Engineering Materials Flashcards: Plastics, Metals and Processing
96 English cards on material properties, metal and polymer families, manufacturing processes, and qualified selection cases, including sourced ABS and PA6 grades.
حول هذه الرزمة
Learn engineering materials through concise retrieval and constrained selection problems. These 96 original English cards connect property vocabulary, metal and polymer families, processing mechanisms and practical evidence checks.
Practise concept-to-explanation recall, selected situation-to-property or process choices, alloy-family recognition, and named-grade interpretation for ABS (INEOS Terluran GP-22) and PA6 (BASF Ultramid B3S and B3EG6). A suggested material or process is a screening candidate, not a qualified design.
The sequence introduces properties, then metals, polymers and manufacturing processes. Each topic progresses from mechanisms to applications. Selected case variants are separated from their foundation cards; the review scheduler handles later spacing.
Excluded: automatic reverse cards for every definition, generic numerical property rankings, machine settings, full phase diagrams and design allowables. Exact material properties require the correct grade, test method, temperature, moisture state, orientation and processing history. This is an evergreen topic deck, not a complete materials course or exam syllabus.
AI-assisted questions, answers and generated cover were independently composed and checked against technical sources. No private learner cards, textbook exercises, exam questions or third-party images were copied. Original wording, organization and generated media are offered under CC0 1.0 to the extent applicable rights exist; facts and third-party source material retain their own status.
Factual references include INEOS Terluran GP-22, BASF Ultramid, University of Illinois materials principles, Instron materials testing terms, TWI injection moulding and American Foundry Society metalcasting.
Independent educational material; no affiliation with or endorsement by the named manufacturers, technical bodies or universities.
بطاقات هذه الرزمة
البطاقة ١
السؤال
Engineering stress in a tensile test: force divided by what?
الإجابة
Original specimen cross-sectional area.
البطاقة ٢
السؤال
Engineering strain in a tensile test: extension divided by what?
الإجابة
Original gauge length. Strain is dimensionless.
البطاقة ٣
السؤال
Elastic deformation: what happens after unloading?
الإجابة
The deformation recovers.
البطاقة ٤
السؤال
Young’s modulus describes which material behaviour?
الإجابة
Resistance to elastic tensile or compressive strain, in the linear elastic region.
البطاقة ٥
السؤال
Yield strength marks the onset of what?
الإجابة
Significant permanent deformation, using the specified yield or proof criterion.
البطاقة ٦
السؤال
Ultimate tensile strength: which point on an engineering stress–strain curve?
الإجابة
The maximum engineering tensile stress.
البطاقة ٧
السؤال
Ductility describes what happens before tensile fracture?
الإجابة
How much plastic deformation the material can undergo.
البطاقة ٨
السؤال
Indentation hardness measures resistance to what?
الإجابة
Localized permanent penetration by an indenter.
البطاقة ٩
السؤال
Tensile toughness: what does the area under the stress–strain curve to fracture represent?
الإجابة
Energy absorbed per unit volume up to fracture under those test conditions.
البطاقة ١٠
السؤال
Density relates which two quantities?
الإجابة
Mass per unit volume.
البطاقة ١١
السؤال
Thermal conductivity describes which ability?
الإجابة
Transferring heat through a material under a temperature gradient.
البطاقة ١٢
السؤال
Electrical conductivity describes which ability?
الإجابة
Carrying electric current under an electric field.
البطاقة ١٣
السؤال
Creep: what changes under a sustained load over time?
الإجابة
Deformation increases with time; temperature and stress affect the rate.
البطاقة ١٤
السؤال
Fatigue damage is associated with what loading pattern?
الإجابة
Repeated or fluctuating loading that can initiate and grow cracks.
البطاقة ١٥
السؤال
Brittle fracture: how much plastic deformation precedes it?
الإجابة
Little plastic deformation compared with ductile fracture under the same test conditions.
البطاقة ١٦
السؤال
A bracket bends too far but recovers fully. Which property should you examine first?
الإجابة
Elastic stiffness: material modulus together with the bracket’s geometry.
البطاقة ١٧
السؤال
A metal clip stays bent after one overload. Which threshold was exceeded locally?
الإجابة
Its yield threshold; permanent deformation occurred.
البطاقة ١٨
السؤال
A housing must absorb a drop without fracture. Which evidence matters beyond tensile strength?
الإجابة
Impact-test performance under relevant temperature, notch and geometry conditions.
البطاقة ١٩
السؤال
Two materials have equal yield strength. Must their tensile toughness be equal?
الإجابة
No. Different ductility can produce different energy absorption before fracture.
