Lecture 1 MMP I Metals.pdf

Materials and Manufacturing Processes I Metals Instructors : Lojain Rafaa, Zati Hazera, Amjad Alshehri, Aqeela alsadiq Lojain Rafaa - 2025 Lojain Rafaa - 2025 Short Activity for 2 min think about the following question: As an industrial designer, what shou...

Materials and Manufacturing Processes I Metals Instructors : Lojain Rafaa, Zati Hazera, Amjad Alshehri, Aqeela alsadiq Lojain Rafaa - 2025 Lojain Rafaa - 2025 Short Activity for 2 min think about the following question: As an industrial designer, what should you know about materials? Lojain Rafaa - 2025 Why do materials matter? c s.HN Materials directlyHbo.wd with é me and manufacturability. affect a product's performance, aesthetics, Designers must balance functionality, cost, and sustainability when selecting materials. E IE In Lojain Rafaa - 2025  JH A. Materials Properties III hmm www.t so Thermal & Id Environmental f Mechanical: Aesthetic: Color, Electrical: Resistance: Strength, flexibility, texture, finish. Conductivity or Corrosion, moisture, durability. insulation. UV resistance. I w.ae sfw Thermal & Electrical: Conductivity or insulation. Lojain Rafaa - 2025  471 I B. Manufacturing Considerations Shipping: Joining Finishing: Cutting, Molding, welded, glued, Polishing, painting, Bending…etc fastened… etc anodizing…etc to gg a it d Thermal & Electrical: Conductivity or insulation. Lojain Rafaa - 2025  is I C. Cost and Availability Material Cost: Is Availability: Readily available Balance material performance materials production in the with client budget. local market. Or importing www 6 regulations and cost. of a.IH Thermal & Electrical: Conductivity or insulation. Lojain Rafaa - 2025  I D. Sustainability I I Environmental Impact: Durability: Is it recyclable or eco-friendly? Long-lasting materials reduce What effect does it have on the waste and replacement costs. natural resources and what is www.s 6 the material life cycle? I at pig o.utd6 am in 44 14 Thermal & Electrical: e I Conductivity or insulation. Lojain Rafaa - 2025  Web E. Safety Regulations new axiom Toxicity: Avoid harmful Idl Fire Resistance: Ensure compliance Industry Standards: Adhere emissions in with fire safety to regulations like products. standards. ISO 9001and/or SASO standers Thermal & 2 11 11 Electrical: Conductivity or insulation. Lojain Rafaa - 2025 F. Product semantical requirements IT I IN Emotion: I Value: I Functionality: How would the What kind of value Choose materials material behave are you providing, S that align with the and interact with is this product for product’s purpose. user? luxury or simple Consider household utility? Thermal & www.T lightweight for portable products; Electrical: heavier for stability. Conductivity or insulation. Lojain Rafaa - 2025 METALS Lojain Rafaa - 2025  METALS I t.is m Are any of a class of substances characterized by high electrical and thermal conductivity, as well as by malleability, ductility, and high reflectivity of light 5 6 41 5 1 12 in industrial design metals are classified according to the content of iron content Ferrous : contains iron 4555 Non-ferrous: does not contain iron content Lojain Rafaa - 2025  ws was mom s I was I 2.6.1 S so i g d ai sit am m In general, metals are known for being strong and tough compared to other materials. This diagram clearly illustrates this in comparison to common materials. www 41 Why a ft www.whgh.iwif.tk Lojain Rafaa - 2025  14 6 661 Mechanical Properties I if If It Is https://civilsnapshot.com/forces-acting-on-structures/ Lojain Rafaa - 2025  Tensile Compressive Yield Impact in i 6 4621 Mechanical Properties I  of Tensile Strength When we speak of tensile strength we are looking at the www.s sniff measurement of the force