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