engineering materials technology

TARLAC STATE UNIVERSITYCollege of Enginering

[ES4] ENGINEERING MATERIALS

CHAPTER 1:ENGINEERING MATERIALS

TECHNOLOGYReported By:

DIMARUCOT, Omar Navarro (BSEE)

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ENGINEERING MATERIALS TECHNOLOGY

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T O P I C S

1.1 Engineering Materials Technology

1.2 The Materials Cycle

1.3 Materials Selection

1.4 Technological Literacy

PAUSE & PONDER

We live in a Materials world!

Many of the advances in society, with the aid of technology resulted from discoveries and developments in engineering materials.

We exist in a world made of an infinite variety of materials.

We are in a Materials Age!

Recent decades have seen an explosion of interest in and knowledge about making our lives better by improving materials and materials processing for finer engineered products.

PAUSE & PONDERThe development of materials over time. The materials of pre-history, on the left, all occur naturally; the challenge for the engineers of that era was one of shaping them. The development of thermochemistry and (later) of polymer chemistry enabled man-made materials, shown in the colored zones. Three - stone, bronze and iron - were of such importance that the era of their dominance is named after them.

PAUSE & PONDER

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Why Study ENGINEERING MATERIALS?

Through this study, we will enhance and broaden our knowledge about and the competencies in structure, processing, properties of engineering materials.

In materials technology, there is only one constant:

CONSTANT CHANGE

PAUSE & PONDER

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Why Study ENGINEERING MATERIALS?

1. Develop an awareness of the importance of engineering materials in everyday life;

2. Recognize society’s dependence on materials;

3. Appreciate the value of a knowledge of engineering materials technology for you as a consumer, citizen, and a member of the technological workforce.

1.1ENGINEERING

MATERIALS TECHNOLOGY

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1.1 ENGINEERING MATERIALS TECHNOLOGY

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Definition of Terms

Materials Materials are the matter of the universe. These

substances have properties that make them useful in structures, machines, devices, products, and systems.

Engineering Materials Engineering Materials is the term often used loosely to

define most materials that go into products and systems.


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Definition of Terms

Materials Engineering Materials Engineering deals with synthesis, and use of

knowledge [structure, properties, processing, and behavior] in order develop, prepare, modify, and apply materials to specific needs.

**Materials Science & Engineering (MSE) MSE involves the generation and application of

knowledge relating the composition, structure, processing, of materials to their properties and uses.


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Definition of Terms

**Materials Science & Engineering (MSE)

The “science” focuses on discovering the nature of materials, which in turn leads to theories or descriptions that explain how structures relates to composition, properties and behavior

The “engineering” deals with use of the science in order to develop, prepare, modify, and apply materials to meet specific needs.


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Definition of Terms

**Materials Science & Engineering (MSE) Material Science & Engineering is interdisciplinary or

multidisciplinary, embracing areas such as metallurgy, ceramics, solid-state physics, and polymer chemistry.

Engineering Materials Technology Engineering Materials & Technology covers fields of

applied science related to materials processing, and the many engineering specialties dealing with materials such as research & development, design, manufacturing, construction, and maintenance.


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MATERIALS

PROPERTIES

Properties describes behavior of materials when subjected to some external force or condition

Review; MATERIALS Materials are the matter of the universe. These

substances have properties that make them useful in structures, machines, devices, products, and systems.


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Materials

CLASSES OF PROPERTIES

Economic

General Physical

Thermal

Electrical & Magnetic

Environmental InteractionProduction

Aesthetic

Mechanical


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Materials


Price and availabilityRecyclability

Density / Relative heaviness

ModulusYield and tensile strengthHardnessFracture toughnessFatigue strengthCreep strengthDamping

Economic

General Physical

Mechanical


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Materials

Thermal conductivitySpecific heatThermal expansion coefficient

ResistivityDielectric constantMagnetic permeability

OxidationCorrosionWear

Thermal

Electrical & Magnetic

Environmental Interaction



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Materials

Ease of manufactureJoiningFinishing

ColourTextureFeel

Production

Aesthetic



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Properties

Bulk Mechanical Properties

Price and Availability

Bulk Non-mechanical Properties

Surface Properties

Production Properties

– Ease of manufacturing, fabrication, joining, finishing

Aesthetic Properties

– Appearance, Texture, Feel

DESIGN

INTRINSIC ATTRIBUTE

How the properties of engineering materials affect the way in which products are designed


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Materials

METALS and Alloys

FAMILY / CLASSES OF MATERIALS

POLYMERS

CERAMICS and GlassesCOMPOSITES

Natural Materials**


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Materials

METALS


• Metallic materials are normally combinations of metallic elements. They have large numbers of non-localized electrons; that is, these electrons are not bound to particular atoms. Many properties of metals are directly attributable to these electrons. Metals are extremely good conductors of electricity and heat and are not transparent to visible light; a polished metal surface has a lustrous appearance. Furthermore, metals are quite strong, yet deformable, which accounts for their extensive use in structural applications.


