Republic of the Philippines

POLYTECHNIC UNIVERSITY OF THE PHILIPPINES

CERT IFIED
COLLEGE OF ENGINEERING CERTIFICATENUMBER
MECHANICAL ENGINEERING DEPARTMENT AJA18-0190

MATERIAL SCIENCE AND ENGINEERING FOR ME

(MEEN 30233)
COMPILATION OF MODULES
(# 1,2,4,5,6,7 AND 8)

Submitted by:

Christian Marjhun M. Briones

BSME 3-1

Submitted to:
Engr. Laarnie Shoemaker
Professor, Material Science for ME

PUP NDC Compound, Anonas Street, Sta. Mesa, Manila 1016 Direct Line: 716-6273
Website: www.pup.edu.ph | Email: ce@pup.edu.ph

THE COUNTRY’S 1st POLYTECHNICU

 POLYTECHNIC UNIVERSITY OF THE PHILIPPINES
COLLEGE OF ENGINEERING
STA. MESA MANILA
_________________________________________________________________________

MATERIAL SCIENCE AND ENGINEERING FOR ME

ACTIVITY 01

NAME BRIONES, CHRISTIAN MARJHUN M. DATE 22/04/2021

STUDENT CLASS
CYS BSME3-1 NUMBER
2018-10517-MN-0
NUMBER
10

Question #1

What is the difference between metals, ceramics, and polymers? How can we
differentiate them from one another?

Answer:

Metal

Metals are a combination of metallic elements, they are lustrous materials that are
known for their hardness, high electrical and thermal conductivity as well as by
malleability –ability to deform under pressure, ductility—ability to plastically deformed
without fracture, and they are not transparent to visible lights. In terms of their atomic
structure, metals have a large number of nonlocalized electrons and usually, these
electrons are not bound to particular atoms.

Ceramic

Ceramics are compounds between metallic and non-metallic elements. They are
characterized by their hardness, abrasive resistance, brittleness, and for being
chemical inertness (not chemically reactive). They usually have lower electrical and
thermal conductivity, more resistant to high temperatures, have lower fracture
toughness than metals and they are resistant to harsh environments than metals and
polymers. These materials are widely categorized into oxide and non-oxide ceramics.
 Polymers

They are plastic and rubber materials that we are familiar with. Polymers are
generally organic compounds based upon carbon and hydrogen. Usually, they have
low density and not stable at high temperatures. The polymer’s strength, stiffness, and
melting temperatures are much lower than metals and ceramics however they are
lightweight, low cost, and easy to process, making them the preferred material for many
applications.

_________________________________________________________________________
Question #2

What are the different types of molecular bonds? What are their differences
between each other?

Answer:

There are three main types of molecular bonding; they are Ionic, Covalent, and
Metallic Bonding.

Ionic bonding

It is the attraction between positive and negative ions. These ions are pulled
together by electrostatic interaction until the electron clouds of the negative and positive
ions start to overlap. When it happens, the ions adopt an equilibrium spacing at a distance
apart where the attractive and repulsive forces balance each other.

Covalent bonding

They are sharing of electrons between atoms usually molecules of non-metallic

elements. When it happens, electrons are being shared to fill the outermost electron shell
thus attaining a stable configuration.
Metallic bonding

It is non-directional, and the electrons are more or less free to travel through solid
since metal atoms are distinguished by their looseness of to the handling of its valence
electrons. Metallic bonding is formed when its valence electrons are not associated with
a particular atom or ion but exist as a cloud of electrons around the ion centers.

_________________________________________________________________________
Question #3

How does various microstructures such as grains, precipitates, dendrites,

spherulites, lamellae and pores form? What are their differences, and/or advantage and
disadvantage?

Answer:

Metals have crystalline structures, and from these structures are known as grains.
These grains are formed from the solidification of molten material, when there is an
interaction with one another and with other ingredients, like phases and contaminations.
In addition, the structure, size, and orientation of these grains varies from one another,
depending on the material composition and the way the materials are made (forging,
casting or additive manufacturing).