البطاقة ٢٠
السؤال
A plastic clamp slowly loosens at fixed deflection. Which time-dependent effect is this?
الإجابة
Stress relaxation: the stress decreases while the imposed deformation is held.
البطاقة ٢١
السؤال
Does a higher hardness alone prove a part will resist every wear mechanism?
الإجابة
No. Wear also depends on contact, loading, lubrication and the wear mechanism.
البطاقة ٢٢
السؤال
Why compare impact results only with matching test conditions?
الإجابة
Specimen geometry, notches, temperature and test method affect measured impact behaviour.
البطاقة ٢٣
السؤال
Can a generic family property range serve as a finished-part design allowable?
الإجابة
No. Select a grade, condition and relevant design data before qualifying the part.
البطاقة ٢٤
السؤال
A lighter material is proposed for the same-size part. Which property predicts its mass change?
الإجابة
Density, provided the volume remains the same.
البطاقة ٢٥
السؤال
Ferrous versus nonferrous metals: what is the defining distinction?
الإجابة
Whether iron is the main constituent. Nonferrous does not mean completely iron-free.
البطاقة ٢٦
السؤال
Steel belongs to which basic alloy family?
الإجابة
Iron-based alloys containing carbon, often with other alloying elements.
البطاقة ٢٧
السؤال
Why specify a steel grade and heat treatment rather than just “steel”?
الإجابة
Composition and processing change its microstructure and mechanical properties.
البطاقة ٢٨
السؤال
What is a grain in a polycrystalline metal?
الإجابة
A crystalline region with a particular lattice orientation.
البطاقة ٢٩
السؤال
What separates neighbouring metal grains with different orientations?
الإجابة
A grain boundary.
البطاقة ٣٠
السؤال
Which crystal defect commonly moves during plastic deformation of metals?
الإجابة
A dislocation.
البطاقة ٣١
السؤال
Cold working usually trades increased strength for what?
الإجابة
Reduced ductility, as plastic deformation impedes further dislocation motion.
البطاقة ٣٢
السؤال
What is a common purpose of annealing a cold-worked metal?
الإجابة
Restore ductility and reduce hardness through a controlled heat treatment.
البطاقة ٣٣
السؤال
Quenching in metal heat treatment means what cooling step?
الإجابة
Rapid cooling using a specified medium; the appropriate regime depends on the alloy and intended result.
البطاقة ٣٤
السؤال
What gives stainless steel much of its corrosion resistance?
الإجابة
A thin chromium-rich passive surface film.
البطاقة ٣٥
السؤال
Why distinguish grey cast iron from ductile cast iron during selection?
الإجابة
Graphite form and resulting mechanical behaviour differ; “cast iron” is not one property set.
البطاقة ٣٦
السؤال
Why are aluminium alloys often screened for lightweight structures?
الإجابة
Their relatively low density can help reduce mass; stiffness, strength and geometry still need checking.
البطاقة ٣٧
السؤال
Why is copper often screened for electrical conductors?
الإجابة
High electrical conductivity; cost, strength and connection design also matter.
البطاقة ٣٨
السؤال
Brass is principally an alloy of copper with which element?
الإجابة
Zinc.
البطاقة ٣٩
السؤال
Traditional tin bronze is principally an alloy of which two elements?
الإجابة
Copper and tin. Other bronze families use different alloying additions.
البطاقة ٤٠
السؤال
Does “stainless” mean immune to chloride corrosion?
الإجابة
No. Grade, environment and surface condition still govern corrosion resistance.
البطاقة ٤١
السؤال
Two dissimilar metals touch in salty water. Which corrosion mechanism should be checked?
الإجابة
Galvanic corrosion, because electrical contact and an electrolyte can form a galvanic couple.
البطاقة ٤٢
السؤال
Can you rank aluminium and steel parts by stiffness using only their material names?
الإجابة
No. Compare the actual moduli and part geometries for the required loading.
البطاقة ٤٣
السؤال
A copper alloy is stronger than pure copper. Must it conduct electricity equally well?
الإجابة
No. Alloying changes conductivity as well as mechanical properties; check that alloy’s data.
البطاقة ٤٤
السؤال
A steel sheet cracks during forming after extensive cold work. What processing step may restore formability?
الإجابة
An appropriate anneal before further forming; confirm the alloy-specific procedure.
البطاقة ٤٥
السؤال
What is a common purpose of tempering a quench-hardened steel?
الإجابة
Improve toughness and ductility, usually with some reduction in hardness.
البطاقة ٤٦
السؤال
How can an insulating washer help a dissimilar-metal joint resist galvanic corrosion?
