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Synthetic composites are manufactured. The forms are: 1 fibers, 2 particles and flakes, and 3 an infiltrated phase in skeletal structures. A whisker is a thin, hairlike crystal of very high strength. Briefly describe each. The two forms are: 1 foamed-core sandwich, in which the core is polymer foam between two solid skins; and 2 honeycomb, in which the core is a honeycomb structure sandwiched between two solid skins.

Examples given in Table 9. Three factors are given in the text: 1 the component materials; 2 the geometric shapes of the constituents - the reinforcing phase in particular - and the resulting structure of the material; and 3 the interaction of the phases. The rule of mixtures applies to certain properties of composite materials; it states that the property value is a weighted average of the property values of the components, the weighting being by proportions of the components in the composite.

A cermet is a composite material consisting of a ceramic and a metal. In the text, it is defined as a composite consisting of ceramic grains imbedded in a metallic matrix. Yes; although the cemented carbide industry does not generally think of cemented carbides as cermets, they fit within the definition. Weaknesses of ceramics include: low tensile strength, poor toughness, and susceptibility to thermal cracking. An advanced composite is a PMC in which carbon, Kevlar, or boron fibers are used as the reinforcing material.

Properties include: high strength-to-weight ratio, high modulus-to-weight ratio, low density, good fatigue strength, good corrosion resistance, and low thermal expansion for many FRPs.

FRPs are used in modern aircraft as skin parts, automobile body panels, printed circuit boards, tennis rackets, boat hulls, and a variety of other items.

The interface is the boundary between the component phases in a composite material. Multiple Choice Quiz There are a total of 22 correct answers in the following multiple choice questions some questions have multiple answers that are correct.

Advantages include: 1 complex part geometries are possible; 2 some casting operations are net shape processes, meaning that no further manufacturing operations are needed to accomplish the final part shape; 3 very large parts are possible; 4 applicable to any metal that can be melted; and 5 some casting processes are suited to mass production. Disadvantages include: 1 limitations on mechanical strength properties; 2 porosity; 3 poor dimensional accuracy; 4 safety hazards due to handling of hot metals; and 5 environmental problems.

A foundry. An open mold is open to the atmosphere at the top; it is an open container in the desired shape which must be flat at the top. A closed mold has a cavity that is entirely enclosed by the mold, with a passageway called the gating system leading from the outside to the cavity.

Molten metal is poured into this gating system to fill the mold. The two types are: 1 expendable molds and 2 permanent molds. The most important casting process is sand casting. The pattern determines the external shape of the casted part, while a core determines its internal geometry. Superheat is the temperature difference above the melting point at which the molten metal is poured. The term also refers to the amount of heat that is removed from the molten metal between pouring and solidification.

Turbulence causes several problems: 1 accelerates formation of oxides in the solidified metal, and 2 mold erosion or gradual wearing away of the mold due to impact of molten metal. The continuity law, or continuity equation, indicates that the volumetric flow rate is constant throughout the liquid flow. Factors include: 1 pouring temperature, 2 metal alloy composition, 3 viscosity of liquid metal, and 4 heat transfer to the surroundings. Heat of fusion is the amount of heat energy required to transform the metal from solid state to liquid state.

Pure metals solidify at a single temperature equal to the melting point. Most alloys exceptions are eutectic alloys start to solidify at the liquidus and complete solidification at the solidus, where the liquidus is a higher temperature than the solidus. A eutectic alloy is a particular composition in an alloy system for which the solidus and liquidus temperatures are equal.

The temperature is called the eutectic temperature. Hence, solidification occurs at a single temperature, rather than over a temperature range. The three contractions occur due to: 1 contraction of the molten metal after pouring, 2 solidification shrinkage during transformation of state from liquid to solid, and 3 thermal contraction in the solid state. A chill is a heat sink placed to encourage rapid freezing in certain regions of the casting.

Multiple Choice Quiz There are a total of 13 correct answers in the following multiple choice questions some questions have multiple answers that are correct. Problems Heating and Pouring Other properties can be obtained from Tables 4. Assume the specific heat has the same value for solid and molten aluminum. Compute the amount of heat that must be added to the metal to heat it to a temperature of F for pouring. The cross-sectional area at the base of the sprue is mm2. Determine: a the velocity of the molten metal flowing through the base of the downsprue, b the volume rate of flow, and c the time required to fill the mold cavity.

The cross-sectional area at the bottom of the sprue is 0. What area should be used at the base of the sprue to avoid aspiration of the molten metal? It is desired to maintain a constant flow rate, top and bottom, in order to avoid aspiration of the liquid metal. The molten metal overflows the pouring cup and flows into the downsprue.

