1

MANUFACTURING
TECHNOLOGY
BJTM 2023

Lecturer
Dr. Hj. Mohd Norhasni Hj. Mohd Asaad
KOLEJ PERNIAGAAN /STML
ROOM STML : 4027
H/P: 013-5111666
BJTM 2023-Dr. Hj. Mohd
Email: [email protected] Norhasni
 2

BJTM 2023-Dr. Hj. Mohd Norhasni

COURSE SYNOPSIS

• The purpose of this coursework is to give exposure on the

latest technical methods in manufacturing industry.
• This will provide understanding to students on the materials
and materials quality, equipments and processes used in
manufacturing.
• Likewise, students are expected to understand the relation
between methods and equipments with manufacturing
productivity.
 3
COURSE OBJECTIVES
Upon completion of the course, students are expected to

BJTM 2023-Dr. Hj. Mohd Norhasni

• Understand the basic principles, materials,
and general processes of manufacturing
1 technology.

• Explain in common and inclusive of all

materials, processes, methods, and
technologies in the manufacturing and
2 production industry.
 COURSE LEARNING OUTCOMES
(CLO)
Upon completion of the course, students will be able to

To explain the concepts and definitions of each of the elements in

manufacturing technology

To explain each of the methods and techniques in manufacturing technology

To discuss the advantages and disadvantages of each of the methods in

manufacturing technology

To apply various methods in manufacturing technology

4
BJTM 2023-Dr. Hj. Mohd Norhasni
 5
COURSE CONTENT

BJTM 2023-Dr. Hj. Mohd Norhasni

1.
Introduction
to 2. Materials 3. Casting
Manufacturin Technology Technology
g
Technology

6. Plastics
4. Materials
Manufacturi 5. Forming
Machining
ng Technology
Technology
Processes

8.
Electronics
7. Joining
Manufacturi
Processes
ng
Processes
INTRODUCTION 6

At the end of this lecture, student will be able to:

classify types of engineering
materials
elaborate different types of material
properties
explain typical used of materials
explain the method of material
selection for particular
manufacturing processes
INTRODUCTION

 Materials is fundamental in the study of manufacturing processes

Material Process Product

INTRODUCTION

 Behavior of the material (when subjected to the particular

forces, temperatures, and other physical parameters of the
process) that determines the success of the operation
 Certain materials respond well to certain types of
manufacturing process and poorly to others
Fundamental of Engineering Materials

 3 basic categories of engineering materials:

 Metals
 Ceramics
 Polymers

 Chemical, mechanical and physical properties of materials

are dissimilar.
 Thus, manufacturing processes are different.
 Composites, non homogeneous mixtures of the other three
types.
 Metal-Ceramics Metals
Composites Metal-Polymer
Composites

Ceramics Polymers

Ceramic-Polymer Composites

Venn diagram showing the three basic material with

composites
Metal
 Most important engineering materials
 Properties that satisfy a wide variety of design and manufacturing
requirements. Example,
 Aluminium
 Steel
 iron
 Ceramics

 Compound containing metallic or

semi metallic and non metallic
elements.
 Variety of traditional and modern
ceramics
 Traditional ceramics are such as
brick, tiles, silica, glasses.
 Modern ceramics include alumina,
nitrides, etc. (not generally clay-
based)
Polymers

 Compound formed of repeating structural units.

 Consist of carbon with other elements such as
hydrogen, nitrogen, oxygen and chlorine.
 3 categories:
 Thermoplastic polymers;
 Thermosetting polymers (Thermoset);
 Elastomers
Composites

 Mixtures of three types;

 Found in nature are such as wood;
 Can be made synthetically;
 Properties depend on the composites
components.
 Some are high strength with light in weight such
as aircraft body.
Application of composite
Can you recognize the
difference?
 Characteristics comparison

Metal Ceramic Polymer

High density Low density Very low density
Medium to high Very high melting Low melting point
melting point point

