Introduction to Materials

Science and Engineering

LECTURE 1
IN MSE 300
MATERIALS ARE …
Engineered structures

Substances whose properties make them

useful in structures, machine, devices or
others products

Usually in the form of solids

Technology: development and transfer of knowledge and
techniques to provide society with its needs
and comforts.
• To continue to offer what consumers expect and
need, designers must keep abreast with NEW
MATERIALS DEVELOPMENT

Materials Science: a discipline involving investigation of

relationships that exist between the
structure and properties of materials.

Engineering materials: materials whose structures are

designed to develop specific
properties for a given application.
 Materials
Science BASIC KNOWLEDGE
 internal structure
 properties

Materials
Science and
Engineering
APPLIED KNOWLEDGE
 processing
Materials  performance
Engineering
“The engineer’s expertise lies in adapting materials and energy to
society’s needs/demands.”
DENSITY OF WATER
Liquid Solid

1.00 g/mL 0.92 g/mL

Materials Engineering: deals with synthesis and use
of knowledge (structure,
properties, processing and
behavior) to develop,
prepare, modify and apply
materials to specific needs.

Materials Science and Engineering:

- A major field of study involving generation and
application of knowledge relating the composition,
structure, and processing of materials to their
properties and uses.
Materials Engineering: deals with synthesis and use of knowledge (structure, properties,
processing and behavior) to develop, prepare, modify
and apply materials to specific needs.

http://www.flickr.com/photos/brampitoyo/3636925679/

Materials Science and Engineering:

- A major field of study involving generation and application of knowledge relating
the composition, structure, and processing of materials to their properties and uses.
Materials Engineering: deals with synthesis and use of knowledge (structure, properties,
processing and behavior) to develop, prepare, modify
and apply materials to specific needs.

Materials Science and Engineering:

- A major field of study involving generation and application of knowledge relating
the composition, structure, and processing of materials to their properties and uses.
Materials Engineering: deals with synthesis and use of knowledge (structure, properties,
processing and behavior) to develop, prepare, modify
and apply materials to specific needs.

Materials Science and Engineering:

- A major field of study involving generation and application of knowledge relating
the composition, structure, and processing of materials to their properties and uses.
Components of Materials Science and Engineering
1. Processing – method by which a material is
manufactured

2. Structure – the arrangement of the internal

components of materials (subatomic, atomic,microscopic,
macroscopic)

3. Properties – materials response (type and magnitude)

to a specific stimulus

4. Performance – ability to conform to its intended use

Components of Materials Science and Engineering

Processing Structure Properties Performance

The interrelationship is LINEAR (Callister, 2003)

Components of Materials Science and Engineering

- an interactive information-transfer network, linking the

interrelationships among components, highlighting the
counter-current flows of scientific and empirical
knowledge (Van Vlack, 1989)
Structure, Processing and Properties

• Processing can change

structure.
– Ex. Structure vs. cooling rate
of steel.

800
700
martensite
Hard ness [ BHN ]

600
500
400 Tempered
300 martensite
200 cementite
pearlite
100
0.01 0.1 1 10 100 1000
Cooling Rate [ C/s ]
Structure, Processing and Properties
• Properties depend on
structure.
– Ex. Hardness vs. structure of
steel.
%Fe3C
0 3 6 9 12 15

280

240
Brinell Hardness

Coarse
Fine
200 pearlite
pearlite
160
Spheroidite
120
80
0 0.2 0.4 0.6 0.8 1.0
Composition [ wt% C ]
STRUCTURE
Structural Feature Dimension [m]
Atomic Bonding < 1010
Missing 1 extra atom 1010
Crystals (ordered atoms) 108  101
Second phase particles 108  104
Crystal texturing > 106
STRUCTURE
Sub atomic

Atomic

Microstructure

Macrostructure
STRUCTURE
Sub atomic
STRUCTURE
Atomic
STRUCTURE
Microstructure
STRUCTURE
Macrostructure

Manganese nodules from the ocean floor (Whitten, 2007)

