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.
За това тесте
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.
Карти в това тесте
Карта 1
Въпрос
Engineering stress in a tensile test: force divided by what?
Отговор
Original specimen cross-sectional area.
Карта 2
Въпрос
Engineering strain in a tensile test: extension divided by what?
Отговор
Original gauge length. Strain is dimensionless.
Карта 3
Въпрос
Elastic deformation: what happens after unloading?
Отговор
The deformation recovers.
Карта 4
Въпрос
Young’s modulus describes which material behaviour?
Отговор
Resistance to elastic tensile or compressive strain, in the linear elastic region.
Карта 5
Въпрос
Yield strength marks the onset of what?
Отговор
Significant permanent deformation, using the specified yield or proof criterion.
Карта 6
Въпрос
Ultimate tensile strength: which point on an engineering stress–strain curve?
Отговор
The maximum engineering tensile stress.
Карта 7
Въпрос
Ductility describes what happens before tensile fracture?
Отговор
How much plastic deformation the material can undergo.
Карта 8
Въпрос
Indentation hardness measures resistance to what?
Отговор
Localized permanent penetration by an indenter.
Карта 9
Въпрос
Tensile toughness: what does the area under the stress–strain curve to fracture represent?
Отговор
Energy absorbed per unit volume up to fracture under those test conditions.
Карта 10
Въпрос
Density relates which two quantities?
Отговор
Mass per unit volume.
Карта 11
Въпрос
Thermal conductivity describes which ability?
Отговор
Transferring heat through a material under a temperature gradient.
Карта 12
Въпрос
Electrical conductivity describes which ability?
Отговор
Carrying electric current under an electric field.
Карта 13
Въпрос
Creep: what changes under a sustained load over time?
Отговор
Deformation increases with time; temperature and stress affect the rate.
Карта 14
Въпрос
Fatigue damage is associated with what loading pattern?
Отговор
Repeated or fluctuating loading that can initiate and grow cracks.
Карта 15
Въпрос
Brittle fracture: how much plastic deformation precedes it?
Отговор
Little plastic deformation compared with ductile fracture under the same test conditions.
Карта 16
Въпрос
A bracket bends too far but recovers fully. Which property should you examine first?
Отговор
Elastic stiffness: material modulus together with the bracket’s geometry.
Карта 17
Въпрос
A metal clip stays bent after one overload. Which threshold was exceeded locally?
Отговор
Its yield threshold; permanent deformation occurred.
Карта 18
Въпрос
A housing must absorb a drop without fracture. Which evidence matters beyond tensile strength?
Отговор
Impact-test performance under relevant temperature, notch and geometry conditions.
Карта 19
Въпрос
Two materials have equal yield strength. Must their tensile toughness be equal?
Отговор
No. Different ductility can produce different energy absorption before fracture.
Карта 20
Въпрос
A plastic clamp slowly loosens at fixed deflection. Which time-dependent effect is this?
Отговор
Stress relaxation: the stress decreases while the imposed deformation is held.
Карта 21
Въпрос
Does a higher hardness alone prove a part will resist every wear mechanism?
Отговор
No. Wear also depends on contact, loading, lubrication and the wear mechanism.
Карта 22
Въпрос
Why compare impact results only with matching test conditions?
Отговор
Specimen geometry, notches, temperature and test method affect measured impact behaviour.
Карта 23
Въпрос
Can a generic family property range serve as a finished-part design allowable?
Отговор
No. Select a grade, condition and relevant design data before qualifying the part.
Карта 24
Въпрос
A lighter material is proposed for the same-size part. Which property predicts its mass change?
Отговор
Density, provided the volume remains the same.
Карта 25
Въпрос
Ferrous versus nonferrous metals: what is the defining distinction?
Отговор
Whether iron is the main constituent. Nonferrous does not mean completely iron-free.
Карта 26
Въпрос
Steel belongs to which basic alloy family?
