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