which would be required to pull something such as a cable, wire, rope, or a structural beam such as a 13 LEE girder to the point at which it breaks. The measurement is am the maximum amount of stress before breaking, m said usually measured in pounds per square inch (PSI). dk M e As an example, cookie dough has low tensile strength, and steel has high tensile strength. imdb.ws 561 I T.si Lojain Rafaa - 2025 https://www.researchgate.net/figure/The-shape-of-a-ductile-specimen-changes-during-tensile-testing_fig1_319773789  Yield Strength Yield strength refers to how well a beam made from a particular metal resists being bending and permanent deformation. This is a very important measurement for structural engineers. Metal will bend to a certain degree and this is the elastic state, a state when the metal will return to its original shape after being bent, a useful property of spring steels. Once the metal has reached the plastic state it has failed. This is measured in Mega Pascals (Mpa) Lojain Rafaa - 2025 https://www.researchgate.net/figure/The-shape-of-a-ductile-specimen-changes-during-tensile-testing_fig1_319773789  www.wwiwojssbk.de I T.sulz.im we Wwii Compressive Strength This is a measure of how well the material resists wt w.x.tw a being squeezed. In more basic terms it is the hardness of the material. This can also be measured in Psi. we Another way to measure compressive strength is the use of the Mohs scale. On this scale of 0-10, 0 is the softest, js d is not w and 10 is the hardest. Not surprisingly, diamonds are 10 on the scale. Compressive strength is an important msn.mn property of tooling materials. https://www.usgs.gov/media/images/mohs-hardness-scale https://civilsnapshot.com/forces- acting-on-structures/ Lojain Rafaa - 2025  81b 48.4.4 I wig s m Impact Strength The ability of a material to i.am resist impact without shattering. Going back to the diamond, it has a Mohs scale of 10 but can be shattered when struck with is a hammer. Whereas steel can be struck with a hammer without shattering, the hammerhead itself is steel. i ge sg ff Lojain Rafaa - 2025  A s di.MN m w w1i4 6H am WHAT IS DUCTILE AND BRITALITY IN MATTERIALS, AND WHY IS IT IMPORTANT ? Him https://www.youtube.com/watch?v=WSRqJdT2COE&t=1s 19 11 Lojain Rafaa - 2025  low a is wjff fdff.mg aoeaw out 104 GYMI Diagram showing what makes an alloy stronger than pure metal Lojain Rafaa - 2025 STRENTH HIGH FOURS Were Types of metals in industry HARDNES HIGH EIOGEN WI Wasnt 4 4 high corrosion resistance High hardness= High strength= high force resistance No d I Lojain Rafaa - 2025 Carbon Steel QLD D I Carbon + iron Alloys bad Lojain Rafaa - 2025  Carbon Steel 94141 Carbon + iron Alloys 033 The most common alloy used It ha three types: disdain Wsi Mild (Carbon) Steel ( >0.25% of Carbon) Relatively soft 6 Easily rolled to plate and rod www.adf.dmwa Cheapest structural material Moses Use for huge-scale reinforcement A6 f Steel framed building, ship plate, etc fHdwtttieu is Medium Carbon Steel (0.25%-0.5% of Carbon) Harden when quenched (metal treatment to harden steel) Enormous scale use for Railroad Tracks High Carbon Steel (0.5%-1.6% of Carbon) The most hard relatively and Use for cutting tools, chisels, cabel, and piano wire (metal strings for piano/violin)Hijo.WS sx wiDo bidcbfi 66 4 Lojain Rafaa - 2025 Carbon Steel GANI Carbon + iron Alloys e bo.MIL USES : blind Concrete reinforcements 41 41 Axles and gears Steel section for construction ww.Wsfiw Bearing at Cranks and shafts Sheet for roofing 6 feb Cutting tools Car body panel 118621 Ice axes Cans and pressed sheets product The.ws Ice skates blades Ewbw k Iw Lojain Rafaa - 2025 STAINLESS STEEL inspaw xD iron Alloys + Chromium + Nickel + Other Elements 034 1114 