Class 5_6 Materials

7/31/2019 Class 5_6 Materials

1/78

Materials and Manufacturing in

product design and development


2/78

Product design Design a product considering its entire life cycle

Detail design (Concept detailing, engineering drawing, CAD/CAM, CAE..),material selection , manufacturing methods, Eco-design, DfX

Identifying customer needs

Initial design (Concept/idea generation,concept evaluation, selection..)

Prototyping

Manufacturing

Production

Marketing

Sales

Services

PurchaseUse

After use

Recycle, reuse, remanufacture

Discard (land fill)

Marketing dept.

Design dept.

Engineering dept.

R&D dept.

Manufacturing dept.

Mrf./Prod./industrial dept.

Marketing dept.

Sales dept.

Service dept.

Sales dept.

Sales dept.

Service dept.


3/78

Engineering materials

Disclaimer: images are from the internet


4/78


5/78


6/78

Materials classification

Elements Alloys

Elements and use

Steels (Ferrous)Carbon SteelsAlloy SteelsStainless Steels

Tool Steels

Non FerrousAluminum AlloysCopper Alloys..
http://pt_preview_080409.jpg/http://pt_preview_080409.jpg/


7/78

Common classification of engineering materialsCommon engineering materials that come within the scope of Material Science may be classifiedbroadly into the following three types:-

Metals (Ferrous and Non-Ferrous)CeramicsPolymersComposites

Please read Dr. Anupam Aggarwals previous course class slides


8/78

Group Important Characteristics Common Examples of Engineering use

Metals and Alloys

Lusture, Hardness, Resistance toCorrosion, Thermal and ElectricalConductivity, Malleability,Stiffness and Property of Magnetism.

Metals: Ferrous metals and alloys (irons, carbon steels, alloysteels, stainless steels, tool and die steels)Nonferrous metals and alloys (aluminum, copper, magnesium,nickel, titanium, precious metals, refractory metals, superalloys)

Ceramics Thermal Resistance, Brittleness,Opaqueness to Light, ElectricalInsulation, High-temperatureStrength, abrasiveness, Resistanceto Corrosion.

GlassesGlass ceramics Graphite Diamond

Silica, Glass, Cement, Concrete, Refractories, Silicon Carbide,Boron Nitride abrasives, Ferrites, Insulators, Garnets, etc.

Organic Polymers

Soft, Light in weight,Dimensionally unstable, PoorConductors of Heat andElectricity, Ductile, Combustible,Low-thermal Resistance.

Thermoplastics plasticsThermoset plasticsElastomersPlastics Poly Vinyl Chloride, Poly Tetra Fluoroethylene,Polycarbonates.Natural and Synthetic Fibers Nylon, Terylene, Leather, etc.Other uses Explosives, Refrigerants, Insulators, Lubricants,Detergents, Fuels, Vitamins, Medicines, adhesives, etc.

Composites Hardness, Poor Conductors of Heat and Electricity, Non-combustible, high thermalregistance

Composites Reinforced plasticsMetal-matrix compositesCeramic-matrix compositesSandwich structuresConcrete


9/78

Materials for special usage

Heat insulating materials: asbestos, glass wool, thermo Cole, cork,mica.

Electrical insulating materials . china clay, leather, bakelite, ebonite,glass wool, rubber, felt.

Sound insulating materials: Cork, fibre boards.

Fabrication materials : Wood, plywood, rubber natural andsynthetic, Glass plate glass, toughened glass, safety glass.

Refractory materials: General characteristics and uses of dolomite,ceramics.

Protective coating materials: Paints, primers, varnishes, enamels,putti, electroplating materials, rubasil, Teflon coating.