Precipitates happen within the metallic materials. The volume fraction, size,
distribution, type of precipitate, and arrangement in the microstructure affects the overall
mechanical properties of a certain metal. For example, nickel-based alloys (steels) have
their precipitates generated within the grain boundary by means of a super heat
treatment. These precipitates are carbides or intermetallic phases (chemical compound
consisting of two or more metals), however due to the formation of the precipitates could
lead to the embrittlement (decrease of ductility) of such steels containing nonmetallic
inclusions or cementite films along grain boundaries
 Dendrites are formed because of having a positive thermal gradient
(a temperature increase with an increase in depth) and instabilities along solid-liquid
interfaces. Meaning, if the solid material absorbs a large heat of solidification then the
liquid’s temperature is be lower than the interface, resulting to a protuberance sticking out
into the liquid. This protuberance has the ability to persist and will grow giving rise to the
characteristic of the dendritic microstructure.

Spherulites are typically two-mineral aggregates formed by the initial spherulitic

growth (recrystallization of spherulites) of one mineral and then crystallization to another
mineral from liquid or glass between fibres. Unlike dendrites, spherulites are aggregate
of separate crystals, rather than single branched crystals.

Lamellae are collections of fine sheets of material that are held adjacent to one
another, often in a gill-shaped structures.

Pores are formed in cast solidifying metals and alloys due to the negative
pressures generated during solidification contraction and pressure being developed by
gases that are dissolved in the molten metal. The generation of pores constitutes to have
major industrial problems since pore structure denotes porosity.

_________________________________________________________________________
Question #4
Why do we study the crystal structure and microstructure in engineering materials?
Answer:

Because it tackles on the molecular structure of materials, and by studying this

one can know the composition, physical and mechanical properties of the material which
is vital when deciding which material is best suited to use.

_________________________________________________________________________
References

A.K Gupta, B. S. (1992). Pore formation in cast metals and alloys. Retrieved from
Springer Link: https://link.springer.com/article/10.1007/BF01197634
Atomic Bonding. (n.d.). Retrieved from Material Science & Engineering:
https://depts.washington.edu/matseed/ces_guide/bonding.htm
Basics about metals, ceramics and polymers. (n.d.). Retrieved from lehigh:
https://www.lehigh.edu/~amb4/wbi/kwardlow/basicsofmcp.htm
GRAIN STRUCTURE. (n.d.). Retrieved from A Level: https://www.the-
warren.org/ALevelRevision/engineering/grainstructure.htm
H. Clemens et., a. (n.d.). Microstructure. Microstructure and Properties of Engineering
Materials, 4-10.
Haikal, S. (2019). How do metals, ceramics and polymers differ? Retrieved from Quora:
https://www.quora.com/How-do-metals-ceramics-and-polymers-differ
Hossain, A. (2014). Evaluation of Microstructure, Conductivity and Hardness of Al-6Si-
0.5Mg-xCu(x=0, 1 & 2) Casting Alloys at Different Ageing Conditions. Retrieved
from GRIN: https://www.grin.com/document/272528
Metal. (n.d.). Retrieved from Britannica: https://www.britannica.com/science/metal-
chemistry
Ravi, R. (2017, August 6). What is the use of the microstructure of any metal. Retrieved
from Quora: https://www.quora.com/What-is-the-use-of-the-microstructure-of-
any-metal
THE STRUCTURAL PROPERTIES OF METALS. (n.d.). Retrieved from Struers:
https://www.struers.com/en/Knowledge/Materials/Metallic-grain-structures#main
 POLYTECHNIC UNIVERSITY OF THE PHILIPPINES
COLLEGE OF ENGINEERING
STA. MESA MANILA
_________________________________________________________________________

MATERIAL SCIENCE AND ENGINEERING FOR ME

ACTIVITY 01

NAME CHRISTIAN MARJHUN M. BRIONES DATE 28/05/2021

STUDENT 2018-01517- CLASS

CYS BSME 3-1 10
NUMBER MN-0 NUMBER

Question:

What is the role of lime/limestone in steel making? How does it affect the process?

