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