LESSON 3 (Classification of Materials)

Question 1

Materials selection process

Answer 1

Define product design
Define subassembly design
Define product element design requirements
Identify material selection criteria for a product element
Identify material options
Evaluate materials
Select Optimum materials

Question 2

Factors that influence both material and process selection

Answer 2

Geometry
Service requirements
Materials properties
Manufacturing data
Economics

Question 3

Shape, size, weight, features, e.g., threads

Answer 3

Geometry

Question 4

Operating conditions and functions

Answer 4

Service requirements

Question 5

Surface finish, tolerances, special treatments, tooling, etc.

Answer 5

Manufacturing data

Question 6

material costs and availability process cost and comparisons

Answer 6

Economics

Question 7

Metals

Answer 7

Non-ferrous
ferrous

Question 8

Polymers

Answer 8

Thermosets
Thermoplastics
Elastomers

Question 9

Ceramics

Answer 9

ceramics

Question 10

composites

Answer 10

composites

Question 11

Natural

Answer 11

organic
inorganic

Question 12

Man-made

Answer 12

Man-made

Question 13

The most commonly used class of engineering
materia

Answer 13

METALS

Question 14

Metal _______ are especially common

Answer 14

alloys

Question 15

They are formed by combining a metal with one or
more other metallic and/or non-metallic materials.

Answer 15

alloy

Question 16

The combination usually occurs through a process
of melting, mixing, and cooling.

Answer 16

METALS

Question 17

The goal of alloying is to improve the properties of
the ________________ in some desirable way.

Answer 17

base material

Question 18

The metals may further classified:

Answer 18

Ferrous Metals
 Non-Ferrous Metals

Question 19

These metals have the iron as their main
constituent:

Answer 19

FERROUS METALS

Question 20

FERROUS METALS

Answer 20

Cast Iron
 Wrought Iron
 Metal

Question 21

These metals have a metal other than iron as their
main constituent:

Answer 21

NON-FERROUS METALS

Question 22

NON-FERROUS METALS

Answer 22

Copper
 Aluminum
 Brass
 Tin
 Zinc
 Etc.

Question 23

These have iron as the base element.

Answer 23

FERROUS ALLOYS

Question 24

These are alloys and include steels and cast irons.

Answer 24

FERROUS ALLOYS

Question 25

These are basically just mixtures of iron and carbon.

Answer 25

CARBON STEELS

Question 26

They may contain small amounts of their elements,
but carbon is the primary alloying ingredient.

Answer 26

CARBON STEELS

Question 27

It has less than about 0.30% carbon.

Answer 27

LOW-CARBON STEEL

Question 28

It is characterized by low strength but high ductility

Answer 28

LOW-CARBON STEEL

Question 29

It contains between about 0.30% to 0.70% carbon.

Answer 29

MEDIUM-CARBON STEEL

Question 30

It can be heat treated to increase strength,
especially with the higher carbon contents

Answer 30

MEDIUM-CARBON STEEL

Question 31

It contains between about 0.70% to 1.40% carbon

Answer 31

HIGH-CARBON STEEL

Question 32

It has high strength but low ductility.

Answer 32

HIGH-CARBON STEEL

Question 33

These are commonly called alloy steels.

Answer 33

LOW-ALLOY STEELS

Question 34

It contains less than about 8% total alloying
ingredients.

Answer 34

LOW-ALLOY STEELS

Question 35

These are typically stronger than carbon steels and
have better corrosion resistance

Answer 35

LOW-ALLOY STEELS

Question 36

Primarily, it is used to make tooling for use in
manufacturing.

Answer 36

TOOL STEELS

Question 37

example: Cutting tools, Drill bits, Punches, Dies,
and Chisels

Answer 37

TOOL STEELS

Question 38

These have good corrosion resistance, mostly due
to the addition of chromium composition of at least
11%

Answer 38

STAINLESS STEELS

Question 39

It is a ferrous alloy containing high levels of carbon,
generally greater than 2%

Answer 39

CAST IRON

Question 40

The most common type of alloy

Answer 40

GRAY CAST IRON

Question 41

The carbon is in the form of graphite flakes.

Answer 41

GRAY CAST IRON

Question 42

The addition of magnesium to _______________________improves the ductility of the material.

Answer 42

GRAY CAST IRON

Question 43

The resulting material of gray cast iron is called ___________________
because the magnesium causes the graphite flakes
to form into spherical nodules

Answer 43

nodular cast iron

Question 44

It has carbon in the form of carbide, which makes
the material hard, brittle and difficult to machine

Answer 44

WHITE CAST IRON

Question 45

GRAY CAST IRON is also called as

Answer 45

ductile cast iron.

Question 46

It is produced by heat treating white cast iron.
PIG IRON

Answer 46

MALLEABLE CAST IRON

Question 47

It is formed by heating coal to 2100° F (1150° C),
then cooling it in quenching towers.

Answer 47

MALLEABLE CAST IRON

Question 48

It is used to remove impurities.

Answer 48

Limestone

Question 49

It is a melting device used in foundries that can be
used to melt cast iron.

Answer 49

CUPOLA or CUPOLA FURNACE

Question 50

used to produce pig iron from iron ore for subsequent processing into steel, and they are also employed in processing lead, copper, and other metals.

Answer 50

Blast furnace

Question 51

IRON MAKING

Answer 51

Blast furnace
CUPOLA or CUPOLA FURNACE