Answer:

Limestone is a naturally occurring and abundant sedimentary rock consisting of high levels
of calcium carbonate (CaCO3) in the form of the mineral calcite. By definition, a limestone
contains at least 50% of calcium carbonate and the rest are small particles and impurities.

However, the basic requirement for a limestone to be used in steelmaking is to have at

least 92 % of calcium carbonate and a very low percent of impurities especially the silica
percentage.

The main uses of limestone in iron and steel industry are:

(i) As a fluxing material,

(ii) Other usage which consists of desulphurizing agent, coating of moulds of pig casting
machine, neutralizing of acidic water, water treatment, waste water(effluent) treatment,
flue gas treatment, and sludge and sewage treatment.

Limestone is normally used in three forms, these are:

(i) Raw limestone which is also the natural form of limestone,

(ii) Calcined limestone or quicklime, or simply lime, and
(iii) As hydrated lime.
_________________________________________________________________________

Question:

Explain or describe the following microstructures of iron/steel, how they affect the
iron/steel properties, and show their illustrations.

Answer:

A. Austenite

Austenite was originally used to describe an

iron-carbon alloy, in which the iron is in the face-
centered-cubic (gamma-iron) form.

Austenite in iron-carbon alloys is generally only

evident above 723°C, and below 1500°C, depending
on carbon content. However, it can be retained to room
temperature by alloy additions such as nickel or
manganese.

B. Ferrite

It was a term originally used for iron-carbon

alloys, in which the iron was in the body-centred cubic
(alpha- or delta-iron) morphology, but is now used for
the constituent in iron alloys, which contains iron in the
alpha- or delta-iron form.

Alpha ferrite forms by the slow cooling of austenite, with the associated rejection
of carbon by diffusion. This can begin within a temperature range of 900°C to 723°C, and
alpha-ferrite is evident to room temperature.

Delta ferrite is the high temperature form of iron, formed on cooling low carbon
concentrations in iron-carbon alloys from the liquid state before transforming to austenite.
In highly alloyed steels, delta ferrite can be retained to room temperature.
C. Pearlite

Pearlite is usually formed during the slow

cooling of iron alloys, and can begin at a temperature
of 1150°C to 723°C, depending on the composition of
the alloy.

It is formed by eutectoid decomposition of austenite upon cooling by diffusion of C

atoms, when ferrite and cementite grow contiguously, C precipitating as Fe3C between
laths of ferrite at the advancing interface, leaving parallel laths of Fe and Fe3C which is
pearlite.

D. Martensite

Martensite is formed in steels when the cooling

rate from austenite is sufficiently fast. It is a very hard
constituent, due to the carbon which is trapped in solid
solution.

Unlike decomposition to ferrite and pearlite,

the transformation to martensite does not involve atom diffusion, but rather occurs by a
sudden diffusion less shear process. The term is not limited to steels, but can be applied
to any constituent formed by a shear process which does not involve atom diffusion or
composition change.

E. Bainite

Bainite is formed at cooling rates slower than that for martensite formation and
faster than that for ferrite and pearlite formation. There are two forms of bainite, known as
upper and lower bainite.

Upper bainite generally forms at temperatures between 550 and 400°C. There are
several proposed formation mechanisms, based on the carbon content and transformation
temperature of the steel, resulting in slightly different morphologies.
 Lower bainite generally forms at temperatures between 400 and 250°C, although
the precise changeover temperature between upper and lower bainite depends on the
carbon content of the steel. The transformation nucleates, like upper bainite, by partial
shear.

Upper Bainite Lower Bainite

F. Cementite

Cementite occurs in steels, in meteorites,

possibly at the core of the Earth and has uses in its pure
form. Its composition can deviate from Fe3CFe3C, but
not by much because the Fe–C bond contributes to its
cohesion.

Its crystallographic unit cell is orthorhombic and

primitive, with large lattice parameters, explaining its
hardness. Many of its properties are anisotropic.

Cementite is metallic and ferromagnetic with a Curie temperature of about 187∘∘C.

