ESE 2017

UPSCENGINEERINGSERVICESEXAMINATION

Preliminary Examination

Paper

General Studies and

Engineering Aptitude

8
Basics of Material Science
and Engineering
Comprehensive Theory with Practice Questions
As per new syllabus of ESE 2017

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ESE-2017 : Preliminary Examination

Paper-I : General Studies and Engineering Aptitude

Basics of Material Science and Engineering

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Preface
The compilation of this book Basics of Material Science
and Engineering was motivated by the desire to provide
a concise book which can benefit students to understand
the concepts of energy and environment topics.
This textbook Basics of Material Science and
Engineering provides all the requirements of the
students, i.e. comprehensive coverage of theory,
fundamental concepts and objective type questions
articulated in a lucid language. The concise presentation will help the readers grasp the theory
of this subject with clarity and apply them with ease to solve objective questions quickly. This
book not only covers the syllabus of ESE but also addresses the need of many other competitive
examinations. Topics like Introduction, Chemical Bonding, Crystallography, Electronic Materials,
Magnetic Properties of Materials, Ceramics, Polymers, Composites, Mechanical Properties of
Materials, Ferrous Metals, Non-Ferrous Metals and Alloys are given full emphasis, keeping in mind
of our research on their importance in competitive examinations.
We have put in our sincere efforts to present detailed theory and MCQs without compromising the
accuracy of answers. For the interest of the readers, some notes, do you know and interesting facts
are given in the comprehensive manner. At the end of each chapter, sets of practice question are
given with their keys, that will allow the readers to evaluate their understanding of the topics and
sharper their question solving skills.
Our team has made their best efforts to remove all possible errors of any kind. Nonetheless, we would
highly appreciate and acknowledge if you find and share with us any printing and conceptual errors.
It is impossible to thank all the individuals who helped us, but we would like to sincerely thank all
the authors, editors and reviewers for putting in their efforts to publish this book.
With Best Wishes
B. Singh
CMD, MADE EASY

General Studies and

Engineering Aptitude

Contents

Basic of Material Science & Engineering

Chapter 1

3.6.1 Simple Cubic Crystal Structure (SCC)..........16

Introduction 1

3.6.2 Body Centred Cubic Structure (BCC)...........17

1.1 Historical Perspective.........................................................1

3.6.3 Face Centered Cubic Structure (FCC)..........17

1.2 Material Science ..................................................................1

3.6.4 Diamond Cubic (DC) Structure......................18

1.3 Classification of Materials.................................................1

3.7 Hexagonal Closed Packing...........................................19

3.8 Miller Indices......................................................................20

1.3.1 Advanced Materials...............................................2

1.3.2 Semiconductors......................................................2

1.3.3 Smart Materials.......................................................2

Chapter 2
Chemical Bonding 3

2.1 Fundamental Concepts................................................... 3

2.2 Electrons in Atoms............................................................. 4

2.3 The Periodic Table.............................................................. 4

2.4 Chemical Bonding............................................................. 5

2.5 Ionic Bond............................................................................. 5

2.6 Covalent Bond..................................................................... 6

2.7 Metallic Bond....................................................................... 7

2.8 Comparison of Primary Bonds...................................... 8

2.9 Dispersion Bonds............................................................... 8

2.10 Dipole Bonds....................................................................... 8

2.11 Hydrogen Bonds................................................................ 9

3.2 Comparison of Crystalline and Noncrystalline

3.5 Bravais Lattices..................................................................14

3.6 Cubic Crystal Structures................................................16

3.11 Crystal Imperfections.....................................................22

3.11.1 Types of Imperfections Present in Solids...22

3.12 Point Imperfections.........................................................22

3.12.1 Vacancies...............................................................23

3.12.2 Interstitial Defect................................................23

3.12.3 Substitutional Imperfections.........................24

3.12.4 Frenkels Defect...................................................24

3.12.5 Schottkys Defect................................................24

4.1 Introduction.......................................................................27

4.2 Ohms Law and Electrical Conductivity....................28

4.3 Energy Band Structure in Solids.................................30

4.4 Classification of Materials based upon Energy Band

Diagram............................................................................32

