INDUSTRIAL MATERIALS

CLASSIFICATION OF METALS

• FERROUS METAL

• NON - FERROUS METAL

FERROUS METAL

IT CONTAINS IRON/FE/FERRITE

NON - FERROUS METALS

IT DOESNT CONTAIN IRON AND ATTRACTED TO MAGNETS

ALLOY

MADE BY COMBINING 2 OR MORE ELEMENTS

ALLOY

METAL RARELY USED IN THEIR PURE FORM

ALLOY

HELPS TO IMPROVE THE WORKING APPEARANCE AND PROPERTIES

METALLON

GREAK WORD FOR METAL

ORE

EARTH CRUST CONTAINING MANY TYPE OF ROCK

METALLIC MINERALS

ARE FOUND NATURALLY IN ROCK/ORE

ORE

OBTAINED BY MINING AND THE METALS CONTAINED W/IN EXTRACTED

EXTRACTION PROCESS

METAL MUST BE EXTRACTED ONCE AN ORE IS MINED FROM THE GROUND

STOCK FORMS

METAL MUST BE EXTRACTED ONCE AN ORE IS MINED FROM THE GROUND BEFORE IT IS PROCESSED INTO

SMELTED, BLAST FURNACE

MOST METALS ARE _______ IN A ______

ELECTROLYSIS

USED TO EXTRACT METALS SUCH AS ALUMINUM

SMELTING

PROCESS OF EXTRACTING METALS FROM THEIR ORES IN A BLAST FURNACE

PIG IRON

COMPOSED OF 93 IRON, 3-5 CARBON

WEAK AND BRITTLE

WROUGHT IRON

MADE FROM PIG IRON WITH SOME SLAG MIXED IN DURING MANUFACTURE.

CAN BE GAS AND ARC WELDED, MACHINED, PLATED, AND EASILY FORMED HOWEVER, IT HAS A LOW HARDNESS AND A LOW-FATIGUE STRENGTH

SLAG

TO RESIST CORROSION AND OXIDATION

CAST IRON

ANY IRON CONTAINING GREATER THAN 2
CARBON ALLOY

CAST IRON HAS A HIGH-COMPRESSIVE STRENGTH AND GOOD WEAR RESISTANCE HOWEVER

IT LACKS
DUCTILITY, MALLEABILITY, AND IMPACT STRENGTH.

STEEL

MANUFACTURED FROM PIG IRON BY DECREASING THE AMOUNT OF CARBON AND OTHER IMPURITIES AND ADDING SPECIFIC AMOUNTS OF ALLOYING ELEMENTS.

AMERICAN NATIONAL STANDARDS INSTITUTE

ANSI

AMERICAN SOCIETY OF MECHANICAL ENGINEERS

ASME

SOCIETY OF AUTOMOTIVE ENGINEERS

SAE

AMERICAN IRON AND STEEL INSTITUTE

AISI

TOOL STEEL

•famous for being hard and both heat and scrape resistant.

•The name is derived from the fact that they are very commonly used to make metal tools, like hammers.

DUCTILE

DRAWN STRETCH

STRETCH W/O BEING DAMAGED

MALLEABLE

HAMMERED W/O BREAKING

ROLLED OR PRESSED

DEROM IF COMPRESSED

HARDNESS

ABILITY TO WITHSTAND ABRASION/SCRATCH

TOUGHNESS

ABILITY TO ABSORB ENERGY AND FRACTURE

WITHSTAND LARGE IMPACTS

FERROUS METALS

CO0NTAIN IRON AND MAY RUST

RUST

IRON AND STEEL CAN CORRODE THIS IS KNOWN AS

NON-FERROUS METALS

DONT RUST AND NOT MAGNETIC

OXIDISATION

CAN BE CAUSED BY CORROSION OR WEATHER EXPOSURE OVER A PERIOD OF TIME

THE THIN LAYER OF TARNISH THAT APPEARS ON THE SURFACE OF THE METAL

VERDIGRIS

GREEN TURQUOISE PATINA OCCURING ON COPPER

BRASS

REFERS TO A RANGE OF COPPER AND ZINC ALLOYS WITH DIFFERING PROPERTIES

BAUXITE

ALUMINUM ORE AND THE MOST COMMON ORE FOUND IN THE EARTH’S CRUST

SMELTING

THE PROCESS OF EXTRACTING METALS FROM THEIR ORES IN A BLAST FURNACE

CASTING

•produced by pouring molten metal into a mould cavity and allowing it to solidify.

