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Herman Terryn Professor Vrije Universiteit Brussel (VUB) Research Group Electrochemical and Surface Engineering (SURF) Department Materials and Chemistry Pleinlaan 2, 1050 Brussels, Belgium Tel:+ 3226293537 (secr 3255) Fax:+3226293200 hterryn@vub.ac.be www.vub.ac.be/SURF part time Professor M2i Materials Innovations Institute Department of Materials Science and Engineering, Tu Delft Surfaces and Interfaces Group, Corrosion Technology and Electrochemistry Mekelweg 2,2628CD Delft,The Netherlands www.m2i.nl
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Reference book
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid. ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Slides are based on that book
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Figure I.1 Section of an automotive engine - the Duratec V-6 - showing various components and the materials used in making them. Source: Courtesy of Ford Motor Company. Illustration by David Kimball.
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AISI 1010 welded tubing, assembly resistance welded and electrostatically painted
Manufacturing of a bicycle
AISI 1010,swaged and cadmium plated AISI 1020,forging and chromium plated
AISI 1010, luster finished coil AISI 1008, press stock,profile milled,resistance formed,welded and plated welded and chromium plated formed,welded and plated
Cold drawn medium carbon steel,( similar to AISI 1035) bright zinc plated
Seamless AISI 1020 tubing swaged tube sections brazed into fork crown,painted
Headed brass,nickel plated Aluminum permanent mold casting,machined , polished and buffed AISI 1040 forging,carburized and chromium plated Hardened high-carbon steel,thread rolled and chromium plated AISI 1010,stamped and chromium plated Case hardened forging quality steel parts, black oxide coating
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Components in Products
Some products are a single components (nail, bolt, fork, coat hanger, etc.) Some products are assemblies of many components (ball point pens, automobiles, washing machines, etc.)
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Figure I.2 Examples of the wide variety of materials and geometries for paper clips.
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Figure I.3a Components of a common incandescent light bulb. Source: Courtesy of General Electric Company.
Figure I.3b Manufacturing steps in making an incandescent light bulb. Source: Courtesy of General Electric Company.
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16 Introduction Figure I.7c Schematic illustration of various sheet metal forming processes
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Laser Cutting
Figure I.8 Cutting sheet metal with a laser beam. Source: Courtesy of Rofin-Sinar, Inc. and Manufacturing Engineering Magazine, Society of Manufacturing Engineers
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Hip Replacement
Figure 1.9 Components of a total hip replacement. Source: Courtesy of Zimmer, Inc.
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Figure 1.10 (a) Manufacturing steps in the production of a roll-formed and machined total hip replacement stem; (b) Manufacturing steps in the production of a forged stem. Hip stems can also be produced by investment casting, metal injection molding, insert injection molding, and assorted other processes. Source: Courtesy of Zimmer, Inc. 22 Introduction
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Manufacturing Technology Whole process of transformation from raw material into a product
Fabrication of a Product Selection of the Materials, mostly objects are constructed by assembling different components, often consisting of a variety of materials Property driven Production of the Material Completely different metals, polymers, ceramics en composites Forming of the Material, Producing its shape Completely Different metals, polymers, ceramics en composites Surface Engineering Joining of Materials Durability degradation (polymers) corrosion (metal, glass) End of Life Recycling Waste
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Cost per Unit Volume for Wrought Metals and Polymers Relative to Cost of Carbon Steel
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Figure 40.1 Advanced materials in the Lockheed C-5A transport aircraft. (Note: FRP is fiber-reinforced plastic.)
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Figure 40.6 Various methods of making a simple part: (a) casting or powder metallurgy, (b) forging or upsetting, (c) extrusion, (d) machining, and (e) joining two pieces
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Figure 40.7 Two methods of making a dish-shaped sheet-metal part: (a) pressworking using a male and female die, (b) explosive forming using one die only. 38 Introduction
Three methods of casting turbine blades A: conventional casting with ceramic mold B: directional solidification C: Method to produce single crystal blade
FIGURE 3.1 Turbine blades for jet engines, manufactured by three different methods: (a) conventionally cast; (b) directionally solidified, with columnar grains, as can be seen from the vertical streaks; and (c) single crystal. Although more expensive, single-crystal blades have properties at high temperatures that are superior to those of other blades. Source: Courtesy of United Technologies Pratt and Whitney.
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