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Design and Manufacture (Materials (Metals (Non-Ferrous (Aluminium (Soft,…
Design and Manufacture
Materials
Metals
Non-Ferrous
Aluminium
Soft, ductile, malleable, good strength-to-weight ratio, lightweight, high resistance to corrosion. Melting point:659°C. Alloyed with other materials to make bike frames, aeroplane parts.
Brass
Good heat/electrical conductor, harder than copper, high resistance to corrosion. Melting point:927°C. Used for decorative fittings.
Copper
Very good heat/electrical conductor, malleable, ductile, high resistance to corrosion. Melting point:1083°C. Used for electrical wires, heating pipes, pots
Tin
Ductile and heavy, high resistance to corrosion Melting point:232°C. Used for coating steel food cans, solder.
Zinc
Soft, ductile and malleable over 100°C, high resistance to corrosion. Melting point:419°C. Used for galvanising
Lead
Heavy, malleable and soft, high resistance to corrosion. Melting point:327°C. Used for roof flashing, batteries, radiation sheilding.
Ferrous
Cast iron
Hard, brittle, strong in compression,weak in tension, self-lubricating, low resistance to corrosion. Melting point:1535°C. Used for machine tools, vices, engine blocks
Stainless Steel
Tough, ductile, higher tensile strength than mild steel, high resistance to corrosion. Melting point:1400 –1450°C. Used for cutlery, kitchen sinks, door handles
High-Carbon Steel
Less ductile than mild steel, malleable and tougher than mild steel, can be hardened, then tempered by heat treatment, low resistance to corrosion. Melting point:1353°C. Used for cutting tools, drills, ball
bearings
Mild Steel
Good tensile strength, tough, reasonably malleable, ductile, low resistance to corrosion. Melting point:1350 –1530°C. Used for car bodies, girders
Alloys
Steel
Bronze
Harder and tougher than brass, high resistance to corrosion. Melting point:913°C.Used for bearings, electrical conductors and springs.
Plastics
Thermoplastics
Acrylonitrile butadiene styrene (ABS)
chemical resistant, durable, strong, scratch resistant, high surface finish. Used for cases for products, helmets, kitchenware, telephones
Cellulose acetate
flexible, hard, light, tough, transparent. Used for containers, packaging, photographic film
Polyamide (PA) [Nylon]
durable, tough, easily machined. Used for self-lubricating bearings, bristles, clothing and upholstery (textiles), gears
Polyethylene (HDPE)
chemical resistant, tough rigid: Used forbuckets, bowl, containers
Polyethylene (LDPE)
soft, pliable, electrical insulator flexible: Used for bags, bottles, sheathing for electrical cables, toys
Poly-methacrylate (PMMA) [Acrylic]
stiff, hard, clear, durable, easily machined and polished, easily scratched. Used for cases, jewellery, reflectors and lenses for lights, signs
Polypropylene (PP)
chemical resistant, light, rigid, resistant to bending and fatigue. Used for crates, seats, medical equipment, kitchen chopping boards, hinges
Polystyrene (PS)
buoyant, light, stiff. Used for water resistant containers, insulation, packaging, toys
Polyvinyl chloride (plasticised)
soft, flexible, electrical insulator hosepipes, wire insulation
Polyvinyl chloride (uPVC)
abrasive resistant, rigid, water and weather resistant bottles, guttering, pipes, window frames
Thermoset
Epoxy resin (ER)
low shrinkage, strong, excellent adhesive qualities. Used for surface coatings, encapsulation, lamination, bonding applications
Melamine formaldehyde (MF)
tasteless, waterproof, odourless, scratch resistant, electrical insulator worktops, electrical insulation, buttons on clothing, tableware
Polyester resin (PR)
brittle, hard, stiff, electrical insulator, can be formed without heat or pressure. Used for car body parts, hulls for boats
Urea formaldehyde
(UF)
brittle, hard, stiff, electrical insulator, good adhesive qualities. Used for electrical fittings, paper and
textile coatings, wood adhesive
Woods
Hardwood
Oak
strong, moderately durable, hard, tough, will stain steel furniture, flooring, boat building, veneers
Softwood
Manufactured Board
Manufacturing Processes
Metals