1.SAND CASTING

2.INVESTMENT CASTING

3.PERMANENT MOULD CASTING

4.DIE CASTING

Classifications of Casting Process

MOULD CAVITY

shape of the required component.

SAND CASTING

The traditional method of casting metals is in sand moulds and has been used for many years.

INVESTMENT CASTING

also known as precision casting or lost-wax casting, is a manufacturing process in which a wax pattern is used to shape a disposable ceramic mold

METAL DIE CONSTRUCTION

The wax pattern and ceramic mold are destroyed during the investment casting process, so each casting requires a new wax pattern.

WAX PATTERN PRODUCTION

The number of wax patterns always equals the number of castings to be produced; each individual casting requires a new wax pattern. Hot wax is injected into a mold or die and allowed to solidify, resulting in a wax pattern that is an exact replica of the part to be produced.

PERMANENT MOULD CASTING

 a process for producing a large number of castings using a single reusable mould.

DIE CASTING

manufacturing process in which molten metal is poured or forced into steel molds.

MOLDS / TOOLS /DIES

created using steel and are specially designed for each project.

MACHINING

Used to remove unwanted materials to achieve the desired product shape

MACHINING

A basic part of the manufacturing industry

MACHINING

A subtractive manufacturing process that involves the use of cutting tools, discs, abrasive wheels, and more to remove excess material from a workpiece

CONVENTIONAL MACHINING PROCESS

• “traditional machining”

CONVENTIONAL MACHINING PROCESS

• Involves the use of cutting tools to remove excess materials from a workpiece on direct contact

CONVENTIONAL MACHINING PROCESS

• occurs when the cutting tool directly interacts with the workpiece

• Turning

• Milling

• Drilling

• Grinding

• Sawing

• Broaching

• Planing

CONVENTIONAL MACHINING PROCESS (TMDGSBP)

TURNING

• works along two axes of motion

• The cutting tool remains stationary while the workpiece rotates

MILLING

• Involves the use of rotating cutters to remove material from a workpiece

• Involves complex processes and often requires a variety of special cutters to perform tasks

FACE MILLING

used for smoothening or flattening the surface of workpieces

SLAB MILLING

used for machining a wide flat surface and making planar cuts

DRILLING

• Involves using drill bits to produce cylindrical holes in solid materials

FLUTES

• Drill bits have two spiral channels _____ that evacuate the swarf or chips out of the hole as the drill bits progress into the material

GRINDING

• Ideal for improving the finish on a machined part’s surface and tightening its tolerance

SURFACE GRINDERS

used for flat surfaces grinders

CYLINDRICAL GRINDERS

used for cylindrical shapes

SAWING

• Aims to create shorter lengths from extruded shapes, bars, and other materials

BROACHING

• Involves using a broach to produce square and spline holes and keyways

B0ACH

• a tool with many teeth arranged in a sequence similar to a file

PLANING

• Ideal for large flat surfaces

NON-CONVENTIONAL MACHINING PROCESS

• Does not require direct contact with the cutting material

ELECTRICAL DISCHARGE MACHINING (EDM)

• “spark machining”

• “die sinking”

• “wire erosion”

• “wire burning”

• Involves material removal through erosion

• Ideal for weak machining materials prone to distortion

• Products manufactured require little to no polishing

ETCHANT

CHEMICAL SOLUTION USED IN CHEMICAL MACHINING

CHEMICAL MACHINING

• Involves dipping a workpiece into a tank containing a chemical solution (etchant)

• Requires a tank, heating coil, stirrer, and workpiece

• Ideal for machining hard, brittle, and difficult-to-machine materials

ELECTROCHEMICAL MACHINING (ECM)

• “reverse electroplating”