PROPERTIES
materials response (type and magnitude) to a
specific stimulus

Stimulus: Property:

Force Mechanical
Electric field Electrical
Heat Energy Thermal
Magnetic Field Magnetic
Light Optical
Chemical Deteriorative
 ELECTRICAL
• Electrical resistivity of copper
Temperature [ F ]
-400 -300 -200 -100 0 +100
6

Electrical resistivity [ 108-m ]

5

0
-250 -200 -150 -100 -50 0 +50
Temperature [ C ]
• Adding impurity atoms to Cu increases resistivity .
• Deforming Cu increases resistivity.
 THERMAL

• Space Shuttle Tiles

– Silica fiber insulation offers low heat conduction
• Thermal conductivity of copper.
– It decreases when Zn is added.

400 250
Cu-Zn alloy

Thermal conductivity
Thermal conductivity

200
300

[ BTU/ft-F ]
[ W/m-K ]

150
200
100
100 50
0
0 10 20 30 40
Composition [ wt%Zn ]
 OPTICAL

• Transmittance:
– Aluminum oxide may be transparent, translucent, or
opaque depending on material structure.

Single crystal Polycrystal

High porosity

Polycrystal
Low porosity
 MAGNETIC
• Magnetic storage: • Magnetic permeability vs.
– Recording medium is composition
magnetized by recording – Adding 3 atomic % Si makes
head. better Fe a better recording
medium!
Recording medium

Fe+3%Si

Magnetizaton
width Fe
gap
Recording
head

Magnetic Field
Signal write read Signal
in out
 DETERIORATIVE
• Stress and saltwater …. - causes cracks!
• Heat treatment: slows crack speed in saltwater

108 as is
Crack speed [ m/s ]

held at 100C for 1 hr

before testing

1010

Increasing load
Material: 7150 – T651 Al “alloy”
(Zn, Cu, Mg, Zr)
MECHANICAL PROPERTIES
Stress (s or σ)
– a measure of force per unit area, F/A.
– commonly used units : N/m2, Pa, psi

Strength – critical stress to initiate failure.

MECHANICAL PROPERTIES
Strain (e or δ)
– dimensional response to stress, expressed as a
fraction or percent, and is therefore dimensionless,
ΔL/L0.

positive (+) under tensile stress

negative (-) under compressive stress

elastic if reversible
plastic if permanent
STRESS-STRAIN DIAGRAM
 ELASTIC LIMIT
Elastic limit
engineering stress

Slope = Young’s modulus

or modulus of elasticity
(measure of stiffness)

engineering strain
Elastic limit – uppermost stress wherein the material will
return to its original length when the load is removed.
 PROPORTIONAL LIMIT
A

Proportional limit
B
engineering stress

Slope = Young’s modulus

engineering strain
Proportional limit - the limit of the proportional range of
the stress-strain curve
YOUNG’S MODULUS
Young’s modulus or modulus of elasticity

– is the measure of stiffness of a material.

– ratio of stress to elastic strain

s ( F / A)
E 
eel (L / L0 )
 YOUNG’S MODULUS
Slope = Young’s modulus
A

Young’s modulus
B
engineering stress

engineering strain
Young’s modulus or modulus of elasticity is the measure of
stiffness of a material.
 YOUNG’S MODULUS
Slope = Young’s modulus
A

Young’s modulus
B
engineering stress

engineering strain
Young’s modulus or modulus of elasticity is the measure of
stiffness of a material.
MECHANICAL PROPERTIES
Hardness – resistance of a material to penetration

Ductility – plastic strain that accompanies fracture

Toughness
– measure of the energy absorbed prior to
fracture.
– proportional to the area under the stress-
strain diagram.
Types of fracture in tension

(a) brittle fracture in polycrystalline metals;

(b) shear fracture in ductile single crystals;
(c) ductile cup-and-cone fracture in polycrystalline
metals;
(d) complete ductile fracture in polycrystalline metals,
with 100% reduction of area.
Mechanical Properties
Sample problem

