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