When alloyed, metallic solutes substitute on to the iron sites; smaller atoms such as boron
replace carbon at interstitial sites.
 G. Ledeburite

Ledeburite is a mixture of 4.3% carbon in iron and is a eutectic mixture

of austenite and cementite. Ledeburite is not a type of steel as the carbon level is too high
although it may occur as a separate constituent in some high carbon steels. It is mostly
found with cementite or pearlite in a range of cast irons.

_________________________________________________________________________

Question:

Explain the figure below:

Answer:

According to the American Iron and Steel Institute, steel is considered to be carbon steel
when no minimum content is specified or required for chromium, cobalt, columbium [niobium],
molybdenum, nickel, titanium, tungsten, vanadium or zirconium, or any other element to be added
to obtain a desired alloying effect; when the specified minimum for copper does not exceed 0.40
per cent; or when the maximum content specified for any of the following elements does not
exceed the percentages noted: manganese 1.65, silicon 0.60, copper 0.60.

The figure above shows that steels can be classified by a variety of different systems
depending on:

• The composition, such as carbon, low-alloy or stainless steel.

• The manufacturing methods, such as open hearth, basic oxygen process, or electric furnace
methods.
• The finishing method, such as hot rolling or cold rolling
• The product form, such as bar plate, sheet, strip, tubing or structural shape
• The deoxidation practice, such as killed, semi-killed, capped or rimmed steel
• The microstructure, such as ferritic, pearlitic and martensitic
• The required strength level, as specified in ASTM standards
• The heat treatment, such as annealing, quenching and tempering, and thermomechanical
processing
• Quality descriptors, such as forging quality and commercial quality.
_________________________________________________________________________
References

AUSTENITE MARTENSITE BAINITE PEARLITE AND FERRITE STRUCTURES. (n.d.). Retrieved from TWI
Global: https://www.twi-global.com/technical-knowledge/faqs/faq-what-are-the-
microstructural-constituents-austenite-martensite-bainite-pearlite-and-ferrite

Bhadeshia, H. (n.d.). Cementite. Retrieved from Taylor Francis Online:

https://www.tandfonline.com/doi/full/10.1080/09506608.2018.1560984

Bhadeshia, H. (n.d.). Interpretation of the Microstructure of Steels. Retrieved from Phase-Trans:

http://www.phase-
trans.msm.cam.ac.uk/2008/Steel_Microstructure/SM.html#:~:text=Austenite%20has%20a%20c
ubic%2Dclose,units%20of%20Fe3C.

Classification of Carbon and Low-Alloy Steels. (2001). Retrieved from Total Materia:
https://www.totalmateria.com/articles/Art62.htm

Satyendra. (2017). Limestone – Its Processing and Application in Iron and Steel Industry. Retrieved from
ISPAT GURU: https://www.ispatguru.com/limestone-its-processing-and-application-in-iron-and-
steel-industry/
 POLYTECHNIC UNIVERSITY OF THE PHILIPPINES
COLLEGE OF ENGINEERING
STA. MESA MANILA
_________________________________________________________________________

MATERIAL SCIENCE AND ENGINEERING FOR ME

ACTIVITY 05

NAME CHRISTIAN MARJHUN M. BRIONES DATE 05/07/2021

STUDENT CLASS
CYS BSME 3-1 NUMBER
2018-01517-MN-0 NUMBER
10

Question:

Answer:

Carburizing, nitriding, and carbonitriding are all metallurgical surface

modification technique that is used to increase the surface hardness of a metal, thereby
reducing wear.

Carburization is a technique that is widely used methods harden the outer layer of
metallic parts and components. This is usually done by facilitating diffusion of carbon
atoms into the surface up to a certain specified depth.

In nitriding, nitrogen is added to the surface of steel parts either using a gaseous
process where dissociated ammonia as the source or an ion or plasma process where
nitrogen ions diffuse into the surface of components. The process has the advantage of
being able to penetrate blind holes, and also allows for the masking of parts to keep areas
which may need further machining soft.

For carbonitriding, the process involves atoms of carbon and nitrogen diffuse
interstitially into the metal, creating barriers to slip, increasing the hardness
and modulus near the surface. This technique is often applied to inexpensive, easily
machined low carbon steel to impart the surface properties of more expensive and difficult
to work grades of steel.
Question:

Answer:

Nucleation occurs when a small nucleus begins to form in the liquid, the nuclei
then grows as atoms from the liquid are attached to it.

