Production%20Technology%20(IND%20006)

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Production Technology(IND 006)
Lecture No. 4

• Preparatory Year,
• Faculty of Engineering,
• Fayoum University

Dr. Ahmed Salah Abou Taleb Lecturer, Industrial
Engineering Dept., Faculty of Engineering, Fayoum
University
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Introduction
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Introduction
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2. NON-FERROUS ALLOYS

• Non-Ferrous materials and alloys defined as the
  materials that contain a negligible amount of
  iron.
• Non-Ferrous metals and alloys play a large and
  indispensable role in modern technology.

Non-Ferrous
Aluminum
Magnesium
Nickel
Copper
Lead Tin
Titanium
Zinc
Precious Mat.
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A- Aluminum
2. NON-FERROUS ALLOYS

• Light and soft material
• Ductile and not very strong.
• High strength to weight ratio.
• Excellent corrosion resistance due to formation
  thin oxide surface film.
• High thermal and electrical conductivity.
• Applications aircraft, cans, foil, cooking pans,
  electric transmission lines, and heat sinks.

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2. NON-FERROUS ALLOYS
B- Copper

• High thermal and electrical conductivity
• High corrosion resistance.
• Low in strength and hardness.
• High ductility and formability.
• Bronze - alloy of 90 copper and 10 tin.
• Brass - alloy of 65 copper and 35 zinc.
• Applications electrical wiring, radiator, heat
  exchangers, and springs.

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2. NON-FERROUS ALLOYS
C- Magnesium

• Lightest engineering metal available.
• High strength to weight ratio.
• Applications aerospace, Aircraft missile
  components, tennis rackets, suitcase frames,
  material handling equipments and sporting goods.

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2. NON-FERROUS ALLOYS
D- Nickel

• Excellent corrosion resistance at elevated
  temperature
• High strength at elevated temperature .
• It is used extensively in stainless steel and in
  nickel-based alloys.
• Applications jet engine components, gas turbine,
  rockets and nuclear power plants, in food
  handling and chemical processing equipment.

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2. NON-FERROUS ALLOYS
E- Zinc

• Low melting point metal,
• Application in galvanizing on iron and steel
  for providing corrosion resistance, and die
  casting of components for automobile and
  appliance industries.

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2. NON-FERROUS ALLOYS
F- Titanium

• Excellent corrosion resistance
• High strength to weight ratio.
• It can be alloyed with aluminum, vanadium,
  molybdenum, manganese, or other alloying elements
  to improve properties such as strength and
  hardenability.
• Applications aerospace, missiles, marine, racing
  cars, chemical eqiupment and golf clubs.

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2. NON-FERROUS ALLOYS
G- Lead and Tin

• Used in soldering alloys due to their low melting
  points

• Lead
• Has properties of high density, resistance to
  corrosion, softness, low strength, ductility and
  good workability.
• Applications storage batteries, X-ray, and
  bearing.

• Tin
• Has lower milting point than lead, low strength,
  low hardness, and good ductility.
• Applications storing food and journal bearing.

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2. NON-FERROUS ALLOYS
H- Precious Materials

• Among huge well-known precious metals, the most
  important ones are
• Gold is soft and ductile and has good corrosion
  resistance at any temperature.
• Silver is a ductile material and it has the
  highest electrical and thermal conductivity of
  any metal.
• Platinum is a soft, ductile and has good
  corrosion resistance even at elevated
  temperature.

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3. CERAMIC MATERIALS

• Are inorganic materials that consists of metallic
  and non-metallic elements chemically bonded
  together.
• Are used extensively in the electrical industry
  because of their high electrical resistance.
• Most of them are hard, brittle, high melting
  point with low thermal and electrical
  conductivity, low thermal expansion, good
  chemical and thermal stability, high modulus of
  elasticity and high compressive strength.

