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ME 102: Engineering Materials

Because without materials, there is no engineering.


Instructor: Prof. Brijesh Tripathi Office: Grnd Floor, Energy Building

Scope: Provide an introduction to the science and engineering of materials (e.g., metals, ceramics, polymers, and semiconductors).
Objective: Develop an awareness of materials and their properties that, as an engineer, you must rely in the future. To introduce basic concepts, nomenclature, and testing of materials. To reveal the relationships between Processing - Structure - Properties - Performance To develop ideas behind materials selection and design.

Chapter-1: Materials and their classifications A branch of science & engineering that deals with the inter-play between structure, properties and processing of materials Properties Materials Science Materials Engineering

Structure Processing Materials Science: investigates relationship between structure & properties of materials Materials Engineering: On the basis of materials science, designing and/or engineering the materials structure to produce desired properties

Materials Science & Engineering in a Nutshell


Performance Materials Engineering Designing the structure to achieve specific properties of materials. Structure Processing
Processing

Properties Materials Science Investigating the relationship between structure and properties of materials.

Structure Properties Performance

What is Materials Science & Engineering?


Casting Forging Stamping Layer-by-layer growth (nanotechnology)

Processing
Texturing, Temperature, Time, Transformations

Extrusion Calcinating Sintering

Properties characterization
Crystal structure Defects Microstructure Microscopy: Optical, transmission electron, scanning tunneling X-ray, neutron, e- diffraction Spectroscopy

MatSE

Physical behavior Response to environment

Mechanical (e.g., stress-strain) Thermal Electrical Magnetic Optical Corrosive Deteriorative characteristics

Six Major Classes of Materials


Metals

Iron and Steel Alloys and Superalloys (e.g. aerospace applications) Intermetallic Compounds (high-T structural materials) Ferrous Steels Stainless Steels High Speed Steels Cast Irons Non-Ferrous Aluminium Copper Brass Titanium, etc

Classes and Properties: Metals


Distinguishing features; Atoms arranged in a regular repeating structure Relatively good strength (defined later) Dense Ductile: high plasticity (defined later) Resistant to fracture: tough Excellent conductors of electricity and heat Opaque to visible light Shiny appearance

Thus, metals can be formed and machined easily, and are usually long-lasting materials. They do not react easily with other elements, however, metals such as Fe and Al do form compounds readily (such as ores) so they must be processed to extract base metals. One of the main drawbacks is that metals do react with chemicals in the environment, such as iron-oxide (rust). Many metals do not have high melting points, making them useless for many applications.

Classes and Properties: Metals


Elemental metals are in yellow we need to recall and use knowledge from the periodic table

Classes and Properties: Metals


Applications Electrical wiring Structures: buildings, bridges, etc. Automobiles: body, chassis, springs, engine block, etc. Airplanes: engine components, landing gear assembly, etc. Trains: rails, engine components, body, wheels Machine tools: drill bits, hammers, screwdrivers, etc. Shape memory materials: eye glasses Magnets Catalysts Examples Pure metal elements (Cu, Fe, Zn, Ag, etc.) Alloys (Cu-Sn=bronze, Cu-Zn=brass, Fe-C=steel, Pb-Sn=solder) Intermetallic compounds (e.g. Ni3Al)

Six Major Classes of Materials Ceramics


Structural Ceramics (high-temperature load bearing) Refractories (corrosion-resistant, insulating) Whitewares (e.g. porcelains) & Glass Electrical Ceramics (capacitors, insulators, etc.) Chemically Bonded Ceramics (cement and concrete)

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)

Classes and Properties: Ceramics


Distinguishing features Except for glasses, atoms are regularly arranged Composed of a mixture of metal and nonmetal atoms Lower density than most metals Stronger than metals High melting point Low resistance to fracture: low toughness or brittle Low ductility or malleability: low plasticity Poor conductors of electricity and heat Single crystals are transparent

Classes and Properties: Ceramics


Where metals react readily with chemicals in the environment and have low application temperatures in many cases, ceramics do not suffer from these drawbacks. Ceramics have high-resistance to environment as they are essentially metals that have already reacted with the environment, e.g. Alumina (Al2O3) and Silica (SiO2, Quartz). Ceramics are heat resistant. Ceramics form both in crystalline and non-crystalline phases because they can be cooled rapidly from the molten state to form glassy materials.

