Non metallic material

 Materials that do not contain, metal and that are able

to combine with hydrogen to form stable compounds,
acids, acidic oxides.
Non metallic materials

 Non metallic materials used in the design and manufacture

of products

• Plastics
• Wood
• Composites
• Ceramics
• Fabrics

Tungsten
Layers
Balsa
Linen,wood
of carbide
polycarbonate,
Acrylic model
cotton,
lens tool bit
nylon, Kevlar
aluminium & acrylic
Plastic
 The word plastics is from the Greek word Plastikos,
meaning “able to be shaped and molded”.
 Why plastics ?
 Light weight.
 High strength to weight ratio.
 Relatively low cost compared to metals and composites.
 Corrosion resistance.
 Low electrical and thermal conductivity, insulator.
 Easily formed into complex shapes, can be formed, casted
and joined.
 Wide choice of appearance, colors and transparencies.
Classification of Plastics

Plastics can be further classified as;

•Thermoplastic
•Thermoset
•Elastomers

Thermoplastics Thermosets Elastomers

Acrylics Epoxy resins Rubbers
Nylons Phenolic Silicones
PVC Phenol
Urea formaldehyde
Polyesters formaldehyde
Polyurethanes
PVC gutters
Polyethylene

Polyethylene
Rubber
Disadvantages of using Plastics

 Low strength
o
 Low useful temperature range (up to 600 F)
 Less dimensional stability over period of time (creep
effect)
 Aging effect, hardens and become brittle over time
 Sensitive to environment and chemicals
 Poor machinability
Wood
 Wood is a renewable resource.
 Wood is reusable, recyclable, biodegradable.
 Wood products require far less energy to manufacture
than other non-wood building materials.
 Growing trees reduce greenhouse gases.
 Wood structures store carbon.
Classification of Wood
 Wood can be further categorised as;
 Hardwood
 Softwood
 Manufactured board Beech
Ash
Oak
Mahogany
Plywood
Cedar with Veneer
Chipboard

Hardwood Softwood Manufactured

Board
Oak Pine Plywood
Ash Cedar Blockboard
Beech Fir MDF
Sycamore Spruce Melamine board
Factors affecting Strength of wood
 Anatomical factors (Str. of organism)
 Density
 Knots
 Slope of grain
 Size
Continue
 Environmental factors
 Moisture
 Biological attack agents
 Temperature
 Fire
Composite
 Two or more chemically distinct materials which when
combined have improved properties over the individual
materials. Composites could be natural or synthetic.
 Wood is a good example of a natural composite, combination
of cellulose fiber and lignin. The cellulose fiber provides
strength and the lignin is the "glue" that bonds and stabilizes
the fiber.
 Composites are combinations of two materials in which one of
the material is called the reinforcing phase, is in the form of
fibers, sheets, or particles, and is embedded in the other
material called the matrix phase.
 Reinforcing materials are strong with low densities while the
matrix is usually a ductile or tough material.
Applications of Composites

 There are about 6000 composites related

manufacturing plants and materials distributors across
the U.S.
 Because of their high strength/stiffness to weight ratio
they are widely used in the;
• Aerospace industry
• Offshore structures
• Boats
• Sporting goods
Classification of Composites

 Examples of composites include;