In the diagram, it shows the rate of nucleation and growth between small and large
particles. It is shown that the rate of nucleation and growth of small particles over time is
fast compared to larger particles. It also shows that the temperature of nucleation didn’t
matter for the growth of the particles.

_________________________________________________________________________
Question:
Answer:

Tempering is a process used to improve the ductility and toughness of the steel by
relieving the residual stress on it. However, this increase in ductility is usually attained at
the sacrifice of the hardness or strength. While, quenching is a process that uses
mediums to adds hardness to the metal.

Martensite is a supersaturated solid solution of carbon trapped in a body-centered

tetragonal structure. This is a metastable condition and as energy is applied by tempering,
the carbon precipitate as carbide and the iron changes to body centered cubic lattice.

This diagram shows the conventional quench and temper method, wherein it
shows how tempering process involves energy, both time and temperature need to be
considered. The same effect can be achieved by using a shorter time at higher
temperature or by using a longer time at a lower temperature.

_________________________________________________________________________
Question:

Answer:

Quenching is an important stage in the heat treatment of metals since it adds

hardness as a physical attribute of the said metal. Basically, the concept of the process
is simple--heat a metal and then rapidly cool it to make it harder.

In quenching there are several medium that can be used it can be oil, water, or polymer.

Oil

Quenching metal in oil is the most popular method because it is relatively severe
but with a diminished risk of cracking and warping. It is a slowed cooling that advertises
lesser strength while giving a moderate hardness in the metal.

Water

Using water as a medium, extracts heat much faster than oil but its disadvantage
is that it gives too much stress on the metal while giving it a much higher hardness as
possible. Quenching using water is a rapid-cooling method.
Polymer

Polymer quenching is particularly useful for quenching high integrity alloy steel
forgings that require impact testing. And if is properly applied, it yields superior results as
compared to oil quenching. However, all quench variables must be controlled to achieve
repeatable results.

References

Different media for quenching metal explained. (2017, February). Retrieved from
PAULO: https://www.paulo.com/different-media-quenching-metal-explained/

Nitriding and Carburizing. (2016, October). Retrieved from MetLab:

https://blog.metlabheattreat.com/posts/nitriding-and-carburizing/

POLYMER QUENCHING. (n.d.). Retrieved from ThermTech:

https://www.thermtech.net/heat-treating-services/hardening/polymer-
quenching.php#:~:text=Polymer%20quenching%20provides%20a%20hardening,
and%20uniform%2C%20repeatable%20mechanical%20properties.

Prabhu, S. (2020, January). Understanding Carburization: The Positive and Negative

Impacts on Metals. Retrieved from CorrosionPedia:
https://www.corrosionpedia.com/understanding-carburization-the-positive-and-
negative-impacts-on-metals/2/6958

Tempering. (n.d.). Retrieved from Practical Maintenance:

https://practicalmaintenance.net/?p=1532
 POLYTECHNIC UNIVERSITY OF THE PHILIPPINES
COLLEGE OF ENGINEERING
STA. MESA MANILA
_________________________________________________________________________

MATERIAL SCIENCE AND ENGINEERING FOR ME

MODULE 06

NAME CHRISTIAN MARJHUN M. BRIONES DATE 25/06/2021

STUDENT CLASS
CYS BSME 3-1 NUMBER
2018-01517-MN-0 NUMBER
10

Question:

Answer:
This table shows the general advantage and disadvantage between the non-ferrous
metals/alloy and steel components of a bicycle.

Non-ferrous alloy bicycle Steel bicycle

Durability Have a short lifespan1 Long lasting

Ease of use Not comfortable2 Comfortable

Material composition It doesn’t contain iron3 Contains iron

The components are usually Its weight depends on how it is

Weight
lightweight manufactured4

Cost They are cheaper They are expensive

Notes:

1 the average alloy bike has a lifetime expectancy of 4-6 years if well used.