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3. CERAMIC MATERIALS

• Glass products are most common examples.
• Used in abrasive applications such as grinding
  because of their high hardness.
• Many ceramics materials such as Tungsten Carbide,
  Titanium Carbide, Silicon Nitride, Cubic Boron
  Nitride, and Polycrystalline Diamond Cutting
  Tools offer greater tool life than High-Speed
  Tool Steel.
• Diamond, is the hardest substance known up to
  now.
• Cement used in concrete

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4. POLYMERS

• Polymers are organic materials. A common synonym
  for polymers is plastics, a name that is derived
  from the deformability associated with the
  fabrication of most polymeric products.
• High corrosion resistance
• High resistance to chemicals
• Low electrical and thermal conductivity
• Low density
• High strength to weight ratio
• Noise reduction
• Wide choice of colors and transparencies
• Ease of manufacturing..

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4. POLYMERS
Thermoplastic
Polymers
Thermosetting
Elastomers
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4. POLYMERS
A- Thermoplastics Polymer

• Can be subjected to multiple heating and cooling
  cycles without altering molecular structure.
• Low in modulus of elasticity, tensile strength,
  hardness and density,
• High in ductility and coefficient of thermal
  expansion.
• Application insulating material for electric
  cables, packing materials, water pipe and Paints.
• such as Polyethylene, polypropylene, .. etc

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4. POLYMERS
B- Thermosetting Polymer

• Do not become soft to any significant extent with
  increasing temperature.
• Cannot be re-melted or softened after
  solidification.
• More rigid, brittle, capable of higher service
  temperature and harder than thermoplastics.
• Used as pot handle, electrical switch cover, and
  printed circuit boards.
• such as Epoxy, Melamines Phenolics and Urethanes

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4. POLYMERS
C- Elastomers Polymer

• have ability to undergo large elastic
  deformations and return to their original shapes
  when unloaded.
• Applications tires, seals, and shock absorbers.
• Such as natural or synthetic rubbers, and
  silicones

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5. COMPOSITE MATERIALS

• Composite materials are mixture of two or more
  materials to produce a new material whose
  properties would not be attainable by
  conventional means.
• Structure consists of particles or fibers of one
  phase mixed in a second phase (matrix). The
  properties depend on components, physical shape
  of components, and the way they are combined to
  form the final shape.

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5. COMPOSITE MATERIALS

• Applications
• Air-dried bricks by mixing the clay with straw,
• Horse hair was used to reinforce the plaster used
  on the walls and ceiling of buildings.
• Carbon fiber reinforced frames for tennis rackets
  and shafts for golf clubs.
• Racing bicycles are made from composite materials
  because.

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5. COMPOSITE MATERIALS

• Fibrous composites High strength continuous or
  discontinuous thin fibers are encased within
  tough matrix. Matrix functions are to bond
  fibers together, to protect fibers from damage
  and to transmit load from one fiber to another.
  Glass fibers is the most common material in this
  category.

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Mechanical Properties
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Mechanical Properties
Tensile Stress
Stress
Compressive Stress
Shear Stress
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Stress - Strain Curve
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Mechanical Properties
Malleability ability of material to be
plastically deformed by hammering or filling into
sheet form. Example Gold. Ductility ability of
material to be plastically deformed by tension
before fracture occurs. Example Wire drawing
(Copper wire). Hardness ability of material to
resist scratching or penetration. Example
Glass. Brittleness tendency to fracture without
appreciable deformation particularly under low
stress. Example Glass. Fatigue the failure of a
material under the action of repeated alternating
stresses. Example Aluminum wire.
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Mechanical Properties
Toughness ability of material to withstand
stresses as well as deformation. Example
Steel. Elasticity ability of material to return
to its original shape after being subjected to a
load that caused deformation. Example Elastic
band. Plasticity ability of material to undergo
some degree of permanent deformation without
rupture. Example Hot working a metal and plaster
sine. Stiffness a measure of a materials ability
to resist deformation or deflection under load.
Example Bridge structure.
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Selection of Materials
A material is selected for any specific
application according to 1- Properties
(mechanical and physics). 2- Processing the
method of processing affect the product's final
properties, service, life and cost. 3- Cost and
availability. 4- Appearance, service life and
recycling.
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Selection of Manufacturing Process
manufacturing process selection depends on 1-
Part shape, size and thickness. 2- Material and
its properties. 3- Final properties. 4-
Dimensional and surface finish. 5- Operational
and manufacturing cost.