Medium to high Very high elastic Low elastic modulus

elastic modulus modulus
Ductile Brittle Ductile and brittle
types
Reactive Unreactive Very reactive
Electrical conductor Electrical insulator Electrical insulator
Thermal conductor Thermal insulator Thermal insulator
Opaque (not May be transparent May be transparent
transparent)
METALS IN
MANUFACTURING
Classifying Metals for Manufacturing Industry

 Common/ general properties of metals are:

 High stiffness/ hardness
 Toughness
 Good electrical conductivity
 Good thermal conductivity
Metals
 Ferrous metals
 Based on Iron (Fe)
 Group includes steel and cast irons
 Pure iron has low commercial value
 Non-ferrous metals
 Include other metallic elements and their alloys
 Do not contain iron as their compounds
 Lower strength than steel irons
 Higher corrosion resistance and strength to weight ratio
 Ex: Aluminum, Copper, Zinc, Magnesium
Ferrous Metals

Ferrous Metals
 Iron is a base metal or pure metallic element.
 Use iron as their basic ingredient.
 Iron seldom used in its pure state.
 Most are alloys or mixtures of two or more metals.

 Types of ferrous metals are:

 Cast Iron
 Steel
CAST IRON

Contains 3.0% to 4.0% carbon.

Hard & brittle with excellent

wear resistance.

It has a low coefficient of

expansion (not greatly affected
by heat or cold conditions).
 STEELS

 Make of iron, carbon & other metallic

elements.
 Content of carbon is between 0.2 –
2.1% by weight.
 Hard, strong metal used to produce
many different materials.
 Steel with increased carbon content
can be made harder and stronger than
iron, but is also less ductile.
 Can you explain the
difference?
Non Ferrous Metals

 Metal elements and alloys that are not an iron based.

 Important nonferrous group metals are:
 Aluminum
 Copper
 Magnesium
 Nickel
 Titanium
 Zinc
 And their alloys
Non ferrous metals- Aluminum

 Represents a large family of aluminum alloys.

 High electrical and thermal conductivity
 A very ductile material and high formability
 Soft & not very strong.
 Adding small amounts of alloying elements, by heat-treating,
can increase strength.
 Alloying can improve corrosion resistance, welding
characteristics, & machinability
Aluminium
Non ferrous metals-
Magnesium
 Lightest of the structural metals.
 Is a base metal commonly used as an alloying element.
 Soft and low strength for engineering application
 Desirable characteristics are:
 high strength-to-weight ratio,
 excellent machinability,
 ability to be worked by all common metalworking
techniques.
Non ferrous metals-
Magnesium

 Alloyed with aluminum, zinc,

manganese, zirconium, or
thorium for higher strength.
Non ferrous metals- Titanium

 One of the strongest metals in use today.

 As strong as steel but only half as heavy.
 Bridges gap between Steel & Aluminum.
 Low coefficient of thermal expansion
 Extremely resistant to corrosion.
 Most can be operated in temps of 800F.
 Used for high-speed aircraft components.
Titanium
Non ferrous metals- Copper

 Excellent conductor of electricity and thermal.

 Corrosion resistant
 Can be easily shaped.
 Low in strength & hardness.
Copper
Non ferrous metals- zinc

 Low melting point makes it ideal for die-castings.

 Base metal used in alloys to resist forms of corrosion.
 Commonly used as a protective coating (galvanizing).
 Moderate strength & toughness.
 Automotive components, home appliances use large
quantities of zinc alloys.
Zinc
Non ferrous metals- Tin

 Low melting point

 Low strength and hardness
 High ductility and good corrosion resistance
 Major ingredient in Pewter.
Tin
Refractory metals

 Metals that are capable of enduring high temperature

 Molybdenum and tungsten
Refractory metals-
Molybdenum
 High melting temperature
 Dense, stiff and strong
 Oxidize at high temperature
Refractory metals-
Tungsten