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Materials

Alloys


Metals in combination with other metals or non metal elements.

Examples: Steel (Iron & Carbon), Brass (Copper & Zinc)


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Materials

METALS and Alloys


Iron and steels

Aluminium and its alloys

Copper and its alloys

Nickel and its alloys

Titanium and its alloys


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Materials

METALS and Alloys



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Materials

POLYMERS


• Polymers include the familiar plastic and rubber materials. Many of them are organic compounds that are chemically based on carbon, hydrogen, and other nonmetallic elements; furthermore, they have very large molecular structures. These materials typically have low densities and may be extremely flexible.


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Materials

POLYMERS


Polyethylene (PE)Polymethylmethacrylate \

(Acrylic and PMMA)Nylon, alias Polyamide (PA)Polystyrene (PS)Polyurethane (PU)Polyvinylchloride (WC)Polyethylene tetraphthalate (PET)Polyethylether Ketone (PEEK)Epoxies (EP)Elastomers, such as natural rubber (NR)


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Materials

CERAMICS and Glasses


• Ceramics are compounds between metallic and nonmetallic elements; they are most frequently oxides, nitrides, and carbides. The wide range of materials that falls within this classification includes ceramics that are composed of clay minerals, cement, and glass. These materials are typically insulative to the passage of electricity and heat, and are more resistant to high temperatures and harsh environments than metals and polymers. With regard to mechanical behavior, ceramics are hard but very brittle.


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Materials



Ceramics are crystalline, inorganic, non-metals.

Glasses are non-crystalline (or amorphous) solids.

Most engineering glasses are non-metals, but a range of metallic glasses with useful properties is now available.


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Materials



Alumina (AI2O3, emery, sapphire)

Magnesia (MgO)

Silica (SO2) glasses and silicates

Silicon carbide (SiC)

Silicon nitride (Si3N4)

Cement and concrete


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Materials

COMPOSITES


• A number of composite materials have been engineered that consist of more than one material type. Fiberglass is a familiar example, in which glass fibers are embedded within a polymeric material. A composite is designed to display a combination of the best characteristics of each of the component materials. Fiberglass acquires strength from the glass and flexibility from the polymer. Many of the recent material developments have involved composite materials.


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Materials

COMPOSITES


Fibreglass (GFRP)

Carbon-fibre reinforced polymers (CFRP)

Filled polymers

Cermets


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Materials

Natural Materials**


Wood

Leather

Cotton / wool / silk

Bone

Natural Materials = Conventional Engineering Materials


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Family / Classes of Materials

Metals and alloys

PolymersCeramics

and glasses

Composites

Wire-reinforced

cement cermets

Steel-cord Tyres

Filled Polymers

GFRPCFRP

The classes of Engineering materials from which articles are made

1.2MATERIALS CYCLE

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1.2 THE MATERIALS CYCLE

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MATERIALS

CYCLE

Recycling/disposing of used

products and systems

Extracting Raw materials

Creating bulk materials,

components and devices

Manufacturing engineered materials

Fabricating products and

systems

Service of products and systems


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Periodic Table of Elements

EXTRACTING RAW MATERIALSThe earth has provided us with the basic ingredients for producing an unlimited variety of materials.


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Definition of Terms

EXTRACTING RAW MATERIALS

Synthesis

Synthesis involves transforming gases, liquids, and solid elements by chemical and physical means, where atoms and molecules are combined to form solid materials.

Materials Processing Materials Processing includes control of structure at

higher levels of aggregation and may sometimes have an engineering aspect.


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Definition of Terms

EXTRACTING RAW MATERIALS

Scitech

Introduced by Lyle Swarts (1996). It describes the complex inter-twinning of science with technological applications such as materials processing and manufacturing.

Shape-limited Sythesis

A new method developed to produce materials that blend synthesis with processing by beginning with one of the chemical agents already in the form of the final shape.