www.WI Lojain Rafaa - 2025 STAINLESS STEEL iron Alloys + Chromium + Nickel + Other Elements and 4k I “ resist corrosion in most normal environments “ www.a.IT III Used eficiently to justify its higher cost exploiting its high strength and corrosion resistance Economic design uses thin rolled gauge, simple sections, concealed weld to eliminate finishing Surface finish can be control by rolling, polishing or blasting Stainless Steel are selected for its So corrosion resistant Wilma Strength I ease of fabrication(most stainless-steel are difficult to bend, draw and cut requiring slow cutting speed and special tool geometry www.t ddewiwm ff.ITebast Available in sheet,strip,plate,bar,wire,tube and pipe. Ready to efi be soldered, braised and weld. oem www i Lojain Rafaa - 2025 STAINLESS STEEL iron Alloys + Chromium + Nickel + Other Elements Uses: Win Food processing equipment's Sink Stoves L Cooking utensils Laundry equipments Surgical tools etc Lojain Rafaa - 2025 Low Alloy Steels (HSLA) Winning www.sodki It stands fo High Strength Low Alloy Steel. Not made from a specific chemical composition but rather a specific mechanical properties T si I djswIii 55 If I Carbon pulled D 464 Content from 0.05% - 0.25% to retain formadibility and weldability 1 OH Copper , titanium , vanadium For strenght idb.is www.t Copper, SH chromium silicon, nickel, ed To increase corrosion resistance and phosphours sit www.ag Zirconium, calcium For shape controle and increasing formadibility 1 31 I www.dl jsSHQs I Lojain Rafaa - 2025  its G Low Alloy Steels (HSLA) It stands fo High Strength Low Alloy Steel. Not made from a specific chemical composition but rather a specific mechanical properties Uses: my Springs Tools Ball bearings Roller ab Connecting rods µ IT Lojain Rafaa - 2025 Extra Notes: For further read on this subtopic, please refer book (Available in design library): Materials and Design 2nd Edition Author: Mike Ashby and Kara Johnson Page 230 to 232 ISBN: 978-1-85617-497-8 Online Reads: For further read on this subtopic online: https://en.wikipedia.org/wiki/Steel https://www.thebalance.com/steel-grades-2340174 https://www.metalsupermarkets.com/types-of-steel/ METAL SUPERMARKETS VIDEO ON STEELS: https://www.youtube.com/channel/UCpEoOKdiy1RbQpGf6i66EnA https://www.youtube.com/watch?v=VBzmGyWeNzo(Types of Steel Part 01) https://www.youtube.com/watch?v=JTu-Zz5jalc (Types of Steel Part 02-Carbon Steel) https://www.youtube.com/watch?v=dpm_uoXzwXE(Types of Steel Part 03-Alloy Steel) https://www.youtube.com/watch?v=TILs8w6myoU (Types of Steel Part 04-Stainless Steel) https://www.youtube.com/watch?v=baZ_lH4TgtQ(Chisels, example of product using Carbon Steel) Lojain Rafaa - 2025  t.IN Aluminum Alloys is Aluminum + copper/zinc/tin/nickel/silicon/magnesium/iron CLI was 6 IT yet will 416 4 www.mail.gb jsawgigo. 405 408 ame Miss I 44 im Is “one of the light alloys” It’s one of the most abundancy metals on earth – extracting it consumes high levels of energy but it is easily recycled at low energy costs Lojain Rafaa - 2025  Aluminum Alloys Aluminum + copper/zinc/tin/nickel/silicon/magnesium/iron Light and strong Easily worked me Outstanding thermal and electrical conductivity was Cost less than copper and more than steel Reactive metal in powered form it can explode Scuff Fatigue of high strength is poor www ae A i Nearly pure aluminums ( 1000 series) Used in small appliancese into 3 High strength (2000 and 7000 serise ) Used in aerospace I'D 48 pox Medium Strength (6000 series) Used in automotive and general engineering www.swams.si Moms Lojain Rafaa - 2025  Lojain Rafaa - 2025 https://www.youtube.com/watch?time_continue=3&v=yn9qhQSMCRk&feature=emb_logo Magnesium Alloys T.to pg magnesium + copper/zinc/tin/nickel/silicon/iron