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Proses ProduksiProses Produksi

Rusnaldy, PhDRusnaldy, PhD

#2 Fundamentals of Materials

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Mengapa Belajar

Tentang Material?

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Mada drops !eight to deli"er dri"ing dynamis

To make the $ody struture lighter

and stronger, the 2%&& Mada

features e'tensi"e use of high(tensile

strength steel, !ith the highest

strength steel )dark $lue* in the

rash(ritial areas+

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Federal-Mogul plans for the future with new diesel piston design 

Federal(Moguls uni-ue remelting proess

for the aluminum(silion alloy used in

DuraBo!l, om$ined !ith a rapid ooling

proess, signifiantly hanges the alloys

mirostruture $y reduing the sie of

hardening phases suh as silionpartiles and intermetallis+ .ho!n is the

$eginning of the proess using a tungsten

gas eletrode+

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Materials

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Materials

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Photo opyright /olani D0F

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1 nsinyur mem$uat produk

1 Produk ter$uat dari satu material atau le$ih

1 Material harus mampu mensupport $e$an, menyekat atau menghantarkan

panas+

1 3ntuk mem$uat produk dari material mem$utuhkan suatu proses atau le$ih

1 0da ri$uan material yang $isa dipakai untuk mem$uat produk

1 0da $anyak proses untuk mem$uat produk

Materials, processes and choice

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 0pa yang harus dipertim$angkan dalam memilih material

1 Properties

1 4etersediaan

1 Mampu dimanufaktur )manufatura$ility*

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Struktur   Sifat

Dengan mengerti struktur logam maka akan bisa

menjelaskan sifat-sifat logam.

 0pa yang mem$edakan

antara material yang

satu dengan yang lain?

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Mechanical properties+

Berkaitan dengan kemampuan material menahan $e$an mekanik

Be$an Mekanik5

1 .tatik 5 Tarik, Tekan, /reep

1 Dinamik

1 Ti$a(ti$a5 mpak

Choosing a material is only half the story. The other half is the

choice of a process route to shape, join and finish it.

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tress

• Simple tension: cable

oσ =

F

A

Ao = cross sectional

Area (when unloaded)

FF

σσ

oτ   =

Fs

A

τ

Note:τ

 = M/AcR here.

M

MAo

R

FsAc

• Simple shear: dri!e sha"t

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#an$on %rid&e' os Alamos' NM

• Simple compression:

Ao

%alanced Roc' ArchesNational *ar o

σ =

F

ANote: compressi!estructure member(σ + , here).

tress

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!roperties

Mehanial properties+

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,.

-

,.

Ma&nesium'Aluminum

*latinum

Sil!er' 0old

 1antalum

2inc' 1i

Steel' Ni

Mol$bdenum

0raphite

Si cr$stal

0lass3soda

#oncrete

Si nitrideAl o4ide

*#

5ood( &rain)

AFR6( 7bers)8

#FR68

0FR68

0lass 7bers onl$

#arbon 7bers onl$

Aramid 7bers onl$

6po4$ onl$

,.9

,.-

9

,

,

9,

,-,,,

,,

,,-,,

,,,,,

9,,

 1in

#u allo$s

 1un&sten

+/,,:

+///:

Si carbide

;iamond

*1F6

<;*6

;*6

**

*ol$ester

*S*61

#FR6( 7bers )8

0FR6( 7bers)8

0FR6( 7bers)8

AFR6( 7bers)8

#FR6( 7bers)8

Metals

Allo$s

0raphite#eramics

Semicond

*ol$mers#omposites

/7bers

6(0*a)

 6ceramics 

6metals 

6pol$mers

,> *a

Modulus "lastisitas

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0raphite/#eramics/Semicond

Metals/Allo$s

#omposites/7bers

*ol$mers

   ?   i  e   l   d  s   t  r

  e  n  &   t   h '    σ  $

   (   M   *  a   )

*@#

   <

  a  r   d   t  o  m  e  a  s  u  r  e '

  s   i  n  c  e   i  n   t  e  n  s   i  o  n '

   "  r  a  c   t  u  r  e  u  s  u  a   l   l  $  o  c  c  u

  r  s   b  e   "  o  r  e  $   i  e   l   d .