Structures........................................................................13
3.4 Unit Cell and Primitive Unit Cell..................................14

Electronic Materials................................27

3.3 Lattice Points, Space Lattice and Crystal

3.10 Interplanar Spacing.........................................................21

Chapter 4

Solids
...................................................................................12

Objective Brain Teasers....................................................25

Crystallography......................................12

3.9 Planar Density...................................................................21

Chapter 3
3.1 Introduction.......................................................................12

Plane........................................................................20

Objective Brain Teasers....................................................10

3.8.1 Determining the Miller Indices of a Given ......

4.4.1 Insulators...............................................................32

4.4.2 Semiconductors..................................................32

4.4.3 Metals.....................................................................32

4.5 Electrical Resistivity of Metals......................................33

4.6 Thermal Conductivity of MetalsWiedemann Franz

law ...................................................................................34

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4.7 Thermoelectric Phenomenon.....................................35

Chapter 5

4.8 Superconductivity...........................................................35

4.8.1 Meissner Effect....................................................36

Magnetic Properties of Materials56

4.8.2 Effect of Magnetic Field (H).............................36

5.1 Introduction.......................................................................56

4.8.3 Silsbees Rule........................................................37

5.2 Magnetic Parameters......................................................56

4.8.4 Other Properties of Superconductivity......37

5.2.1 Magnetic Dipole Moment...............................56

4.8.5 Types of Superconductors...............................37

5.2.2 Magnetisation......................................................56

4.8.6 Applications of Superconductor...................38

5.2.3 Magnetic Susceptibility....................................57

4.9 Insulators.............................................................................38

4.10 Dielectrics...........................................................................39

5.3 Classification of Magnetic Materials..........................57

5.3.1 Diamagnetic Substance...................................58

4.10.1 Dielectric Constant............................................40

5.3.2 Paramagnetic Substances...............................59

4.10.2 Dielectric Strength.............................................41

5.3.3 Ferromagnetic Substances..............................59

4.11 Electric Dipole Moment and Polarization...............41

5.3.4 Antiferromagnetic Substances......................61

4.12 Types of Polarization.......................................................43

5.3.5 Ferrimagnetic Substances...............................61

4.12.1 Electronic Polarization......................................43

5.4 Curie Temperature...........................................................62

4.12.2 Ionic Polarization................................................44

5.5 Laws of Magnetic Materials..........................................63

4.12.3 Orientation Polarization...................................44

5.5.1 Curie Law...............................................................63

4.12.4 Space Charge Polarization..............................44

5.5.2 Curie-Weiss Law.................................................63

4.13 Phase Difference and Dielectric Loss........................44

5.5.3 Neel Law................................................................63

4.13.1 Power Factor.........................................................45

5.6 Domain Theory.................................................................64

4.14 Polar Molecules.................................................................45

5.7 Magnetisation Curve and Magnetic Hysteresis

4.15 Nonpolar Materials..........................................................45

4.16 Other Electrical Characteristics of Materials...........45

Loop...................................................................................65

5.8 Soft Magnetic Materials.................................................66

4.16.1 Ferroelectricity.....................................................45

5.9 Hard Magnetic Materials...............................................68

4.16.2 Piezoelectricity....................................................47

5.10 Magnetic Storage.............................................................70

4.17 Use of Dielectrics..............................................................48

4.18 Semiconductor Materials..............................................48

4.19 Electrons and Holes in an Intrinsic Semiconductor

Objective Brain Teasers....................................................70

Chapter 6

Ceramics72

(Pure Semiconductor).................................................49

4.20 Extrinsic Materials............................................................49

6.1 Introduction.......................................................................72
6.2 Silicate Ceramics...............................................................73

