van Vlack, Addison Wesley Publishing Co., Latest
Edition2
Introduction to Physical Metallurgy by Sidney H.
Avner, McGraw Hill publishing Co., Latest Edition.
Engineering with Polymers by P.C. Powell. , Latest
Edition.
Manufacturing Processes by Amstead, Begeeman
and Ostwald, John Wiley & Sons, Latest Edition.
Materials and Processes in Manufacturing by E. Paul
Degarmo, J. Black, Ronald A. Kosher. , 10 th Edition.
 Marks distribution
50% Finals
30% First-term and mid-term
10% Quiz
10% Project Assignment + Report
 Contact
Dr. Khurram Kamal
Department of Mechatronics
Ext. No: 4414
Email: khurram_kamal@hotmail.com
Website:
http://khurramkamal.wordpress.com/
 What is manufacturing?
The word manufacturing, is derived from the Latin
word manu factus, meaning made by hand. The
word manufacture first appeared in 1567, and the
word manufacturing appeared in 1683. In modern
sense, manufacturing involves making products from
raw materials by means of various processes,
machinery, and operations, through a well-organized
plan for each activity required. In a simpler way,
manufacturing is a method/technique used to convert
input in any form by the use of certain processes into
a valuable output, going through a series of
transition/value-adding processes.
 Types of manufactured
goods
Manufactured goods are classified
into two types
Producer Goods: are used to
manufacture either producer or
consumer goods.
Consumer Goods: are those
purchased directly by the consumer
or the general public.
 Why manufacturing?

Manufacturing is critical to a countrys economic

welfare and standard of living to its people.
The standard of living in any society is determined,
primarily , by the goods and services that are
available to its people.
Manufacturing companies contribute about 20% of
the GNP, employ about 18% of the workforce, and
account for 40% of the exports of the United States.
In most cases, materials are utilized in the form of
manufactured goods.
 Manufacturing Process
A manufacturing process converts unfinished
materials to finished products, often using machines
or machine tools.
For example, injection molding, die casting,
stamping, arc welding, are commonly called
processes or manufacturing processes.
The term process often implies a sequence of steps,
processes, or operations for production of goods and
services.
A machine tool is an assembly of related
mechanisms on a frame or bed that together
produce a desired result.
 Generally, motors, controls, and auxiliary
devices are included.
Cutting tools and workholding devices are
considered separately.
A machine tool may do a single process
(e.g., cutoff saw) or multiple processes, or
it may manufacture an entire component.
Machine sizes vary from a tabletop drill
press to a 1000-ton forging press.
Olympic Medal
MATERIAL CHARACTERISTIC AND
SELECTION