10/78

Materials usage

Source: Galway technology service support service

http://www.google.co.in/url?sa=t&source=web&cd=4&ved=0CDAQFjAD&url=http%3A%2F%2Fwww.t4.ie%2FProfessional_Development%2FRD9_Technology%2FMaterials%2520Technology%2FClassification%2520of%2520Materials.ppt&ei=JoPkTeKaLIPjrAfPysSfBg&usg=AFQjCNE62x65YCGYwd3Nji4HIMDwCBzQrA


11/78

Classification of Materials

Materials used in the design and manufacture of products

Plastics Wood Composites Ceramics Metals Fabrics Acrylic lensBalsa wood modelLayers of polycarbonate,

aluminium & acrylicTungsten carbide tool bitSteel, aluminiumLinen, cotton, nylon, Kevlar


12/78

Classification of Materials (Plastics)

Plastics can be further classified as; Thermoplastic Thermoset Elastomers

Thermoplastics Thermosets ElastomersAcrylics Epoxy resins Rubbers

Nylons Phenolic SiliconesPVC Polyesters PolyurethanesPolyethylene

PolyethylenePVC guttersPhenol formaldehydeUrea formaldehyde

RubberRubber


13/78

Classification of Materials (Wood) Wood can be further categorised as;

Hardwood Softwood Manufactured board

Hardwood Softwood ManufacturedBoardOak Pine Plywood

Ash Cedar BlockboardBeech Fir MDF

Sycamore Spruce Melamineboard

MahoganyOakAshBeechCedarChipboard with VeneerPlywood


14/78

Classification of Materials (Composites)

A composite is a combination of two or more chemicallydistinct materials whose physical characteristics aresuperior to its constituents acting independently.

Because of their high strength/stiffness to weight ratiothey are widely used in the;

Aerospace industry Offshore structures Boats Sporting goods


15/78

Classification of Materials (Composites)

Examples of composites include;

Reinforced Plastics Ceramic-matrix Metal-Matrix

Laminates

Kevlar, taffeta polyester sailsGlass reinforced plastic hullCarbon reinforced plasticThrust chamber for rocketCombustion chamber of jet engineCylinder liningsCylinder liningsOuter skin panels & fuselage A380


16/78

Classification of Materials (Ceramics)

Ceramics are compounds of metallic and non-

metallic elements, examples include;

Oxides (alumina insulation and abrasives,zirconia dies for metal extrusion and abrasives)

Carbides (tungsten-carbide tools) Nitrides (cubic boron nitride, 2 nd in hardness todiamond)


17/78

Classification of Materials (Metals)

Metals can be further classified as Ferrous &Non-Ferrous, some examples include;

Ferrous Non-Ferrous

Steels Aluminium

Stainless Steels Copper

High Speed Steels Brass

Cast Irons Titanium

AluminiumCopperBrassStainless SteelHigh Speed steel


18/78


19/78


20/78

Classification of Materials (SmartMaterials)

Other more modern examples of smartmaterials include;

Shape memory polymers and alloys

Heat shrink tubing and packaging

Automatic actuators open/close greenhouse windows

Thermostats for heating control

Smart Wire

Actuators, linear, angular and rotary

Anthromorphic actuation human like robotic motion

Smart Link Silicone

Allows rotary motion between shafts up to 360 0 Smart Fluids

Motion control gel CD tray opening/closing, camera lensesFerro fluids earthquake dampers in buildings, hard disks

Piezoelectric MaterialsSensors, musical cards, motors, actuators, clocks Chameleon Colours

Car paints, printing inks, packaging


21/78


22/78

The word, polymer , implies that polymers are constructed from pieces(monomers ) that can be easily connected into long chains ( polymer

Latin: Plasticus, that which can be molded. This name honors plastics useful property

of being easily molded.


23/78

GlucoseStructural formula.

Straight chainglucose

H-C=O|

H-C-OH|

HO-C-H|

H-C-OH|

H-C-OH|CH 2 OH

Glucoseglucose bending

GlucoseTwo ring-shape

versions

alpha-glucose

beta-glucose

Glucose bends itself into 4different shapes millions of times

a second

1

4

6

2

3

5

Used inmakingcellulose

Used inmakingstarch

flips

eitherwaybends


24/78

Why use plastics Plastic are easily formed materials.

The advantage to the manufacturer is that plastic products can be mass-produced and require less skilled staff .

