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Understand how to
select materials
using materials
indices
Understand how to
co-select materials
and shapes
Important because it
gives us a way of
quantifying trade-off
between desired
properties
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Metals,
ceramics, glasses
MATERIALS
Polymers,
composites
SHAPES
Prismatic,
3-D
Casting ,
moulding
PROCESSES
powder
methods,
machining...
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Processes
1. Shaping
Sand casting
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2. Joining
Fusion welding
3. Surface
Thermal-spray coating
Shaping
Kingdom
Family
Class
Member
Attributes
Size Range
Joining
Processes
Shaping
Surfacing
Casting
Compression
Deformation
Rotation
Min. section
Tolerance
Roughness
Moulding
Injection
Economic batch
Composite
RTM
Material
Powder
Blow
Rapid prototyping
Structured
information
Shape
Supporting information
-- specific
Unstructured
information
-- general
Benefits
Drawbacks
Casting
Porosity (metals)
Need to machine surface
Deformation
Molding
Polymers
Inexpensive
Unique to polymers
Composite
Polymer Composites
Techniques improving
Labour intensive
Relatively simple shapes
Small quantities
Powder
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Deformation: Extrusion
Comments: Heated
metal/polymer is forced through a die
to form simple shape. Process is
limited to ductile metals/polymers.
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Family
Class
Size Range
Solder
Section thickness
Welding
Gas
Fasteners
Arc
e -beam ...
Processes
Shaping
Heat treat
Paint/print
Surface
treatment
Coat
Polish
Texture ...
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Attributes
Braze
Adhesives
Joining
Member
Electroplate
Material
Joint geometry
Supporting information
Coating thickness
Surface hardness
Anodise
Powder coat
Material
Metallize...
Purpose of coating
Supporting information
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Joining Methods
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Benefits
Mechanical
Rivet, Stitch,
Staple
Solid State
Cold weld,
diffusion bonding,
friction welding
Liquid State
Resistance weld,
arc weld, thermal
Liquid/Solid
Brazing, soldering,
adhesive
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Drawbacks
Inexpensive
Simple to replace
Does not change structure of
joined parts
Cheap
Simple
Strong bond (if done correctly)
Corrosion
Change of structure at bond (heat
affected zone HAZ)
Simple
Cheap (on small scale)
Can form bond with little change
in structure
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Surface Treatments
Often it is the surface of a structure that
determines its function
e.g. wear resistance = function of surface
properties
e.g. Superalloys for turbine blades
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Benefits
Drawbacks
Heat
Treatment
Metals
Changes the structure of the
metal only at surface
One material
Painting
Simple
Cheap
Polishing &
Etching
Coatings
Expensive
Interaction of two or more
materials?
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Shaping:
J. A. Schey Introduction to Manufacturing Processes
Evans and de Joghe The production of inorganic materials
Edwards & Endean Manufacturing with Materials Open University Text
D.H. Martin-Jones Polymer Processing
P.C. Powell, Engineering with Polymers
Joining:
Edwards & Endean Manufacturing with Materials Open University Text
K. Easterling, Introduction to the Physical Metallurgy of Welding
J. A. Schey Introduction to Manufacturing Processes
J. F. Lancaster, Metallurgy of Welding
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