It woods size.im ehDGiI imdb.si Is IkHI 5 “one of the light alloys” 860 Lighter than aluminum by more than half times , nearly twice energy needs to extract compare to aluminum, but one fifth energy used to recycle the material compare to aluminum Lojain Rafaa - 2025 Magnesium Alloys magnesium + copper/zinc/tin/nickel/silicon/iron Light density sway Good mechanical damping 3 5 Better thermal conductivity than steel i.b www.ilsybb o 5 4 8j Good electrical conductivity but not better than alumiun , copper or water. Corrodes over salt water and acides ibdlsuloss Costs more than aluminum and less than titanium WowigpfiDugiawi Uses: Automotive Sports goods Nuclear fuel cans Engine case casting Office equipment's Lawnmowers Lojain Rafaa - 2025  t.LI Titanium Alloys titanium + copper/zinc/tin/nickel/silicon/magnesium/iron t.es Hill method a i T.SI itI d it a I “one of the light alloys” Lighter than aluminum by more abnormal difficult to extract, ten times the price of aluminum , it can be recycled if not contaminated by oxygen Lojain Rafaa - 2025 Titanium Alloys titanium + copper/zinc/tin/nickel/silicon/magnesium/iron e as we e High melting point (1600c) Resist corrosion in most chemicals Poor thermal and electrical conductivity ws bones l.wAi 8SHeWeWmdfatew.SI Because its Strong, light and corrosion resistance be implemented in the body to repair broken isss5 Limited ductility as Uses: Aircraft turban blades www.T General aerospace applications Chemical engineering d.ME Heat exchanges IW.gg Bioengineering WW Marine handwear 31s Casing for mobile phones and laptops. Ideimini Lojain Rafaa - 2025 Zinc Alloys Zinc + copper/tin/nickel/silicon/magnesium/iron I www.t we fi Lojain Rafaa - 2025 Zinc Alloys Zinc + copper/tin/nickel/silicon/magnesium/iron Leading in die-casting A.AE I Low meting point miss f Fluidity 5 mil Mold are relatively cheap, es arehI and details dddI accurately produced Zinc vapor is toxic ( but adequate protection is now universal ) Zinc is non-toxic, low energy consumption and can be recycled in bulk I Used in galvanizing steel s.es wI ME of sina.fi Hygienic, survives exposure to acids and alkalis. em Easy to shape taobao.ae Cheap metal infism Uses: Roofing and gutters. Nov 1 Handles Flashlight reflectors 66 Kitchen countertops ahem Radio shielding Jewelry Photoengraving plates To Lojain Rafaa - 2025 Nickel Alloys SHIH Nickel + copper/tin/aluminium/silicon/magnesium/iron SI 1,4 e.IN IN t.si X Lojain Rafaa - 2025 Nickel Alloys Nickel + copper/tin/aluminium/silicon/magnesium/iron Is.web.id The metal that gives ductility tWtdswaHoadlwb.de eI and corrosion resistance to stainless steel , have extraem properties that made it called Super alloy 10% of population sensitive to nickel WI whatnot Nickel carbonyl that is used in the extraction process is deadly www.twfpdd cg Cheap metal c Competing materials : irone based super alloys < nickel based super alloys< cobalt based supper alloys in I wisest selfies In www.i ajx Good electric and thermal conductivity we Corrosion resistance Low thermal expansion ( glass joints) www.mail.sk Commercial names such as nimonic, Inconel and Hastelloy Uses: sI6oIibt.iIh IgbtlswH Blades. Disks Springs 4 Food equipment IT Heating wire Lojain Rafaa - 2025 11M Lojain Rafaa - 2025 Red Metals 0 41 Copper, Brass, Bronze. miss It Distinguish place in the history of civilization Enabled the technology of bronze age ( 3000-1000 Bc) Easy to recycle 50 61 6,6 8 5M 43 35 postes wt Lojain Rafaa - 2025  Copper game sina.im oflefrgwabo is y Copper is used in a wide range of products due to its excellent electrical and thermal conductivity, good strength, good formability and resistance to corrosion. They can be readily dm Hisand brazed, soldered so and many can be welded by various 2 gas, arc and resistance methods. die 3 They can be polished and buffed to almost any desired texture and luster. 