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