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