Отговор
Iron-based alloys containing carbon, often with other alloying elements.
Карта 27
Въпрос
Why specify a steel grade and heat treatment rather than just “steel”?
Отговор
Composition and processing change its microstructure and mechanical properties.
Карта 28
Въпрос
What is a grain in a polycrystalline metal?
Отговор
A crystalline region with a particular lattice orientation.
Карта 29
Въпрос
What separates neighbouring metal grains with different orientations?
Отговор
A grain boundary.
Карта 30
Въпрос
Which crystal defect commonly moves during plastic deformation of metals?
Отговор
A dislocation.
Карта 31
Въпрос
Cold working usually trades increased strength for what?
Отговор
Reduced ductility, as plastic deformation impedes further dislocation motion.
Карта 32
Въпрос
What is a common purpose of annealing a cold-worked metal?
Отговор
Restore ductility and reduce hardness through a controlled heat treatment.
Карта 33
Въпрос
Quenching in metal heat treatment means what cooling step?
Отговор
Rapid cooling using a specified medium; the appropriate regime depends on the alloy and intended result.
Карта 34
Въпрос
What gives stainless steel much of its corrosion resistance?
Отговор
A thin chromium-rich passive surface film.
Карта 35
Въпрос
Why distinguish grey cast iron from ductile cast iron during selection?
Отговор
Graphite form and resulting mechanical behaviour differ; “cast iron” is not one property set.
Карта 36
Въпрос
Why are aluminium alloys often screened for lightweight structures?
Отговор
Their relatively low density can help reduce mass; stiffness, strength and geometry still need checking.
Карта 37
Въпрос
Why is copper often screened for electrical conductors?
Отговор
High electrical conductivity; cost, strength and connection design also matter.
Карта 38
Въпрос
Brass is principally an alloy of copper with which element?
Отговор
Zinc.
Карта 39
Въпрос
Traditional tin bronze is principally an alloy of which two elements?
Отговор
Copper and tin. Other bronze families use different alloying additions.
Карта 40
Въпрос
Does “stainless” mean immune to chloride corrosion?
Отговор
No. Grade, environment and surface condition still govern corrosion resistance.
Карта 41
Въпрос
Two dissimilar metals touch in salty water. Which corrosion mechanism should be checked?
Отговор
Galvanic corrosion, because electrical contact and an electrolyte can form a galvanic couple.
Карта 42
Въпрос
Can you rank aluminium and steel parts by stiffness using only their material names?
Отговор
No. Compare the actual moduli and part geometries for the required loading.
Карта 43
Въпрос
A copper alloy is stronger than pure copper. Must it conduct electricity equally well?
Отговор
No. Alloying changes conductivity as well as mechanical properties; check that alloy’s data.
Карта 44
Въпрос
A steel sheet cracks during forming after extensive cold work. What processing step may restore formability?
Отговор
An appropriate anneal before further forming; confirm the alloy-specific procedure.
Карта 45
Въпрос
What is a common purpose of tempering a quench-hardened steel?
Отговор
Improve toughness and ductility, usually with some reduction in hardness.
Карта 46
Въпрос
How can an insulating washer help a dissimilar-metal joint resist galvanic corrosion?
Отговор
By interrupting the electrical connection, if the whole joint is electrically isolated.
Карта 47
Въпрос
Before approving a welded metal component, which material region besides the weld metal needs consideration?
Отговор
The heat-affected zone, whose thermal cycle can change properties without melting it.
Карта 48
Въпрос
What is the key processing–structure–property lesson for metal selection?
Отговор
A chemical composition alone does not determine performance; processing changes microstructure.
Карта 49
Въпрос
A polymer is built from what kind of molecular structure?
Отговор
Large molecules containing many linked repeating units.
Карта 50
Въпрос
Which polymer class can usually be reheated and reshaped: thermoplastics or cured thermosets?
Отговор
Thermoplastics. Cross-links in a cured thermoset prevent ordinary melt reshaping.