Which part has the greater stress:

(a) rectangular aluminum bar of 24.6 mm x 30.7 mm

cross section, under a load of 7640 kg, or

(b) a round steel bar whose cross sectional diameter is

12.8 mm, under a 5000-kg load?
Mechanical Properties
Sample problem

When the stress on the wire 1 mm in diameter is 37 Mpa,

the elastic strain is 0.054%. What is the elastic modulus?

s ( F / A)
E 
eel (L / L0 )
Mechanical Properties
Sample problem

If the average modulus of elasticity of the steel used is

205,000 MPa, by how much will a wire 2.5 mm in
diameter and 3 m long be extended when it supports a
load of 500 kg?

s ( F / A)
E 
eel (L / L0 )
Mechanical Properties
Sample problem

An iron 0.50 inch in diameter supports a load elastically of

1540 lbm.

(a) What is the stress placed on the rod in MPa?

(b) How much will the rod be strained by that load?

Electrical Properties
The resistance of a wire in a circuit is a function of the size
of the wire as well as the material.

L
R   
 A
R = electrical resistance, ohm
ρ = resistivity, ohm-m
L = length, m
A = cross sectional area, m2
σ = electrical conductivity, 1/ρ, ohm-1-m-1
Electrical Properties
Sample problem

A copper (ρ = 17 ohm-nm) wire has a diameter of 0.9 mm

(a) What is the resistance of a 30-cm wire?

(b) What must be the length of the wire describe above

to have an end-to-end resistance of 0.015 ohm?
Electrical Properties
Sample problem

What is the difference in the end-to-end resistance of a 2-

mm in diameter aluminum (ρ = 29 ohm-nm) wire that is
30.5 m in length and a copper (ρ = 17 ohm-nm) wire with
the same dimensions?
Thermal Properties
Thermal Conductivity is expressed as power per unit area
along a temperature gradient (W/m-K).

Thot Tcold

q dT
q k
A dx
X

Thermal Conductivity (k) varies with temperature.

Thermal Properties

Heat Capacity – quantity of heat required to change the

temperature of a SYSTEM by one degree.

If the system is one mole of a substance, therefore it is

termed as molar heat capacity.

Specific heat capacity or specific heat…

If the system is one gram of a substance
Thermal Properties
Sample problem

Determine the thermal conductivity of the following

engineering materials. (Use Appendix B of Callister)

(a) steel alloy A36

(b) Gold (pure)
(c) Tungsten (pure)
(d) Aluminum oxide
(e) Borosilicate glass
(f) Nylon 6,6
(g) Red oak (12% moisture)
Thermal Properties
Sample problem

Using the data below, estimate the thermal conductivity of

Copper at 350K, 745K,and 868K.

Thermal conductivity of Copper at different temperatures

T, K 300 400 600 800 1000 1200
k, W/mK 398 392 383 371 357 342
Thermal Properties
Sample problem

A cylindrical iron sample (height to diameter ratio is 2:1)

is heated to 97.5°C, then immersed in 247 mL of water
originally at 20.7°C. When thermal equilibrium has been
reached, the water and iron are both at 36.2°C. Calculate
the dimensions (diameter and height) of the iron sample.

Properties of Iron:
Specific heat = 0.45 J/g°C
Density = 7.87 g/cm3
Properties of Water
Specific heat = 4.18 J/g°C
Density = 1.0 g/cm3
Thermal Properties
Sample problem

A spherical iron sample is heated to 97.5°C, then

immersed in 247 mL of water originally at 20.7°C. When
thermal equilibrium has been reached, the water and iron
are both at 36.2°C. Calculate the radius (in inches) of the
iron sample.

