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