This course introduces students to advanced

materials and their processing for recent

engineering applications, The course syllabus
emphasized on the materials properties,
structure, and applications in aerospace,
biomedical, automotive field. Topics include
light-weight materials, amorphous alloys,
composites, biomaterials (classes and
applications in medical), and thin coating for
high temperature applications, shape
memory alloys for micro-electro mechanical
system (MEMS), and magneto rheological
(MR) fluid in semi-active suspension.

COURSE OUTCOME
By the end of semester, students should be able to:
CO1:
Distinguish advanced materials: light-weight alloys,
amorphous alloys, composites, biomaterials, smart materials,
and thin coatings.
CO2:
Explain rapid solidification and casting techniques
for processing light weight alloys, amorphous alloys,
biomaterials, shape memory alloys and reactive alloys.
CO3: Explain powder processing for smart materials and light
weight alloys.
CO4: Distinguish processing techniques for thin coatings and
surface modification.
CO5: Develop and present a process flow of a conceptual
product byconsidering sustainability to the selected product
and process.

Assessme
nt
Assignmen
t
Test
Project
Final Exam
Total

CO1

CO2

CO3

CO4

CO5

10%

30%
20%
40%
100%

Distribution

Topic Contents

Introduction.
Materials Science and Engineering
Classification of Materials
Explain definition and types of advanced
materials and brief history of
engineering materials revolution.
Explain significance of advanced
materials for aerospace and biomedical
applications, high thermal resistance.
and sensor development.

HISTORICAL PERSPECTIVE

Every segment of our everyday lives is influenced to one degree

or another by materials: transportation, housing, clothing,
communication, recreation or food production.

The development & advancement of societies are produced and

manipulate materials.

Earliest humans had access to only a very limited number of

materials that occur naturally: stone, wood, clay etc.

With time the techniques for producing materials were

discovered: pottery, and various metals.

Materials utilization was totally a selection process by virtue of

its characteristics.

Came to understand the relationships between the structural

elements of the materials and their properties.

Tens of thousands of different materials that meet the needs of

our modern and complex society: metals, plastics, glasses and
fibers.

Improving the suitable materials is never ending process to meet

humans need.

Development of Engineering Materials

(after Ashby 1992)

10 000 BC 5000 BC
Gold

1000

1500

1800

1900

1940

1960

1980

1990

2000 2010

2020

Copper
Bronze
Iron

METALS

RELATIVE IMPORTANCE

Cast Iron

Glassy Metal
Al - Lithium Alloys Development Slow
Dual Phase Steels Mostly Quality
Micro Alloyed Steels Control and Processing
New Super Alloys

Steels
Wood
Skin
Fibers

POLYMERS,
ELASTOMERS

Alloy Steels

Glues

COMPOSITES
Straw-brick

Stone

Light Alloys
Super Alloys

Rubber

paper

High Temperature
Titanic
Polymers
Zirconium Alloys
Bakelite
High Modulus
Flint
Etc
Polymers
Nylon
c- s
mi site
Pottery
Polyesters
a
r
o
Ce p
Glass
Exposies
C com
PE
M
PMA Arcrylics
Cement
ar-M
evl
P
K
PC
PS
Refractories
R
PP
F
C
CERAMICS
FRP
Portland Cement
GFRP
Fused
Tough Engineering
CermentsPyroSilica
ceramics (Al2O3,Si4,etc)
Ceramics

10 000 BC 5000 BC DATE

0
1000
(Year) 1500

1800

1900

1940

1960

1980

1990

2000

2010

2020

The use of other competitive materials in replacement to metals

and alloys
becomes prominent as technological development requires
higher

Evolution of Materials

Understanding of Subject
The relationship among structures,
properties, processing, and
performance of materials

Better understanding of
structure-composition-properties

Materials Science & Engineering

2003 Brooks/Cole Publishing / Thomson Learning

ENGINEERING
MATERIALS

Mechanical
properties
&
Physical
properties

Properties of Materials
Properties are the way material responds to environmental and external
forces;
Mechanical properties: Response to mechanical forces, strength and etc.
Electrical and magnetic properties: Response to electrical and magnetic
fields, conductivity and etc
Thermal properties are related to transmission of heat and heat capacity
Optical properties include to absorption, transmission and scattering of
lights
Chemical stability in contact with environment corrosion resistance

Engineering Materials Application

Metallic Materials
Definition:
Inorganic substances which composed of one or two
metallic elements and may also contain nonmetallic elements.