Plastics require little or no finishing , painting, polishing etc. Plastic is referred to asa self-finishing material . Particular finishes can be achieved at relatively low cost.

Plastics can be easily printed, decorated or painted.

Plastics are corrosion resistant , and generally waterproof although certain typesof plastics such as UPVC can become brittle and it is possible for the suns rays tocause the colour of the plastic to fade. It becomes bleached.

Plastics are lighter than metals , giving deeper sections for a given weight, andhence stronger sections .


25/78

Origins of Plastics - synthetic plastics . The main source of synthetic plastics is

crude oil .

Coal and natural gas are also used.

Petrol, paraffin, lubricating oils and highpetroleum gases are bi-products,produced during the refining of crude oil.

These gases are broken down into

monomers. Monomers are chemicalsubstances consisting of a single molecule.

A process called Polymerisation occurswhen thousands of monomers are linkedtogether. The compounds formed ascalled polymers .

Combining the element carbon with oneor more other elements such as oxygen,hydrogen, chlorine, fluorine and nitrogenmakes most polymers.


26/78

Natural Plastics

Natural plastic products occur in such things as animals horns, animals milk,insects, plants and trees.

Animals horns - Casein (glue)

Animals milk - Formaldehyde (glue)

Insects - Shellac (French polishing)

Plants - Cellulose (table tennis balls), Cellulose acetate (cloth, photographic film,handles), Cellophane (wrapping), Bitumen (roads, flat roofs)

Trees - Latex (rubber)


27/78

Common plastics


28/78

A polymer madeform just one

monomer is polyethylene. It

is the mostcommon plastic

you see.It is used for

bottles, buckets, jugs, containers,

toys, evensynthetic lumber,

and many otherthings.


29/78

LDPELow density polyethylene

Makes bottles that requires

flexibility

Produces grocery bags andgarbage bags, shrink andstretch film and the coatingfor milk cartons


30/78


31/78

HDPEHigh Density Polyethylene

Used in milk, juice and watercontainers in order to take

advantage of its protectivebarrier properties

Its chemical resistance

properties make it a goodchoice as container forhousehold chemicals anddetergents.


32/78

PETPolyethyleneTerephthalate

A clear, tough, polymer withexceptional gas and moisturebarrier properties.

PETs ability to contain carbondioxide (carbonation) make it agood choice in soft drinkbottles.


33/78

Polythene (polyethelene)

High-density polythenehas been used tomanufacture milk

crates, bottles, buckets,bowl and gear wheels.


34/78

VinylPolyvinyl chloride, or PVC

Excellent clarity, punctureresistance and cling

Film vinyl can breathe,making it ideal for meats


35/78


36/78

PSPolystyrene

In its crystalline form, it is a colorlessplastic plastic that can be clear andhard.

It can also be foamed to provideexceptional insulation properties.Foamed or expanded polystyrene (EPS)

is used for products such as meat trays,egg cartons and coffee cups.

It is also used for packaging andprotecting appliances, electronics andother sensitive products


37/78


38/78

Expanded polystyrene

This is used fordisposable foodpackaging, disposable

cups, heat insulationand protective packaging for electricalequipment.


39/78

Clear Acrylic (Perspex)

It was first used to makeaircraft canopies. It isten times more impact

resistant than glass.


40/78

Nylon

Nylon is hard, tough, self-lubricating, has a highmelting point and has verygood resistance to wear andtear.

It has been used to makeclothing, bearings andpropellers.


41/78

PVC

The rigid type is used tomake pipes , guttering androofing. It is verylightweight and is resistantto acids and alkalis.

The plasticised type is usedfor suitcases, hosepipes,electrical wiring and floorcoverings.


42/78


43/78

The favorite properties of plastics are that they are inert and won't reactwith what is stored in them. They also are durable and won't easilydecay , dissolve, or break apart. These are great qualities for things you

keep, but when you throw them away, they won't decompose .

h d d h l h


44/78

Since they dont decompose, the answer is to recycle theplastics so they can be remade into something else. Herewe see a bunch of CDs getting recycled.

li l i


45/78

Codes Descriptions Properties PackagingApplications

RecycledProducts

Polyethylene Terephthalate (PET, PETE). PET isclear, tough, and has good gas and moisturebarrier properties. Commonly used in soft drinkbottles and many injection molded consumerproduct containers. Other applications includestrapping and both food and non-food containers.