If the sprue is 25 cm long, determine the proper diameter at its base so as to maintain the same volume flow rate. At the end of pouring the sprue is filled and there is negligible metal in the pouring cup. The downsprue is 6.

It takes a total of 3. This is more than the theoretical time required, indicating a loss of velocity due to friction in the sprue and runner. Find: a the theoretical velocity and flow rate at the base of the downsprue; b the total volume of the mold; c the actual velocity and flow rate at the base of the sprue; and d the loss of head in the gating system due to friction. Determine the dimensions and volume of the final cube after cooling to room temperature if the cast metal is copper.

Assume that the mold is full at the start of solidification and that shrinkage occurs uniformly in all directions. Solution: For copper, solidification shrinkage is 4. Determine the dimensions of the final casting after cooling to room temperature if the cast metal is aluminum. Express your answer in terms of decimal fraction inches of elongation per foot of length compared to a standard rule.

Express your answer in terms of millimeters of elongation per meter of length compared to a standard rule. Solution: For brass, solidification shrinkage is 4. The gray cast iron has a volumetric contraction of Determine the dimensions of the mold cavity to take shrinkage into account. Assume that shrinkage occurs uniformly in all directions. Determine how long it will take for the casting to solidify.

What adjustment must be made in the units of Cm? The cube was 50 mm on a side. This casting takes 6. Another cylindrical-shaped casting with the same diameter-to-length ratio weighs 12 lb. This casting is made of the same steel and the same conditions of mold and pouring were used. Determine: a the mold constant in Chvorinov's Rule; and b the dimensions, and c the total solidification time of the lighter casting.

The same casting alloy is used in the three cases. Accordingly, we might revise our answer to part b and choose the sphere on the basis that it wastes less metal than the other shapes. For a given cylinder volume, determine the diameter-to- length ratio that will maximize the time to solidify. If the total solidification time of the casting itself is known to be 3.

The length of the cylinder is to be 1. The casting geometry is illustrated in Figure P The two categories are: 1 expendable mold processes, and 2 permanent mold processes. What is the difference between a split pattern and a match- plate pattern? A split pattern is a pattern that consists of two pieces; a match-plate pattern consists of the two split patterns attached to opposite sides of a plate. Chaplets are metal supports of various designs used to hold the core in place in the sand mold.

The usual properties are: 1 strength - ability to maintain shape in the face of the flowing metal, 2 permeability - ability of the mold to allow hot air and gases to escape from the cavity, 3 thermal stability - ability to resist cracking and buckling when in contact with the molten metal, 4 collapsibility - ability of the mold to give way during shrinkage of the casting, 5 reusability - can the sand be reused to make other molds? The Antioch process refers to the making of the mold.

This mold has greater permeability than a plaster mold. Vacuum permanent-mold casting is a form of low- pressure casting in which a vacuum is used to draw molten metal into the cavity. Vacuum molding is sand casting in which the sand mold is held together by vacuum pressure rather than a chemical binder. Common die cast metals include: zinc, tin, lead, aluminum, brass, and magnesium.

Hot-chamber machines are faster because cold- chamber die casting machines require molten metal to be ladled into the chamber from an external source. Flash is a thin portion at the exterior of a casting that results from molten metal being squeezed into the spaces between the die halves of the mold at the parting line, or into the clearances around the cores and ejector pins.

In true centrifugal casting, a tubular mold is used and a tubular part is produced. In semicentrifugal casting, the shape is solid; an example is a railway wheel.

The mold is rotated so that centrifugal force is used to distribute the molten metal to the exterior of the mold so that the density of the final metal is greater at the outer sections.

A cupola is a vertical cylindrical furnace equipped with a tapping spout near its base. Cupolas are used for melting cast irons. These operations include: 1 trimming, in which the sprues, runners, risers, and flash are removed, 2 core removal, 3 surface cleaning, 4 inspection, 5 repair if needed, 6 heat treatment, and 7 machining. General defects include: 1 misruns, 2 cold shuts, 3 cold shots, 4 shrinkage cavity, 5 microporosity, and 6 hot tearing.

Multiple Choice Quiz There are a total of 28 correct answers in the following multiple choice questions some questions have multiple answers that are correct. Determine the buoyancy force in Newtons tending to lift the core during pouring.

It is used in the casting of a cast iron pump housing. Determine the buoyancy force that will tend to lift the core during pouring. Solution: From Table The design of the caplets and the manner in which they are placed in the mold cavity surface allows each caplet to sustain a force of 10 lbs.