Properties:
Crystalline structure,
Good thermal and electrical conductors,
Strong and ductile at room temperature,
Good strength at high temperature,
Shiny when polished.

Examples:
Metallic elements:
iron, copper,
aluminium, nickel,
titanium.

Nonmetallic elements:
carbon, nitrogen,
Metals and alloys classification: oxygen.
Ferrous metals and alloys (steels, cast irons)
Nonferrous metals and alloys (aluminium, copper,
zinc, titanium, nickel)

Application of Metallic Materials

Application: Aircraft Turbine Engine

Polymeric Materials
Definition:
Consist of organic long molecular
Chains or networks.
Properties:
Structure: most are crystalline, some are mix.
Vary strength, and ductility.
Poor conductors of electricity
Good insulators
Low density, low softening temperature.
Application example:
Manufacturing of digital video disks (DVDs)

Ceramic Materials
Definition:
Inorganic substances consist of metallic elements
and nonmetallic elements chemically bonded.
There are usually combination of metals or
semiconductor with oxygen, nitrogen or carbon
(oxides, nitrides or carbide).
Properties:
Structure: Crystalline, non-crystalline, mixtures of both.
High hardness, high temperature strength.
Brittle, light weight, high strength.
Good heat and wear resistance, reduced friction.
Insulative properties.

Applications of Ceramic Materials

Domestic

Engineering

Industry

Building

Applications of Ceramic Materials

a) Advanced engine applications. b) Turbocharged diesel engine

Composite Materials
Composite is a material which is made up of two or
more distinct materials (matrix and reinforcement).
Example:
A familiar composite is concrete,
which is basically made up of sand
and cement.

The reinforcement is
usually stiffer than the
matrix, thus stiffening
the composite material.

Types of composite:
PMC, MMC, CMC

Applications of Composite Materials

Applications of Composite Materials

Electronic materials-semiconductor
Unique properties :
Capable to alter electrical
conductivities in their surface
chemistries in very localized areas
(E.g. Integrated Circuit).
The conductivity is as good as metals
because no free electron and the
electron valence is full.

Engineering Materials Production

Engineering Materials Usage

Competitive Costs of Engineering

Materials

WHAT IS AN ADVANCED MATERIAL?

There are many different definitions of advanced materials
and they have become so commonly used that most tend to
assume that advanced materials are just materials. For a
physical scientist considers that advanced materials could
just as easily have been Polymers, for these are some of
the most versatile advanced materials in use today and often
are confused as plastics by many people.

WHAT IS AN ADVANCED MATERIAL?

Some scholars define advanced materials as those
that involve knowledge (and creation of materials) at
the molecular and/or atomic scale for the purpose of
advancing technology and improving the human
experience. These might be materials such as tiny
carbon nanotubes that are being used in new types of
X-ray tubes that are more efficient and safer than
those now in use at airports and in doctors offices.
These are also new coatings and methods of
manufacturing of Teflon, which is an example of a
polymer material made with chemical processing
methods that causes much less pollution and is
environmentally friendly. Other possibilities include
materials used in new diagnostic methods such as
those for medical biopsies.

WHAT IS AN ADVANCED MATERIAL?

Advanced materials research involves discoveries of
fundamental principles of Chemistry, Mathematics
and Physics that can be applied to control the
molecular-level properties of new materials, and then
fashioning materials and/or nanostructures for real-life
applications. It involves knowing the conditions under
which a material will be used and identifying
candidate materials for this purpose.

WHAT IS AN ADVANCED MATERIAL?