4.20.1 n-type Material....................................................49

4.20.2 p-type Material....................................................50

6.2.1 Silica........................................................................75

4.21 Charge Densities in a Semiconductor......................50

6.2.2 Feldspars................................................................75

4.22 Electrical Properties of Semiconductors..................51

6.3 Material Preparation.......................................................75

4.22.1 Conductivity.........................................................51

6.3.1 Dry Pressing..........................................................76

4.22.2 Intrinsic Concentration.....................................51

6.3.2 Isostatic Pressing.................................................76

4.22.3 Energy Gap...........................................................51

6.3.3 Hot Pressing..........................................................76

4.22.4 Mobility..................................................................51

6.3.4 Slip Casting...........................................................76

6.3.5 Extrusion................................................................77

4.23 Hall Effect............................................................................51

4.23.1 Applications of Hall Effect...............................52

6.4 Thermal Treatments........................................................77

4.24 Thermistors........................................................................52

6.4.1 Drying and Binder Removal............................78

4.25 Photoconductors.............................................................52

6.4.2 Sintering................................................................78

Objective Brain Teasers.................................................53

6.4.3 Vitrification............................................................78

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6.5 Electrical Properties of Ceramics................................78

Chapter 8

6.6 Mechanical Properties....................................................79

Composites94

6.7 Thermal Properties of Ceramics..................................80

8.1 Introduction.......................................................................94

6.8 Glass ...................................................................................80

8.2 General Characteristics of Composites....................94

6.9 Carbon.................................................................................81

8.3 Particle-reinforced Composites..................................96

6.9.1 Diamond................................................................82

6.9.2 Graphite.................................................................82

6.9.3 Fullerenes..............................................................83

Chapter 7

8.4 Fibre-Reinforced Composites......................................98

Objective Brain Teasers....................................................83

8.3.1 Large-particle Composites..............................96

8.4.1 Continuous and Aligned Fibre

Composites...........................................................99

8.4.2 Discontinuous and Aligned Fibre

Polymers85

Composites...........................................................99

7.1 Introduction.......................................................................85

8.5 Laminar Composites.......................................................99

7.2 Basic Definitions...............................................................85

7.2.1 Polymers................................................................85

7.2.2 Mer...........................................................................85

7.2.3 Monomer...............................................................85

7.2.4 Polymerisation.....................................................86

7.2.5 Degree of Polymerisation................................86

7.3 General Characteristics of Polymer...........................86

7.4 Molecular Structure of Polymers................................87

7.4.1 Linear Chain Structure......................................87

7.4.2 Branched Chain Structure...............................87

7.4.3 Crosslinked Structure........................................88

7.5 Classification of Plastics.................................................88

8.5.1 Sandwich Structures..........................................99

8.6 Polymer-Matrix Composites (PMCs)....................... 100

8.6.1 Glass Fibre-Reinforced Polymer (GFRP)
Composites........................................................ 100

8.6.2 Carbon Fibre-Reinforced Polymer (CFRP)

Composites........................................................ 100

8.6.3 Aramid Fibre-Reinforced Polymer

Composites........................................................ 101

Objective Brain Teasers................................................. 101

Chapter 9
Mechanical Properties of Materials 103

7.5.1 Thermoplastics....................................................88

9.1 Introduction.................................................................... 103

7.5.2 Thermosetting Plastics.....................................88

9.2 Normal Stress................................................................. 103

9.3 Strain ................................................................................ 104

9.4 Tension Test for Mild Steel......................................... 104

7.6 Thermoplastic Materials................................................89

7.6.1 Polythelene...........................................................89

7.6.2 Polyvinyl Chloride (PVC)...................................89

9.4.1 Specifications of Specimen.......................... 104

7.6.3 Teflon......................................................................89

