QUEZON CITY UNIVERSITY

INDUSTRIAL ENGINEERING DEPARTMENT

MODULE 2

INDUSTRIAL MATERIALS AND PROCESSES

ENGINEERING MATERIALS (METALS)

TYPES, PROPERTIES AND USES

INTRODUCTION

This module aims to determine what metal is and its properties and types based on their
characteristics. This module covers the aspects of properties from the viewpoint of the material
selection and manufacturing and its relevance to the service life of the component. It helps the
students understand the importance and benefits of this to our technology now a days.

LEARNING OUTCOMES

1. Discuss and determine what metals mean: Properties, Types, and Composition

2.Identify and explain by using the concept map to classify the properties of metals.

3.Cite examples of products formed by metals and its properties.

4.Discuss the importance and benefits of this to the design and manufactured of product in
assessing the various properties and how it affects to everyday life.

Lesson 1:

Meaning, Types, Properties, and Uses of Metals

Metal
Types

Ferrous Amorphous Non Ferrous

Steel Iron Aluminum

Stainless steel Nickel Copper

Tool and dyes Chromium Titanium

Cast Iron Alloy with carbon Tungsten

Carbon and alloy steel Metallic Glasses Others

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Metal
Properties

Mechanical Physical Electrical Magnetic Optical Chemical Manufacturing

What is metal

-metals appear lustrous (beneath any patina form mixtures alloy) when combined to other metals;
tend to lose when they react with other substances and each form at one predominantly basic
oxide.

-most metals are silvery looking, high density, relatively and easily deformed solid with good
electrical and thermal conductivity closely packed structures, low ionization energies and
electronegative and are found in combined states.

-metals is an element that are readily forms positive ions (cations) and has a metallic bond. Metal
can sometimes describe as a lattice of positive ions surrounded by a surrounded by a cloud of
delocalized electrons

-metals occurs in solid state. All metals are solid except with an exception for mercury which is in
liquid state in its natural form.

TYPES OF METALS

FERROUS METALS- are metals and alloys are among the most useful of all the metals of its
properties.

Corrosion resistance and have low thermal and electrical conductivity and heavier as per to
nonferrous.

NONFERROUS METALS are more expensive than ferrous metals, wide range of materials, from the
more common metals such as aluminum, copper, and magnesium to high-strength high-
temperature alloys, such as those of tungsten, tantalum and molybdenum. Nonferrous metals and
alloys have an important application because of properties such as corrosion resistance, high
thermal and electrical conductivity, low density and ease of fabrication.

AMORPHOUS METALS- are metals that do not have a long-range crystalline structure. They have no
grain boundaries, and the atoms are randomly and tightly packed. These alloys exhibit excellent
corrosion resistance, good ductility, high strength and very low loss from magnetic hysteresis.
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PROPERTIES OF METALS

1.Mechanical Properties

It is material capacity to cope with range of applied external form such as shear stress, load and
weather condition and others. Engineers can measure the ability of metals to resists shearing,
twisting, compressing or breaking under a given set or condition. This property is used to ascertain
whether the material can withstand sudden loads and stresses and its suitability to specific tasks.
Mechanical properties such as:

a. Strength- it is done by true stress-true strain curves. The curves start at a finite level
of stress: The elastic regions have too steep a slope, the curve starts at the yield
stress, Y, of the material. Strength also is the ability to resist force.
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b. hardenability- the hardenability of a metal denotes the depth of metal that can be
hardened to a specific hardness by using a hat process. While hardness denotes
resistance to penetration, hardenability shows how deep the metal can be
penetrated by hardening plays the big part in the strength of the steel parts.
Hardness of the metal
Is important property that allows it to resist penetration and distortions such as
buckling, warping and twisting. Hardness is also referred to as temper or stiffness.
There
are many ways to test the hardness of the metals with the Rockwell, Brinell and
Vickers test.

c. Elasticity- flexible or adjustable and adaptable or capable of recovering size and

shape and size after deformation. The absolute value on modulus of elasticity, is the
ratio between stress and strain and it is a measure of the stiffness of the material.
d. Malleability- is a material ability to molded something else without breaking.
e. Toughness- is the amount of energy per unit volume the metal can soak up before
deformation permanently occurs or functioning. To have required toughness, the
metals needs adequate ductility, elasticity and yield strength. The toughness of
metals or metals parts can be evenly affected by cracks, grooves, tool marks and
other changes to the material cross section.
f. Brittleness- is crisp, crumbly, flaky, friable and easily broken. Even high strength
brittle metals provide very low impact test values and soak up little energy before
breaking. Possible reasons for this brittleness include impurities in the casting,
covers grain structure or incorrect heat treatment.
g. Ductility- is a qualitative, subjective property of material. It usually indicates the
trend to which a metal can be deformed without fracture. It is property of a metal
that allows it shape to be changed without the metal breaking. It allows the metal to
be pulled into a thin wire form and is resolved by the percentage reduction and
elongation of the metals area.
h. Fatigue - a test indicate the endurance limit of materials- that is the maximum stress to
which a material can be subjected without fatigue failure, regardless of the number of
cycles. A fatigue is the tendency of the material to break under repeated stress.