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Definition of Terms

Bulk Materials

Bulk Materials are the products of synthesis, materials extraction, and processing. These are usually made in large quantities through continuous processing and then supplied to manufacturers of components and devices.

CREATING BULK MATERIALS, COMPONENTS AND DEVICES

Components Components include gears, electrical wires, screws, nuts, jet

engine turbine blades, brackets, levers, and the thousands of constituent parts that go into many parts and systems.


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Definition of Terms

Devices Devices are usually more complex than components and are

designed to serve a specific purpose.

CREATING BULK MATERIALS, COMPONENTS AND DEVICES

Products Products are individual units.

Systems Systems are an aggregate of products, components, and

devices.


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Definition of Terms

Designed Materials The new generation of Engineering Materials.

MANUFACTURING ENGINEERED MATERIALS

They have been engineered to provide designated properties. Instead of designers selecting from a list of available

materials, they may specify the desired properties for their needs, and then rely on materials engineers and technologist to create materials to suit the need.

Examples: Advanced Composites, Advanced Ceramics


MaterialsScience

Engineering Mechanics Durability

Engineering Design

Manufacturing

Life-cycle concernsFundamental Laws

InteractionsReliability

QualityCost



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Definition of Terms

Intelligent Processing of Materials (IPM)


IPM is an evolving technology that uses computer modeling of processes and sensors put in place to monitor and permit control of processing.

IPM yields better quality and more reliable products.

Smart Materials A term referring to a variety of liquids and solids that have the

ability at the predetermined condition to sense stresses and respond to alter their properties


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Definition of Terms

Biomimicking


To study nature and attempt to mimic its wonders which may lead to better techniques for fabricating integrated circuits for computers and microprocessors.


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Definition of Terms

MANUFACTURING ENGINEERING Manufacturing Engineering is the study of

techniques to turn bulk materials into finished products and systems.

FABRICATING PRODUCTS AND SYSTEMS


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Definition of Terms


Automation Automation is the common element today in manufacturing,

with less manual labor involved. Computers, sensors, robotics, machine vision, adaptive

control, and artificial intelligence are applied by manufacturing engineers to perform to perform the manufacturing processes once carried out by humans.

Improved quality, smaller lot sizes, more product options, and reduction in price have


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Automation


Benefits of AUTOMATION Improved quality

Smaller lot sizes

More product options

Reduction in price

Fabrication of products & services is done in a safer work environment


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Definition of Terms


Just-In-Time (JIT) Manufacturing Technique that rely on computer assistance

keep raw materials and parts moving with a minimum warehousing.

People who wish to work in manufacturing are expected to be well educated because of their newer role as “problem solvers” rather than laborers.


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Definition of Terms


Computer-integrated manufacturing (CIM) CIM is a technological team approach to manufacturing that

places the materials engineers and technologists together with the design engineers, technicians, and manufacturing engineers, plus the environmental engineers and even marketing personnel for a “systems approach” to products.



The classes of process. The first row contains the primary shaping processes; below lie the secondary processes of machining and heat treatment, followed by the families of joining and finishing processes.


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PRIMARY SHAPING

Casting methods: Sand, Die, Investment

Molding methods:

Deformation methods:

Powder methods:

Injection, Compression, Blow molding

Rolling, Forging, Drawing

Sintering, HIPing, Slip casting



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PRIMARY SHAPING

Composite forming: Hand lay-up, Filament winding, RTM

Special methods: Rapid prototype, Lay-up,Electro-form



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Primary Shaping

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Primary Shaping

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Primary Shaping

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SECONDARY PROCESS

Machining: Cut, turn, plane, drill, grind

Heat treat: Quench, temper, age-harden



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JOINING

Fastening, Riveting

Welding, Heat bonding

Snap fits, Friction bond

Adhesives, Cements



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62Joining

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63Joining

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SURFACE TREATMENT

Polishing, Texturing

Plating, Metallizing

Anodize, Chromizing

Painting, Printing



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SurfaceTreatment

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SurfaceTreatment

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SurfaceTreatment

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SurfaceTreatment

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Rationale

Shifts in manufacturing have resulted in a larger service work force and a smaller manufacturing work force. The complexity of products makes it harder for the average person to make repairs on his or her own products. Special diagnostic equipment is used to analyze everything from automobiles to robots to appliances.

SERVICE OF PRODUCTS AND SYSTEMS

The demand for better quality in products and systems has resulted in improved, long term warranties. Manufacturers are very interested in analyzing materials that fail so that they can improve materials engineering and product design.


