Materials Flashcards
Materials are split into…
Groups or classifications
What are the classifications?
- Metal
- Woods
- Polymers
- Papers and boards
- Composites
- Smart materials
- Modern materials
What are the types of classification associated with Metals?
- Ferrous
- Non-Ferrous
- Alloy
What is meant by Ferrous?
A metal which contains mostly iron and carbon. they are magnetic and will rust
What are some examples of ferrous?
Low carbon steel, medium carbon steel iron cast
What is meant by non-ferrous?
A metal that does not contain iron. they are not magnetic and do not rust
What are some examples of non-ferrous metals?
Aluminium, copper, zinc, silver, gold, titanium, tin
What is meant by Alloy?
A metal made of two or more metals or combining two or more elements, one of which must be a metal.
alloys can also be sub-classified as ferrous alloys or non-ferrous alloys
What are some examples of ferrous alloys?
stainless steel and die steel (tool steel)
What are some examples of non-ferrous alloys?
bronze, brass, duralumin, pewter
Metals occurs naturally in the form of…
Ore
What percentage of the Earths crust is metal ore?
Approximately 25%
What are the two most common metal ores?
Bauxite followed by iron
How is the raw metal extracted from the ore?
Through a combination of crushing, smelting or heating, with the addition of chemicals and huge amounts of electrical energy.
most metals can be…
recycled, saving natural resources and limiting the amount of materials imported from abroad
what are the ores for these metals?
- Copper
- Aluminium
- Tin
- Zinc
- Chalcopyrite
- Bauxite
- Cassiterite
- Zinc blende
What metals are non-ferrous?
- aluminium
- copper
- zinc
- silver
- gold
- titanium
- tin
Non-Ferrous metals:
Properties of Aluminium
- Lightweight
- ductile
- malleable
- corrosion-resistant
- electrical and thermal conductor
- can be metal inert gas (MIG) and tungsten inert gas (TIG) heat welded
- melting temp: 660°C
Non-Ferrous metals:
Uses of Aluminium
- Drink cans
- aircraft bodies
- bike frames
- window frames
- packing
- baking foil
Non-Ferrous metals:
Properties of copper
- ductile
- malleable
- tough
- corrosion-resistant
- good electrical and thermal conductor
- can be soldered and brazed
- melting temp: 1083°C
Non-Ferrous metals:
uses of copper
- electrical wire
- printed electrical circuits
- water pipes
- hot water tanks
- central heating pipes
Non-Ferrous metals:
properties of Zinc
- low melting point
- good corrosion resistance
- melting temp: 420°C
Non-Ferrous metals:
uses of zinc
- galvanising steel as a protective coating for dustbins
- dustbins
- farm gates
- intricate die casting
Non-Ferrous metals:
properties of tin
- ductile
- malleable
- low melting point
- corrosion-resistant
- melting temp: 232°C
Non-Ferrous metals:
uses of tin
- soft solder
- coatings for food cans
- rarely used in pure form
What are examples of ferrous metals?
- low-carbon steel
- medium carbon steel
- cast iron
- mild steel
Ferrous metals:
properties of Low carbon steel
- ductile
- high tensile strength
- tough
- malleable
- poor resistance to corrosion
- 0.15-0.30% carbon content
- melting temp: 1427°C
Ferrous metals:
uses of low carbon steel
- nuts
- bolts
- washers
- screws
- car bodies
- outer panels for white goods
Ferrous metals:
properties of medium carbon steel
- harder than low carbon steel
- less ductile then low carbon steel
- malleable
- tough
- 0.30-0.70% carbon content
Ferrous metals:
uses of medium carbon steel
- springs
- gardening tools (trowels, forks)
Ferrous metals:
properties of cast iron
- hard outer skin but brittle core
- good under compression
- 3.5% carbon
- melting temp: 1149°C
Ferrous metals:
uses of cast iron
- disk brakes
- machine parts
- engine blocks
- sheet furniture (ie decorative bollards, bins and lighting)
Ferrous metals:
properties of mild steel
- strong
- malleable
- 0.4% carbon
- high tensile strength
- high impact strength
- melting temp: 1410°
Ferrous metals:
uses of mild steel
- construction
what are examples of ferrous alloys?
- stainless steel
- high speed steel (HSS)
- die steel (tool steel)
Ferrous Alloys:
properties of stainless steel
- tough
- hard
- corrosion-resistant
- 10% chrome
- 8% nickel
- melting temp: 1510°C
Ferrous alloys:
uses of stainless steel
- sinks
- kitchenware
- cutlery
What are examples of non-ferrous alloys?
