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