2 Alloy based bicycle are not comfortable to ride as it doesn’t soak up road
vibrations as well as other materials.
 3 Since the components of a non-ferrous alloy bikes doesn’t contain iron, it means
that they don’t corrode compared to components that are made up of iron.

4 Very high-grade steel can be quite light but to make it so, it needs to be thin, and
that means handmade, not manipulated by factory robots. For that reason,
modern, high grade steel bikes are more expensive, whilst lower grade versions
have a bad reputation for being heavy.

_________________________________________________________________________
Question:

Answer:

The reason why non-ferrous metals/alloys are corrosion resistant compared to

steel is primarily due to iron (FE). If you combine iron to carbon you will get steel, and
because of this combination there is an increase to its mechanical properties but iron-
based materials react easily to oxygen, forming to rust. And this will affect the physical
properties of the material.

While materials that aren’t made of iron (non-ferrous material) does not rust easily.
But when it does, the oxide creates a thin film that protects the rest of the metal from
further corrosion.

_________________________________________________________________________
References
Advantages and disadvantages of different materials bike frame. (2020, May). Retrieved from
Speeder:http://www.speedercycling.com/detail/news/22.html#:~:text=Strength%20and%
20comfor%20is%20the,and%20being%20denser%20than%20aluminum.

Brennan, M. (2013, December). What is your bike made of? Bike frame materials and their
properties. Retrieved from London Cyclist: https://www.londoncyclist.co.uk/bike-made/

FERROUS VS. NON-FERROUS METALS — WHAT’S THE DIFFERENCE? (n.d.). Retrieved

from All Metals Fabrication: https://www.allmetalsfab.com/ferrous-non-ferrous-metals-
whats-difference/

Material categories and properties. (n.d.). Retrieved from Bite SIze:

https://www.bbc.co.uk/bitesize/guides/z74bcj6/revision/3

Olsen, D. (2020, November). What Is Non-Ferrous Metal? Retrieved from Metal Tek:
https://www.metaltek.com/blog/what-is-non-ferrous-metal/

STEEL VS ALUMINUM BIKE FRAME: PROS AND CONS. (2021, May). Retrieved from Where
The Road Forks: https://wheretheroadforks.com/steel-vs-aluminum-bike-frame-pros-and-
cons/
 POLYTECHNIC UNIVERSITY OF THE PHILIPPINES
COLLEGE OF ENGINEERING
STA. MESA MANILA
_________________________________________________________________________

MATERIAL SCIENCE AND ENGINEERING FOR ME

MODULE 07

NAME CHRISTIAN MARJHUN M. BRIONES DATE 26/06/2021

STUDENT 2018-01517- CLASS

CYS BSME3-1 NUMBER NUMBER
10
MN-0

Question:

Answer:

In metal hot working, the metal is soft and ductile therefore large deformation can
be successively repeated. Most metal that undergoes this process will experience some
surface oxidation resulting in material loss and poor final surface finish.

On the other hand, cold working process allow desirable metal qualities that
cannot be obtained by hot working. Resulting to a much more compact with a higher
dimensional accuracy that a metal can be obtained with cold working. Furthermore, the
final products have a smoother surface than those of hot working and the strength,
hardness as well as the elastic limit are increased. However, the ductility of the metal
decreases due to strain hardening thus making the metal more brittle.
This table shows the detailed differences between hot and cold metal working process.

Cold Working Process Hot Working Process

It is done at a temperature below the Hot working is done at a temperature

recrystallization temperature. above recrystallization temperature.

It is done below recrystallization

Hardening due to plastic deformation is
temperature so it is accomplished by strain
completely eliminated
hardening.

Cold working increases ultimate tensile

In hot working, ultimate tensile strength,
strength, yield point hardness and fatigue
yield point, corrosion resistance is
strength but decreases resistance to
unaffected.
corrosion.

Internal and residual stresses are Internal and residual stresses are not
produced. produced.

It requires less energy for plastic

Cold working required more energy for deformation because at higher
plastic deformation. temperature metal become more ductile
and softer.

