LJMU HD in AME

Module Name with Code -Automotive materials and

manufacturing processes -5501ICBTAE
Semester - Semester 3
Batch Number -
Lecturer Name -
Center Name -

LJMU Higher Diploma 1

Content

LJMU Higher Diploma 2

• The practical application of engineering materials in manufacturing
engineering depends upon through knowledge of their particular
properties under wide range of conditions.
• The term “property” is a qualitative or quantitative measure of response
of materials to externally imposed conditions like forces and temperature.
• However, the range of properties found in different classes of materials is
very large.

LJMU Higher Diploma 3

 Materials
Iron ore

Hematite Pellets of iron ore

Metals
 Classification

1. According to General Properties

2. According to Nature of Materials

3. According to Applications
1. According to General Properties

(a). Metals (e.g. iron, aluminium, copper, zinc, lead, etc) Iron as the
base metal, and range from plain carbon (> 98 % Fe) to
(i). Ferrous: high alloy steel (< 50 % alloying elements), e.g. cast iron,
wrought iron, steel, alloys like high-speed steel, spring steel, etc

(ii). Non-Ferrous: Rest of the all other metals and their alloys, e.g.
copper, aluminium, zinc lead, alloys like brass, bronze, duralumin, etc

(b). Non-Metals (e.g. leather, rubber, asbestos, plastics, etc)

2. According to Nature of Materials

(a). Metals: e.g. Iron & Steel, Alloys & Super alloys, Intermetallic
Compounds, etc.

(b). Ceramics: e.g. Structural Ceramics (high-temperature load

bearing), Refractories(corrosion-resistant, insulating), White wares
(porcelains), Glass, Electrical Ceramics (capacitors, insulators,
transducers), Chemically Bonded Ceramics (cement & concrete)

(c).Polymers: e.g. Plastics, Liquid Crystals, Adhesives

(d). Electronic Materials: e.g. Silicon, Germanium, Photonic materials

(solid-state lasers, LEDs)
(e). Composites: e.g. Particulate composites (small particles
embedded in a different material), Laminate composites (golf club
shafts, tennis rackets), Fiber reinforced composites(fiberglass)

(f). Biomaterials: e.g. Man-made proteins (artificial bacterium),

Biosensors, etc.

(g). Advanced / Smart Materials: e.g. materials in computers

(VCRs, CD Players, etc.), fibreoptic systems, space crafts, aircrafts,
rockets, shape-memory alloys, piezoelectric ceramics,
magnetostrictive materials, optical fibers, microelectromechanical
(MEMs) devices, electrorheological / magnetorheological fluids,
Nanomaterials, etc.
3. According to Applications

(a). Electrical Materials: e.g. conductors, insulators, dielectrics,

etc

(b). Electronic Materials: e.g. conductors, semi-conductors, etc

(c). Magnetic Materials: e.g. ferromagnetic, paramagnetic &

diamagnetic materials, etc

(d). Optical Materials: e.g. glass, quartz, etc

(e). Bio Materials: e.g. man-made proteins, artificial bacterium

Classification of Engineering Materials

Engineering
materials

Metals and their

alloys Non metals
iron, steel, copper,
aluminium glass, rubber, plastic

-Ferrous Metals
Ferrous Metals Containing iron as their primary
cast iron, wrought elements
iron and steel.
-Non ferrous Metals
Not containing iron as primary
elements
Non ferrous
Metals
copper, aluminium,
brass, tin, zinc
 Application of Materials

• Ferrous Metals: iron and steel.

Automotive applications: chassis, engine parts, drive train,

body parts

• Nonferrous Metals and Alloys: aluminum, magnesium, copper,

nickel, titanium, super alloys, beryllium, zirconium, low-melting
alloys, precious metals.

Automotive applications: aluminum engine blocks, copper wiring,

mag wheels
• Plastics: thermoplastics, thermosets, elastomers.
Automotive applications: body panels, instrument panels,
electrical and thermal insulation, seals, hoses, tires

• Ceramics: glass, graphite, diamond.

• Automotive applications: Windscreen
• Composite materials: reinforced plastics, metal-matrix and
ceramic-matrix composites, honeycomb structures.
Materials are used to build a modern car
 Ferrous Materials - Steels

➢ Steels - alloys of iron-carbon. May contain other alloying elements.

Several grades are available.

• Low Alloy (<10 wt%)
–Low Carbon (<0.25 wt% C)
–Medium Carbon (0.25 to
0.60wt%)
–High Carbon (0.6 to 1.4 wt%)

• High Alloy
–Stainless Steel (> 11 wt% Cr)
–Tool Steel
 Selection of Materials for
Engineering Purposes

• Availability of the materials

• Suitability of the materials for the working conditions in service

• The cost of the materials.

Ex:- plastic -electrical insulator and prevents electric shock, cheap,

tough, and easily moulded to shape
 Properties of materials

Mechanical Properties: e.g. strength, ductility, hardness,

toughness, etc.

Physical Properties: e.g. density, appearance, shape, weight, boiling

point electrical conductivity, thermal conductivity, etc.

Chemical Properties: e.g. reactivity, corrosion resistance in various

environments.

Manufacturing Properties: e.g. formability, machinability, ease of

joining, etc.
 Mechanical properties of materials

• Hardness
• Toughness
• Malleability
• Ductility
• Elasticity
• Strength
 HARDNESS

• It is the ability of material to resist to permanent shape change due to

external stress. A material is hard if it is not easily worn away or
dented. Cutting tools and some kitchen utensils are made from hard
materials.
• A simple test to compare the hardness of different materials can be
carried out using a centre punch. Drop the punch from the height of
500 mm onto each sample in turn and compare the dents. The smaller
the dent, the harder the material.
 TOUGHNESS

• A tough material is one that can withstand sudden shocks without breaking.
(a material that breaks easily with a sudden shock is said to be brittle.) car
bumpers and cycle helmets are made from tough materials.
 MALLEABILITY

• A malleable material is one that can be permanently deformed without

cracking or tearing when it is compressed.

• Malleable materials can be hammed into new shapes, an essential property

when making some jewelers and decorative products.
 DUCTILITY

•A ductile material is one that can be permanently deformed without

cracking or tearing when it is tension. Some rods and wires are made from
ductile materials.

• With rise of temperature, the ductility of material increases.

 ELASTICITY

• An elastic material is one that returns to its original shape after being
deformed. Springs, rubber bands and trampolines and car bumpers are
made from elastic materials.

• A material that does not return to its original shape after being deformed is
said to be plastic.
• A strong material is one that can resist a force without breaking or
permanently distorting. A material will have different strengths
STRENGTH
against different types of force.

▪ A material has tensile strength if it resists stretching forces

▪ A material has compressive strength if it resists squashing
forces

▪ A material has bending strength if it resists bending forces

▪ A material has torsional strength if it resists twisting forces
▪ A material has shear strength if it resists shear forces (forces
that attempt to cause one part of the material to ‘slide past’
another part)
Different types of force
 Recommended readings

LJMU Higher Diploma 26