There is always a real need for better materials and/or
nanostructures - the issue is how much better and at
what cost. An applied scientist, with a particular
application in mind, will scour lists of known materials
and/or nanostructures looking for one that meets his
or her needs. If existing materials are unsuitable, the
applied and basic scientist must work together to
develop new materials and/or nanostructures. This
synergism between what is available and what needs
to be developed reflects the important and
complementary roles of the basic and applied
sciences in Materials Science. Neither one takes
precedence over the other. Rather, they work hand-inhand to fulfill our ever-growing need for new
materials.

ADVANCED MATERIALS:

Materials that are utilized in high-technology application

High-tech, a device or product that operates or functions
using relatively intricate and sophisticated principles
Electronic equipment, computers, fiber optic systems,
spacecraft, aircraft, and military rocketry.
They might be of all material types whose properties
have been enhanced or newly developed

Materials of the Future

A. SMART MATERIALS

A group of new and state of the art materials now being

developed that will have a significant influence on many
technologies.

Smart implies the ability to sense charges in environments

and then respond to the changes in predetermined
manners-traits that are also found in living organisms.
Component of smart materials (or system):
Some type of sensor (detect an input signal)
An actuator (perform a responsive and adaptive
function)

Materials of the Future

B. NANOTECHNOLOGY
To understand the chemistry and physics of materials by studying
large and complex structures to investigate the fundamental
building blocks of these structures that are smaller and simpler.
Top-down sciences
By SPM (scanning probe microscopes) permits to observe the
individual atoms and molecules, and it has become possible to
manipulate and move atoms and molecules to form new
structures, thus, design new materials that are built from simple
atomic level constituents (i.e. materials by design)
It enables to carefully arrange atoms to develop mechanical,
electrical, magnetic, and other properties. Bottom-up
sciences called nanotechnology.
Nano = 10-9, nanotechnology < 100 nm
equivalent 500 atom diameters

Modern Materials Needs

The development of more sophisticated and specialized
materials, as well as consideration of the environmental
impact of material production.
Nuclear energy: many problem remain in materials, from
fuel to containment structures to facilities to the disposal of
radioactive waste.
Transportation: facing low operating temperature engine
etc.
Fuel cell energy: facing low operating temperature for high
energy output.
Manufacturing process: facing toxic as a product of the
process

Modern Materials Needs

Non renewable materials such as polymer, some of metals,
oil will be depleted for:
The discovery of additional reserves,
The development of new materials having comparable
properties with less adverse environmental impact,
and/or
Increased recycling effort and the development of new
recycling technology

The Materials Selection

Process
1.

Pick

Application

Determine required Properties

Properties: mechanical, electrical, thermal,

magnetic, optical, deteriorative.

2.

Properties

Identify candidate Material(s)

Material: structure, composition.

3.

Material

Identify required Processing

Processing: changes structure and overall shape

ex: casting, sintering, vapor deposition, doping
forming, joining, annealing.

36

Selecting the RIGHT

material!

Stiffness-Weight Design
Considerations
Example
Stiffer material

Stress

Strain

Engineerin
g
Application
s

With cost considered, now polymers and metals area useful!

Why we need to study Mat. Sci.

&Eng. ?
Cost?
Effective?
Fabrication?
Safety?
Mechanical Engineer
Civil & Structure Engineer
Electrical Engineer
Electronic Engineer
Aerospace Engineer
Chemical Engineer
Etc

MATERIAL SELECTION: DRIVING

FORCES
1. Cost reduction
2. Cost reduction
3. Cost reduction
4. Weight reduction, linked with cost through
operating cost reduction (increased payload/range)
5. Maintenance cost (life cycle cost reduction)
Advanced technologies are only the means to
achieve all but only financial goals in all phases of
the products life!
Safety is always a built-in feature granted through
compliance with ever more stringent regulations
as issued by (multi)national authorities (EASA,
FAA,...)
U. Thomann

21:37
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41

COST REDUCTION THROUGH

COMPOSITES

Design integration fewer parts

reduction of structural
assembly labour cost reduction
Low density/high strength
reduction of empty weight
increased payload/range
increased operating profit
Improved corrosion resistance
lower life cycle cost
Potential estimated at 30 %
weight reduction, 40 % cost
reduction compared with
standard metal leight weight
design (1990s)
U. Thomann

