ENG 218 Material

- = ENGINEERING WORKSHOP MATERIALS erials are the bases for any technological advancemen In engineering, materials are widely useful. They are the uitding blocks in engineering technology. Enginesring materials can be classified into five major groups, These are: Oreanic palymers &: Compasites > Semi-conductors orats and Atay = Metals are polyerystalin in nature bocause they are made up of ereat number of fine erystals Be eigeriby the mixture of two dF more metals, or the mhture of metals with non metals Alloys must be Sotsined cf two components. Examples of alley are Brass, Steel, Bronz, ete. tofiron and psteMie Materials can further be classified as either ferrous or non ferrous. Ferrous materials con aligys of iron « fan ferrous materials are materials without Iron or alloys without iron. Examples of motal are They have good Coramie Meteriais: These are non metallic matecials and they are made up of inorganic compounds. {Wgo), glass, cement, thera, el: ctricat, mwanetic und chemica! properties. Examples are magnesium oxide cations in electranic control devices, computers, structures, nucte: ar enginoert * Tile consists of carbons that are chemically combined with hydrogen, oxygen orsome other Sibstanee They are foros by chemical combination of simple molecules to form long chain motzcules. Examples “Ste Py!00, The cost of the material and > Auailability of the material | Pure metals ind less application in engineering because, one, they are dificult to produce in pure form and secondly they have poor strength when in pure state. To improve on the strength of pure metals the mixture of ciferent metals was developed hence we have alloys. The mixture of different metals to form alloys has helped engineers to achieve desired results in terms of strength, toughness and hardness of materials. “The usefulness of a material fora particular job is determined by ts mechanical properties. Understanding both the physical and mechanieal properties ofa material and how they are measured help engineers to make better selection of material for the job. PROPERTIES OF MATERIALS “The factors that influence the quantitative and qualitative responses of a material to an imposed stimuli or constraints are the properties of such a material. les aoe ‘Materials have different properties that determine their charact (2) Mechanical properties (2) Physical properties (2) Electrical properties (a) Magnetic properties (5) Chemical properties (6) Thermal properties and (7) Optical properties “Three ofthe above properties ~machanica, electrical and chemical properties willbe Jooked into. -the mechanical property of materials the property that determines the behaviour ofthe axtion ofan external force an ‘There are about sixteen mechanical prot y Sunes, ae toughness, brittleness, hardness, etc. : erties of a material which at determines its ability to conduct electrical current. Such sat or resistance, dielectric strength and ability of the material to easily combine with ties include corrosion resistance,JOINING AND FASTENING PROCESSES re brought Joining and fastening is an engineering process where two or more engineering materials are brouel together temporarily or permanently with or without the application of heat and pressure: ‘The point at which such materials are joined together = called joint. ‘there are different types of joints and fastenings. Examples 21® pott joint, rivet, welding, brazing and soldering. Brazing ‘This sa joining process in which two metals at their molten state 2fe joined together by introduction ofa non: ferrous alloy and then allowed to solidify. n this case, the temperature of the filler metal could be up 40 450% but must be lower than the parent metals undergoing the joining process: tn order to prevent the formation of oxides, fluxis added to the brazed joint. The method of application of fluxis either by spraying or by brushing. The type of flux that's generally used for braze joint are Borav boric acid, chlorides, fluorides, and some wetting agents: ‘The «ype of filler metals that can be used for brazing are ‘Aluminium Silicon, Copper phosphorus, COPPSE zine, Silver, brazing, magnesium, Nickel, etc- {ris applied in fastening of tanks, carbide tips on tools, radiators, heat exchangers and in electrical parts. — eis used to join cast metals to wrought metals and also for porous metal components. {tis to join bicycle frames and rims. jon in brazed joints owing to low temperature used. easly without much ski= When the colou : ir of the filler metals is different from the parent metal it can affect their matching. soldering soldering i ts ringis a process of joining in which an alloy or metal with a low melting points introduced to the liquid state of the work piece being joined together and then allo wed to solidify. The filler metal in this case is the solder and it is below 450°c. ‘Various Soldering Methods Joining process through soldering can be carried out in various ways Soldering iron method = Torch method Spray method Induction method Deep and wave method Resistance method = Ultrasonic method Condensation method _The most commonly used from above method fs the soldering iron method. soldering application — soldering is used to connect wireless sets such as rato and Television sets. Itis used for the connection of battery terminals, It is used for radiator tubes in motor cars. ‘Adhesion: This is the process that is us ised mainly to join plastics, and some few engineering: materials. It does not involve any metallic bondin ig. Bonding is created through chemical action being joined. Joints or bonds created by this type of process have Jow strength compared between the adhesive isthe process of joining two similar or dissimilar ding on the type of welding process, fillerClassification of welding processes ‘There are six major classes of welding process based on their source of heat supply. These are 1, Gas Welding 2. Arc welding 3. Resistance welding 4. Solid state welding 5, Thermo chemical welding and 6. Radiant energy welding Gas Welding Process: In gas welding, heat is supplied to melt the surfaces of the two metals to be welded at a very high temperature flame. The flame is obtained through the mixture of two gases. The two gases are mixed in a specific proportion in what is called blowpipe or torch. Examples of gas welding processes are Oxy-acetylene, oxy-hydrogen and air acetylene. ‘Arc Welding Process: This isthe type of welding process where heat is applied to the metals to be at the point of joint. Enough heat is supplies welded .d to allow flow at the joints toward each other. A filler metal is used in this case, Examples of arc welding are carbon arc welding, plasma welding, shield metal arc welding, Tungsten Inert Gas Welding (T.1.G) and Metal Inert Gas welding (M.1.6) Resistance welding process: This is the type of welding process where a heavy electric urrent is passed through the m ‘etals to be joined over a limited area, causing them to be locally heated to a plastic state completed by application of press and Lure. Filler material is not required in this process. Examples include spot welding, seam welding, projection welding, butt welding and flash butt welding, Solid State Welding process: Ths is a type of welding process that involves joining of two work piece that are brought closely to each other through application of pressure and temperature. The temperature must be below the melting point of the parent metal. Examples are cold fusion welding, diffusion welding, forge welding, hot pressure welding and roll welding ‘Thermo chemical welding: This is the type of welding where the metals to be welded are superheated to their liquid state and fusion of the metals takes place through chemical reaction between the metals. Examples include hermit welding and atomic welding, Radiant energy welding: this is the type of welding process where heat is supplied through streams of electrons or beams of electromagnetic radiations. Unlike arc and gas welding processes, radiation energy welding can be carried out in a vacuum a very low pressure. This welding process produces high quality welds. Examples of this welding process are electric beam welding and laser beam welding‘the beauty of welding in comparison to other process of joining metals i that, it's €25Y and there isa possibility of having @ 100% joint. Advantages of Weld joint over other joints. Buildings structures and bridges can be built lighter and higher due t° reduce weight. — Welded joints have higher corrosion resistance. = They are fluid tight for tanks and vessels. — They can be altered easily and economically. — Different type of joints are possible through welding,

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