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

• Engineering materials & Applications

• Metals and their alloys
1. Ferrous metals
2. Non Ferrous metals

• Non metals

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Metals and their alloys

• Ferrous metals
 Ferrous metals (wrought iron, steel and cast iron)

Wrought Iron
• Has very low strength and hardness.
• Very ductile and resistant to corrosion.
• Carbon = 0.020%, Silicon = 0.120%, Sulphur = 0.018%,
Phosphorus = 0.020%, Slag = 0.070%,
and the remaining is iron.(99.5%)

• Applications:- Sheeting for ships, water and steam pipes

Steel

• Steel is a material composed primarily of iron(Fe)

• Most steel contain more than 90% of iron.
• All type of steel contain a second element of C
• Many other alloying elements are used in most steel, but iron
(Fe) and C are the only elements found in all steels.
• The percentage of C in steel ranges from just above 0% to
approximately 2%.
• However most steel has between 0.15% and 1% of carbon.
 Major types of steel

Steel

Carbon Alloy Other

Tool Stainless
steel steel steel
steel steel

Low
carbon
Medium
carbon
High
carbon
 Cast Iron
• Contains about 2% to 6% C and small amount of Si. Other
alloying elements are also used.
• There are types of cast iron as gray, white, malleable, ductile
and special alloy

Properties:
Lower melting point
Low shrinkage and good fluidity and casting ability.
Application:-
• Car parts – cylinder heads, blocks and gearbox cases
• Because of its high damping capacity and compressive strength, it is used
for frames of large equipment and machinery.
• Because of its good resistance to wear, it is used for engine blocks, piston
rings, brake drums, rolls and crushers
 Microstructure behavior of steel and Cast iron

In steel, Iron dissolves Carbon

In gray cast iron, C precipitate out as In ductile cast iron, the dissolved C
small carbon flakes precipitates as small round nodules
 Low Carbon Steel

➢Most abundant grade of steel is low carbon steel – greatest

quantity produced; least expensive.
➢Not responsive to heat treatment; cold working needed to
improve the strength.
➢Good Weldability and machinability
 Medium Carbon Steel

• Carbon content in the range of 0.3 – 0.6%.

• Medium carbon steels have low hardenability
• Addition of Cr, Ni, Mo improves the heat treating capacity
• Heat treated alloys are stronger but have lower ductility
Applications – Railway wheels and tracks, gears, crankshafts.
 High Carbon Steel
• High carbon steels – Carbon content 0.6 – 1.4%
• High C content provides high hardness and strength. Hardest
and least ductile.
• Strong carbide formers like Cr, V, W (Tungsten) are added as
alloying elements to from carbides of these metals.

Application:

• Used as tool and die steels owing to the high hardness and
wear resistance property
 Alloy steel
Aluminum alloys

Corrosion resistance
Easy to fabrication
High thermal conductivity
 Effects of Alloying Elements on Steel

• Manganese – strength and hardness; decreases ductility and

weldability; effects hardenability of steel.
• Phosphorus – increases strength and hardness and decreases
ductility and notch impact toughness of steel.
• Sulfur decreases ductility and notch impact toughness
Weldability decreases. Found in the form of sulfide inclusions.
• Silicon – one of the principal deoxidizers used in steel making. In
low-carbon steels, silicon is generally detrimental to surface
quality.
• Copper – detrimental to hot-working steels; beneficial to corrosion
resistance (Cu>0.20%)
• Nickel - ferrite strengthener; increases the hardenability and impact
strength of steels.
• Molybdenum increases the hardenability; enhances the creep resistance of
low-alloy steels

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 Tool steel

• Tools steels fall into three basic categories:

▪ Cold work tool steels

▪ Hot work tool steels
▪ High-speed tool steels
 Stainless steel

• Extremely corrosive resistant

• Cost more than carbon steel
• Harder to cut and machine
• Use commonly to meet special sanitation requirements, transfer chemical
through pipes
• Contains of high quantities of chromium and many types contain high
quantities of nickel alloys
• Non – Ferrous Metals
• Aluminum

• Aluminum is strong,
• lightweight,
• electrically- and thermally-conductive, and
• corrosion resistant

• Application:- engine components, e.g. blocks, heads, and

manifolds, Ocean transportation and ships
• Copper

• It is a ductile and malleable metal.

• It is often red / brown in colour.
• It is a very good conductor of heat and electricity.

Application:- wiring and electrical applications, piping

and tubing
 • Magnesium

• lighter than aluminum

• fairly strong
• Corrosion resistant
• Low density
• Low ductility

• Application:- wheel rims, aircraft, space vehicles

Applications of Mg Alloys in motor vehicles
• Nickel
• Tough metal
• Strong resistant to corrosion and oxidation
Application:- Nickel based super alloys are used in aircraft
components, jet engine parts.
• Titanium

• Low density
• Corrosion resistant
• High melting temperature
• High strength

• Application :-Titanium alloys are used in aircraft components , compressor

blades in jet engines and wings of fighter planes
Non metals
 Classification of non metallic materials

1. Non – metallic (synthetic materials)

2. Non – metallic (Natural materials )
Classification of non metallic materials (synthetic materials )
Plastics
Plastics can be further classified as;
• Thermoplastic
• Thermoset
• Elastomer
Characteristics and Applications of some common
Thermoplastics
 Thermoplastic

• Thermoplastics are long-chain polymers that slide easily past one

another when heated, hence, they tend to be easy to form, bend, and
break.
 Thermoset

• Thermosets are cross-linked polymers that form 3-D networks,

• hence are strong and rigid.
Characteristics and Applications of some
common Thermosetting
 Elastomers

EX:- Polybutadiene - elastomer material used on the wheels

or tires of vehicles, given the extraordinary wear resistance.
 Non – metallic (Natural materials )

Such materials are so diverse that only a few can be listed hereto give
a basic introduction to some typical applications.

Wood:
This is naturally occurring fibrous composite
material used for the manufacture of casting patterns.

Rubber :
This is used for hydraulic and compressed air hoses and oil seals.
Naturally occurring latex is too soft for most engineering uses but it is
used widely for vehicle tyres when it is compounded with carbon
black.
Glass :
This is a hardwearing, abrasion-resistant material with excellent
weathering properties. It is used for electrical insulators, laboratory
equipment, optical components in measuring instruments, in the form of
fibers, is used to reinforce plastics. It is made by melting together the
naturally occurring materials : silica (sand), limestone (calcium carbonate )
and soda (sodium carbonate).
Emery :
This is a widely used abrasive and is a naturally occurring aluminum
oxide. Nowadays it is produced synthetically to maintain uniform
quality and performance

Ceramic:
These are produced by baking naturally occurring clays at high
temperatures after moulding to shape. They are used for high –
voltage insulators and high – temperature – resistant cutting tool tips.
• Advanced Ceramics: Automobile Engine parts
Advantages:
Operate at high temperatures – high efficiencies; Low frictional losses;
Operate without a cooling system; Lower weights than current engines
Disadvantages:
Ceramic materials are brittle; Difficult to remove internal voids (that
weaken structures); Ceramic parts are difficult to form and machine
Potential materials: Si3N4 (engine valves, ball bearings), SiC (MESFETS),
& ZrO2 (sensors),
Possible engine parts: engine block & piston coatings
 Recommended readings

LJMU Higher Diploma 39