21:37
15

BUT...
42

... THE ALUMINIUM FACTION

DID NOT LAZE!
Friction Stir Welding

Advanced joining technologies

design integration fewer
parts reduction of structural
assembly labour cost
reduction
New alloys lower
density/higher strength
reduction of empty weight
increased payload/range
increased operating profit
Potential estimated at 20 %
weight reduction, 20 % cost
reduction compared with
standard metal light weight
design (1990s)
U. Thomann

Laser Beam Welding

or extrusion

21:37
15

43

A380 ALUMINIUM STRUCTURE

BENCHMARK

U. Thomann

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44

Composite weight percentage

AIRFRAME MATERIALS: PAST, PRESENT, FUTURE

Tendency:
More composite materials
Tailored matieral mix to improve over all systems
performance
U. Thomann

21:37
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45

EXAMPLES OF MATERIAL SELECTIONS (OR

REFUSALS)
INTERNAL REFERENCE: MP-00-MI-10-061, ISSUE 1

EFFICIENCY IMPROVEMENT THROUGH ADVANCED

MATERIAL TECHNOLOGIES

Tmax Tambient

Tmax

Higher combustion temperatures yield higher thermodynamic

efficiency and thus lower fuel consumption
Todays technology with single crystal nickel alloys and oxide
dispersioned strengthened (ODS) super alloys with bleed air cooling
cannot provide the required step change in fuel consumption
New high temperature/high strength materials along with new
design concepts required Ceramic matrix composites
U. Thomann

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47

WEIGHT REDUCTION THROUGH

HIGH STRENGTH MATERIALS

Typical steel applications: Heavily stressed

bolts, bushings and special fittings in the
landing gear and engine pylon, moderately
temperature stressed portions of engine
shrouds,...
Despite the tendency of decreasing steel
weight fraction of the airframe there is still
some weight saving potential by employing
novel high strength, corrosion resistant steels
However, such novel alloys like e.g. nitrogen
alloyed pressure electro slag remelted
austhenitic stainless steels are still not
offered (nor demanded) in aerospace
certificated grades
Weight saving potential is probably not big
enough to off-set certification cost
U. Thomann

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48

LESS OBVIOUS MATERIAL SELECTION CRITERIA:

PC-21 FIREWALL

Frame to separate cockpit from

engine is manufactured from
titanium
Firewall has to withstand an
engine fire for a defined duration
without allowing the heat to
penetrate into the front cockpit
Titanium has much lower heat
conductivity than steel or
aluminium and retains
reasonable strength at higher
temperatures
U. Thomann

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49

ELASTOMERS

Still the best material to cope with excessive wear experienced by

the tires is natural rubber!
O-ring seals and flexible hoses: make sure to select the right material
depending on media to be sealed against or flowing through:
Chloroprene withstands fuel but not ozone and UV light
Isoprene is easy with ozone und UV light but not with fuel or
hydraulic fluids
Nitrile butadiene rubber (NBR) happily swims in hydraulic fluids
but should not be exposed to ambient air with ozone and UV light
Fluoropolymer rubbers are expensive but cope with almost every
environment, even at somewhat elevated temperatures

U. Thomann

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50

POLYSULFIDE SEALANTS
Sealants are the true cost
savers throughout an
aeroplanes life
Making the pressurised fuselage
air tight and the integral wing
tank fuel tight is only the most
obvious primary function of a
true but modest champion
Seals crevices to prevent
corrosion due to moisture
entrapment
Releases chromates to prevent
microbial attack in the integral
tank
Chromates also actively inhibit
corrosion in general
U. Thomann

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51

COMPOSITES FOR
PROTOTYPING
Some composites
manufacturing
processes allow
for quick
prototyping at
modest tooling
and production
cost
Ideal for validation
of concept studies
specifically for full
scale aerodynamic
tests
Risk mitigation,
development cost
reduction
PC-21 UWT H-tail fin: 5 days from design to
prototype
U. Thomann