Cleaned, recycled PET flakes and pellets are ingreat demand for spinning fiber for carpet yarns,producing fiberfill and geo-textiles. Nickname:Polyester.

Clarity, strength,toughness, barrierto gas andmoisture,resistance to heat

Plastic soft drink,water, sports drink,beer, mouthwash,catsup and saladdressing bottles.Peanut butter, pickle,

jelly and jam jars.Ovenable film andovenable preparedfood trays.

Fiber, tote bags,clothing, film andsheet, food andbeverage containers,carpet, strapping,fleece wear, luggage

and bottles.

High Density Polyethylene (HDPE). HDPE is used tomake bottles for milk, juice, water and laundryproducts. Unpigmented bottles are translucent,

have good barrier properties and stiffness, and arewell suited to packaging products with a shortshelf life such as milk. Because HDPE has goodchemical resistance, it is used for packaging manyhousehold and industrial chemicals such asdetergents and bleach. Pigmented HDPE bottleshave better stress crack resistance thanunpigmented HDPE bottles.

Stiffness, strength,toughness,resistance to

chemicals andmoisture,permeability togas, ease of processing, andease of forming.

Milk, water, juice,cosmetic, shampoo,dish and laundry

detergent bottles;yogurt and margarinetubs; cereal box liners;grocery, trash andretail bags.

Liquid laundrydetergent, shampoo,conditioner and motor

oil bottles; pipe,buckets, crates, flowerpots, garden edging,film and sheet,recycling bins, benches,dog houses, plasticlumber, floor tiles,picnic tables, fencing.

Recycling plasticsThe table below shows the recycling codes for the most easily recycled plastics, anddescribes what functions they are useful for. All of these are thermoplastics this meansthat they can be reheated, softened and reformed.


46/78

Codes Descriptions Properties PackagingApplications

RecycledProducts

Vinyl (Polyvinyl Chloride or PVC): Inaddition to its stable physical properties,PVC has excellent chemical resistance,good weatherability, flow characteristicsand stable electrical properties. Thediverse slate of vinyl products can bebroadly divided into rigid and flexiblematerials. Bottles and packaging sheet aremajor rigid markets, but it is also widelyused in the construction market for suchapplications as pipes and fittings, siding,carpet backing and windows. Flexible vinyl

is used in wire and cable insulation, filmand sheet, floor coverings syntheticleather products, coatings, blood bags,medical tubing and many otherapplications.

Versatility, clarity,ease of blending,strength,toughness,resistance togrease, oil andchemicals.

Clear food and non-food packaging,medical tubing,wire and cableinsulation, film andsheet, constructionproducts such aspipes, fittings,siding, floor tiles,carpet backing andwindow frames..

Packaging, loose-leaf binders,decking, paneling,gutters, mud flaps,film and sheet,floor tiles and mats,resilient flooring,cassette trays,electrical boxes,cables, trafficcones, garden hose,mobile home

skirting.

Low Density Polyethylene (LDPE).Usedpredominately in film applications due toits toughness, flexibility and relativetransparency, making it popular for use inapplications where heat sealing isnecessary. LDPE is also used tomanufacture some flexible lids and bottlesand it is used in wire and cableapplications

Ease of processing,strength,toughness,flexibility, ease of sealing, barrier tomoisture.

Dry cleaning, breadand frozen foodbags, squeezablebottles, e.g. honey,mustard.

