engineering materials resource 4 manufacturing techniques
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Engineering Materials
Resource 4
Manufacturing Techniques
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Aims & Objectives
• Identify engineering materials & uses• Differentiate metallic & non-metallic materials• Understand the hardening & tempering processes
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• Select appropriate materials for manufacturing activities• Identify materials properties & uses• Manufacturing processes for a range of materials• Harden & temper materials
Aims & Objectives
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Materials
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Ferrous Metals
• Mild steel• Cast iron• Wrought iron• High carbon steel• Stainless steel
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Uses
• Mild steel – Structures, Bridges, Steel products, Nuts & bolts
• Cast Iron – Castings, Engines, Machine vices
• Wrought Iron – Gates, railings
• High Carbon Steel – Tools, drills, centre punch, chisels, files
• Stainless Steel – Cutlery, Kitchen & bathroom appliances, medical instruments
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Non Ferrous Metals
• Copper • Brass• Lead• Aluminium• Silver• Gold• Zinc
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Uses
• Copper – Pipes, electrical wiring, kitchen ware
• Brass – musical instruments, tableware, ornaments
• Lead – Batteries, soldering, roofing & cladding
• Aluminium – Aircraft, Window frames, Kitchen ware, cans
• Silver – Jewellery, coins, cutlery
• Gold – Jewellery, coins, cutlery, dentistry
• Zinc – Galvanising steel products
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Alloys
Some metals can be used in their pure form or combined with other metals to produce an Alloy metal. An alloy is a combination of two or more metals to improve the mechanical properties of the materials. A few materials are listed below: -
• Brass• Bronze• Stainless steel• High carbon steel
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Forms of supply
Materials can be cut in various shapes & sizes.
Round Flat Square Hexagonal Octagonal Sheet Channel Angle Square Tube Round Tube
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Grain Structures
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Crystalline & Amorphous
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Crystalline
During the solidification process, crystals begin to form, multiply and grow until the material is completely solidified. These crystal contain atoms that are packed tightly together forming patterns.
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Amorphous
Rapidly increasing the cooling rate during the solidification process can produce minuscule micro crystals or in some cases amorphous that
is, non-crystalline solid liquid metals. The non-crystalline liquid structure is retained since the opportunity
for crystallisation is avoided due to the extreme temperature change.
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Heat treatment processes
HardeningHardening is accomplished by heating the material (metal) to a required temperature between 800°C & 1500°C (depending on the properties required) then quenching in either oil or water.
TemperingTempering consists of re-heating the material between 200°C & 600°C (depending on the properties required) then quenching in either oil or water.
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Case Hardening
Case hardening produces a hard, wear resistant surface on low carbon steels.
The process is accomplished by heating the material between 800°C & 1500°C and infusing carbon elements onto the materials surface.
Re-heat material between 800°C & 1500°C (depending on the properties required) then quenching in either oil or water.