ENGINEERING TECHNOLOGY

Manufacturing > Communication > Transportation and Power > Construction > Industrial Design

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Engineering Technology Teachers Unit Kurikulum, Jabatan Pelajaran Perak.

ENGINEERING TECHNOLOGY
Manufacturing > Communication > Transportation and Power > Construction > Industrial Design MAIN PAGE

ENGINEERING MATERIALS
LEARNING OUTCOMES CATEGORIES OF ENGINEERING MATERIALS THE MECHANICAL PROPERTIES OF METALS NON-METALLIC MATERIALS

FERROUS METALS

NON-FERROUS METALS

LEARNING OUTCOMES
I. list and differentiate between types of ferrous and non-ferrous metals, and non-metallic materials identify some uses of ferrous and non-ferrous metals, and non-metallic materials list and define the mechanical properties of metals explain the uses and advantages of every material based on its mechanical properties

II.
III. IV.

CATEGORIES OF ENGINEERING MATERIALS

ENGINEERING MATERIALS
Metallic material Non-metallic material
Natural material Synthetic material

Ferrous metal

Nonferrous metal

FERROUS METALS
Ferrous metal is a metal that is largely composed of iron element. Ferrous metals are produced in larger quantities than any other metal type. Examples of ferrous metals: I. Steel II. Cast iron

STEEL

ALLOY STEEL
Stainless steel High speed steel

CARBON STEEL
Low carbon steel Mild steel Medium carbon steel High carbon steel

Stainless Steel
Contain steel mixed with 18% chromium and 8% nickel Properties: hard, robust, impact resistance and rust resistance Typical applications: sinks, kitchen appliances, water tanks, surgical tools

Cutlery

Micrometer

High-speed Steel
Contain steel mixed with tungsten, chromium, vanadium and molybdenum Properties: Able to retain hardness at high temperature but brittle. Can be heat treated to improve their mechanical properties Typical applications: cutting edge for lathes and drills

Drill Bits

Countersunk Drill bit

Low-carbon Steel
Contain less than 0.15% carbon Properties: soft but have outstanding ductility and toughness, robust and malleable Typical applications: wires, rivets, thin sheets
Wire

Mild Steel
Contain 0.15%- 0.30% carbon Properties: high tensile strength, robust and malleable, easy to machine, cannot undergo heat treatment Typical applications: multipurpose steels, bar tubes, sheets, bolts, nuts

Bolt and Nut

Medium-carbon Steel
Contain 0.3% to 0.7% carbon Properties: high strength and wear resistance compared to low-carbon steels but less ductile Typical applications: springs, crankshafts, woodwork chisels, hammer heads

Ball pein hammer

Chisels

High-carbon Steel
Contain 0.7% to 1.4% carbon. Properties: the hardest, strongest and yet least ductile of the carbon steels. Typical applications: cold chisels, shearplate edges, axes, knives, drills bits and moulds for hand tools, ball bearings, lathe cutting tools

CAST IRON
Generically, cast irons are a class of ferrous alloys with carbon contents above 2.14%. They are easily melted and cast. Some cast irons are very brittle, and casting is the most convenient fabrication technique. The most common cast iron types are: I. Grey cast irons II. White cast irons III. Wrought irons

Grey Cast Iron

Contain 1.7% to 4.5% carbon Properties: high compression strength, low tensile strength, easy to machine and cast Typical applications: diesel engine castings, large pipes, supports, gearboxes

Pipes

White Cast Iron

Contain 2% to 3.5% carbon Properties: very hard and have a high compression strength, high degree of ductility. Brittle, almost unmachineable Typical applications: rollers in rolling mills, machine component that requires durability to friction

Wrought Iron
Wrought irons are quenched white cast irons Properties: more ductile, machineable, higher tensile strength. Typical applications: connecting rods, crankshafts, pulleys, cylinder heads

NON-FERROUS METALS
Non-ferrous metals do not contain iron element. The examples of non-ferrous metals are:
Aluminium Copper Brass (copper-based alloy) Tin

Aluminium
Properties: I. high electrical and thermal conductivity II. Resistant to corrosion III. Easily formed (cast, forge, machine) IV. Silvery white in colour V. Low melting temperature (650oC)

Typical Applications Of Aluminium

Aircraft structures, aircraft pump parts, truck wheels, rivets, food/ chemical handling & storage, cooking utensils, window frames

Aircraft

Copper
i.
Properties: Highly resistance to corrosion in diverse environments, seawater and some industrial chemicals Ductile, flexible High electrical and thermal conductivities Can be shaped through cold and hot work Reddish brown Melting temperature (1083oC)

ii. iii. iv. v. vi.