I. Creep- is the permanent elongation of a component under a static lo ad maintained for a

period of time. The specimen eventually fails by rapture (necking and fracturing), as it does
in tension test.

j. Failure and fracture - is an important aspect of materials behavior when it is subjected to

deformation in manufacturing operations Impurities and inclusions play a major role in the
fracture of metals and alloys. Fracture is a breaking of metal.
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2. PHYSICAL PROPERTIES

Physical property is another property of metals it shows the appearance, size and shape here are
the following:

a. Physical state - it is solid at room temperature exception being with mercury, gallium
and bromine.
b. Density- is the quantity of something per unit volume and another way to express
material density is in that relation to that of water this quantity is specific gravity.
The significant role that density plays is the specific strength (strength-to-weight
ratio) and the specific stiffness (stiffness-to-weight ratio) of materials and structures.
c. Melting point- the melting points depends on the energy required to separate its
atom. Melting point of a metal has a number of indirect effects on manufacturing,
the choice of material for high temperature applications is the most obvious effect
application and also the selection of equipment because they affect the design, and
service requirements and compatibility with other materials including tools, dies and
workpieces and because it also in the service life of the components.
d. Specific heat- in a material specific heat is the energy required to raise the
temperature of a unit mass of it by one degree. The temperature rises in a
workpiece if excessive can decrease product quality by adversely affecting its surface
finish and dimensional accuracy, can cause excessive tool and die wear and can
result in adverse metallurgical changes in the material.
e. Thermal conductivity- indicates the rate at which heat flows within and through a
material. Metallically bonded materials (metals) generally have a high thermal
conductivity. For example, the main difficulty in machining the titanium is caused by
its very low thermal conductivity. Low thermal conductivity can also result in high
thermal gradients and in this way, cause inhomogeneous deformation in
metalworking processes.

f. Thermal expansion-alloying elements have a relatively minor effect on the thermal

expansion of metals. Shrink fits utilize thermal expansion and contraction. Improper
selection of materials and assembly can cause thermal stresses and resultant
cracking or loosening of components in the structure during their service life.
Thermal fatigue results from thermal cycling and causes a number of surface cracks,
especially in tools and dies for casting and metalworking operations (heat checking).
Thermal expansion is used describe development of cracks after a single thermal
cycle.
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3. ELECTRICAL PROPERTIES

a. Electrical conductivity and the dielectric properties of materials are of great

importance not only in electrical equipment and machinery, but also in
manufacturing processes as the magnetic-pulse forming of sheet metals and the
electrical-discharge machining and electrochemical grinding of hard and brittle
materials.
b. Conductors- materials with high conductivity, such as metals, are generally referred
to as conductors. Electrical resistivity is the inverse of conductivity. Materials with
high resistivity are referred to as dielectrics or insulator.
c. Dielectric strength- a material’s dielectric strength is its resistivity to direct electric
current. It is defined as the voltage required per unit distance for electrical
breakdown and has the unit of V/m or V/ft.
d. Superconductors- Superconductivity is the phenomenon of almost zero electrical
resistivity that occurs in some metals and alloys below a critical temperature.
e. Semiconductors- the electrical properties of semiconductors such as single- crystal
silicon, germanium, and gallium arsenide are extremely sensitive to temperature
and to the presence and type of minute impurities. Thus, by controlling the
concentration and type of impurities(dopants) such as phosphorous and in boron
and silicon, electrical conductivity can be controlled.
This property is utilized in the semiconductor (solid state) devices used extensively
in miniaturized electronic circuitry. They are very compact, very efficient and
relatively inexpensive; they consume little power; and they require no warmup time
for operation.

4. MAGNETIC PROPERTY

a. Ferromagnetism – is the phenomenon characterized by high permeability and

permanent magnetization that are due to the alignment of iron, nickel, and cobalt
atoms in domains. It is important in such applications as electric motors, electric
generators, electric transformers and microwave devices.
b. Ferrimagnetism- is a permanent and a large magnetization exhibited by some
ceramic materials such as cubic ferrites
c. Piezoelectric Effect- is exhibited by some materials such as quartz crystals and some
ceramics, in which there is a reversible interaction between an elastic strain and an
electric field.
d. Magnetostriction – the phenomenon of expansion or contraction of a material when
it is subjected to a magnetic field is magnetostriction. Some materials, such as pure
nickel and some iron-nickel alloys, exhibit this behavior. Magnetostriction is the
principle behind ultrasonic machining equipment.
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5. CHEMICAL PROPERTIES

Chemical properties also play a significant role, both in hostile and in normal environment. Some
examples of this property to metals because of the following; metals form metal oxides when they

Come contact to oxygen, metals have low electro-negativities, they are electropositive elements and
metals are also good reducing.

