Lesson-2 PDF - Industrial Materials & Processes

Industrial Materials & Processes  Industrial materials are substances employed in industrial processes for the creation of goods and artifacts. Materials may be classif ie d in different ways: nature of constituents, usage, etc.... That is, for some metals, mechanical, chemical, electric...

Industrial Materials & Processes  Industrial materials are substances employed in industrial processes for the creation of goods and artifacts. Materials may be classif ie d in different ways: nature of constituents, usage, etc.... That is, for some metals, mechanical, chemical, electrical, etc., properties can be modified by adding alloys. Materials processing is def in ed as the series of steps or “unit operations” used in the manufacture of raw-materials into f in ished goods. The operations involve a succession of in du strial processes w ith v ariou s mechanical or chemical procedures, usually produced in large quantities or batches. Processed materials are materials which have been ref in ed or built by humans from raw materials. Some examples include paper, steel and glass.  Different types of materials Materials can be classified into four main groups: metals Polymers ceramics composites. Metal A metal (from Greek μέταλλον métallon , "mine, quarry, metal") is a material that, when freshly prepared, polished, or fractured, shows a lustrous appearance, and conducts electricity and heat relatively well. Metals are typically malleable (they can be hammered into thin sheets) or ductile (can be drawn into wires). Polymers A polymer (/ˈpɒlɪmər/; Greek poly-, "many" + -mer , "part") is a substance or material consisting of very l a rge m ol ecul es, or m a crom ol ecul es, composed of many repeating subunits. Due to their broad spectrum of properties, both synthetic a n d n a t u ra l p ol y m er s p l a y es s en t i a l a n d ubiquitous roles in everyday life. Ceramics A ceramic is an inorganic non-metallic solid m ad e up o f e it he r m e t al o r no n-m e t al compounds that have been shaped and then hardened by heating to high temperatures. In general, they are hard, corrosion-resistant and brittle. Composite A composite material is a combination of two materials with different physical and chemical properties. When they are combined they create a material which is specialised to do a certain job, for instance to become stronger, lighter or resistant to electricity. They can also improve strength and stiffness.  Raw Material are materials that have not been processed. They are in the form in which they are found in nature without any thing done to them. Raw materials are made into other things. Raw materials usually come from: A plant or tree An animal A mine Examples of raw materials: Grains such as wheat and rice Vegetables such as carrots and onions Meat such as beef and chicken Wood from a tree Honey from a bee's nest Minerals or metal from a mine Crude oil Things that are not raw materials because they have been processed Bread and pasta Toothpaste and soap Sausages Furniture such as chairs and tables Machines such as cars Jewelry Clothing and shoes Gasoline Oil that goes in cars Industrial Processes Industrial processes are procedures involving chemical, physical, electrical or mechanical steps to aid in the manufacturing of an item or items, usually carried out on a very large scale. Industrial processes are the key components of heavy industry. Chemical processes
Smelting – extracting metals from ores Haber process – chemically binding gaseous nitrogen from the atmosphere to make ammonia Disinfection – chemical treatment to kill bacteria and viruses Pyroprocessing – using heat to chemically combine materials, such as in cement. Types of Manufacturing Processes Casting and molding Machining Joining Shearing and forming. Casting and molding Casting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Machining Machining is any process in which a cutting tool is used to remove small chips of material from the workpiece (the workpiece is often called the "work").... The shape of the tool and its penetration into the work surface, combined with these motions, produce the desired shape of the resulting work surface. Joining Joining includes welding, brazing, soldering, adhesive bonding of materials. They produce permanent joint between the parts to be assembled. They cannot be separated easily by application of forces.... In some welding processes a filler material is added to facilitate coalescence. Shearing and Forming Shearing, also known as die cutting, is a process which cuts stock without the formation of chips or the use of burning or melting. Strictly speaking, if the cutting blades are straight the process is called shearing; if the cutting blades are curved then they are shearing-type operations. The most commonly sheared materials are in the form of sheet metal or plates, however rods can also be sheared. Shearing-type operations include: blanking, piercing, roll slitting, and trimming. It is used in metalworking and also with paper and plastics. Shearing metal process Thank You!