Several caplets are located beneath the core to support it before pouring; and several other caplets are placed above the core to resist the buoyancy force during pouring.

At least 2 caplets are required beneath to resist the weight of the core. Probably 3 or 4 caplets would be better to achieve stability. A total of 9 caplets are required above the core to resist the buoyancy force. What is the weight of the final casting? Ignore considerations of shrinkage. The lengths will be 1. Solution: From Eq. Is the operation likely to be successful? Solution: The mass of molten metal would be unaffected by the absence of gravity, but its weight would be zero.

However, this all assumes that the metal is inside the mold and rotating with it. In the absence of gravity, there would be a problem in pouring the molten metal into the mold cavity and getting it to adhere to the mold wall as the mold begins to rotate. With no gravity the liquid metal would not be forced against the lower surface of the mold to initiate the centrifugal action.

If the rotational speed computed in that problem were used in the steel casting operation, determine the G-factor and c centrifugal force per square meter Pa on the mold wall. Solution: a Use inside diameter of mold in Eq. At what speed must the tube be rotated during the operation in order to achieve these specifications? If the rotational speed during solidification is rpm, determine the inside diameter at the top of the bushing if the diameter at the bottom is mm.

Defects and Design Considerations The larger component has the shape of a dish sink and the second component is a flat cover that is attached to the first component to create an enclosed space for the machine parts. Sand casting is used to produce the two castings, both of which are plagued by defects in the form of misruns and cold shuts. However, it is known that the same components are cast successfully in other foundries.

What other explanation can be given for the defects? Solution: Misruns and cold shuts result from low fluidity. One possible reason for the defects in this case is that the thickness of the casting cross-sections is too small. However, given that the casting of these parts is successfully accomplished at other foundries, two other possible explanations are: 1 the pouring temperature is too low, and 2 the pouring operation is performed too slowly.

Solution: a What are the possible corrective steps? In the case of step 1 , the risk is for cold shuts and misruns. Steps 2 and 3 would reduce permeability of the sand, thus increasing the risk of sand blows and pin holes.

What is the difference? Glass is vitreous - it is in the glassy state, whereas traditional and new ceramics are, by and large, polycrystalline materials. Silica - SiO2.

Finishing operations e. Name three of the four types. The four types are: 1 pot furnaces, 2 day tanks, 3 continuous tank furnaces, and 4 electric furnaces. Spinning in glassworking is similar to centrifugal casting in metalworking.

A gob of molten glass is dropped in to a conical mold which spins, causing centrifugal force to spread the glass upward onto the mold surface. In the press-and-blow process, the initial forming step is pressing of the part, while the first step in the blow-and-blow process is blowing.

Name and briefly describe one of them. The methods described in this test are: 1 rolling, in which the hot glass is squeezed between opposing cylindrical rolls; and 2 the float process, in which the melted glass flows onto a molten tin surface to achieve uniform thickness and smoothness.

In the Danner process, molten glass flows around a rotating hollow mandrel through which air is blown while the glass is being drawn. The temperature of the air and its volumetric flow rate as well as the drawing velocity determine the diameter and wall thickness of the tubular cross-section. During hardening, the glass tube is supported by a series of rollers extending beyond the mandrel. The two processes in the text are: 1 drawing, in which fine glass fibers are pulled through small orifices in a heated plate; and 2 centrifugal spraying, in which molten glass is forced to flow through small orifices in a rapidly rotating bowl to form glass fibers.

Annealing is performed on glass to remove internal stresses that result from shaping and solidification. The glass is heated to a temperature above the annealing temperature and the surfaces are then quenched by air jets to cool and harden them while the interior of the piece remains plastic; as the interior cools and contracts, it puts the previously hardened surfaces in compression, which strengthens it.

Laminated glass, in which two sheets of glass are laminated on either side of a polymer sheet. This has good impact resistance and does not splinter when broken. The guidelines are: 1 subject ceramic parts to compressive, not tensile loads; 2 ceramics are brittle, so avoid impact loading; 3 use large radii on inside and outside corners; 4 screw threads should be course.

See Section Multiple Choice Quiz There are a total of 10 correct answers in the following multiple choice questions some questions have multiple answers that are correct. It is a slow process for these large products. That would indicate an annealing time of 0. Some of the reasons are: 1 many of the processes are net shape processes; 2 in general, less energy employed than in metalworking processes; 3 lower temperatures are required to process plastics than metals or ceramics; 4 great flexibility in geometry; and 5 painting and other finishing processes generally not required.

