ENGINEERING

MATERIALS
DR JAMIL BIN ABD. BASER
FAKULTI OF TECH. EDU. AND VOCATIONAL
UTHM

drJ09

OBJECTIVES
At the end of this chapter,
students should be able to:

List and differentiate between various types of

ferrous and non-ferrous metals and non-metallic
materials.
Identify some uses of ferrous and non-ferrous
metals and non-metallic materials.
List and define the mechanical properties of
metals
Explain the uses and advantages of every
material based on its mechanical properties.
mrJ09

ENGINEERING
MATERIALS

METALLIC
MATERIALS

FERROUS
METALS

NON-METALLIC
MATERIALS

NON-FERROUS
METALS

NATURAL
MATERIALS

PURE METAL
EX: IRON

PURE METAL
EX:ALUMINIUM,
COPPER, TIN

ALLOY METAL
EX: STEEL

ALLOY META
EX: ALUMINIUM
ALLOY
mrJ09

MAN-MADE
MATERIALS

FERROUS METALS

Ferrous metals are those of which iron is

the main constituent.
Ferrous metals are produced in larger
quantities than any other metal type.

mrJ09

FERROUS METAL

CAST
IRON

STEEL

mrJ09

STEEL

ALLOY
STEEL

STAINLESS
STEEL

HIGH
SPEED
STEEL

CARBON
STEEL

LOW
CARBON
STEEL

SOFT
STEEL

mrJ09

MEDIUM
CARBON
STEEL

HIGH
CARBON
STEEL

Stainless Steels

mrJ09

Contain steel added with

18% chromium and 8%
nickel
Properties: highly resistant
to corrosion (rusting) in
variety of environments,
high strength and
toughness
Typical applications:
automotive exhaust
components, valves,
combustion chambers,
cutlery, surgical tools
7

High-speed Steel

mrJ09

Contain steel added with

tungsten, chromium, vanadium
and molybdenum
Properties: brittle but can
maintain hardness at a high
temperature. Can be heat
treated to improve their
mechanical properties
Typical applications: cutting
edge for drilling machine and
lathe machine

Low-carbon Steel

mrJ09

Contain less than 0.15%

carbon
Properties: soft but have
outstanding ductility and
toughness, machinable,
weldable
Typical applications:
automobile body
components, structural
shape (I-beam, channel),
sheets that are use in
pipelines, bridges and tin
cans

Soft Steel
Contains 0.15% - 0.3% carbon
Properties:
-High tensile strength, robust and
malleable
-Softer than the medium and high
carbon steel
-easy to machine
-cannot undergo heat treatment
-not suitable for tempering and hardening
Usage:
-multipurpose steels, bar tubes, sheets, bolts and nuts

mrJ09

10

Medium-carbon steel

Contain 0.3% to 0.7% carbon

Properties: high strength and wear

resistance compared to low-carbon steels
but less ductile and tough

Typical applications: railway wheels and

tracks, gears, crankshafts, chisels, hammers

mrJ09

11

Example of medium carbon steel

mrJ09

12

High-carbon Steel

Contain 0.7% to 1.4% carbon.

Properties: the hardest, strongest and yet least ductile

of the carbon steels.

Typical applications: utilized as cutting tools and dies

for forming and shaping materials-knives, razors,
hacksaw blades, springs and high-strength wire

mrJ09

13

Examples of high carbon steel

mrJ09

14

CAST
IRON

GREY
CAST
IRON

WHITE
CAST
IRON

mrJ09

WROUGHT
IRON

15

Cast Iron

I.
II.

III.

Generically, cast irons are a class of ferrous

alloys with carbon contents above 2.14%.
They are easily melted and amenable to
casting. Furthermore, some cast irons are very
brittle, and casting is the most convenient
fabrication technique.
The most common cast iron types are:
Grey cast irons
White cast irons
Malleable cast irons

mrJ09

16

Grey Cast Iron

Contain 1.7% to 4.5% carbon

Properties: weak and brittle in tension, strong and

ductile under compressive loads.

Typical applications: diesel engine castings,

pressure-containing parts such as valve and
pump bodies, pinions, gears

mrJ09

17

Examples of grey cast iron

mrJ09

18

White Cast Iron

RAILWAYS

Contain 2% to 3.5%
carbon
Properties: very hard and
have a high compression
strength, high degree of
ductility and almost
unmachinable
Typical applications:
limited to applications that
necessitate a very hard
and wear resistance
surface such as rollers in
rolling mills
mrJ09

19

Wrought (Malleable Cast) Iron

mrJ09

Malleable cast irons are

quenched white cast irons
Properties: more ductile,
machinable, higher
tension strength.
Typical applications:
connecting rods,
transmission gears, pipe
fittings and valve parts for
railroad, marine

20

NON-FERROUS
METALS

Nonferrous
metal has
no iron
element.