- brass
- bronze
- duralumin
Non-Ferrous alloys:
properties of brass
- corrosion-resistant
- good electrical conductor
- good thermal conductor
- low melting point
- casts well
- 65% copper
- 35% Zinc
- melting temp: 930°C
Non-Ferrous alloys:
uses of brass
- boats fittings
- door furniture
- cast valves and taps
- ornaments
Non-Ferrous alloys:
properties of Duralumin
- equivelant strength and properties to low carbon steel but more lightweight
- ductile
- becomes harder as it is worked
- 4% copper
- 1% magnesium and manganese
Non-Ferrous alloys:
Uses of the Duralumin
- Air crafts
- Vehicle parts
metal stock forms:
sheets are…
large flat sections of metal in varying thicknesses from less than 1mm up yo approximately 3mm
metal stock forms:
plates are…
generally thicker than 3mm and narrower than sheet metals
metal stock forms:
bars are…
solid form, flat bar, square bar, round bar or hexagonal bar
metal stock forms:
tubes are…
hollow in cross-section and can be square, rectangular (also called box section), round or hexagonal
metal stock forms:
structural is…
angular shapes such as H beams, L beams (angle), i beams, tee beams and channel
what are the 3 types of wood?
- Hardwood
- Softwood
- Manufactured board
what are examples of hardwoods?
- oak
- jelutong
- mahogany
- balsa
- beech
What is meant by hardwood?
- a wood from broad-leafed (deciduous) trees
- generally slow-growing
- lose leaves in autumn
Hardwoods:
Properties of Oak
- Hard
- tough
- attractive grain
- good weather resistance
- contains tannic acid which corrodes steel screws or fixings
Hardwoods:
Uses of Oak
- floorings
- furniture
- boat building
- cladding
- interior and exterior joinery
Hardwoods:
Properties of Mahogany
- can contain an interlocking grain (makes it more difficult to work with)
- rich dark red colour
Hardwoods:
Uses of mahogany
- indoor furniture
- shop fittings and cabinets
- veneers commonly used on manufactured boards
Hardwoods:
Properties of beech
- tough
- close-grained
- hard
- available in steamed (white colour) and un-steamed (pink tinge)
- does not impart a taste to food
Hardwoods:
Uses of beech
- chairs
- chopping boards
- tools (mallets)
- steam-bent laminated furniture
- turned bowls
Hardwoods:
Properties of jelutong
- low density
- straight grain
- fine texture
- rated non-durable to perishable
- diffuse-porous
- sour odour
- can cause skin irritation
Hardwoods:
Uses of jelutong
- patternmaking
- carving
Hardwoods:
Properties of balsa
- pale reddish-brown
- most boards of balsa are made from sapwood which is white to off-white or tan, sometimes with a pink or yellow hue
- straight grain
- perishable
- susceptible to insect attack
*
Hardwoods:
uses of balsa
- buoys
- rafts
- surfboards
- model aeroplanes
- musical instruments
- packing/transport cases
- core stock in sandwich laminations
- fishing lures
*
What is meant by softwood?
- a wood from coniferous (cone-bearing) trees
- fast growing
- tend to be evergreen
what are examples of softwood?
- pine
- redwood
- cedar
- larch
Softwoods:
Properties of pine
- straight grain
- knotty
- can contain resinous knots
Softwoods:
Uses of pine
- construction work
- roof beams
- timber frame construction
- interior joinery
Softwoods:
Properties of Cedar
- straight grain
- can corrode ferrous metals due to acidic nature
- low density
- good sound damping
- good resistance to moisture
Softwoods:
uses of cedar
- exterior cladding
- sheds
- greenhouses
- beehives
- interior panelling
Softwoods:
Properties of Larch
- Hard
- tough
- attractive grain pattern fades to silver upon exposure
- good resistance to moisture
Softwoods:
Uses of Larch
- garden furniture
- cladding
- decking
- fencing
Softwoods:
Properties of Redwood
- Grain is straight
- Coarse texture
- moderately durable regarding decay resistance
- distinct odour
- resin canals absent
Softwoods:
Uses of Redwood
- veneer
- construction lumber
- beams
- posts
- decking
- exterior furniture
- trim
what is manufactured wood?
a man-made wood-based composite materials.
manufactured boards are available in much larger sizes than solid wood
what are examples of the manufactured board?