Shipping envelopes,garbage can liners,floor tile, furniture,film and sheet,compost bins,paneling, trashcans, landscapetimber, lumber


47/78


48/78

Processing of plastics


49/78

33/49

Processing of Plastics There are a wide variety of manufacturing processes that exist for plastic production. A wide variety of plastic

manufacturing processes exist

Extrusion Lamination (Calendaring) Thermoforming Casting Molding

Compression Molding Transfer Molding Rotational Molding Reaction Injection Molding Blow Molding Injection Molding

Expansion Foaming Spinning Solid-Phase Forming


50/78

33/50

ExtrusionOne of the most common process for creating plastic for further processing isextrusion. The Extrusion process combines color pigments and performance additiveswith resin by pushing it through rotating screws. The heat and pressure producedwithin the screw barrels disperses and melts the ingredients into homogeneousmolten mixture. At the end of the mixture is usually cool die. The mixture is pushedthrough the die and onto the finishing operation such as pelletizing, calendaring, ormolding.


51/78

33/51

Lamination (Calendering) In calendering, sheets of plastic are laminated together by rolling through heated

roller. Basically, warm or molten plastic (usually from an extruder) is fed through aseries of heated rolls as in this figure. The gaps between the rolls determine thefinal sheet size. Each additional roll would reduce the sheet thickness further.Then, once the laminated sheet is the correct thickness, the sheet is then strippedoff.

Schematic illustration of calendering. Sheets produced bythis process are subsequently usedin thermoforming.

Reinforced- plastic components for a Hondamotorcycle. The parts shown are front andrear forks, a rear swingarm, a wheel, and brakedisks.


52/78


53/78

33/53

Casting Casting used for both thermosetting and thermoplastic materials. Basically, casting

places plastic in a mold then hardens it into a rigid article or form. In potting, the plastic is cast around a part, and the case becomes part of the final

component. In encapsulation, the component is covered with plastic and thecomponent and plastic are ejected from the mold. Both processes are usedextensively in electronics for insulation and dielectric properties

Schematic illustration of (a) casting,(b) potting, (c) encapsulation of

plastics.


54/78

33/54

Molding Molding is the most common plastic forming or finishing method. There are many different methods in plastic

molding. Methods for molding include:

Compression Molding Transfer Molding Rotational Molding Reaction Injection Molding Blow Molding Injection Molding


55/78

33/55

Blow Molding (Bottles) Blow molding is a modified extrusion and injection molding process, wherein a

tube is extruded (usually turned so that it is vertical) and clamped into a mold witha cavity much larger than the tube diameter. Air is blown inside the tube openingand the plastic expands to fill the mold cavity shape. Blow molding is similar toblowing up a balloon inside a bottle. Mostly, blow molding forms hollow plasticparts with relatively thin walls. Examples of blow molding products are bottles,bumpers, bags and ducting.


56/78

33/56

Injection Molding The last and more popular process is injection molding. This process is used to

form complex plastic parts. Typical injection molded parts are fittings, containers,bottle tops, housings, and much more. Here is a pictorial of a typical injectionmolding machine and part. It is the most common of the plastic forming processestoday, accounting for approximately 30% of all plastics produced.


57/78

33/57

Common Polymers ABS (Acrylanitrile Butadiene Styrene): amorphous, good Impact Strength, excellent appearance,

easy to process computer housings, small appliances, automotive interior, & medical components Acrylic : amorphous polymers, excellent clarity, excellent weatherability optical & outdoor

applications Cellulosics : among the first thermoplastics developed: smell funny, very flammable Nylon 6 : semi-crystalline polymer, good cost to performance ratio, lower numbered nylons, 6 ,6-6,

4-6, absorb moisture and change their properties as a result Polycarbonate : amorphous material, excellent Impact Strength, clarity, & optical properties

currently long lead times for this material. Polyethylene High Density : widely used, inexpensive, thermoplastic, easy to process, good to

excellent chemical resistance, soft & not for use above 150 F Polypropylene : semi-crystalline material, low temperature material, excellent chemical resistance

difficult to mold to extremely close tolerances Polystyrene High Impact (HIPS): few cents more than crystal styrene, to pay for the rubber

modifier, opaque & very widely used, lower modulus, better elongation, & less brittle than crystalstyrene

PVC Polyvinyl Chloride Rigid : properties similar to ABS (except appearance) at a slightly reducedcost primarily for water pipe and pipe fittings, occasionally for electrical enclosures *in plasticphase PVC is corrosive to molds & machines (non corrosive as a solid)

Why Design with Plastics?