Classes and Properties: Ceramics


Elemental occurring in ceramics

Classes and Properties: Ceramics


Applications Electrical insulators Thermal insulation and coatings Corrosion resistant applications Electrical devices: capacitors, transducers, etc. Biocompatible coatings (fusion to bone) Self-lubricating bearings Magnetic materials (audio/video tapes, hard disks, etc.) Optical wave guides Night-vision Examples: Simple oxides (SiO2, Al2O3, Fe2O3, MgO) Mixed-metal oxides (SrTiO3, MgAl2O4, YBa2Cu3O7-x, having vacancy defects.) Nitrides (Si3N4, AlN, GaN, BN, and TiN, which are used for hard coatings.)

Six Major Classes of Materials Composites: A composite is a combination of two or more


chemically distinct materials whose physical characteristics are superior to its constituents acting independently Particulate composites (small particles embedded in a different material) Laminate composites (golf club shafts, tennis rackets, Damaskus swords) Fiber reinforced composites (fiberglass)

Aerospace industry Offshore structures Boats Sporting goods

Classes and Properties: Composites


Distinguishing features Composed of two or more different materials (e.g., metal/ceramic, polymer/polymer, etc.) Properties depend on amount and distribution of each type of material. Collective properties more desirable than possible with any individual material. Examples: Fiberglass (glass fibers in a polymer) Space shuttle heat shields (interwoven ceramic fibers) Paints (ceramic particles in latex) Tank armor (ceramic particles in metal)

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Six Major Classes of Materials


Polymers: Two main types of polymers are thermosets and thermoplastics. Thermosets are cross-linked polymers that form 3-D networks, hence are strong and rigid. Thermoplastics are long-chain polymers that slide easily past one another when heated, hence, they tend to be easy to form, bend, and break.

Classes and Properties: Polymers


Distinguishing features Composed primarily of C and H (hydrocarbons) Low melting temperature. Some are crystals, many are not. Most are poor conductors of electricity and heat. Many have high plasticity. A few have good elasticity. Some are transparent, some are opaque Polymers are attractive because they are usually lightweight and inexpensive to make, and usually very easy to process, either in molds, as sheets, or as coatings. Most are very resistant to the environment. They are poor conductors of heat and electricity, and tend to be easy to bend, which makes them very useful as insulation for electrical wires.

Classes and Properties: Polymers


Elements that compose polymers: limited

Classes and Properties: Polymers


Applications and Examples Adhesives and glues Containers Moldable products (computer casings, telephone handsets, disposable razors) Clothing and upholstery material (vinyls, polyesters, nylon) Water-resistant coatings (latex) Biodegradable products (corn-starch packing peanuts) Biomaterials (organic/inorganic intefaces) Liquid crystals Low-friction materials (teflon) Synthetic oils and greases Gaskets and O-rings (rubber) Soaps and surfactants

Six Major Classes of Materials


Electronic Materials Silicon and Germanium III-V Compounds (e.g. GaAs) Photonic materials (solid-state lasers, LEDs) Distinguishing features Made primarily from metalloids Regular arrangement of atoms (crystals, but not, e.g., solar cell amorphous Si) Extremely controlled chemical purity Adjustable conductivity of electricity Opaque to visible light Shiny appearance Some have good plasticity, but others are fairly brittle Some have an electrical response to light

Semiconductors define the Digital Revolution and Information Age. Starting with extremely pure crystalline form, their electrical conductions can be controlled by impurity doping (and defect). The result is a tiny electrical switching called a "transistor". Transistors (at present) can be packed to about 1 billion in the size of a Lincoln Penny. Applications and Examples Computer CPUs Electrical components (transistors, diodes, etc.) Solid-state lasers Light-emitting diodes (LEDs) Flat panel displays Solar cells Radiation detectors Microelectromechanical devices (MEMS)