- plywood
- chipboard
- Medium-density fibreboard (MDF)
- hardboard
manufactured wood:
Properties of Plywood
- thin layers of wood placed and glued at a 90-degree angle to each other and compressed to form the board
- good strength in all directions
- no grain weakness
- always has an odd number of layers
manufactured wood:
Uses of plywood
- structual work
- desktops
- indoor furniture
- floorboards
manufactured wood:
Properties of MDF (Medium-density fibreboard).
- compressed wood fibres
- sometimes urea-formaldehyde is added as an additional resin
- 2 smooth faces
- available in either standard grade or veneered with a layer of timber
manufactured wood:
Uses of Medium-density fibreboard (MDF)
- model making
- mould making
- some furniture items such as book shelves
manufactured wood:
Properties of chipboard
- model making
- mould making
- furniture items such as bookcases
- cabinets and desks
manufactured wood:
Uses of Chipboard
- flat-pack furniture and work surfaces
- the carcass of kitchen units and worktops and flooring
manufactured wood:
Properties of hardboard
- made from wood fibre extracted from chips and pulped wood waste
- the pulp is exploded under pressure
- held together by lignum and other glues
- grainless
- with one smooth glossy surface and one textured surface
- to prevent warping moisture is added in a humidification chamber
- absorbs water
- oil tempered - stiffer, harder, more resistant to scratches and moisture
manufactured wood:
Uses of hardboard
- furniture components
- wall panelling
- moulded door skins
- underlayment
- perforated boards
What are the 3 types of polymers?
- Thermoplastic
- Thermosetting polymer
- Elastomer
what is meant by thermoplastic?
A material which can be repeatedly reheated and reshaped, allowing it to be recycled after its initial use. Thermoplastics have long linear chain molecules held by van de walls forces.
what are examples of thermoplastics?
- low-density polyethylene (LDPE)
- high-density polyethylene (HDPE)
- polypropene (PP)
- acrylonitrile butadiene styrene (ABS)
- polyethylene terephthalate (PET)
- rigid and flexible polyvinyl chloride (PVC)
- Acrylic
thermoplastics:
Properties of low-density polyethylene (LDPE)
- very tough
- good chemical resistance
- weatherproof
- available in translucent
- low level of rigidity
Thermoplastics:
Uses of low-density polyethylene
- squeezy detergent bottles
- toys
- carrier bags
- bin liners
- general packaging
- food wrap film
- food trays
thermoplastics:
Properties of High-density polyethylene (HDPE)
- available in translucent
- weatherproof
- tough
- good
- chemical resistance
- safe working temperature 65 degrees Celcius
thermoplastics:
Uses of High-density polyethylene
- chemical drums
- jerry crews
- toys
- household and kitchenware
- long life carrier bags
- buckets
- bowls
thermoplastics:
Properties of Polypropylene (PP)
- Available in translucent
- good chemical resistance
- tough
- good fatigue resistance (Hinge properties)
- safe working temperature 100°C
thermoplastics:
Uses of polypropylene (PP)
- rope
- folders
- folio cases
- food containers
- medical equipment
- hinged containers lids
thermoplastics:
Properties of Acrylonitrile butadiene styrene (ABS)
- extremely tough
- hard
- available in opaque
- safe working temperature 80°C
thermoplastics:
Uses of Acrylonitrile butadiene styrene (ABS)
- telephone headsets
- rigid luggage
- domestic appliances (food mixers)
- handles
- computer housings
- remote control castings
- calculator castings
thermoplastics:
Properties of Polyethylene terephthalate (PET)
- highly flexible
- colourless
- semi-rigid to rigid (depending on processing)
- good dimensional stability
- resistance to impact
- resistant to moisture
- resistance to alcohols and solvents
thermoplastics:
Uses of Polyethylene Terephthalate (PET)
- wiper arm
- gear housings
- headlamp retainer
- engine cover
- connector housing
thermoplastics:
Properties of flexible polyvinyl chloride (PVC)
- available in translucent
- tough
- flexible
- good weathering resistance
- good chemical resistance
- safe working temperature 95°C
thermoplastics:
Uses of flexible Polyvinyl chloride (PVC)
- hose pipes
- cable insulation
- medical grade tubing
- inflatable products
- imitation leather
- seat coverings
Thermoplastics:
Properties of Rigid Polyvinyl Chloride (uPVC)
- Rigid
- opaque
- tough
- hard
- good
- weathering resistance
- good chemical resistance
- fire retardant
- safe working temperature 95°C
thermoplastics:
Uses of Rigid polyvinyl chloride (uPVC)
- window frames
- external doors
- guttering and drainpipes down buildings
- water service pipes
- bank cards
thermoplastics:
Properties of Acrylic
- strong
- stiff
- optical clarity
- weather and sunlight resistant
- rigid
- good impact strength
- dimensional stability
- low mould shrinkage
- poor solvent resistance (especially by ketones, esters, chlorocarbons, aromatic hydrocarbons and freons)
- subject to stress cracking
- combustible
thermoplastics:
Uses of Acrylic
- lenses
- automotive trim
- household items
- light fixtures
- decorator items signage
- point of purchase displays
what is meant by thermosetting polymer?