58/78

Ken Youssefi Mechanical Engineering 58

Why Design with Plastics?

Cost

Relatively low cost compared tometals and composites

Density

Light weight, high weight to strengthratio, particularly when reinforced


59/78

33/59

Properties Advantages

Light Weight High Strength-to-Weight Ratio Complex Parts - Net Shape Variety of Colors (or Clear) Corrosion Resistant Electrical and thermal Insulation

High Damping Coefficient Low pressures and temperature required

Disadvantages Creep Thermally Unstable- can not withstand Extreme Heat U-V Light Sensitive Relatively low stiffness Relatively low strength Difficult to Repair/Rework Difficult to Sort/Recycle


60/78

Ken Youssefi Mechanical Engineering 60


61/78

Metals

METALS


62/78

METALSMetals are Solid at room temperature, except

mercury, which is liquid !

Metals have very high melting point.

Metals are shiny when they cut.

Metals are good conductors of heat and electricity.

Metals areusually strong & malleable so they can behammered into shape.

METALS


63/78

METALS

METALS


64/78

METALS



65/78


Metals Non-Metals

Pure metals Alloys

Read classification of materials

Non-FerrousFerrous

Iron AluminumCopperSilverGoldZincTin

Steel (Iron+ carbon)

Brass (Copper +Zinc)Bronze (copper +Tin)Stainless steel (Steel+Chromium)


66/78

Most popular

The Society of Automotive Engineers (SAE) has established standards for specific analysis of


67/78

steels. In the 10XX series, the first digit indicates a plain carbon steel. The second digitindicates a modification in the alloys.

Classification of steels


68/78

SAE - AISINumber

Classification

1XXX Carbon steels Low carbon steels: 0 to 0.25 % C Medium carbon steels: 0.25 to 0.55 % C High carbon steels: Above 0.55 % Carbon

2XXX Nickel steels 5 % Nickel increases the tensile strength without reducing ductility. 8 to 12 % Nickel increases the resistance to low temperature impact 15 to 25 % Nickel (along with Al, Cu and Co) develop high magnetic properties. (Alnicometals) 25 to 35 % Nickel create resistance to corrosion at elevated temperatures.

3XXX Nickel-chromium steels These steels are tough and ductile and exhibit high wear resistance , hardenability and highresistance to corrosion.

4XXX Molybdenum steels Molybdenum is a strong carbide former. It has a strong effect on hardenability and hightemperature hardness. Molybdenum also increases the tensile strength of low carbon steels.

5XXX Chromium steels Chromium is a ferrite strengthener in low carbon steels. It increases the core toughness andthe wear resistnace of the case in carburized steels.

86XX 87XX 93XX 94XX 97XX

98XX

Triple Alloy steels which include Nickel (Ni), Chromium (Cr), and Molybdenum (Mo). These steels exhibit high strength and also high strength to weight ratio, good corrosionresistance.


69/78

METALS


70/78

METALS & ALLOYSMetals are available in pure or alloy form.

Pure Metals such as pure aluminium or pure copper,contain only one type of metal. They are not mixed withany other metal.

Alloys are mixture of two or more pure metals.

Alloys tend to have better strength properties than puremetals.

Alloys and pure metals often have special physicalproperties .

PROPERTIES OF METALS


71/78

1. Strength - The ability of a material to stand up to forces beingapplied without it bending, breaking, shattering or deforming in anyway.

2. Elasticity - The ability of a material to absorb force and flex indifferent directions, returning to its original position.

3. Plasticity - The ability of a material to be change in shapepermanently.

4. Ductility - The ability of a material to change shape (deform) usuallyby stretching along its length.

5. Tensile Strength The ability of a material to stretch withoutbreaking or snapping.

6. Malleability - The ability of a material to be reshaped in all directionswithout cracking.

7. Toughness - A characteristic of a material that does not break orshatter when receiving a blow or under a sudden shock.

