Slide 1

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 2

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 3

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 4

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 5

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 6

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 7

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 8

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 9

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 10

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 11

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 12

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 13

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 14

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 15

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 16

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 17

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 18

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 19

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 20

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 21

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 22

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 23

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 24

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 25

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 26

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 27

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 28

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29


Slide 29

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
1

Introduction

2

Introduction

3

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

Titanium

Lead & Tin

Zinc

Precious Mat.
4

2. NON-FERROUS ALLOYS
A- Aluminum:
•
•
•
•

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.

5

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.

6

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.

7

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 nickelbased alloys.
• Applications: jet engine components, gas turbine,
rockets and nuclear power plants, in food handling and
chemical processing equipment.
8

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.

9

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.

10

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.

11

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.

12

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.

13

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

14

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..

15

4. POLYMERS
Thermoplastic

Polymers

Thermosetting

Elastomers

16

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

17

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

18

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

19

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.
20

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. `
21

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.

22

Mechanical Properties

23

Mechanical Properties
Tensile Stress

Stress

Compressive Stress

Shear Stress

24

Stress - Strain Curve
Stress,

s

25

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.
26

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.
27

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.
28

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.

29