الإجابة
By interrupting the electrical connection, if the whole joint is electrically isolated.
البطاقة ٤٧
السؤال
Before approving a welded metal component, which material region besides the weld metal needs consideration?
الإجابة
The heat-affected zone, whose thermal cycle can change properties without melting it.
البطاقة ٤٨
السؤال
What is the key processing–structure–property lesson for metal selection?
الإجابة
A chemical composition alone does not determine performance; processing changes microstructure.
البطاقة ٤٩
السؤال
A polymer is built from what kind of molecular structure?
الإجابة
Large molecules containing many linked repeating units.
البطاقة ٥٠
السؤال
Which polymer class can usually be reheated and reshaped: thermoplastics or cured thermosets?
الإجابة
Thermoplastics. Cross-links in a cured thermoset prevent ordinary melt reshaping.
البطاقة ٥١
السؤال
What deformation behaviour distinguishes an elastomer?
الإجابة
It can undergo substantial deformation and recover toward its original shape when the load is removed, within its working range.
البطاقة ٥٢
السؤال
What does “semi-crystalline polymer” mean?
الإجابة
Ordered crystalline regions coexist with amorphous regions.
البطاقة ٥٣
السؤال
Which polymer regions undergo glass transition: amorphous or crystalline?
الإجابة
Amorphous regions. Around the glass transition, motion of chain segments becomes much easier.
البطاقة ٥٤
السؤال
What structural feature prevents a cured thermoset from flowing like a thermoplastic melt?
الإجابة
A covalently cross-linked network.
البطاقة ٥٥
السؤال
Why are plasticizers added to some polymer formulations?
الإجابة
To increase flexibility; the amount and compatibility affect the final properties.
البطاقة ٥٦
السؤال
Why add UV stabilizers to a polymer intended for outdoor exposure?
الإجابة
To reduce degradation caused by ultraviolet exposure; the formulation and exposure still need verification.
البطاقة ٥٧
السؤال
Why can adding glass fibres make moulded polymer properties direction-dependent?
الإجابة
Fibres become oriented during flow, so reinforcement differs with direction.
البطاقة ٥٨
السؤال
What structural change separates glass transition from crystalline melting in a polymer?
الإجابة
Glass transition increases chain-segment mobility in amorphous regions; melting breaks down the ordered crystalline regions.
البطاقة ٥٩
السؤال
ABS is an abbreviation for which polymer name?
الإجابة
Acrylonitrile butadiene styrene.
البطاقة ٦٠
السؤال
PA6 is another name for which polyamide?
الإجابة
Polyamide 6, also called nylon 6.
البطاقة ٦١
السؤال
Why distinguish “dry” from “conditioned” polyamide property data?
الإجابة
Moisture conditioning changes the material state and can change mechanical behaviour.
البطاقة ٦٢
السؤال
Does one grade’s ABS datasheet establish the properties of every ABS grade?
الإجابة
No. Formulation, grade, test method and conditions must match the claim.
البطاقة ٦٣
السؤال
INEOS Terluran GP-22 is specified for which main shaping process?
الإجابة
Injection moulding; it is a general-purpose ABS grade.
البطاقة ٦٤
السؤال
BASF Ultramid B3S is supplied for which main shaping process?
الإجابة
Injection moulding; BASF describes this PA6 grade as easy-flowing and finely crystalline.
البطاقة ٦٥
السؤال
A warm polymer bracket carries a constant load for months. Which data are needed beyond a short tensile test?
الإجابة
Long-term creep data for the relevant load, temperature and material condition.
البطاقة ٦٦
السؤال
Ultramid B3EG6 differs from unreinforced PA6 by which reinforcement?
الإجابة
BASF specifies glass-fibre reinforcement for this PA6 injection-moulding grade.
البطاقة ٦٧
السؤال
Which part category does INEOS identify as a particular application for Terluran GP-22?
الإجابة
Housings, including appliance housings. This is a candidate application, not automatic design approval.
البطاقة ٦٨
السؤال
Why keep opened Ultramid B3S granule containers carefully closed?
الإجابة
To limit moisture absorption before processing.
البطاقة ٦٩
السؤال
Can glass-filled PA6 data replace unfilled PA6 data in a design check?
الإجابة
No. Reinforcement changes the material; use the exact grade and relevant orientation data.
البطاقة ٧٠
السؤال
Must a thermoplastic part be accepted by the local recycling system?
الإجابة
No. Remeltability alone does not establish collection, sorting or recycling compatibility.
البطاقة ٧١
السؤال
For an outdoor ABS housing, is a good indoor impact result enough evidence?