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Definition of Terms

Design for Assembly Places emphasis on designed products that lend themselves

to easy assembly by robots and other automated equipment.

SERVICE OF PRODUCTS AND SYSTEMS

Design for Disassembly A concept that places recycling at the beginning or design

state of the materials to ensure that waste going into landfills are minimized.


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Rationale

The last stage of the materials cycle can become the first stage through the resurrection of material when recyling is employed. Most materials can be recycled. However, It is very difficult for manufacturers to develop a full materials cycle that will ensure recycling.

RECYCLING/DISPOSING OF USED PRODUCTS AND SYSTEMS


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Rationale

Laws have put mandates on recycling by restricting the amount of solid waste that can be placed on landfills. Clean air and water regulations have restricted the amount and type of waste that can be incinerated or dumped into the ocean. But much remains to be accomplished to develop the proper attitudes and habits among our citizens if we are to make the total materials cycle efficient and thus protect the environment and natural resources for future generations.

RECYCLING/DISPOSING OF USED PRODUCTS AND SYSTEMS


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Limited Resources

CONSEQUENCES OF THE STAGES OF THE MATERIALS CYCLE

Energy Waste

Harmful by-products of material processing Material Disposal

COUNTERMEASURE:It is expected that every-one will apply knowledge of materials to ensure that our natural resurces are best utilized and that engineering materials technology safeguards the environment.

1.3MATERIALS SELECTION

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1.3 MATERIALS SELECTION

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Rationale

We are surrounded by materials and we rarely think about how these materials are selected.

With the nearly limitless range of materials available to the designer or architect, how do they make materials selection for products and buildings? What selection criteria are most important?

With the nearly limitless range of materials available to the designer or architect, how do they make materials selection for products and buildings? What selection criteria are most important?


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T O P I C S

THE IDEAL MATERIAL

SELECTION AND COMPROMISE

OBSTACLES TO CHANGE

ALGORITHM FOR MATERIALS SELECTION


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Rationale

THE IDEAL MATERIAL

1.) Endless & readily available source of supply

What is an IDEAL MATERIAL?

2.) Cheap to refine and produce

3.) Energy efficient

4.) Strong, stiff, and dimensionally stable at alltemperatures

5.) Lightweight


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Rationale

THE IDEAL MATERIAL

6.) Corrosion resistant

What is an IDEAL MATERIAL?

7.) No harmful effects on the environment or people

8.) Energy efficient

9.) Numerous secondary uses


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Rationale

Materials selection is not simply a matter of making decisions a matter of making decisions about cost and material properties.

“COMPROMISE is the RULE, not the EXEMPTION”

SELECTION AND COMPROMISE


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Rationale

This focuses attention on a leading problem of all new materials: It requires time before both designers and fabricators gain sufficient experience to become comfortable with them and the associated processes required to make products or systems.

OBSTACLES TO CHANGE

This problem is exacerbated when human life might be in jeopardy, such as when designing an aircraft. As a consequence, new materials and processes are usually slower to enter the marketplace than might be expected.


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Rationale

Materials selection is a problem-solving issue that requires algorithm for its solution.

Algorithms are well-defined methods for solving specific problems. Computer programs are written after an algorithm has been developed to lay out clearly the steps that the program is to solve.


ALGORITHM


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Sub – Topics


I. Selection Tools

II. Properties of Materials

III.Material Systems

IV. Additional Selection Criteria


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I. Selection Tools


Databases / Periodicals / Manuals

Graphical techniques

Databases involves tables listing properties of materials, such as tensile strength, hardness, corrosion resistance, and the ability to withstand heat.

Bar Charts Bubble Charts


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I. Selection Tools


A bar chart of mudulus. It reveals the difference in stiffness between the families.


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I. Selection Tools

Graphical techniques A bubble chart of

modulus and density. Families occupy discrete areas of the chart

A graphical plot of two important properties shows a relationship of stiffness (Young’s Modulus) to weight (density)


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ALGORITHM FOR MATERIALS SELECTION Publications present

values for the performance criteria (properties) for metals, polymers, and ceramics, with updates on newer materials.


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ALGORITHM FOR MATERIALS SELECTION Periodicals can provide current data and performance criteria

that involve structural (load bearing) materials:

1) STRENGTH (tensile, compressive, flexural, shear, and torsional)

6) CORROSION RESISTANCE

2) RESITANCE TO ELEVATED TEMPERATURES3) FATIGUE RESISTANCE (repeated loading and unloading)4) TOUGHNESS (resistance to impact)5) WEAR RESISTANCE (hardness)


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ALGORITHM FOR MATERIALS SELECTION The designer must use such data to determine if a material

has appropriate physical, mechanical, and chemical properties to withstand the service conditions to which a part will be subjected.