Highest melting
point

Stiffest, hardest of
all pure metals

Oxidize at high
temperature
Precious
metals
 Include gold, platinum
and silver
 Chemically inactive
 High density, good
ductility, high electrical
conductivity and
corrosion resistance
 Moderate melting point
 Ceramics
NON
METTTALIC Polymers
MATERIALS
Composite
CERAMICS

 An inorganic, non-metallic solid prepared by the

action of heat and subsequent cooling
 Properties of Ceramics
– high electrical resistance
– high melting temperatures
– hard hardness
– brittle and no ductility
– good electrical and thermal insulation
– low electrical and thermal conductivity
– high compressive strengths
CERAMICS

 For processing purposes, ceramics divide

into:
1. Crystalline ceramics – includes:
 Traditional ceramics, such as clay (hydrous
aluminum silicates)
 Modern ceramics, such as alumina (Al2O3)
2. Glasses – mostly based on silica (SiO2)
CERAMICS

Traditional Ceramics

 Silica (SiO2) based

 Whitewares, table wares, pottery
 Structural clay products
• brick, tile, and terracotta
 Refractories
• high temp resistant products
• high thermal insulation and chemical resistance reaction
 Portland cement
• used in concrete production
 Abrasives
• used in grinding such as silicon carbide and oxides.
Traditional
Ceramics
 Disadvantages
 Weak because they
contain many pores and
cracks
 Low elastic moduli
 CERAMICS
New Ceramics

 Developed synthetically
 Chemical compounds categories: oxides, carbides,
nitrides.
 Oxides Ceramics
 Example is alumina, produced synthetically
using electrical furnace method
 Application in electrical components, electrical
insulators, cutting tool inserts and other
engineering components
 Carbides Ceramics
 SiC, WC, TiC, Cr3C2
 Used in cutting tools for hardness and wear
resistance
 GLASS AND GLASS CERAMICS

Glass:
 Inorganic, metallic compound and in glassy state
as a solid material.
 SiO2 based.
 Low thermal expansion coefficient, thus very
resistance to thermal shock.
GLASS AND GLASS CERAMICS

Glass Ceramics:

 first shaped as a glass and

then heat treated
– good resistance to thermal
shock
– strength is greater than
traditional glasses
 Applications in cooking wear,
heat exchangers, etc.
 POLYMERS

 Polymer means “many parts”.

• organic compounds
– carbon is the backbone
 Separated into plastics and rubbers categories.
 Made naturally, synthetically and chemically.
Polymers
 PLASTICS

2 Main Groups of Plastics (behavior at elevated

temps)
 Thermoplastics Polymers (TP)
• Solid at room temperature, but viscous liquid at
temp of a few hundred degrees.
• Easily and economically shaped into products
• Repeated cooling and heating does not significantly
degrade the polymer.
• E.g. PET, PE, PP
 SOME OF IMPORTANT 55
THERMOPLASTICS

Polyoxymethyle • High stiffness, low friction and excellent dimensional stability

ne  (POM or • Automotive door handles, appliance hard ware and machinery
Acetal): components.

• Transparency and resistance to breakage and elasticity

Polyacrylates
• Tail light lenses of automobiles, optical instruments, aircraft
(Acrylics):
windows.

Acrylonitrile
• Used to make light, rigid, molded products 
butadiene
• Components for automobiles, pipes and fittings.
styrene (ABS)
SOME OF IMPORTANT
THERMOPLASTICS

Polycarbonate (PC):

• high impact resistance, temperature resistance, optical properties

• Used as safety helmets, housing for business machines.

Polyesters (PE):

• Used as fibers in apparels, blow molded containers.