• Removes materials instead of adding them

• Ideal for mass production

ABRASIVE JET MACHINING

• Involves hitting a workpiece with a high-speed stream of abrasive particles

• Ideal for removing parting lines from injection molded parts and engraving marks

ULTRASONIC MACHINING

• Uses low amplitude and high-frequency vibrations to remove material

• Ideal for use on materials that have high hardness or a brittle nature

ELECTRONIC BEAM MACHINING (EBM)

• Involves focusing and concentrating electrons on a small spot on a metal material

• Ideal for machining very hard or brittle material that cannot undergo conventional machining techniques

LASER BEAM MACHINING

• Involves the use of a laser beam and heat energy for removing materials

• Ideal for use in both drilling and cutting processes

JOINING

• A manufacturing process by which two or more materials can be permanently or temporarily joined or assembled together with or without the application of external element in order to form a single unit.

TEMPORARY JOINT

• Can be easily dismantled by separating the original parts without any damage to them

PERMANENT JOINING

• Cannot be separated to their original shape, size, and surface finish

• WELDING

• BRAZING

• SOLDERING

• ADHESIVE BONDING

• MECHANICAL FASTENING

Types of Joining Processes

WELDING

• A fabrication process whereby two or more parts are fused together by means of heat, pressure, or both forming a joint as the parts cool

• Used for permanent joints

GAS METAL ARC WELDING

• “Metal Inert Gas”

• Uses a thin wire as an electrode

• The wire heats up as it is fed through the welding instrument and towards the welding site

GAS TUNGSTEN ARC WELDING

• “Tungsten Inert Gas”

• Uses consumable tungsten electrode that delivers the current to the welding arc

ARGON

• Used as a shielding gas

SHIELDED METAL ARC WELDING

• “stick welding”

• Relies on manual technique using a consumable electrode coated in flux

• Requires minimal equipment

• Does not require a shielding gas and can be performed outdoors in the wind or rain

FLUX CORED ARC WELDING

• Revolves around a continuous wire feed process

• Inexpensive and easy to learn

BRAZING

• A process that joins two or more metal surfaces together with a filler metal that has a low melting point

• Considered to form permanent joints

SOLDERING

• Used to join different types of metals together by melting solder

• Considered to form a permanent joint

SOLDER

• a metal alloy usually made of tin and lead which is melted using a hot iron

ADHESIVE BONDING

• A manufacturing process in which two or more surfaces are joined using an adhesive

• Joins the surfaces together temporarily or permanently

MECHANICAL FASTENING

• Temporary joint (screws) and permanent joint (snap-fits)

• Most common method of joining many materials within the industry

• Used form metal joining

FINISHING OPERATIONS

• Processes that are applied to the workpiece at the end of a manufacturing process, and after completing all other relevant operations that bring the product to its required dimensions.

POLISHING

• Produces a smooth and shiny surface in the metal parts

ELECTROPLATING

• provides a thin metallic coating on the workpiece surface

• the workpiece is dipped inside a solution having dissolved metal, and a positive current is passed through the metallic solution

• the workpiece is maintained at a negative side

ELECTROLESS PLATING

• is similar to electroplating, but in place of electric current, the method utilizes a chemical reagent to dissociate the ions

• This is also called the electrochemical process. The reagent is contained inside the metallic solution.

HOT DIPPING

• is known as the hot galvanizing process which involves coating the surface with liquid metals.

• This involves the workpiece being dipped in hot liquid aluminum, tin, zinc and tin.

GRINDING

• Makes use of abrasive media in the form of a wheel known as a grinding wheel

• Is a material removal process

• The abrasive media of the grinding wheel behaves as a multi-point cutting tool where each and every grain on the wheel behaves as a cutting tool

SANDBLASTING

• Also known as abrasive blasting

• a suitable gas in a cylinder remains pressurized with a mixture of abrasive slurry. This pressurized gas is made to propel through a nozzle targeting the workpiece. The surface irregularities are removed, and the surface deburrs from abrasion.

SUPERFINISHING OPERATIONS

• These processes are applied to achieve a high degree of surface finish and accurate tolerances.

• In this process, the tool used has fine particles suspended or bonded through suitable adhesives.