ALUMINIUM
COPPER

BRASS
TIN
mrJ09

21

Aluminium

I.
II.

III.

IV.
V.
VI.

Properties:
high electrical and thermal conductivities
A resistance to corrosion include in the
ambient atmosphere
Easily formed by virtue of high ductility
Machinable, malleable, light
White metallic in colour
Low melting temperature (650oC)

mrJ09

22

Typical Applications Of Aluminium

Aircraft structures, aircraft pump parts, rivets,

food/ chemical handling & storage, cooking
utensils

tray

Curtain track
mrJ09

23

Copper

I.

II.
III.
IV.
V.
VI.

Properties:
Highly resistance to corrosion in diverse
environments, seawater and some industrial
chemicals
Soft, ductile
high electrical and thermal conductivities
Can be formed by cold and hot works
Yellow-red in colour
Melting temperature (1083oC)
mrJ09

24

Typical Applications Of Copper

Electrical wire
Automotive radiator cores
Welding and soldering rods

mrJ09

25

Brass (copper-based alloy)

I.
II.
III.

IV.
V.

Properties:
Harder than copper and zinc
Machinable
Good electrical and thermal
conductivities
High corrosive resistance
Melting temperature (980oC)
mrJ09

26

Typical
Applications
Of
Brass
Costume jewelry
cartridge casings
musical instruments
electronic packaging
coins

Brass Pipe connectors

mrJ09

jewelry

27

TIN

Properties:
-Soft, ductile
-Does not corrode
-Not easily tarnished even in humid
conditions
-Easy to forge
-Melting point temperature of 2320 C
-Silvery white

mrJ09

28

Typical Applications of Tin

Tin Jewel
Tin plate
Aluminium
mrJ09

29

MECHANICAL

PROPERTIES OF METAL

HARDNESS

ROBUSTNESS

STRENGTH

FORGEABILITY

ELASTICITY

DUCTILITY

BRITTLENESS

mrJ09

30

HARDNESS
Hardness means the ability of metal to
withstand penetration by other objects. For
example, it is not easily scratched, nicked or
punctured

mrJ09

31

STRENGTH
Strength is the ability of metal to support a
load or force without changing its shape

mrJ09

32

BRITTLENESS
Brittleness is a metal property that easily
breaks or cracks when impacted or
hammered.

mrJ09

33

ROBUSTNESS
Robustness is the ability to maintain strength
even after it has undergone permanent
change in shape. This is the opposite of
brittleness.

mrJ09

34

FORGEABILITY
This is the ability of metal to be shaped using
forging or hammering method.

mrJ09

35

ELASTICITY
Elasticity is the ability of metal to regain its
original condition after undergoing a change
in shape.

mrJ09

36

DUCTILITY
Ductility is the ability of metal to be stretched
without snapping or breaking even in taut
condition.

mrJ09

37

ENGINEERING
MATERIALS
SUBTOPIC:
NON-METALLIC MATERIALS

mrJ09

38

Non-metallic
materials

Natural
material

Man-made
material

Polymer

Rubber

wood
leather

plastic
Thermoplastic

silica

rubber

adhesives

Thermosetting
plastic

glass
concrete
ceramic
mrJ09

39

Rubber

A linear elastomer material with the ability to

restore itself completely to the original size and
shape after its load is released.
Vulcanization process (adding of 30% sulphur to
hot rubber before reheating at a certain
temperature) must be carried out to increase the
strength of natural rubber.
Eg: tyres, shoes and pipes manufacturing

mrJ09

40

Rubber Product

Rubber Cord

Rubber Mould

Rubber gasket

mrJ09

41

WOOD

Important in construction sector, furniture and

paper manufacturing.
Drying process must be carried out so that the
wood becomes stronger, more resilient and less
likely to break, shrink or warp.
Wood must also be cured to avoid attacked by
moss, pests and protected from uncertain weather
conditions

mrJ09

42

GLASS

Used as ornaments, bottles, windows and

lenses.
In the manufacturing industry transparent,
stained and opaque flat glass are used
widely.
Fiberglass widely used in making boats,
cars and fishing rods

mrJ09

43

POLYMER

a)
b)
c)

Definition:
A huge molecule built
of small molecules
called monomer
Examples of
polymer:
Plastic
Rubber
Adhesives

mrJ09

44

PLASTIC

Plastic refers to a non organic material with

polymer properties that can be shaped into the
desired object through a certain process such as
moulding.
It is a multipurpose material produced to imitate or
replace other engineering materials.
Plastic are categorized as thermoplastic and
thermosetting plastic based on the basis of the
polymer chain formation.