a material which when heated undergoes a chemical change whereby the molecules form rigid cross-links. thermosetting polymers cannot be reheated and reshaped, even at very high temperatures.
what are examples of thermosetting polymers?
- Urea Formaldehyde (UF)
- polyester resin (PR)
- epoxy resin (ER)
thermosetting plastics:
Properties of Urea-formaldehyde (UF)
- hard
- heat resistant
- good electrical insulator
- brittle
- safe working temperature 80°C
thermosetting plastics:
Uses of Urea-formaldehyde (UF)
- electrical fittings
- adhesives
thermosetting plastics:
Properties of polyester resin (PR)
- rigid
- heat resistant
- chemical resistant
- brittle
- safe working temperature 95°C
thermosetting plastics:
Uses of polyester resin (PR)
- Castings
- used in lay-up process for glass-reinforced plastic (GRP) for boat hulls
- car parts
- chair seats
thermosetting plastics:
Properties of Epoxy resin (ER)
- rigid
- clear
- hard
- tough
- chemical resistant
- 80-200°C
thermosetting plastics:
Uses of Epoxy Resin (ER)
- Adhesives
- surface coatings
- encapsulation of electrical components
- cardiac pacemakers
- aerospace applications
- used in lay-up techniques with Carbon Fibre Reinforced plastic
what is meant by elastomer?
- a material which at room temperature can be deformed under pressure and then upon the release of the pressure will return to its original shape.
- elastomers have weak bonds which allow them to stretch easily. they can be stretched repeatedly and upon immediate release of the stretch, will return with force to the original length
what are examples of elastomers?
- natural rubber
Elastomers:
Properties of natural rubber
- high tensile strength
- low elongation
- good hardness compared to other elastomers
- tough
- electrical insulator
- good cold resistance
Elastomers:
Uses of natural rubber
- automotive industry such as tyres
- tube
- hoses
- gaskets
- belts
- balloons
- toys
- footwear
what are composites?
a material comprised of two or more different materials, resulting in a material with enhanced properties
composites can be:
- fibre-based (CFRP, GRP, Fibre concrete)
- particle-based (tungsten carbine, concrete)
- sheet-based ( aluminium composite board, engineered wood)
what are examples of composites?
- Carbon fibre reinforced plastic (CFRP)
- Glass fibre-reinforced plastic (GRP)
- Medium-density fibreboard (MDF)
- Hardboard
- chip-board
- plywood
Composites:
Properties of Carbon fibre reinforced plastic (CFRP)
- Lightweight
- Corrosion-resistant
- tough
- hard
- good compressive strength
- low thermal expansion
Composites:
Uses of Carbon fibre (CFRP)
- Sports equipment ie bicycle frames
- tennis racquets
- fishing rods
- racing car bodies and parts
- helmets
- prosthetics
Composites:
Properties of Glass Fibre Reinforced Plastic (GRP)
- Lightweight
- corrosion-resistant
- tough
- hard
- low thermal expansion
- good compressive strength
Composites:
Uses of Glass Fibre (GRP)
- Boat hulls
- pond liners
- kayak shells
- sports car bodies and parts
- locomotive train cabs
what are papers and boards?
compliant materials. this means they can be scored, folded and cut with basic tooling to form items such as nets for packaging.
what are types of papers and boards?
- drawing paper
- commercial printing papers
- boards
what are examples of drawing papers?
- layout paper
- cartridge paper
- tracing paper
- copier paper
drawing papers:
Properties of layout paper
- thin
- translucent
- smooth surface
drawing papers:
Uses of layout paper
- sketching
- quick ink
- technical drawing
- tracing
drawing papers:
Properties of tracing paper
- translucent
- slightly thicker than layout
drawing papers:
Uses of Tracing paper
- copying images when sketching
drawing papers:
Properties of Copier paper
- smooth
- bright white to show print clearly
- uncoated surface
- takes colour well
- cheap
- readily available
drawing papers:
Uses of Copier paper
- printing
- photocopying
drawing papers:
Properties of cartridge paper
- off-white
- slightly textured
- thick
- heavier than copier
drawing papers:
Uses of cartridge paper
- For all colour mediums
what are examples of commercial printing papers?
