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