mrJ09

45

PROPERTIES OF MOST PLASTIC

Good insulator of electricity and heat

Does not rust
Resist chemical reaction
Light
Easy to mould into various shape
Easy to tint
Has a low moisture absorption property
Less brittle compared to glass
Commendable strength and rigidity
Durable for certain types of plastics
Burns easily

mrJ09

46

Plastic Product

monitor frame

Plastic bags

kettle

Plastic product by
mrJ09
injection mould

Diskette box

3 pin socket

47

MOLECULAR BONDING
STRUCTURES

THERMOPLASTIC

THERMOSETTING PLASTIC
mrJ09

48

THERMOPLASTIC

THERMOSETTING
PLASTIC

Soften when heated and

harden when cooledprocesses that are totally
reversible and may be
repeated
Durable and soft

Become permanently
hard when heat is applied
and do not soften upon
subsequent heating

Melt at a low
temperature, 93oC

Melt at a high
temperature, 260oC

mrJ09

Harder and tougher than

thermoplastic, quite brittle

49

THERMOPLASTIC
NAME OF PLASTIC
Polythene
chemical name:
Polythene
1.

PROPERTIES
There are two grades:
1. Low density polythene
Durable and flexible,
good chemical
resistance, good
insulator of electricity
and soft.
2. High density polythene
Hard and fairly chemical
resistant

mrJ09

USAGE
Plastic bottle and
toy, bag and plastic
sheet, insulator for
telecommunication
cable.

Water tank, pipe,

machine part such
as gear wheel.

50

THERMOPLASTIC

NAME OF PLASTIC

2. Polyvinyl chloride
(PVC)
chemical name:
Polychlorethane
3. Polystyrene

PROPERTIES
Hard, rigid and robust at
room temperature, light,
good acid and alkaline
resistant

Hard and rigid

chemical name:
Polyphenylethene

mrJ09

USAGE
Raincoat, musical
record, electric
wire coating, water
tank, pipe.

Food container,
film, plastic fork
and spoon, toy

51

THERMOPLASTIC

NAME OF PLASTIC
4. Acrylate
chemical name:
Polymethyl
methylpropenoate

PROPERTIES
Hard, rigid,
transparent, easy to
machine, a good
insulator of electricity
resists various acid
and weather.

mrJ09

USAGE
Lens, clock
surface, aircraft
windows,
perspec

52

THERMOSETTING PLASTIC

NAME OF PLASTIC

Polyester resin
chemical name:
Unsaturated
polyester resin
1.

PROPERTIES

Good insulator of
electricity and heat, rigid,
hard but brittle,
waterproof and resists
ultra violet rays.

USAGE

Yacht, corrugated
sheet, furniture

If mixed with glass, it will

be a glass reinforced
plastic, i.e. a strong
material.

mrJ09

53

THERMOPLASTIC

NAME OF PLASTIC
2.

Urea
formaldehyde
chemical name:
Urea methanol

3. Melamine
Formaldehyde
chemical name:
Melamine methanol

PROPERTIES
Rigid, hard, strong but
brittle, a good insulator of
heat.

Rigid, hard and strong.

Low resistance to
chemicals, high
resistance to stains.

mrJ09

USAGE
Domestic
equipment.
Adhesive for wood.

Dining set, formica.

54

CONCRETE

Contains cement, fine aggregate (sand), coarse

aggregate and water in a fixed ratio.
The quality of the concrete produced depends
on two factors:
- conditions of the materials
- ratio of the concrete mixture
By increasing the concrete density its usually
increases the concrete strength. This is done by
increasing the cement to aggregate ratio and
decreasing the water to cement ratio.

mrJ09

55

CONCRETE PROPERTIES

High compression strength

Durable
Watertight
Can be cast into various shapes
Fairly low tensile strength

mrJ09

56

Concrete

mrJ09

57

TYPICAL APPLICATIONS OF
CONCRETE

Roads/ highways
dams
building structures
WATER TANK

BRIDGE
mrJ09

HOUSING
STRUCTURES

58

CERAMICS

Ceramics is a material that contains metal

atoms, which is bonded to non-metal atoms
such as oxygen.
Most widely used ceramic oxide is alumina
(aluminium oxide Al2O3)
Ceramic breaks easily, is not ductile and
has fairly low tensile strength.

mrJ09

59

TYPICAL APPLICATIONS OF
CERAMIC
PROPERTIES

USAGE

Hard and has high compression

strength

Cutting tools and abrasive, wear

and corrosion resistant
components

Heat resistance

Refractory, fire clay bricks in

furnace construction

Electric insulator

Insulators, dielectric in capacitor

Chemical resistance

Dental surgery, biology materials

(to replace human bone)

mrJ09

60

CERAMICS

mrJ09

61

THE END

mrJ09

62