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52

A SPOTLIGHT ON COMPOSITES:
BENEFITS AND CHALLENGES
INTERNAL REFERENCE: MP-00-MI-10-061, ISSUE 1

Challenges

Advantages

ALUMINIUM VS. COMPOSITE

Aluminum
Composite
TRUCTURE

Long-term experience
High automation level
Advanced joining technologies
Standardized material
Standard Certification procedure

Fatigue
Corrosion
Subprocesses

21:37

Low density (weight reduction)

High strength and stiffness
Improved fatigue behavior
Less corrosion
Design freedom
Reduced manufacturing costs
Reduced Direct Operating Costs

Design
Impact sensitivity
Environmental influences
Material + manufacturing diversity
Certification (not standardized mat.)
High material cost

U. Thomann

54

IMPROVED CORROSION RESISTANCE ONLY HALF

OF THE TRUTH!

Yes, by and large carbon fibre composites are pretty much

unaffected by corrosive environments, but...
... aluminium alloys are even more affected when in direct contact
with carbon fibres due to extreme electrochemical potential
difference between carbon and aluminium
Cadmium plated stainless steel/nickel fasteners needed:
More expensive
heavier than aluminium fasteners
More titanium in direct contact with carbon fibre composites
employed:
More expensive raw material and more complex production
processes than aluminium
Similar specific strength/stiffness as aluminium

U. Thomann

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55

RAW MATERIAL DIVERSITY

Composite
Reinforcement (Fibers)
Filament

UD fabric

Matrix (Polymer)

Woven fabric

Mat

Polymer

Fiber
Carbon

Glass
HTA

HTS

AS4

IMS

T700

T800

U. Thomann

Thermosets
Aramid

Natural

Thermoplastics

Epoxy

PEEK

Bismaleimide

PPS

Cyanesther

PEI

Phenolic

Diversity due to user-defined raw material combination

Objective:
Material combination = Design and manufacturing requirem
21:37
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56

MANUFACTURING PROCESS
DIVERSITY

U. Thomann

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57

COMPOSITE DESIGN, MANUFACTURING, MATERIAL

Design, e.g.:
- Integral or differential
- Monolithic and/or sandwich
- Frame-Stringer or Spar-Rips, etc.
Design philosophy
- Safe life
- Fail safe
- damage tolerance

Process limitations
Laminate quality:

Strength and stiffness requirements

Static and dynamic analysis

- Fiber volume fraction

- Internal and external defects

Further considerations:
- Inspection

- Dimensions

- Repair procedure
- Lightning protection

Surface condition
Quantity

Design

Quality control
Process qualification

- Electrical grounding

Interaction
Material properties
Semi-finished products

Material

Costs

Manufacturing

Environmental influences:
- Temperature
- Humidity
Quality control
Availability

Thomann
U.
Price

21:37
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58

CERTIFICATION
Composite

Metal

Proof Tests
Aircraft-specific specimens
Demonstrate ultimate load or
fatigue capability
Include defects, damage,
environmental effects
Validate Design

Same as composite

Very little tests in case

of special design
features

Material Tests
Generic specimens
Determine material
data
Understand
deformations and
failure modes
Establish Design

U. Thomann

No tests due to
standardized material
and long-term
experience
21:37
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59

CERTIFICATION
E.g. coupons tests:
Mechanical properties, e.g.:
Laminate: Strength and stiffness etc. in tension, compression and shear.
Engineering data: Strength in tension and compression with and without
holes; bearing strength; Compression After Impact strength
Physical properties, e.g.:
Density, glass transition temperature Tg, volume fraction, cured ply
thickness
Environmental influences, e.g.:
From -55C to +55C OAT in dry and wet conditions
Contaminations (hydraulic fluid, jet fuel, solvents, paint stripper)

Requirements for storage, handling, processing, machining etc.

Data must be established by means of a qualification programme for each

specific composite material.

