Proses Produksi

#2 Fundamentals of Materials

Rusnaldy, PhD

Mengapa Belajar
Tentang Material?

Mazda drops weight to deliver driving dynamics

To make the body structure lighter

and stronger, the 2011 Mazda
features extensive use of high-tensile
strength steel, with the highest
strength steel (dark blue) in the
crash-critical areas.

Federal-Mogul plans for the future with new diesel piston design

Federal-Mogul's unique remelting process

for the aluminum-silicon alloy used in
DuraBowl, combined with a rapid cooling
process, significantly changes the alloy's
microstructure by reducing the size of
hardening phases such as silicon
particles and intermetallics. Shown is the
beginning of the process using a tungsten
gas electrode.

Materials

Materials

Photo copyright Colani DAF

Materials, processes and choice

Insinyur membuat produk
Produk terbuat dari satu material atau lebih
Material harus mampu mensupport beban, menyekat atau menghantarkan
panas.
Untuk membuat produk dari material membutuhkan suatu proses atau lebih
Ada ribuan material yang bisa dipakai untuk membuat produk
Ada banyak proses untuk membuat produk

Apa yang harus dipertimbangkan dalam memilih material

Properties
Ketersediaan
Mampu dimanufaktur (manufacturability)

Apa yang membedakan

antara material yang
satu dengan yang lain?
Struktur

Sifat

Dengan mengerti struktur logam maka akan bisa

menjelaskan sifat-sifat logam.

Mechanical properties.
Berkaitan dengan kemampuan material menahan beban mekanik
Beban Mekanik:
Statik : Tarik, Tekan, Creep
Dinamik
Tiba-tiba: Impak

Choosing a material is only half the story. The other half is the
choice of a process route to shape, join and finish it.

Stress
Simple tension: cable

Ao = cross sectional
Area (when unloaded)

Ao

Simple shear: drive shaft

Ac
M

2R

Fs

Ao

Fs

Ao

Note: = M/AcR here.

Stress
Simple compression:

Ao

Canyon Bridge, Los Alamos, NM

Balanced Rock, Arches

National Park

Ao

Note: compressive
structure member
( < 0 here).

Properties
Mechanical properties.

Modulus Elastisitas
Metals
Alloys
1200
1000
800
600
400

E(GPa)

200
100
80
60
40

109 Pa

Graphite
Composites
Ceramics Polymers
/fibers
Semicond
Diamond

Si carbide
Tungsten
Al oxide
Molybdenum Si nitride
Steel, Ni
<111>
Tantalum
Si crystal
Platinum
<100>
Cu alloys
Zinc, Ti
Silver, Gold Glass-soda
Aluminum

C arbon fibers only

CFRE(|| fibers)*
Aramid fibers only

AFRE(|| fibers)*
Glass fibers only

Magnesium,
Tin

GFRE(|| fibers)*
Concrete
GFRE*

20
10
8
6
4
2
1
0.8
0.6
0.4
0.2

CFRE *
GFRE( fibers)*

Graphite

Polyester
PET
PS
PC

CFRE( fibers)*
AFRE( fibers)*

Epoxy only

PP
HDPE
PTFE
LDPE

Wood(

grain)

E ceramics
>E metals
>>Epolymers

Yield Strength
Metals/
Alloys

200

Al (6061)ag
Steel (1020)hr
Ti (pure)a
Ta (pure)
Cu (71500)hr

100
70
60
50
40

Al (6061)a

30
20

10

Tin (pure)

dry

PC
Nylon 6,6
PET
PVC humid
PP
HDPE

LDPE

Hard to measure,

300

in ceramic matrix and epoxy matrix composites, since

in tension, fracture usually occurs before yield.

700
600
500
400

Ti (5Al-2.5Sn)a
W (pure)
Cu (71500)cw
Mo (pure)
Steel (4140)a
Steel (1020)cd

since in tension, fracture usually occurs before yield.

1000

Composites/
fibers

Steel (4140)qt

Hard to measure,

Yield strength, y (MPa)

2000

Graphite/
Ceramics/ Polymers
Semicond

y(ceramics)
>>
y(metals)
>>y(polymers)
Room T values

Kuat Tarik
Metals/
Alloys

Tensile strength, TS(MPa)

5000
3000
2000
1000

300
200
100
40
30
20

Graphite/
Ceramics/ Polymers
Semicond

Composites/
fibers
C fibers
Aramid fib
E-glass fib

Steel (4140)qt
Diamond
W (pure)
Ti (5Al-2.5Sn)aa
Steel (4140)
Si nitride
Cu (71500)cw
Cu (71500)hr Al oxide
Steel (1020)
Al (6061)ag
Ti (pure)a
Ta (pure)
Al (6061)a
Si crystal
<100>

Glass-soda
Concrete
Graphite

AFRE(|| fiber)
GFRE(|| fiber)
CFRE(|| fiber)

Nylon 6,6
PC PET
PVC
PP
HDPE

wood(|| fiber)
GFRE( fiber)
CFRE( fiber)
AFRE( fiber)

LDPE

10

wood(

fiber)

TS (ceram)
~TS (met)
~TS (comp)
>>TS (poly)

Thermal properties

Electrical, magnetic and optical properties.

Chemical properties:

The menu of engineering materials.

There is sense in this: the members of a family have certain

features in common: similar properties, similar processing
routes and, often, similar applications.

Material
1. Logam
2. Polymer
3. Keramik
4. Komposit

Logam Paduan
Ferrous
Non Ferrous

Baja

Logam Ferrous
Besi Cor

Name
Low carbon (mild)
Medium carbon
High carbon
Cast iron

Carbon Content
0.05% - 0.32%
0.35% - 0.55%
0.60% - 1.50%
>2.00%

Examples
Sheet, structural
Machinery
Machine tools
Castings

Design Requirements

Apa yang membedakan

antara material yang
satu dengan yang lain?

Strategi

Constraints & Objectives

Contoh

Contoh

Contoh

The design-limiting properties are those directly relating to the constraints:

modulus E, strength y, fracture toughness K1c and corrosion resistance.

Cost of Materials
Metals/
Alloys

Relative Cost ($)

100000
50000
20000
10000
5000

Pt
Au

20
10
5
2
1
0.5
0.1
0.05

Composites/
fibers

Diamond

Si wafer

2000
1000
500
200
100
50

Graphite/
Ceramics/ Polymers
Semicond

Si nitride
Ag alloys
Tungsten
Ti alloys

Si carbide

Cu alloys
Al alloys
Mg alloys

Al oxide

high alloy

CFRE prepreg

Glass-soda

Steel
pl. carbon

Concrete

AFRE prepreg
Carbon fibers
Aramid fibers
GFRE prepreg
Nylon 6,6
PC
Epoxy
PVC PET
LDPE,HDPE
PP
PS

E-glass fibers
Wood

$/kg
($/kg)ref material

Reference
material:
--Rolled A36 plain
carbon steel.
Relative cost, $,
fluctuates less
over time than
actual cost.

Contoh
Springs

Springs

Springs

TUGAS
Terbuat dari Material Apa Komponen-komponen di bawah ini:
1.Cylinder Block
2.Cylinder head
3.Piston
4.Piston Ring
5.Connecting Rod
6.Crankshaft
7.Camshaft
8.Valve