It does not require pickling because no Heavy oxidation occurs during hot working
oxidation of metal takes place so pickling is required to remove oxide

There is chance of embrittlement by

Embrittlement does not occur in cold
oxygen in hot working hence metal working
working due to no reaction with oxygen at
is done at inert atmosphere for reactive
lower temperature.
metals.

_________________________________________________________________________
Question:

Answer:

Sand Casting

Sand casting usually use silica and other synthetic materials as base. It consists
of finely ground grains of sand that can be packed together into a smooth molding surface.

This casting method is designed to reduce the probability of having a tear, cracks and
other flaws made by allowing a moderate degree of flexibility and shrinkage during the
cooling phase of the process.

In addition, this method is less costly compared to other methods, especially in

low-volume runs. It also has the ability to fabricate large components, and cast both
ferrous and non-ferrous materials.

Despite this, sand casting yields a lower degree of accuracy than do alternate
methods and it can be difficult to sand cast components with a predetermined size and
weight specifications. Furthermore, this process has a tendency to yield products with a
comparatively rough surface finish.

Investment Casting

Investment casting uses a disposable wax pattern for each cast part. Wherein the
wax is injected directly into a mold, removed, then coated with a refractory material and
a binding agent.

This casting is known for its accurate and precise when it comes to mold making,
its ability to create thin-walled parts with complex geometries and also capable of casting
both ferrous and non-ferrous materials.
 Although it is highly precise, investment casting is usually more expensive than
other comparable casting techniques and is typically only cost-efficient when sand or
plaster castings cannot be used. However, the expense can sometimes be compensated
for with reduced machining and tooling costs due to investment castings’ high-quality
surface results.

Die Casting

Die casting is a method of molding materials under high pressure. This method
usually uses reusable mold as a base then it is coated with a lubricant to help regulate
the die’s temperature and to assist with component ejection.

And then the molten metal is injected into the die under high pressure, which will
remain continuous until the workpiece solidifies (This pressurized insertion is rapid,
preventing any segment of the material from hardening before being cast). After the
process is completed, the component is taken out of the die and any scrap material is
removed.

Despite this, die casting as a metal casting process has relatively high tool costs,
making it more cost-efficient in high-volume product runs. It can also be difficult to ensure
the mechanical properties of a die-cast component, meaning these products usually do
not function as structural parts.

_________________________________________________________________________

Question:

Answer:

3D-printing also known as additive manufacturing (AM), is a digital manufacturing

process that uses 3D design data to build objects by depositing material, usually layer
upon layer.
 Powder-based additive manufacturing, is another method of AM process which
uses metal powder to produce materials. And due to the practicality of this method,
especially for selective laser sintering (SLS) and inkjet 3D printing (3DP), there is a rapid
increase of demand for powder metals. These powdered metals are produced exclusively
for powder metallurgy (PM) processes which involve consolidation of powders under
pressure in dies or molds to form precision parts.

However, powders produced for PM processes may not be suitable for AM

processes, and understanding the powder requirements for both types of processes is a
major key to successful applications.

_________________________________________________________________________

Question:

Answer:

Extrusion on metal working process is extensively used in pipes and steel rods
manufacturing.

The following are the applications of extrusion:

❖ Extrusion process is generally used in the formation of hollow pipes

❖ Extrusion process is widely used to make plastic materials.
❖ Aluminum extrusion is utilized in structure work in various industries.
❖ Extrusion process, helps in the production of pharmaceutical products
❖ Ready-to-eat foods are manufactured using cold extrusion process

_________________________________________________________________________
References
ADVANTAGES & DISADVANTAGES OF ADDITIVE MANUFACTURING PROCESS VS. PM.
(n.d.). Retrieved from Horizaon Technology:
https://www.horizontechnology.biz/blog/advantages-and-disadvantages-of-additive-
manufacturing-process-vs-powder-metallurgy

Different Types of Casting Processes Used in Manufacturing. (n.d.). Retrieved from

https://www.thomasnet.com/articles/custom-manufacturing-fabricating/types-of-casting-
processes/

Extrusion Process : Working, Types, Application, Advantages and Disadvantages. (n.d.).

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