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