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