Polyethylene Terephthalate (PET):

• used in synthetic fibers; beverage, food and other liquid containers;
thermoforming applications; and engineering resins often in combination
with glass fiber.
Thermosetting Plastics
(Thermosets)
 Retain mechanical properties
at elevated temps
• cannot be re-melted =>
burn and soften.
• cannot tolerate into
repeated heating cycles.
e.g. melamine,
polyimide
ELASTOMERS

 An elastomer is a material with the mechanical (or material)

property that it can undergo much more elastic deformation under
stress than most materials and still return to its previous size
without permanent deformation. 
 Oldest commercial elastomer => rubber
 Large number of cycles to failure
 2 Types
• Natural
– rubber => tires, gaskets, and hoses
• Artificial/ Synthetic
– silicon rubber => electric insulation and o-rings
Elastomer products
Composite material

 Composite materials (or composites for short) are

engineered materials made from two or more constituent
materials with significantly different physical or chemical
properties which remain separate and distinct on a
macroscopic level within the finished structure.
 2 or more components of metals, plastics, & ceramics
WHY COMPOSITES?

– high stiffness
– high strength with low weight
– high temperature application
– corrosion resistance
– high hardness
– many combinations possible
COMPONENTS IN COMPOSITE MATERIAL

 Metal Matrix Composites (MMC)

 Contains at least two constituent parts, one being a metal.
 Ceramic Matrix Composites (CMC).
 Not common, composites of Aluminum Oxide and Silicon
Carbide with fibers.
 Polymer Matrix Composites (PMC)
 Fiber-reinforced polymers (FRP).
 Thermoplastics reinforced with powders
Types of Composites
Fiberglass Prepeg
Graphite Prepeg Tapes
Woven Composites
Composite
Material
Snowboard
 Applications

1. Aerospace 8. Materials Handling

2. Automotive 9. Heavy Equipment
3. Chemical 10. Offshore Exploration
4. Electrical/ 11. Food Processing
Electronics 12. Wastewater
5. Medical Treatment

6. Semiconductor 13. Infrastructure

14. Tomorrow's Industry
7. Oil Refinery
Material selection

 The
interdependence of materials and the
manufacturing process must also be recognized.
 A change in material may require a change in the
process.
 Improvements in processes will often lead to
reevaluation of the materials being processed.
 Improper processing of a well-chosen material may
result in defective product.
 Design

Material Selection

Procedure Process Selection

for material
Production
selection
Evaluation

Redesign (if necessary)

Procedure for material selection 72

 Case – history method:

 Evaluating what has been done in the past or
 What is currently being done by the competitor.
 Duplication or modification of the materials and method of
manufacture
Procedure for material selection 73

 Modification of existing product:

 The objective is to reduce cost, improve quality or
overcome a problem or defect
 Ex: A customer may request the same product but
require capability of operating at high temperature.
 Development of entirely new product
Procedure for material selection

 The first step in material selection process is to define the

needs/ requirement of the product.
 There are three major needs of a product:
 Shape and geometry
 Property requirements
 Manufacturing concerns
Procedure for material selection

 Shape and geometry:

 What is the relative size of the component?
 How complex is the shape?
 How many dimensions must be specified? How precise?
 Etc.
Procedure for material selection

 Property requirement:
 How much strength?
 Are there any electrical requirements?
 Are there any optical requirements?
 Are there any surface treatment/ process needed?
 What will be the effect of temperature of the product?
 Is there any preferred color?
 Etc
Procedure for material selection

 Manufacturing concern:
 How many components are to be produced? At what
rate?
 What is the level of quality?
 Are there any assembly or disassembly required?
 What are the largest and smallest thickness?
 Etc
Other factors to consider

 Material availability
 The material must be ready in the required
size, quantity or shaped
 Material cost
 Etc
Compatibility charts of materials and processes
Y – Can be used
0 – Can be used but has difficulty
Blank – Not recommended
Material

Iron Steel Aluminum Copper Nickel Zinc Refractory

Process Metals

Sand Y Y Y Y Y 0
Casting
Die Casting Y 0 Y
Investment Y Y Y 0
Casting
Powder Y Y 0 Y 0 X
Metallurgy
Questions…?
 81
81

BJTM 2023-Dr. Hj. Mohd Norhasni