Карта 51
Въпрос
What deformation behaviour distinguishes an elastomer?
Отговор
It can undergo substantial deformation and recover toward its original shape when the load is removed, within its working range.
Карта 52
Въпрос
What does “semi-crystalline polymer” mean?
Отговор
Ordered crystalline regions coexist with amorphous regions.
Карта 53
Въпрос
Which polymer regions undergo glass transition: amorphous or crystalline?
Отговор
Amorphous regions. Around the glass transition, motion of chain segments becomes much easier.
Карта 54
Въпрос
What structural feature prevents a cured thermoset from flowing like a thermoplastic melt?
Отговор
A covalently cross-linked network.
Карта 55
Въпрос
Why are plasticizers added to some polymer formulations?
Отговор
To increase flexibility; the amount and compatibility affect the final properties.
Карта 56
Въпрос
Why add UV stabilizers to a polymer intended for outdoor exposure?
Отговор
To reduce degradation caused by ultraviolet exposure; the formulation and exposure still need verification.
Карта 57
Въпрос
Why can adding glass fibres make moulded polymer properties direction-dependent?
Отговор
Fibres become oriented during flow, so reinforcement differs with direction.
Карта 58
Въпрос
What structural change separates glass transition from crystalline melting in a polymer?
Отговор
Glass transition increases chain-segment mobility in amorphous regions; melting breaks down the ordered crystalline regions.
Карта 59
Въпрос
ABS is an abbreviation for which polymer name?
Отговор
Acrylonitrile butadiene styrene.
Карта 60
Въпрос
PA6 is another name for which polyamide?
Отговор
Polyamide 6, also called nylon 6.
Карта 61
Въпрос
Why distinguish “dry” from “conditioned” polyamide property data?
Отговор
Moisture conditioning changes the material state and can change mechanical behaviour.
Карта 62
Въпрос
Does one grade’s ABS datasheet establish the properties of every ABS grade?
Отговор
No. Formulation, grade, test method and conditions must match the claim.
Карта 63
Въпрос
INEOS Terluran GP-22 is specified for which main shaping process?
Отговор
Injection moulding; it is a general-purpose ABS grade.
Карта 64
Въпрос
BASF Ultramid B3S is supplied for which main shaping process?
Отговор
Injection moulding; BASF describes this PA6 grade as easy-flowing and finely crystalline.
Карта 65
Въпрос
A warm polymer bracket carries a constant load for months. Which data are needed beyond a short tensile test?
Отговор
Long-term creep data for the relevant load, temperature and material condition.
Карта 66
Въпрос
Ultramid B3EG6 differs from unreinforced PA6 by which reinforcement?
Отговор
BASF specifies glass-fibre reinforcement for this PA6 injection-moulding grade.
Карта 67
Въпрос
Which part category does INEOS identify as a particular application for Terluran GP-22?
Отговор
Housings, including appliance housings. This is a candidate application, not automatic design approval.
Карта 68
Въпрос
Why keep opened Ultramid B3S granule containers carefully closed?
Отговор
To limit moisture absorption before processing.
Карта 69
Въпрос
Can glass-filled PA6 data replace unfilled PA6 data in a design check?
Отговор
No. Reinforcement changes the material; use the exact grade and relevant orientation data.
Карта 70
Въпрос
Must a thermoplastic part be accepted by the local recycling system?
Отговор
No. Remeltability alone does not establish collection, sorting or recycling compatibility.
Карта 71
Въпрос
For an outdoor ABS housing, is a good indoor impact result enough evidence?
Отговор
No. Check weathering, temperature and the exact grade’s suitability for the exposure.
Карта 72
Въпрос
BASF lists grips and fixing clamps for Ultramid B3S. What remains to verify for a loaded clamp?
Отговор
Grade-specific long-term behaviour at the actual temperature and moisture state, plus the part geometry.