The categories are: 1 extrusion, 2 molding, 3 forming of continuous sheets and films, 4 fibers, 5 foamed products, and 6 discrete formed sheets and films.

Upon what parameters does viscosity depend? Viscosity of a polymer melt depends on: 1 temperature, and 2 shear rate. Of course, 3 the molecular weight of the polymer also affects viscosity. A polymer melt exhibits pseudoplasticity, which means that its value decreases with increasing shear rate. Briefly define each of the properties identified.

Other properties include: viscoelasticity, a combination of viscous and elastic properties which cause the melt to exhibit memory - the tendency to return to its previous shape, as exhibited by die swell in extrusion. Die swell is the tendency of the extrudate to expand in cross-section dimensions immediately on exiting the die orifice.

It results from the viscoelastic properties of the polymer melt. In plastic extrusion, a polymer melt is compressed to flow through a die orifice and thus the continuous length of the plastic assumes a cross-sectional shape that is approximately the same as the profile of the orifice. The functions are: 1 filter dirt and lumps, 2 build pressure, 3 straighten the flow and remove memory.

Sheet stock has a thickness greater than 0. The blown-film process is a widely used process for making thin polyethylene film for packaging. It combines extrusion and blowing to produce a tube of thin film. The process begins with the extrusion of a tube which is immediately drawn upward while still molten and simultaneously expanded in size by air inflated into it through the die mandrel.

Calendering is a process for producing sheet and film stock out of rubber or rubbery thermoplastics such as plasticized PVC. In the process, the initial feedstock is passed through a series of rolls to work the material and reduce its thickness to the desired gage. See Figure A fiber is a long, thin strand of material whose length is at least times its diameter; a filament is a fiber of continuous length.

Polyester is the most important commercially, followed by nylon, acrylics, and rayon. See beginning of Section The components of an injection molding machine are: 1 the injection unit and 2 the clamping unit. The clamping units are: 1 mechanical toggle clamp and 2 hydraulic.

In addition, there are hydromechanical units which combine hydraulic and mechanical actuations. The functions of gates in an injection mold are: 1 to increase shear rate to increase viscosity and temperature of the polymer melt, 2 the thinner cross- section of the gate freezes more rapidly to seal off the cavity; and 3 parts can be more easily broken off the runner at the gate. As the mold opens, the three-plate mold automatically separates the molded part s from the runner system.

The defects include: short shots, in which the polymer melt solidifies before filling the cavity; flashing, in which the polymer melt is squeezed into the parting surfaces between the mold halves and around ejection pins; sink marks, in which the surface is drawn into the molding by contraction of internal material; and weld lines where the melt has flowed around a core or Structural foam molding is an injection molding process in which a gas or gas-producing ingredient is mixed with the polymer melt prior to injection into the mold cavity; this results in the part having a tough outer skin surrounded by a foam core.

The differences in injection molding of thermosets are: 1 shorter barrel length, 2 lower temperatures in the barrel, these first two reasons to prevent premature curing; and 3 use of a heated mold to cause cross-linking of the TS polymer.

Reaction injection molding involves the mixing of two highly reactive liquid ingredients and immediately injecting the mixture into a mold cavity where chemical reactions leading to solidification occur. The two ingredients form the components used in catalyst-activated or mixing-activated thermoset systems Section 8. Blow molding is used to produce hollow, seamless containers, such as bottles. Thermoforming starts with a thermoplastic sheet or film. A positive mold has a convex shape; a negative mold has a concave cavity.

In mechanical thermoforming, matching mold halves are required; while in other thermoforming processes, only one mold form is required. There are several foaming processes: 1 mechanical agitation - mixing a liquid resin with air by, then hardening the polymer by means of heat or chemical reaction; 2 mixing a physical blowing agent with the polymer - a gas such as nitrogen N2 or pentane C5H12 which can be dissolved in the polymer melt under pressure, so that the gas comes out of solution and expands when the pressure is subsequently reduced; and 3 mixing the polymer with chemical compounds, called chemical blowing agents, that decompose at elevated temperatures to liberate gases such as CO2 or N2 within the melt.

Some of the general considerations are : 1 Plastics are not as strong or stiff as metals and should not be used in applications where high stresses will be encountered.

Also, some plastics degrade in oxygen and ozone atmospheres. Finally, plastics are soluble in many common solvents. Multiple Choice Quiz There are a total of 36 correct answers in the following multiple choice questions some questions have multiple answers that are correct. Degree of polymerization a is correlated with molecular weight, and rate of flow c is related to shear rate.