- bond
- coated
Commercial printing papers:
Properties of Bond
- characterized by a degree of stiffness
- durability for repeated handling and filing
- resistance to penetration and spreading of ink
- bright colour
- cleanliness
- there are two types
Commercial printing papers:
types of bond paper
- rag content pulp
- chemical wood pulp
Commercial printing papers:
Properties of Rag Content Pulp
- vary from 25 to 100% cotton content.
Commercial printing papers:
Uses of bond papers
- leatherhead stationery
- advertising pieces
- leases
- deeds
- writs
- judgements and other legal documents
- currency
- certificates
- insurance policies
Commercial printing papers:
Properties of Coated papers
- The coating process limits the amount of ink and moisture that the paper can absorb
- more opaque
- resistant to wear and dirt and hence less liable to finger marking
- less white
Commercial printing papers:
Uses of coated
- magazine
- catalogue
- high resolution images
what are examples of boards?
- corrugated card
- foam board
- mount board
- foil-lined card
- folding boxboard
boards:
Properties of Mounting board
- Hard
- tough
- durable
- biodegradable
boards:
uses of Mounting board
- presenting artwork
- picture mounting
- modelling
boards:
properties of corrugated card
- usually with carbon outer layers and a corrugated middle
- provides protection against impact
- strong
- hard
- tough
- durable
- biodegradable
boards:
uses of corrugated card/board
- protective packaging
- model making
- prototyping ideas
- food packaging such as take away boxes
Boards:
properties of foam board
- durable
- recyclable
- low water absorption
- light weight
Boards:
uses of foam boards
- picture mounting
- mood board backing
- presentation boards
- modelling
Boards:
properties of Foil-lined board
- strong
- hard
- tough
- durable
Boards:
uses of Foil-lined board
- milk cartons
- drink packages
Boards:
properties of Folding boxboard
- strong
- hard
- tough
- durable
Boards:
uses of folding boxboard
- general carton applications
- food packaging
what is meant by smart materials?
a material whose physical properties change in response to an input or charge in the environment, such as electricity, pressure, temperature or light
what are examples of smart materials?
- thermo-ceramics
- shape memory alloys (SMA)
- reactive glass
- liquid crystal displayed (LCD)
- photo-chromatic materials
- Thermo-chromatic materials
- quantum tunneling composites
Smart Materials:
Properties of Thermo-ceramics
- high heat resistance
- high strength
- doesn’t expand or deform
- stable material
- hard
- durable
- lightweight
Smart Materials:
Uses of Thermo-Ceramics
- Turbine blades
- Automotive parts
- High-quality skateboard bearings
- Metal cutting tools
Smart Materials:
Properties of Shape memory alloys (SMA)
- Shape memory effect
- superelasticity
- elastic deformation
- good conductivity
- strong
- malleable
- ductile
- durable
Smart Materials:
Uses of shape memory alloys (SMA)
- dental wire
- eyewear frames
- aerospace air flaps
Smart Materials:
Properties of Reactive glass
- highly conductive
- tough
- durable
- retains heat
Smart Materials:
Uses of Reactive glass
- welding masks
- goggles
- windows
Smart Materials:
Properties of Liquid Crystal Displays (LCD)
- good conductivity
- good plasticity
- malleable
- hard
- tough
- durable
Smart Materials:
Uses of liquid crystal displays
- tv screens
- smartphones
- laptops
Smart Materials:
Properties of Photochromic materials
- good plasticity
- malleable
- durable
- colour changes with light intensity
Smart Materials:
Uses of photochromic materials
- welding
- clothing industry
Smart Materials:
Properties of thermochromic materials
- good plasticity
- malleable
- durable
- colour changes with temperature
Smart Materials:
Uses of thermochromic materials
- food packaging
- colour changing mugs
- colour changing kettles
Smart Materials:
Properties of quantum tunnelling composites
- strong
- elastic
- plastic
- malleable
- hard
- tough
- durable
Smart Materials:
Uses of quantum tunnelling composites
- switches on power tools
What are textiles?
a type of cloth or woven fabric.
What are examples of types of textiles?
- Natural fibres
- Manmade fibres
- Textile treatments
What are examples of Natural fibres?
- Cotton
- Linen
- Wool
What are examples of manmade fibres?
- Nylon
- Polypropylene
- Polyester
What are examples of textile treatments?
- Flame resistant
- Polytetrafluoroethylene (PTFE)