Classes and Properties: Semiconductors


Elements occurring in semiconductors

Six Major Classes of Materials


Biomaterials (really using previous 5, but bio-mimetic) Man-made proteins (cytoskeletal protein rods or artificial bacterium) Biosensors (Au-nanoparticles stabilized by encoded DNA for anthrax detection) Drug-delivery colloids (polymer based) Potential Nanotechnology Self-assembled 'artificial bacterium' comprised of charged membranes and cytoskeletal protein rods. These rigid-walled, nano-scale capsules have potential drug delivery applications.
Nanometers: things that span ~109 m,100 nm ~ 500 atom diameters

Properties of Materials
An alternative to major classes, you may divide materials into classification according to properties. One goal of materials engineering is to select materials with suitable properties for a given application, so its a sensible approach. Just as for classes of materials, there is some overlap among the properties, so the divisions are not always clearly defined

Mechanical properties A. Elasticity and stiffness (recoverable stress vs. strain)


B. Plasticity (non-recoverable stress vs. strain) C. Strength D. Brittleness or Toughness E. Fatigue

Properties of Materials Electrical properties A. Electrical conductivity and resistivity Dielectric properties A. Polarizability B. Capacitance C. Ferroelectric properties D. Piezoelectric properties E. Pyroelectric properties Magnetic properties A. Paramagnetic properties B. Diamagnetic properties C. Ferromagnetic properties

Properties of Materials Optical properties A. Refractive index B. Absorption, reflection, and transmission C. Birefringence (double refraction) Corrosion properties Deteriorative properties Biological properties A. Toxicity B. bio-compatibility

Engineering Requirements of Materials Fabrication requirements


Easily be Fabricated (machinability, ductility, castability, heat treatability and weldability) Service Requirements Materials must stand for service demand (Proper Strength, wear resistance, corrosion resistance). Economic requirements Can be achieved by proper technical and market variables of materials.

Engineering Materials: controlling Processing - Structure - Properties - Performance


Realistically engineering materials: Trade-off Properties (What do we need or want?) Deterioration (How long will it last?) Cost (Whats the biggest bang for the buck?) Resource depletion (How to find new reserves, develop new environmentally-friendly materials, and increase recycling?) How to decide what materials to use? Pick Application Required Properties (mech., electrical, thermal, ) Properties Required Materials (type, structure, composition) Material Required Processing (changes to structure and desired shape, via casting, annealing, joining, sintering, mechanical, )

Structure, Properties & Processing


Properties depend on structure Processing for structural changes Can you correlate structure and strength and ductility?
Strength versus Structure of Brass and changes in microstructure
Tensile Strength (MPa) Annealing T (F)

Callister: Figs. 21 c-d and 22

Grain size (mm)

Annealing T (C)

Ductility (%EL)

Electrical: Resistivity of Copper


Increase resistivity of Cu by adding impurities by mechanical deformation

Resistivity 10-8 Ohms-m

Fig. 19.8 Callister

T (0C)

Thermal: Conduction of Brass


low from ceramic oxide (structure and conduction properties) changes due to alloying in metals (even though same structure)
Silica (SiO2) fibres in space shuttle tiles

Brass, Cu-Zn Conductivity (W/m (W/m-K)


Fig. 20.4 Callister

Fig. 23.18 Callister

Wt % Zn

Optical: transmission of light


e.g., Light transmission of Alumina (Al2O3 a.k.a. sapphire). single crystal, polycrystals (low and high porosity)

Which one is single crystal? Why? These reflect the effects of processing.
Fig. 1.2 Callister

Motivation: Materials and Failure


Without the right material, a good engineering design is wasted. Need the right material for the right job! Materials properties then are responsible for helping achieve engineering advances. Failures advance understanding and materials design.

ME 102: Engineering Materials


Because without materials, there is no engineering.
Engineering

Requires Consideration of Materials The right materials for the job - sometimes need a new one.

We will learn about the fundamentals of Processing Structure Properties Performance We will learn that sometime only simple considerations of property requirements chooses materials. Consider in your engineering discipline what materials that are used and why. Could they be better?

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