1. Materials

2. Properties of Materials
Mechanical Properties: strength, toughness, ductility, hardness, elasticity, fatigue, creep.
Behavior Under Loading: tension, compression, bending, torsion, shear.
Physical Properties: density, specific heat, thermal expansion, thermal conductivity, melting point, electrical and magnetic properties.
Chemical Properties: oxidation, corrosion, degradation, toxicity, flammability.

3. Types of Materials Ferrous Metals: iron and steel.
Nonferrous Metals and Alloys: aluminum, magnesium, copper, nickel, titanium, superalloys, beryllium, zirconium, low-melting alloys, precious metals.
Plastics: thermoplastics, thermosets, elastomers.
Ceramics: glass, graphite, diamond.
Composite materials: reinforced plastics, metal-matrix and ceramic-matrix composites, honeycomb structures.

4. Ferrous Metals: Applications
Structural: building structures, concrete reinforcement
Automotive: chassis, engine parts, drive train, body parts
Marine: ship hulls, structure, engines
Defense: tanks, weapons
Consumer Products: appliances, recreational vehicles, toys, utensils and tools

5. Nonferrous Metals: Applications
Architectural: aluminum windows and doors
Automotive: aluminum engine blocks, copper wiring, mag wheels
Marine: brass/bronze fittings, bearings, propellers
Defense: brass shell casings
Consumer Products: electrical wiring, utensils, jewelry, electronics

6. Plastics (Polymers)
Compared to metals, plastics have lower density, strength, elastic modulus, and thermal and electrical conductivity, and a higher coefficient of thermal expansion
The design of plastic parts should include considerations of their low strength and stiffness, and high thermal expansion and low resistance to temperature.

7. Plastics: Applications
Architectural: electrical and thermal insulation, weather seals, carpets, wall coverings, paint
Aerospace: electrical and thermal insulation, instrument panels,upholstery, seals
Automotive: body panels, instrument panels, upholstery, electrical and thermal insulation, seals, hoses, tires
Consumer Products: toys, sporting goods, appliances, tools, utensils, clothing, shoes, packaging

8. “The Process of Converting Raw Materials Into Products”
Manufacturing
“The Process of Converting Raw Materials Into Products”

9. Manufacturing a Product: General Considerations
Material Selection
Processing Methods
Final Shape and Appearance
Dimensional and Surface Finish
Economics of Tooling
Design Requirements
Safety and Environmental Concerns

10. Choosing Methods of Production
Use a Selection Chart

11. Manufacturing Processes for Metals
Casting: expendable mold and permanent mold.
Forming and Shaping: rolling, forging, extrusion, drawing, sheet forming, powder metallurgy, molding
Machining: turning, boring, drilling, milling, planing, shaping, broaching, grinding, ultrasonic machining, chemical machining, electrical discharge machining (EDM), electrochemical machining, high-energy beam machining
Joining: welding, brazing, soldering, diffusion bonding, adhesive bonding, mechanical joining
Finishing: honing, lapping, polishing, burnishing, deburring, surface treating, coating, plating

12. Casting Processes
Introduction of molten metal into a mold cavity; upon solidification, metal conforms to the shape of the cavity.
Die Casting
Sand Casting

13. Forming and Shaping Processes
Bulk deformation processes that induce shape changes by plastic deformation under forces applied by tools and dies.
Forging
Extrusion

14. Machining Processes
Material removal from a work piece: cutting, grinding, nontraditional machining processes.
Milling
Lathe Machine

15. NC Machine Tool and Controller

16. NC Punch Press Machine

17. Manufacturing Processes for Plastics
Plastics are shipped to manufacturing plants as pellets or powders and are melted just before the shaping process. Polymers melt at relatively low temperatures and are easy to handle.
Plastics can be molded and formed, as well as machined and joined, into many shapes with relative ease.

18. Injection Molding of Plastics

19. Selective Laser Sintering System
Courtesy of the University of Texas