BASIC CHAPTER Most materials can b classified into 4 basic categories (metals, ceramic, polymers, composite) Composite(metal-matrix, ceramic

matrix) Metals (ferrous, nonferrous) Polymer(thermoplastic, thermoset) Selection of materials- properties of materials, cost and availability, service life, material substitution in product. Factors affecting process selection- component/part shape,part size and dimensional accuracy, manufacturing and operational cost, material characteristics-formability,weldability,machinability Production systems- 1. Production facilities- the physical equipment and arrangement of equipment in the factory 2. Manufacturing support systems- the procedures used by company to manage production and solve the technical and logistics problems CHAPTER 3 Density of a material is its mass per unit volume. Weight saving is important for aircraft and aerospace structures, for automotive bodies and components, and for other products where energy consumptions and power limitations are a concern. A significant role that density plays is in the strength-to-weight ratio and stiffness-to-weight ratio of materials and structures. Density is an important factor in the selection of materials for high speed equipment such as magnesium in printing and textile machinery. There are applications where weight is desirable. Examples are counterweights for various mechanisms (flywheels, ballast on yachts). The melting point of metals depends on the energy required to separate its atoms. Melting point of a metal alloy can have a wide range depending on its composition. The temperature range within which a component or structure is designed to function is an important consideration in selection of materials. Plastics, for example, have the lowest useful temperature range, while graphite and refractory-metal alloys have a highest useful range. Melting point also plays an important role in the selection of the equipment and the melting practice employed in casting operations. The higher the melting point, the more difficult the operation becomes. A materials specific heat is the energy required to raise the temperature of a unit mass by 1 degree. Alloying elements have a relatively minor effect on the specific heat of metals. The temperature rise in the workpiece, resulting from forming or machining operations, is a function of the work done and of the specific heat of the workpiece material. An excessive temperature rise in a workpiece can decrease product quality by adversely affecting its surface finish and dimensional accuracy, can cause excessive tool and die wear, and can result in undesirable metallurgical changes in the material. Thermal conductivity indicates the rate at which heat flows within and through a material. Metallically bonded materials generally have a high thermal conductivity, while ionically or covalent bonded materials have poor conductivity. Alloying elements can have a significant effect on the thermal conductivity of alloys. Materials with high electrical conductivity also have high thermal conductivity. Thermal conductivity is an important consideration in many applications. High thermal conductivity is

desirable in cooling fins, cutting tools, and die-casting molds to extract heat. In contrast, materials with low thermal conductivity are used in furnace lining, coffee cups and pans. Thermal expansion of materials can have several significant effects, particularly the relative expansion or contraction of different materials in assemblies such as electronic and computer components and coating on cutting tools. Generally, the coefficient of thermal expansion is inversely proportional to the melting point of the material. Alloying elements have a minor effect on the thermal expansions of metals. Thermal expansion in conjunction with thermal conductivity plays the most significant role I causing thermal stresses, both in manufactured components and in tools and dies. To reduce thermal stress, a combination of high thermal conductivity and low thermal expansion is required. CHAPTER 5 Ferrous metals and alloys contain iron as their base metal and are generally classified as carbon alloy steel, stainless steel, tool and die steels, cast iron and cast steels. Ferrous alloys are produced as sheet steel for automobile, plates for boilers, and tools and dies. Carbon and alloy steels Various elements are added to steels in order to import properties such as hardenability, strength, hardness, toughness, wear resistance, weldability and machinability. Higher the carbon content the greater the hardenability of the steel, strength, hardness, and wear resistance, but ductility, weldability, and toughness are reduced. Carbon steel Carbon steels generally are classified by their proportion of carbon content. (Low carbon steel, medium, high) Stainless steel Stainless steels are characterized by their corrosion resistance, high strength and ductility, and high chromium content. They are called stainless because in the presence of oxygen (air), they develop a thin, hard, adherent film of chromium oxide that protects that metal from corrosion. CHAPTER 6 Alumunium The important advantages of aluminium and its alloys are their light weight, high strength-to-weight ratio, resistance to corrosion by many chemicals, high thermal and electrical conductivities, nontoxicity, reflectivity, appearance and ease of formability and machinability, they are also nonmagnetic. The principle uses of aluminium and its alloys in decreasing order of consumption, are in containers and packaging, architectural and structural application, transportation (aircraft, buses, automobile), electrical applications, consumer durables (cooking utensils, furniture) and portable tools.

Two types of wrought alloys of aluminium: 1. Alloys that can be hardened by cold working and are not heat treatable. 2. Alloys that can be hardened by heat treatment. Magnesium Magnesium is the lightest engineering metal available. It has good vibration damping characteristics. Its alloys are used in structural and nonstructural applications wherever weight is a primary importance. Magnesium is also an alloying element in nonferrous metals. Uses of magnesium alloys are in aircraft, ladders, bicycles, sports goods, and missile components. Magnesium alloys are available either in casting or as wrought products. Magnesium alloys are also used in printing and textile machinery to minimize inertial forces in high speed components.Because it is not sufficiently strong in its pure form, magnesium is alloyed with various elements in order to gain specific properties, particularly high strength to weight ratio. Magnesium alloys have good casting, forming and machining characteristics. Copper They have properties similar to aluminium and its alloys. They are among the best conductors of electricity and heat. Good corrosion resistance. Copper alloys can be processed easily by various forming, machining, casting and joining techniques. Application : Springs, coin, heat exchangers, pure copper can b used as solid lubricant in hot metal forming. Brass(alloy of copper and zinc). Bronze(alloy of copper and tin) Nickel Nickel has high strength, toughness and corrosion resistant.Nickel used in high temperature application (jet engine,rocket,nuclear power plant). Nickel are also used in electromagnetic application such as solenoid. Refractory metals and alloys There are four refractory metals(molybdenum,niobium,tungsten,tantalum). They are called refractory because of their high melting point.They maintain their strength at high temperatures. Application: rocket engine,gas turbine) Molybdenum,Mo-High melting point,high modulus of elasticity,good resistance to thermal shock,good electrical and thermal conductivity. Application: rocket engine,heating elements,electronic components Tungsten,W- High melting point,high density,brittle at low temperatures,offers poor resistance to oxidation,imparts strength and hardness to steel. Precious metals: gold(good corrosion resistance,ductile,good electrical conductivity), Silver (ductile,high electrical and thermal conductivity), Platinum(Corrosion resistance,expensive than gold)