8. Conductivity - The ability of a material to conduct electricity.9. Hardness The ability of a material to resist scratching, wear and

tear & indentation.


72/78

Common metals

FERROUS-METALS


73/78

1. Mild SteelComposition: Iron alloy with 0.3% carbon

Properties: Malleable and ductile, and therefore bends fairly easilyUses: nuts, bolts, screws, tubes etc.

Methods of Identification

Appearance: Bright drawn mild steel has a smooth, bright surface;black mild steel is covered with a blue-grey oxideDropping: Gives out a ringing note

Grinding: Gives off a shower of long white sparksEffect of Heating: Slightly tougher but little change

FERROUS-METALS


74/78

2. Tool Steel / cast steel / carbon steelComposition: Iron alloy with 0.5%-1.5% carbon

Properties: Tough rather than hard, and fairly ductileUses: Springs and most tools such as hammer heads, drills, chisels,shears etc

Methods of Identification

Appearance: Has a smooth skin of black oxideDropping: Gives out a high ringing note

Grinding: Moderate number of red sparksEffect of Heating: Becomes hard and brittle


75/78

Use of non-ferrous metals


76/78

Aluminium:Aluminium is a widely used non ferrous metal. It is Grayish-Whitein colour, soft and malleable. This non ferrous metal is conductiveto heat and electricity. It is corrosion resistant. Aluminium can bewelded but this is difficult. Special processes need to be adoptedin order to weld it properly. Due to its light weight, it is used inthe manufacturing of aircrafts and boats. Its other uses arewindow frames, saucepans, packaging and insulation, pistons andcranks.

Aluminium alloys (Duraluminium): Aluminium alloys (Duraluminium) is composed of Aluminium,Copper and Manganese. Its also Ductile, Malleable, WorkHardens. It is used in the manufacturing of aircrafts and vehicleparts.

Source: http://www.bracebridgeengineering.co.uk/engineering_non_ferrous_metal.asp

Non Ferrous metals are those metals which does not contain iron . They are not magneticand are usually more resistant to corrosion than ferrous metals. Most commonly used nonferrous metals are Aluminum, Copper, Brass, Lead, Tin, Gilding Metal and Zinc.

Copper :


77/78

Copper is another very important pure non ferrous metal. Its red incolour, tough and ductile. It is very good electrical conductor andoffers great resistance to corrosion. Copper can work hard or coldbut it needs frequent annealing. Copper is mostly used in themanufacturing of electric wires, cables and conductors. Its otheruses are water and central heating pipes and cylinders, Printedcircuit boards and manufacturing of special roofs.

Brass :Another important non ferrous metal is Brass which is not a puremetal but combination of Copper and Zinc. It contains 65% copperand 35% Zinc. This non ferrous metal is very corrosive, yellow incolour, tarnishes very easily. It is harder than copper and its goodelectrical conductor.

Lead :Lead is a pure and an important non ferrous metal. It is the heaviestcommon metal. The other characteristics are its softness,malleability and brightness. It is shiny metal when new but quicklyoxidizes to a dull grey. It has resistant to corrosion. Its uses aredifferent than other non ferrous metals. It is used in protection

against X-Ray machine, Paints, roof coverings, flashings etc.


78/78

Zinc :Lead is also a pure and an important non ferrous metal. Alayer of oxide protects it from corrosion. It is bluish-white

in colour and easily worked. It is used to makes brass bymixing and processing with Copper. It is used as coatinglayer for steel galvanized corrugated iron roofing, tanks,buckets, rust-proof paints etc.

Tin :

Tin is a pure non ferrous metal. It is white in colour, softand corrosion resistant. It is used in Tinplate and makingbronze.

Gilding metal:This non ferrous metal comprises of 85% copper and 15%

zinc. It is corrosion resistant, golden in colour and enamelswell. Its uses are Beaten metalwork and artificial jewellerymanufacturing.

Class 5_6 Materials

Documents

Transcript of Class 5_6 Materials