الإجابة
No. Check weathering, temperature and the exact grade’s suitability for the exposure.
البطاقة ٧٢
السؤال
BASF lists grips and fixing clamps for Ultramid B3S. What remains to verify for a loaded clamp?
الإجابة
Grade-specific long-term behaviour at the actual temperature and moisture state, plus the part geometry.
البطاقة ٧٣
السؤال
Metal casting shapes a part by which change of state?
الإجابة
Liquid metal solidifies inside a mould.
البطاقة ٧٤
السؤال
Forging shapes metal by what basic mechanism?
الإجابة
Compressive plastic deformation of solid metal; it may be performed hot or cold.
البطاقة ٧٥
السؤال
Extrusion is particularly suited to which basic geometry?
الإجابة
A continuous length with a substantially constant cross-section, formed through a die.
البطاقة ٧٦
السؤال
CNC machining is additive or subtractive?
الإجابة
Subtractive: controlled cutting removes material from a workpiece.
البطاقة ٧٧
السؤال
Injection moulding of a thermoplastic: what happens after the cavity fills?
الإجابة
The melt cools and solidifies before the part is ejected.
البطاقة ٧٨
السؤال
Thermoforming starts from which form of plastic stock?
الإجابة
A sheet heated until formable, then shaped over or into a mould.
البطاقة ٧٩
السؤال
Blow moulding is commonly used for which type of plastic part?
الإجابة
Hollow parts, such as bottles, formed by inflating a heated preform or tube in a mould.
البطاقة ٨٠
السؤال
Additive manufacturing builds geometry by what basic approach?
الإجابة
Adding material, commonly layer by layer, from a digital model.
البطاقة ٨١
السؤال
In milling, what typically rotates to remove material?
الإجابة
The cutting tool.
البطاقة ٨٢
السؤال
Why may a cast part still need machining?
الإجابة
Selected surfaces may need tighter tolerances or a better finish than the casting provides.
البطاقة ٨٣
السؤال
Sand casting and permanent-mould casting mainly differ in what tooling feature?
الإجابة
Sand moulds are expendable; permanent moulds are reused.
البطاقة ٨٤
السؤال
Why can injection moulding be costly for a very small production run?
الإجابة
Tooling cost is spread across too few parts; compare total cost at the required volume.
البطاقة ٨٥
السؤال
A long plastic tube has the same cross-section throughout. Which process is a natural first candidate?
الإجابة
Extrusion, followed by cooling and cutting to length.
البطاقة ٨٦
السؤال
A thin plastic packaging tray must be formed from sheet. Which process is a natural first candidate?
الإجابة
Thermoforming; check wall thinning and the required detail.
البطاقة ٨٧
السؤال
Why should a forged part’s grain flow be considered in design?
الإجابة
Deformation creates directional structure; the load direction and process route affect performance.
البطاقة ٨٨
السؤال
A design needs a few changing metal prototypes. Why consider CNC machining before buying a production mould?
الإجابة
It can make revised parts directly from stock without dedicated mould tooling.
البطاقة ٨٩
السؤال
What distinguishes a fusion-weld heat-affected zone from the fusion zone?
الإجابة
The heat-affected zone changes thermally but does not melt; the fusion zone melts and resolidifies.
البطاقة ٩٠
السؤال
Why clean and prepare a metal surface before applying a protective coating?
الإجابة
Contaminants and surface defects can impair coating adhesion and performance.
البطاقة ٩١
السؤال
Does a corrosion-resistant coating make the underlying material irrelevant?
الإجابة
No. Damage, adhesion, exposure and substrate compatibility still matter.
البطاقة ٩٢
السؤال
Why check build orientation when selecting a layer-built polymer part?
الإجابة
Layer bonding and deposition can make strength depend on direction.
البطاقة ٩٣
السؤال
A hollow plastic bottle needs a shaped enclosed body. Which process family should you screen first?
الإجابة
Blow moulding; select the exact variant for the material and geometry.
البطاقة ٩٤
السؤال
Many identical thermoplastic housings are needed. Which process deserves early cost comparison?
الإجابة
Injection moulding, because repeat production can spread tooling cost over many parts.
البطاقة ٩٥
السؤال
Why does choosing a process also affect material selection?
الإجابة
Materials must tolerate that process and achieve the required finished-part properties.
البطاقة ٩٦
السؤال
Before releasing a selected material–process combination, what evidence closes the selection loop?
الإجابة
Verify the exact grade, processing condition and part performance against the actual requirements.
٩٦ بطاقة
Engineering Materials Flashcards: Plastics, Metals and Processing
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