a. Oxidation- is the act or process of oxidizing or the condition of being oxidized

example metal rusts because it is oxidized by exposure to the air. Metal lose
electrons easily. Their outer shell has 1, 2, 3 electrons.
b. Reduction- the act of reducing. Metals is a good reducing agent
c. Corrosion- refers to the deteriorations of metals and ceramics. Corrosion is an
important aspect of material selection for applications in manufacturing operations.
In addition to various possible chemical reaction from the elements and compounds
present environmental oxidation and corrosion of components and structures is the
main concern particularly at elevated temperatures and in automobiles and other
vehicles. Corrosion not only leads to deterioration of the surface of components and
structures but also reduces their strength and structural integrity. Resistance to
corrosion depends on the particular environment and composition of the material.

6. MANUFACTURING PROPERTIES

The methods used to process materials to be process to the desired shapes can adversely affect the
product’s final properties, service life, and cost.

These are the following manufacturing properties of engineering material like metals are:

a. Casting- is a process of pouring molten metal into a mold cavity, where upon
solidification, it takes the shape of the cavity.
b. Forming- is changing the shape of the existing solid body. Example, a metal body for
an automobile is made by forming sheet metals in dies, starting with flat sheet.
c. Shaping- it is usually done by molding and casting. The resulting product is usually at
or near the final desired shape and may require little or no further finishing.
d. Machining- The parts to be machined maybe produced by casting, forging, extrusion
and powder- metallurgy. The closer the blank to be machined to the final shape
desired, the fewer the number and extent of the subsequently machining processes
is required.
e. Joining- is an all – inclusive term - joining processes such as welding, brazing,
soldering,
adhesive bonding, and mechanical fastening.
f. Finishing – is a process of completing the surface and body to make it complete to
end product.
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USES OF METALS

a. Shiny metals such copper, silver and gold are often used as decorative arts,
jewelry, and coins.
b. Strong metals such as iron and metal alloys such as stainless steels are used to
build structure, ships and vehicles dues to its strength and flexibility while
copper is used for architectural parts such as roofs and gutter due to its
durability and appearance, used in electronic industry and in electrical wiring.
c. Gold is used in computer technology and silver is often used in electronic
industry.
d. Aluminum has become the important used metals in aircraft manufacturing, ship
building and trains and automobile industry. Aluminum is resistant and light
material that reduces the weight of transport vehicles, minimizing their fuel
consumption.

e. In the case of food and drink industry, stainless steel is the ideal alloy due to its
inertness and resistance to many acids present in foods, and it is also tolerant to
the wide range of temperatures allowing heating and freezing and in stainless
steel equipment can be repeatedly by sterilized.
f. Metals have also been extensively used for medical implants.
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INDUSTRIAL ENGINEERING DEPARTMENT

g. Titanium alloys and stainless steel are commonly used in biomedical devices
such as joint replacement parts while gold, silver and platinum are often used in
dentistry, an anti-cancer drugs with different metals are also used in
chemotherapy.

ACTIVITIES:

Videos to watch:
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INDUSTRIAL ENGINEERING DEPARTMENT

Link to read:

a. https://drive.googl.com/file/d/1BLPpwfMvkuvFQph26L_oZ7FJRXOY7/view?usp=
drives dk
b. www.by jus.com>chemistry>metals and nonmetals
c. www.open.educ>what metal>content-section 4
d. www.vedantu.com/chemistry/metals-nonmetals
e. Manufacturing Engineering and Technology fourth edition by Serape Kalpak Jian
and Steven R. Schmid

ASSESMENT

Direction:

After reading the module, answer the following questions carefully. Write the answer on the
space provided.

____________________1. A kind of metals are not so expensive.

____________________ 2. to have a required____________ the metals needs adequate

ductility, elasticity and yield strength.

_____________________3. Are metals that have a long- range crystalline structure

_____________________4. A property of metals that is solid at room temperature

exception being with mercury and bromide.

____________________ 5. Resistance to__________ depends on the particular

environment composition of the materials.

REFLECTION

As an engineering student how can you relate these different properties and other aspects
of metals in your life and how it is important to our technology. States some of your
observations at 3 and explain your answer.

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INDUSTRIAL ENGINEERING DEPARTMENT

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ASSIGNMENT:

1.From your own observation, write a list of parts, components or product that have
corroded and to be replaced or to be rejected.

2.Lists and explain the desirable for a) paperclip b) a wire coat hanger c) bracket for a
cabinet d) staple and e) hinges for the door.

references: en.wekipedia.org/wiki properties of metals nonmetals, en.wikipedia.org>wiki>metals

https://drive.googl.com/file/d/1BJqBLPpwfMvkuvFQph26L_oZ7FJRXOY7/view?usp=drivesdkref book:
Manufacturing Engineering and Technology fourth edition by Serape Kalpakjian and Steven R. Schmid
QUEZON CITY UNIVERSITY
INDUSTRIAL ENGINEERING DEPARTMENT