Typical Applications Of Copper

Electrical wires Automotive radiator cores soldering tool tip

Electrical wires

Brass
Properties: I. Harder than copper and zinc II. Machinable III. Easy to solder IV. Can be casted V. Good electrical and thermal conductivities VI. High corrosive resistance but easily tarnished VII. Yellowish VIII. Melting temperature (980oC)

Typical Applications Of Brass

Valves Screws Locks Electronic packaging Coins

Tin
Properties: I. Soft II. Does not corrode III. Not easily affected even in humid conditions IV. Easy to forge V. Ductile VI. Silvery white VII. Melting temperature (232oC)

Typical Applications Of Tin

Tin plating Solder material Pewter

THE MECHANICAL PROPERTIES OF METAL

Hardness Strength Brittleness

MECHANICAL PROPERTIES OF METALS Ductility Elasticity Forgeability Robustness

THE MECHANICAL PROPERTIES OF METAL

Hardness The ability of metal to withstand penetration by other objects The ability of metal to support a load without changing its shape A property that easily breaks or cracks when impacted The ability to maintain strength even after it has undergo change in shape The ability of metal to be shaped using forging method The ability of metal to regain its original condition after undergo change in shape

Strength
Brittleness Robustness Forgeability Elasticity Ductility

The ability of metal to be strecthed without snapping

NON-METALLIC MATERIALS

Polymer
Concrete

Ceramic

POLYMER
Definition: A huge molecule built of small molecules called monomers Examples of polymer: a) Plastic b) Rubber c) Adhesives

COMPARISON BETWEEN THE PROPERTIES OF THERMOPLASTIC AND THERMOSETTING PLASTIC

THERMOPLASTIC Soften when heated and harden when cooledprocesses that are totally reversible and may be repeated Durable and soft THERMOSETTING PLASTIC Become permanently hard when heat is applied and do not soften upon subsequent heating Rigid, hard and strong compared to thermoplastic, fairly brittle

Melt at a low temperature, 93oC

Can withstand high temperature up to 260oC

THERMOPLASTIC
HEATED

HARD

CONTINUOUS CYCLE

SOFT

COOLING

THERMOSETTING PLASTIC
HEATED

PERMANENTLY HARDENED

SOFT

COOLING

TYPICAL APPLICATIONS OF THERMOPLASTICS

Polyethylene : chemical resistance and electrically insulating-flexible bottles, toys, tumblers, film wrapping materials acryllate : outstanding light transmission and resistance to weathering-lenses, drafting equipment, outdoor signs PVC : good low cost, general purpose materials, ordinarily rigid-floor coverings, pipe, electrical wire insulation

TYPICAL APPLICATIONS OF THERMOSETTING PLASTICS

Polyester resin : yacht, corrugated sheet, furniture Urea formaldehyde : domestic equipment, adhesive for wood Melamine formaldehyde : dining set, formica

CONCRETE
Contains cement, sand, gravel and water in a fixed ratio The quality of concrete depends on: the condition of materials the ratio of concrete mixture Concrete properties
High compression strength Durable Watertight Can be casted Fairly low tensile strength

I.
II.

TYPICAL APPLICATIONS OF CONCRETE

Roads/ highways dams building structures

CERAMICS
Ceramics are compounds between metallic and non metallic elements; they are most frequently oxides, nitrides and carbide The most widely used is alumina (Al2O3)

TYPICAL APPLICATIONS OF CERAMIC

PROPERTY Heat resistance
Electric insulator Chemical resistance

USAGE Refractory, fire clay bricks in furnace construction

Insulators, dielectric in capacitor Dental surgery, replacement material (artificial joint in human bodies)

END OF CHAPTER 4