9.4.2 Stress Strain Curve for Tension.................... 104

7.6.4 Polystyrene...........................................................90

9.4.3 Actual Curve v/s Engineering Curve in ............

7.7 Thermosetting Materials...............................................90

Tension................................................................ 105

7.7.1 Phenol Formaldehyde (PF) or Bakelite........90

9.4.4 Compression Curve for Mild Steel............. 105

7.7.2 Polyester................................................................91

9.4.5 Stress-strain Curve for other Grades of Steel .

7.7.3 Melamine...............................................................91

7.7.4 Epoxies...................................................................91

in Tension............................................................ 106

9.4.6 Stress-strain Curve for Various Materials in ....

7.8 Mechanical Behaviour of Plastics...............................92

7.9 Compounding Materials...............................................92

9.5 Common Terms of Mechanical Properties........... 106

7.10 Comparison of Polymers with Ceramics

9.6 Failure of Materials in Tension and

and Metals..........................................................................93

Objective Brain Teasers....................................................93

Tension................................................................ 106

Compression................................................................... 112

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9.6.1 Ductile Metals in Tension Test..................... 112

9.6.2 Brittle Metals in Tension Test....................... 112

10.6 Special Alloys Steels..................................................... 124

9.6.3 Ductile Metals in Compression Test.......... 112

10.6.1 Stainless Steels.................................................. 124

9.6.4 Brittle Metals in Compression Test............ 112

10.6.2 High Speed Steels............................................ 124

9.7 Fracture............................................................................. 112

10.6.3 High Temperatures Resisting Alloys.......... 125

9.8 Hookes Law.................................................................... 113

10.6.4 Magnetic Steels................................................. 125

9.8.1 Assumption in Hookes Law......................... 113

10.6.5 Cryogenic Steels............................................... 125

9.9 Elastic Constants........................................................... 113

Objective Brain Teasers................................................. 125

9.9.1 Relationship between Elastic Constants......114

Chapter 11

9.10 Difference between Linearly and Non-linearly

Non-Ferrous Metals and Alloys 127

Elastic Materials.......................................................... 114

Objective Brain Teasers................................................. 115

Chapter 10
Ferrous Metals117

11.1 Introduction.................................................................... 127

11.2 Aluminium....................................................................... 128

11.2.1 Uses of Aluminium.......................................... 128

11.2.2 Limitation of Aluminium in Power Cables...129

10.1 Introduction.................................................................... 117

10.2 Pig Iron.............................................................................. 117

11.3.1 Duralumin.......................................................... 129

10.3 Cast Iron........................................................................... 118

11.3.2 Y-alloy.................................................................. 129

10.3.1 Forms of Carbon in Cast Iron....................... 118

11.3.3 Hindalium........................................................... 130

10.3.2 Grey Cast Iron.................................................... 118

11.3.4 Magnelium......................................................... 130

10.3.3 White Cast Iron.................................................. 119

10.3.4 Malleable Cast Iron.......................................... 120

11.4.1 Brasses................................................................. 131

10.3.5 Nodular Cast Iron............................................. 120

11.4.2 Bronze.................................................................. 132

10.3.6 Alloy Cast Iron................................................... 121

11.4.3 Differences between Brass and Bronze... 133

10.4 Wrought Iron.................................................................. 121

10.5 Steel ................................................................................ 122

10.5.1 Classification of Carbon Steel with

Percentage of Carbon..................................... 122

10.5.2 Alloy Steel........................................................... 123

10.5.3 Effect of Alloying Elements on Carbon

Steels.................................................................... 124

11.3 Aluminium Alloys.......................................................... 129

11.4 Copper.............................................................................. 130

11.5 Lead ................................................................................ 134

11.6 Tin

11.7 Nickel ................................................................................ 134

11.8 Magnesium..................................................................... 135

11.9 Titanium........................................................................... 135

11.10 Tungsten........................................................................ 135

................................................................................ 134

Objective Brain Teasers................................................. 136

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