4There are grades of unalloyed Copper, and they can vary in the amount of impurities that are contained. Oxygen-free copper grades are used specifically in functions where high conductivity and ductility are needed. 5 One of the most important properties of copper is its ability to fight bacteria. 5 6 After extensive antimicrobial testing by the Environmental Protection Agency, it IX was found that 355 copper alloys, including many brasses, were found to kill more than 99.9% of bacteria within two hours of contact. 7 Copper was one of the earliest metals discovered. The Greeks and Romans made it into tools or adornments; the application of copper to sterilize wounds and purify drinking water. losing dims are t.tt their 8 Today it is most commonly found in electrical materials such as wiring because of its ability to effectively conduct electricity. Sb bald.ms B 0 Lojain Rafaa - 2025  mido Brass 0dB's www.woagawdbde tfjbbdos.ms on Brass is mainly an alloy that consists of copper with zinc added. Brasses can have varying amounts of zinc or other elements added. These varying mixtures produce a wide range of properties and variation in color. 2 Increased amounts of zinc provide the material with improved strength and ductility. Brass can range in color from red to yellow wings is Ida it D added to the depending on the amount of zinc alloy. axons on D If the zinc content of the brass ranges from 32% to 39%, it will have increased hot-working abilities but the cold-working will be limited. www I higher strength and lower ductility (at room temperature). w w.izatfidjbx 5 If the brass contains over 39% zinc (example – Muntz Metal), it will have a f b.w oslils disguised 6 Brass is commonly used for decorative purposes primarily because of its resemblance to gold. It is also a commonly used to make musical instruments due to its high workability and durability. mfHsH said www.t e e1dk6f were t Lojain Rafaa - 2025  Bronze is i EE i efe www.t wI Bronze is an alloy that consists insHw jd primarily of copper jdbubd.lk with the addition of other ingredients. In most cases the ingredient added is typically tin, but arsenic, phosphorus, aluminum, manganese, and silicon out I www.t can also be used to produce different properties in sutlo m.gg the material. All of these ingredients produce an alloy much D harder than copper alone.986 1 15 2 Has Bronze is characterized by its dull-gold color. 3 You can also tell the difference between bronze and brass because bronze will have faint rings on its iwi www.s www.wwm surface. t Bronze is used in the construction of sculptures, rb www.nd w www i 4 musical www.addj fff instruments and s.ws.se divonod medals, and in industrial applications such as bushings and bearings, where its low metal on metal friction is an advantage. Bronze also has nautical www.MSN.twnd JH Hik ii applications because of its resistance to corrosion. www.j doIXd.i.wwh udw Lojain Rafaa - 2025 www.t.g.de h idI https://www.youtube.com/watch?v=ysInnHOoouc&t=10s Lojain Rafaa - 2025 Silver & Gold Lojain Rafaa - 2025 https://www.youtube.com/watch?v=zWJe6XvMamc Lojain Rafaa - 2025 Workshop 1 5% Mini design challenge In groups of 3 select one random card from each group's A & B & C Task one is to justify that the two cards are compatible. Task two uses the shape card to design a simple product as many as you can (such as small containers) utilizing this material, and work with this material only do not add any other material. Task three sketch your designs and elaborate. Bring your colors, markers, or digital rendering tools. Lojain Rafaa - 2025