N$lon '

;*6

,

,

9,

,B,

,,

,

C,

,,

C,,

9,,

B,,,,,,

,,,

,,,

 1in (pure)

Al (,)a

Al (,)a&

#u (B,,)hr 1a (pure) 1i (pure)aSteel (,,)hr

Steel (,,)cd

Steel (99,)a

Steel (99,)Dt

 1i (BAl3.BSn)a5 (pure)

Mo (pure)#u (B,,)cw

   <  a  r   d   t  o  m  e  a  s  u  r  e '

   i  n  c  e  r  a  m   i  c  m  a   t  r   i  4  a  n   d  e  p  o  4  $  m  a   t  r   i  4  c

  o  m  p  o  s   i   t  e  s '  s   i  n  c  e 

   i  n   t  e  n  s   i  o  n '   "  r  a  c   t  u  r  e  u  s  u  a   l   l  $  o  c  c  u  r  s

   b  e   "  o  r  e  $   i  e   l   d .

<;*6**

humid

dr$

*#*61

¨

Room 1 !alues

 σ$(ceramics) σ$(metals) 

σ$(pol$mers)

 #ield trength

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Si cr$stal+,,

0raphite/#eramics/Semicond

Metals/Allo$s

#omposites/7bers

*ol$mers

   1  e  n  s   i   l  e  s   t  r  e  n  &   t   h '   1

   S   (   M   *  a   )

*@#

N$lon '

,

,,

,,C,,

,,,

Al (,)a

Al (,)a&

#u (B,,)hr

 1a (pure) 1i (pure)a

Steel (,,)

Steel (99,)a

Steel (99,)Dt

 1i (BAl3.BSn)a5 (pure)

#u (B,,)cw

;*6

**

*# *61

,

C,9,

,,,

C,,,

B,,,

0raphite

Al o4ide

#oncrete

;iamond

0lass3soda

Si nitride

<;*6

wood( 7ber)

wood( 7ber)

0FR6( 7ber)

0FR6( 7ber)

#FR6( 7ber)

#FR6( 7ber)

AFR6( 7ber)

AFR6( 7ber)

63&lass 7b# 7bersAramid 7b   1S(ceram) 

E 1S(met) 

E 1S(comp) 1S

(pol$)

$uat Tarik

Thermal properties

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Thermal properties

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6letrial, magneti and optial properties+

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/hemial properties5

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The menu of engineering materials+

There is sense in this5 the mem$ers of a family ha"e ertain

features in ommon5 similar properties, similar proessing

routes and, often, similar appliations+

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Material

&+7ogam

2+Polymer 

8+4eramik9+4omposit

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7ogam Paduan

Ferrous

:on Ferrous

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7ogam FerrousBaja Besi /or 

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7o! ar$on )mild* %+%;< ( %+82< .heet, struturalMedium ar$on %+8;< ( %+;;< Mahinery=igh ar$on %+>%< ( &+;%< Mahine tools/ast iron 2+%%< /astings

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Design 'e(uirements

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Design 'e(uirements

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 0pa yang mem$edakan

antara material yangsatu dengan yang lain?

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trategi

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trategi

Constraints ) *bjecti+es

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Constraints ) *bjecti+es

Contoh

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Contoh

Contoh

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Contoh

Contoh

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Contoh

The design-limiting properties are those diretly relating to the onstraints5

modulus E , strength σ y, frature toughness K & and orrosion resistane+

Cost of Materials

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Cost of Materials

• Re"erence

material:  33Rolled AC plain  carbon steel.• Relati!e cost' $'

uctuates less  o!er time than  actual cost.

0raphite/#eramics/Semicond

Metals/Allo$s

#omposites/7bers

*ol$mers

   R  e   l  a

   t   i  !  e   #  o  s   t   (        $   )

pl. carbon

Au

Si wa"er

*616po4$

N$lon '

,.,B,.

B

,,,,,

,,,,

,,,,

B,,,,

B,,,

,,,

,,,B,,

,,

,,

B,

,

,

,.B

Steel

hi&h allo$

Al allo$s#u allo$s

M& allo$s

 1i allo$s

A& allo$s

*t

 1un&sten

Al o4ide

#oncrete

;iamond

0lass3soda

Si carbide

Si nitride

*#

;*6'<;*6***S

*@#

Aramid 7bers#arbon 7bers

63&lass 7bers

AFR6 prepre&

#FR6 prepre&

0FR6 prepre&

5ood

 

$  =

G/&

(G/&)re" material

Contoh

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Contoh

.prings

prings

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prings

prings

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p gs

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T3@0.

Ter$uat dari Material 0pa 4omponen(komponen di $a!ah ini5&+/ylinder Blok

2+/ylinder head

8+Piston

9+Piston Ring

;+/onneting Rod>+/rankshaft

A+/amshaft

+Cal"e