U. Thomann

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60

QUALITY CONTROL

Raw material testing

Physical

and chemical tests

Mechanical

Manufacturing control
Process

coupons tests

control

Component testing
Visual

inspection

Dimension
Ultrasonic

and weight control

inspection

Mechanical

test of coupons which accompanied the curing

process
U. Thomann

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61

SOME CRITICAL COMMENTS

Use of composites in aerospace is
about to degenerate to a marketing
crusade
Composites should not be used for the
sake of composites usage but for their
beneficial properties in some (but not
all) applications
There is still a lot of black metal design
even in the most recently developed
products, which by and large defeats
most of the composites advantages
over standard materials
The holy grail lies in design integration
and eventually certification of
advanced joining techniques
U. Thomann

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62

U. Thomann

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63

SUMMARY
Deep knowledge of the present state of the
art in each class of materials is essential
There is no right or wrong material
selection; it is rather a complex decision
making process depending on
OEMs design and manufacturing skill and
experience level
Requirements
Balance of value and cost

Mastering the art of selecting the best

performing material for any given purpose
of application is really at the core of the
successful design of an aerospace vehicle
U. Thomann

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64

Advanced Machining
Processes

Chemical Milling
Photochemical Blanking
Electrochemical Machining
Pulsed Electrochemical Machining
Electrochemical Grinding
Electrical-Discharge Machining
Electrical-Discharge Grinding
Electrical-Discharge Wire Cutting
Laser-Beam Machining
Electron Beam Machining
Plasma Arc Cutting
Water Jet Machining
Abrasive Water Jet Machining
Abrasive Jet Machining

Examples of Parts

Chemical Milling
Produces shallow cavities on a
workpiece, usually to reduce weight
The area affected by the chemical
reagent is controlled by masking or
by partial immersion

Chemical Milling

Chemical Milling
Procedure:
1. Relieve residual stresses to prevent warping
2. Clean the material surface
3. Apply masking material
4. Remove the masking on regions that require
etching
5. Apply the reagents
6. Wash the part
7. Remove remaining masking
8. Additional finishing or chemical milling
procedures may be used

Photochemical Blanking
Uses chemicals and photographic
processes to remove material,
usually from a thin sheet
Can produce complex shapes on
metals as thin as .0025 mm without
forming burrs

Photochemical Blanking

Examples of Parts

Photochemical Blanking
Procedure:
1. Prepare the design at a magnification of up
to 100x; make a photographic negative and
reduce it to the size of the part
2. Coat the blank with photosensitive material
3. Place the negative over the part and
expose it to ultraviolet light to harden the
exposed photosensitive coating
4. Dissolve the unexposed coating
5. Apply the chemical reagent
6. Remove the masking and wash the part

Chemical Machining
Design Considerations:
- Avoid sharp corners, deep narrow cavities,
steep tapers, folded seams and porous
workpieces
- Undercuts may develop
- Most of the workpiece should be shaped by
other processes to speed production
- Variations may occur depending onhumidity
and temperature
- Computerized designs must be converted to
a format compatible with the photochemical
artwork equipment

Electrochemical Machining
Uses an electrolyte and electrical current
to ionize and remove metal atoms
Can machine complex cavities in highstrength materials
Leaves a burr-free surface
Not affected by the strength, hardness or
toughness of the material

Electrochemical Machining

Electrochemical Machining

Electrochemical Machining
Design Considerations:
- The electrolyte erodes away sharp
profiles
- It is difficult to control electrolyte
flow; irregular cavities may not be
formed accurately
- Allow for small taper in holes made
this way

Pulsed Electrochemical
Machining
A form of electrochemical machining;
the current is pulsed to eliminate the
need for high electrolyte flow
Improves fatigue life of the part

Electrochemical Grinding
Uses a rotating cathode embedded with
abrasive particles for applications
comparable to milling, grinding and
sawing
Most of the metal removal is done by the
electrolyte, resulting in very low tool wear
Adaptable for honing

Electrochemical Grinding

Electrochemical Grinding
Design Considerations:
(in addition to those for
electrochemical machining)
- Avoid sharp inside radii
- Flat surfaces to be ground should be
narrower than the width of the
grinding wheel