The other parameters, b and d , are probably more recognizable to the reader as correct answers to this question. The resistance to forward flow is called back pressure flow. Problems Extrusion The head pressure at the die end of the barrel is 5. The viscosity of the polymer melt is given as Pas. Find the volume flow rate of the plastic in the barrel. The viscosity of the polymer melt is 75 Pas, and the head pressure in the barrel is 4. Determine the extruder characteristic by computing Qmax and p max and then finding the equation of the straight line between them.

This is called the "square" angle in plastics extrusion - the angle that provides a flight advance equal to one diameter for each rotation of the screw.

From Eq. Determine the volume flow rate of the plastic in the barrel. The specific gravity of the polymer is 1. If a T-shaped cross-section is extruded at a rate of 0. Solution: Its intended use is to compute the oversized dimension of a mold cavity in injection molding.

Instead, we are using the shrinkage term to calculate the amount of volumetric reduction in size of the part after the polymer is injected into the cavity. In fact, a slightly different shrinkage parameter value may apply in this case. Compute the corresponding dimension to which the mold cavity should be machined, using the value of shrinkage given in Table The important dimension of the part is specified as However, the actual molded part measures Compute the correct value of the mold dimension, given that the shrinkage value for polyethylene is 0.

The mean diameter of the parison is observed to swell to a size of If the diameter of the blow molded container is to be mm, determine a the corresponding wall thickness of the container and b the wall thickness of the parison.

The observed die swell is 1. Using a micrometer, measure the wall thickness to compare with your answer in a. Some wall thickness are less. The inside and outside diameters of the die that produced the parison are 18 mm and 22 mm, respectively. If the minimum wall thickness of the blow molded container is to be 0. The ball will be 1. What weight of PE powder should be loaded into the mold in order to meet these specifications?

The specific gravity of the PE grade is 0. The operation is conventional pressure thermoforming using a positive mold, and the plastic is an ABS sheet with an initial thickness of 3.

Solution: a As the starting flat sheet is draped over the convex cup-shaped mold, the portion contacting the base of the cup experiences little stretching. However, the remaining portions of the sheet must be stretched significantly to conform to the sides of the cup.

Hence, thinning in these sides results. The rubber industry is organized into three parts: 1 rubber growing plantations produce natural rubber, 2 the petrochemical industry produces synthetic rubber, and 3 fabricators take the NR and SR and produce finished rubber goods. The rubber is usually recovered as follows: 1 the latex is collected into tanks and diluted to half natural concentration; 2 formic or acetic or other acid is added to the solution which causes the rubber to coagulate; 3 the coagulum is then squeezed through rolls to drive off water; and 4 the resulting sheets are dried in smokehouses for several days.

The resulting raw rubber is called ribbed smoked sheet. The typical sequence is: 1 production of the raw rubber, 2 compounding, 3 mixing, 4 shaping, and 5 vulcanization. The additives and functions are: vulcanizing chemicals, reinforcing fillers, extenders to reduce cost, antioxidants, coloring pigments, plasticizers to soften the rubber, and blowing agents to make foam rubber.

The categories are: 1 extrusion, 2 calendering, 3 coating, and 4 molding. Calendering, skimming, dipping, and spraying; see Article Vulcanization causes cross-linking of the rubber molecules; this strengthens and stiffens the rubber while extensibility is retained.

Diagonal ply and belted bias both have their carcass plys running in a diagonal direction relative to the tire circumference; radial ply has its carcass plies running in a radial direction; belted bias and radial ply tires use belts, which are additional plies around the outside circumference of the tire; whereas diagonal ply tires do not have these belts.

The three steps are: 1 preform the components, 2 building the carcass and adding the rubber for the sidewall and treads, and 3 molding and curing. The bead coil provides a rigid support for the tire when it is mounted onto the wheel rim. TPE stands for thermoplastic elastomer; it is a thermoplastic polymer that behaves like a rubber. However, the extreme flexibility of rubber results in certain differences.

What are some examples of these differences? Three examples: 1 no draft is needed on the part for mold removal; 2 holes should be molded into rubber parts rather than machined, whereas holes can be machined or molded in a plastic part; and 3 screw threads are not normally used on rubber parts.

Multiple Choice Quiz There are a total of 11 correct answers in the following multiple choice questions some questions have multiple answers that are correct. Principal polymer matrices in FRPs are unsaturated polyesters and epoxies. Review Type. All 31, Positive 27, Negative 3, All 31, Steam Purchasers 24, Other 7, All Languages 31, Your Languages 14, Customize.

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