Карта 73
Въпрос
Metal casting shapes a part by which change of state?
Отговор
Liquid metal solidifies inside a mould.
Карта 74
Въпрос
Forging shapes metal by what basic mechanism?
Отговор
Compressive plastic deformation of solid metal; it may be performed hot or cold.
Карта 75
Въпрос
Extrusion is particularly suited to which basic geometry?
Отговор
A continuous length with a substantially constant cross-section, formed through a die.
Карта 76
Въпрос
CNC machining is additive or subtractive?
Отговор
Subtractive: controlled cutting removes material from a workpiece.
Карта 77
Въпрос
Injection moulding of a thermoplastic: what happens after the cavity fills?
Отговор
The melt cools and solidifies before the part is ejected.
Карта 78
Въпрос
Thermoforming starts from which form of plastic stock?
Отговор
A sheet heated until formable, then shaped over or into a mould.
Карта 79
Въпрос
Blow moulding is commonly used for which type of plastic part?
Отговор
Hollow parts, such as bottles, formed by inflating a heated preform or tube in a mould.
Карта 80
Въпрос
Additive manufacturing builds geometry by what basic approach?
Отговор
Adding material, commonly layer by layer, from a digital model.
Карта 81
Въпрос
In milling, what typically rotates to remove material?
Отговор
The cutting tool.
Карта 82
Въпрос
Why may a cast part still need machining?
Отговор
Selected surfaces may need tighter tolerances or a better finish than the casting provides.
Карта 83
Въпрос
Sand casting and permanent-mould casting mainly differ in what tooling feature?
Отговор
Sand moulds are expendable; permanent moulds are reused.
Карта 84
Въпрос
Why can injection moulding be costly for a very small production run?
Отговор
Tooling cost is spread across too few parts; compare total cost at the required volume.
Карта 85
Въпрос
A long plastic tube has the same cross-section throughout. Which process is a natural first candidate?
Отговор
Extrusion, followed by cooling and cutting to length.
Карта 86
Въпрос
A thin plastic packaging tray must be formed from sheet. Which process is a natural first candidate?
Отговор
Thermoforming; check wall thinning and the required detail.
Карта 87
Въпрос
Why should a forged part’s grain flow be considered in design?
Отговор
Deformation creates directional structure; the load direction and process route affect performance.
Карта 88
Въпрос
A design needs a few changing metal prototypes. Why consider CNC machining before buying a production mould?
Отговор
It can make revised parts directly from stock without dedicated mould tooling.
Карта 89
Въпрос
What distinguishes a fusion-weld heat-affected zone from the fusion zone?
Отговор
The heat-affected zone changes thermally but does not melt; the fusion zone melts and resolidifies.
Карта 90
Въпрос
Why clean and prepare a metal surface before applying a protective coating?
Отговор
Contaminants and surface defects can impair coating adhesion and performance.
Карта 91
Въпрос
Does a corrosion-resistant coating make the underlying material irrelevant?
Отговор
No. Damage, adhesion, exposure and substrate compatibility still matter.
Карта 92
Въпрос
Why check build orientation when selecting a layer-built polymer part?
Отговор
Layer bonding and deposition can make strength depend on direction.
Карта 93
Въпрос
A hollow plastic bottle needs a shaped enclosed body. Which process family should you screen first?
Отговор
Blow moulding; select the exact variant for the material and geometry.
Карта 94
Въпрос
Many identical thermoplastic housings are needed. Which process deserves early cost comparison?
Отговор
Injection moulding, because repeat production can spread tooling cost over many parts.
Карта 95
Въпрос
Why does choosing a process also affect material selection?
Отговор
Materials must tolerate that process and achieve the required finished-part properties.
Карта 96
Въпрос
Before releasing a selected material–process combination, what evidence closes the selection loop?
Отговор
Verify the exact grade, processing condition and part performance against the actual requirements.
96 карти
Engineering Materials Flashcards: Plastics, Metals and Processing
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