• Reinforced Plastics
• Ceramic-matrix
• Metal-Matrix
• Laminates

Carbon
Outer Cylinder
Thrust
Combustion
reinforced
Kevlar,
skin
Cylinder
Glass
panels &linings
chamber
taffeta
reinforced
plastic
chamber
linings for
polyester
fuselage
of rocket
plastic
jet
A380
sails
engine
hull
Ceramics
 Ceramics are compounds between metallic and
nonmetallic elements; they are most frequently oxides,
nitrides, and carbides.
 Some of the common ceramic materials include
aluminum oxide (or alumina,Al2O3), silicon dioxide (or
silica, SiO2), silicon carbide (SiC), silicon nitride
(Si3N4)
 Types of ceramics
 Whitewares - Floor and wall tiles, Electrical porecelin
 Refractories - Firebricks for furnaces and ovens
 Glasses -
 Abrasives
 Cements
Amorphous Ceramics (Glasses)
 Main ingredient is Silica (SiO2)
 If cooled very slowly will form crystalline
structure.
 If cooled more quickly will form amorphous
structure consisting of disordered and linked
chains of Silicon and Oxygen atoms.
 This accounts for its transparency as it is the
crystal boundaries that scatter the light, causing
reflection.
 Glass can be tempered to increase its toughness
and resistance to cracking.
Glass Containers
Pressed Glass Processing

Softened
Gob
Blow Molding

Softened
glass
Glass in Buildings
Ceramic Armour
 Ceramic armour systems are used to protect military
personnel and equipment.

 Advantage: low density of the material can lead to weight-

efficient armour systems.

 Typical ceramic materials used in armour systems include

alumina, boron carbide, silicon carbide, and titanium
diboride.

 The ceramic material is discontinuous and is sandwiched

between a more ductile outer and inner skin.

 The outer skin must be hard enough to shatter the projectile.

Ceramic - Composite Armor

Ceramic-
Outer hard Discontinuous
skin

Projectile

Personnel
and
Equipment

Inner
ductile
skin

Ceramic Armor System

 Silicon Carbide
 Body armour and
other components
chosen for their
ballistic properties.
 ALON – aluminium
oxynitride
Applications of Ceramics

• Oxides (alumina – insulation and abrasives, zirconia –

dies for metal extrusion and abrasives)
• Carbides (tungsten-carbide tools)
• Nitrides (cubic boron nitride, 2nd in hardness to diamond)
Decisions, decisions!
So many materials, so much information.
Best material
How do we decide?
 Availability – Readily, large quantity
 Cost – material, processing
 Mechanical properties
 Manufacturing considerations
Weighted point method
 Desirable properties of material
 Assign the values for properties
 Go – No go limit for properties
 Give weightage on importance of property
 Arrange in descending order of weightage

 Main drawback of this method is the skill and judgement

required for assigning weightage.
Case Study - Drink Container
 What are the
requirements?
Case Study - Drink Container
 Provide leak free environment for storing liquid.
 Comply with food standards & protect liquid from
health hazards.
 For fizzy drinks, withstand pressure.
 Brand image & identity
 Easy to open
 Easy to store & transport
 Cheap for high volumes
Possible Materials
 Steel
 Aluminium
 Glass
 Plastic
 Paper
Steps in design
Manufacturing Processes
 Manufacturing is the production of workpieces
having defined geometric shapes.
 It is one of the important production technology.
 Process technology
 Energy technology
Primary shaping process
 Primary shaping is manufacturing of a solid body
from an amorphous material.
 Amorphous – Gases, liquid, powders, chips, fibres and
melts etc.
 Casting
 Powder metallurgy
 Plastic technology
Forming process
 Forming processes – Make use of suitable stresses like
compression, tension, shear or combined stresses to cause
plastic deformation of material to produce required shape.
 Forging
 Extrusion
 Rolling
 Sheet metal working
Machining process
 To generate required surface by providing suitable
relative motions between workpiece and tool.
 Subjected to lower stresses than forming process
 Turning
 Drilling
 Milling
 Grinding
 Shaping and Planing
Joining process
 In this process two or more pieces of metal parts are
joined together as a need of component.
 Permanent joint
 Welding
 Brazing
 Soldering
 Separable joint
 Threaded joint
 Riveted joint
Surface finishing process
 These processes are utilized to provide intended surface
finish on the metal surface of a job.
 Either a very negligible amount of metal is removed from
or certain material is added to the surface of the job.
 Plastic coating
 Metallic coatings
 Anodizing
 Electro-plating