Selection of specific materials requires many more detailed specifications. General databases from handbooks will provide much detail, but the final selection often requires that material manufacturers supply their own properties database for their product lines.


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Part of a record for a material, ABS. It contains numeric data, text and image-based information.


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III. Material Systems

ALGORITHM FOR MATERIALS SELECTION Materials rarely exist in isolation, without interacting with

other materials. A combination of materials is selected to complement

one another.

Each component is compatible with the others while contributing its distinctive properties to the overall characteristics of the system of which it is a part.


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Specifications / Standards

Availability

Processibility

Near-net-shape production

Quality and Performance

Consumer acceptance


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Design for disassembly

Design for Service

Cost

Product liability


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Specifications / “Standards” Specification / Standards have a lot of influence on the choice of

material and are used when re-designing an improved model of the product.

Current specifications are set by standardizing agencies: International Standards Organization (ISO) American National Standards Institute (ANSI) USFDA / BFAD (Philippines) OSHA


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The ease with which raw materials can be transformed into finished product.

Focuses on low-energy processing

Processibility

Availability Material be easily available in the quantities, sizes, and shape

required by the production demand.


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Involves incorporating numerous separate parts into a single, integrated assembly, thus saving over-all production costs.

Focuses on low-energy processing


The near-net-shape concept is a growing trend because it is consistent with the new thinking about design/manufacturing; that is, the concept design, engineering analysis, materials selection, and processing orchestrated in a team approach.


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CAD/CAM Technologies

Artificial Intelligence (AI)


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Two aspects that achieve consumer satisfaction

The high cost of most durable goods and the competition for customer acceptance has resulted in extended warranties.

Quality and Performance

Materials selection must ensure that parts will not rust, break under repeated stress, or fail to perform in any other way for the predicted service life of the product.


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Society as a whole as well as government agencies are requiring a closer look at manufactured products.

Consumer Acceptance

Any product has to be considered in terms of its total life cycle.

What are the results of the processing methods? Are pollutants being released in the environment? Does the product safeguard our health during use? How can it be disposed of safely?


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Established procedures ensures that products can be broken into components for easy sorting prior to recycling.

Design for disassembly

Design for Service A new program that helps product designers consider repair

issues early in the design stage. Includes making repairs less costly and extending the

functioning life of the products.


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The primary selection criterion that will determine final choice of the material.

Cost

Product liability

“Lower cost materials would be the logical choice”

Civil liability of the manufacturer to an ultimate user for injury resulting from defective product.

“Material Selection might MAKE or BREAK a company”

1.4TECHNOLOGICAL

LITERACY

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1.4 TECHNOLOGICAL LITERACY

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INTRODUCTION & TOPICS

THE MATERIALS CONSUMER

THE INTELLIGENT CITIZEN

Technologically Literate… Understand the language and concepts of technology

Understand new technological advances


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Rationale


To be an informed and intelligent consumer requires a basic understanding of materials.

The selection of a product can be improved by a greater understanding of the nature and the properties used in the product.

Learning about the structure of materials, hence how materials behave, should permit an intelligent analysis of a failure and possibly pinpoint its source and cause.


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Rationale


A knowledgeable consumer stands a much better chance of success in demanding remedial action from both manufacturers and retailers of faulty products than does one with less knowledge of the behavior of materials and poor technical vocabulary with which to explain such behavior.


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Rationale

The technology of materials also provides us the necessary knowledge to make decisions based on personal values relating to political, social, and ecological issues.

THE INTELLIGENT CITIZEN

“A Better informed citizen is a better citizen”

APPLICATIONS & ALTERNATIVES

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Applications & alternatives

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MATERIAL SYSTEMS IN BIOTECHNOLOGY

Combines biology and medicine with many specialties in engineering and material science to foster technological developments to aid human beings and animals.

BIOENGINEERING

Produces artificial organs, limbs, and related anatomic structures.

Applications & alternatives

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MATERIAL SYSTEMS IN BIOTECHNOLOGY

BIOENGINEERING

END OF TOPIC

Thank you for Listening!

112

engineering materials technology

Business

metallic materials

bulk materials

rubber materials

development of materials

properties of metals

engineered materials

raw materials

wide range of materials