Electrical-Discharge
Machining
Uses a shaped electrode and electric
sparks to remove metal; discharges
sparks at about 50-500 kHz
A dielectric (nonconductive) fluid removes
debris and acts as an insulator until the
potential difference is high enough
Can be used on any material that
conducts electricity

Electrical-Discharge
Machining

Electrical-Discharge
Machining

Electrical-Discharge
Machining
Design Considerations:
- Design parts so that the electrodes
can be made economically
- Avoid deep slots and narrow openings
- Do not require very fine surface finish
- Most of the material removal should
be done by other processes to speed
production

Electrical-Discharge
Grinding
The grinding wheel lacks abrasives and
removes material by electrical
discharges
Can be combined with electrochemical
grinding
Can be used for sawing, in which the saw
has no teeth

Electrical-Discharge Wire
Cutting
The wire moves through the workpiece
like a band saw, removing material by
electrical discharge
Dielectric fluid is applied to the work area
The wire is generally used only once; it is
inexpensive

Electrical-Discharge Wire
Cutting

Electrical-Discharge Wire
Cutting

Example of a wire EDM machine

Courtesy of Edison Industrial Service Center

Electrical-Discharge Wire
Cutting

Example of a wire EDM machine

Courtesy of Edison Industrial Service Center

Electrical-Discharge Wire
Cutting

Example of a wire used for an EDM machine

This wire has been used; the wave pattern was formed during
take-up
Courtesy of Edison Industrial Service Center

Electrical-Discharge Wire
Cutting

Example of cores removed from a part using wire EDM to

create the cavity in a high-pressure nozzle
Holes were drilled in the interiors so that the wire could be
strung through
Courtesy of Edison Industrial Service Center

Laser-Beam Machining
Uses a concentrated beam of light to
vaporize part of the workpiece
Usually produces a rough surface with
a heat-affected zone
Can cut holes as small as .005 mm
with depth/diameter ratios of 50:1

Laser-Beam Machining

Laser-Beam Machining

Laser-Beam Machining

Example of a part cut by laser-beam machining

Splatter marks appear where the laser first cuts into the
material

Laser-Beam Machining
Design Considerations:
- Non-reflective workpiece surfaces are
preferable
- Sharp corners are difficult to
produce; deep cuts produce tapers
- Consider the effects of high
temperature on the workpiece
material

Electron Beam Machining

Vaporizes material using electrons
accelerated to 50-80% the speed of light
Produces finer surface finish and narrower
cut width than other thermal cutting
processes
Requires a vacuum; generates hazardous
X rays

Electron Beam Machining

Electron Beam Machining

An electron beam in a very low-pressure atmosphere of

helium

Plasma Arc Cutting

Uses plasma (ionized gas) to rapidly
vaporize material
Material removal rates are much
higher than those for laser beam
machining and electron beam
machining; produces good surface
finish and thin cut width

Plasma Arc Cutting

Plasma Arc Cutting

Close-up view of a plasma arc

Plasma Arc Cutting

Electron Beam Machining and

Plasma Arc Cutting
Design Considerations:
(in addition to those for laser-beam
machining)
- Parts should match the size of the
vacuum chamber
- Consider manufacturing the part as a
number of smaller components

Water Jet Machining

A pressurized jet of water cuts a groove
in the material
Effective for many nonmetallic materials
Cuts can be started at any location; does
not produce heat; produces very little
burring

Water Jet Machining

Water Jet Machining

Abrasive Water Jet

Machining
The water jet contains abrasive
particles; this increases the material
removal rate
Can cut metallic, nonmetallic, and
advanced composite materials
Suitable for heat-sensitive materials

Abrasive Jet Machining

A high-speed jet of dry air, nitrogen or
carbon dioxide carries abrasive
particles
Good for cutting hard or brittle materials
Can be used for deburring, cleaning, or
removing oxides or surface films

Abrasive Jet Machining

Summary
Advanced machining processes offer
alternatives where conventional
procedures would be insufficient or
uneconomical