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