In any finished product, it normally involves one or more

than one type of material. Material can be obtained in
either their original form or artificial form. There are lot of
material involved in engineering application, alloys alone
already consists of thousands of types. Not only alloys,
the same with ceramics and polymers, their application is
also very wide in engineering application.
Nowadays, more and more materials are being
developed and researched to suit a specific application.
Thus, an engineer has no choice but to know how to
choose/select the best possible alternative for production
to achieve their needs.
 Material Selection
Every produced product must be able to
function as it is designed in a proper working
condition for an acceptable period of time
without failure.
Material selection play an important role in this,
because selection of material will determine
the characteristic, function, and also the cost of
the product.
There are few crucial factors that are needed to
be considered for material selection, these are:
 Suitability of material in term of function usage of material in
finished goods and also processing of the material to produce the
product.
Reliability of material in term of ability/repeatability in producing
desired dimension, surface texture, and tolerances.
Manufacturability of the material, the consideration if it can be
formed/casted/welded/heat-treated/etc. easily as desired.
Processing effect towards the final characteristics of the material
also should be considered, as it might affect the final
quality of the products, life of the products, and performance of
the products.
Durability of the material is always in the consideration as it will
somehow determine how long the product can last, especially in
some areas like wear with time, compatibility with other material,
safety factors, etc.
 Availability of material and the ease to obtain supply of
material in reasonable cost should be considered during
material selection. This is to prevent your production
from facing the possibility in shortage of materials, or
running at a material costing.
Manufacturing cost should be reasonable in order to stay
competitive with the competitors. Thus, various
manufacturing processes should be considered in order
to get the best possible methods that suit your
production.
Waste elimination of material should be considered in
order to avoid illegal disposable of material. If possible,
go for some material which can be recycled.
 Engineering Materials
Materials used in engineering
application can basically divided into
three categories;
Metals
Ceramics
Polymers
Composites
 The common metallic materials include
iron, copper, aluminum, magnesium,
nickel, titanium, lead, tin, and zinc as well
as the alloys of these metals, such as
steel, brass, and bronze.
They possess the metallic properties of
luster, high thermal conductivity, and high
electrical conductivity; they are relatively
ductile; and some have good magnetic
properties.
 Physical and mechanical
properties
A common means of distinguishing one material from
another is through their physical properties.
These include such features as density (weight); melting
point; optical properties (transparency, opaqueness, or
color); the thermal properties of specific heat,
coefficient of thermal expansion, and thermal
conductivity: electrical conductivity; and magnetic
properties.
In some cases, physical properties are of prime
importance when selecting a material, however,
material selection is dominated by the properties that
describe how a material responds to applied loads or
forces.
 These mechanical properties are usually
determined by subjecting prepared specimens
to standard test conditions.
When using test results, however, it is
important to remember that they apply only
to the specific conditions that were employed.
The actual service conditions of engineered
products rarely duplicate the conditions of
laboratory testing, so considerable caution
should be exercised when applying test
results.
STRESS AND STRAIN
 When a force or load is applied to a material, it deforms or
distorts (becomes strained), and internal reactive forces
(stresses) are transmitted through the solid.
For example, if a weight, W, is suspended from a bar of
uniform cross section and length, the bar will elongate by an
amount L. For a given weight, the magnitude of the
elongation, L, depends on the original length of the bar.
The amount of elongation per unit length, expressed as e =
L /L, is called the unit strain.
Although the ratio is that of a length to another length and is
therefore dimensionless, strain is usually expressed in terms
of
millimeters per meter, inches per inch, or simply as a
percentage.
 Application of the force also produces reactive stresses,
which serve to transmit the load through the bar and on to
its supports.
Stress is defined as the force or load being transmitted
divided by the cross-sectional area transmitting the load.
The stress is S = W/A, where A is the cross-sectional area
of the supporting bar. Stress
is normally expressed in mega pascals (in SI units, where
a pascal is 1 newton per square meter)
meter) or pounds per square inch (in the English system).
In figure, the weight tends to stretch or lengthen the bar,
so the strain is known as a tensile strain and the stress as
a tensile stress.
 Other types of loadings produce other
types of stresses and strains.
Compressive forces tend to shorten
the material and produce compressive
stresses and strains.
Shear stresses and strains result when
two forces acting on a body are offset
with respect to one another.
Tensile Strength Test
Engineering stress-strain
curve
 Strength
Strength: is a materials ability to
withstand a force without failure.
Depending on the type of forces
applied, each and every material will
have different strength level for
different type of strength test. For
example, a material might be having
a good tensile strength but weak
hardness strength.
 Elasticity
Elasticity :is the ability of
material to return to its
original condition whenever a
force applied is released.
 Plasticity
Plasticity: is the ability of
material to form under
pressure and remain in its
new shape whenever the
pressure is released.
 Ductility
Ductility: is the ability of
material to deform plastically
without fracture.
Indication of ductility can be
given by percentage reduction
in the area
i.e. (A o - A f )/ A o x 100%
 Brittleness
Brittleness: If a material fails
with little or no ductility then
it is said to be brittle. Thus
brittleness can be seen as
opposite to ductility.
 Resilience
Resilience is the ability of a material to absorb
energy when it is deformed elastically, and release
that energy upon unloading. The modulus of
resilience is defined as the maximum energy that
can be absorbed per unit volume without creating a
permanent distortion. It can be calculated by
integrating the stress-strain curve from zero to the
elastic limit. In uni-axial tension,
U r = 2y / 2 E

where Ur is the modulus of resilience, y is the

yield strength, and E is the Young's modulus.
 Hardness
Hardness is the ability of material to
withstand wear or scratches or the
ability to avoid warping or being
penetrated by
external forces.
 Chemical Properties
These characteristics explain the
suitability of certain materials in the
process selection. It includes
machinability, formability, castability,
weldability, and etc.
 PHYSICAL PROPERTIES
Physical properties that needed to be
taken into consideration is density,
specific heat, thermal expansion,
conductivity, melting point, electrical
properties, magnetic properties, and
etc.
 Properties related to
manufacturability
This characteristics explain the
suitability of certain materials in the
process selection. It includes
machinability, formability, castability,
weldability, and etc.