Properties of Iron:
Specific heat = 0.45 J/g°C
Density = 7.87 g/cm3
Properties of Water
Specific heat = 4.18 J/g°C
Density = 1.0 g/cm3
 MATERIALS CYCLE
Extracting
raw materials

Recycling/disposing of Creating bulk materials,

used products and systems components and devices

Services of products Manufacturing

and systems engineered materials

Fabricating products
and systems
Material Engineering Engineering
Science Mechanics Durability Design

Life-cycle concerns
Fundamental laws
Interactions between material
components
Quality
Reliability
Cost

MANUFACTURING
 ROLES OF ENGINEERS IN
MANUFACTURING
 Manufacturing Engineers – select and coordinate
specific processes and equipment to be used.
 Design Engineers – design the machines and
equipment used in manufacturing, select and
specify the materials to be used in order to meet
the requirements.
 Materials Engineers – devote their major efforts
toward developing new and better materials for
use in commercial products.
Materials Scientists – study how the structure of materials
relates to their properties
 Materials Selection
• What selection criteria are important to
suit the requirements of products
needed.
• How do designers select to arrive at the
best material?
• What is an ideal material?
In materials selection,
COMPROMISE is the rule not
the exception.
 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. Materials  Identify required processing

Processing: changes structure and overall shape.
Ex. Castings, sintering, vapor deposition,
doping, forming, joining, annealing
4. Additional selection criteria
CHARACTERISTICS OF AN IDEAL
MATERIAL
 endless and readily available source of supply
 cheap to refine and produce
 energy efficient
 strong, stiff, and dimensionally stable at all
temperatures
 lightweight
 corrosion resistant
 no harmful effects on the environment or people
 biodegradable
 numerous secondary uses
SELECTION TOOLS AND FACTORS
 Availability – material must be
available at a reasonable cost and in the
desired form (if not available in the
desired state, the material should be
convertible to the desired form).
 Economics – cost of materials and
processing must be considered.
 Properties – materials performance
characteristics
ALGORITHMS OR STEPS:
 Selection Tools
 Properties of materials
 Materials systems
 Additional Selection Criteria
 existing specifications
 availability
 Processibility
 Near-net-shape production
 Quality and performance
 Consumer acceptance
 Design for assembly
BASIC APPROACHES TO
FINAL MATERIALS SELECTION
 minimum investment and high maintenance
 high investment and low maintenance
 optimum investment and maintenance
REASONS WHY MATERIAL SELECTION DECISIONS
ARE AMONG THE MOST IMPORTANT THE DESIGN
ENGINEER MUST MAKE:
 The number of materials available is large and
constantly increasing.
 Domestic and foreign competitions increasingly
require product reevaluation.
 Service requirements and consumer demands for
reliability as well as function have become more
severe.
 In many cases, the material has a direct relationship
to the appearance of the product and its sales appeal.
 In many cases, the material dictates what processing
must be used in order to manufacture the product.
 Because of strict and comprehensive product-liability
laws, failure of products can result in very costly
litigation and damages.
AIDS TO MATERIALS
SELECTION
 A broad basic understanding of the
nature, properties and processing of
materials.
 Tables of properties of engineering
materials. Data must be computerized to
allow easier access)
 Magazines, periodicals, books, journals,
compilation of current lists or charts of
cost indices and quotations.
 Rating charts.
 Three materials X, Y, and Z are available for a certain
usage. Any material selected must have a good weldability. Tensile
strength, stiffness, stability and fatigue strength are required with
fatigue strength considered being the most important and stiffness
the least important of these factors. The three materials are rated as
follows in these factors.
Properties X Y Z
Weldability E P G
Tensile strength G E Fair
Stiffness VG G G
Stability G E G
Fatigue strength Fair G E
Which material should be selected?
Classification of Materials
1. Metals
2. Ceramics
3. Polymers
4. Composites
5. Electronic-related materials
6. Biomaterials
 Summary
Course Goals
• Use the right material for the job.

• Understand the relation between

properties, structure and processing.

• Recognize new design opportunities

offered by materials selection.
References:
[1] de Garmo, Paul E., Temple J. Black, and Ronald A.
Kohser, Engineering Materials and Processes 8th ed., John Wiley and
Sons, Inc., New York (1999).

[2] Callister, William D. Jr., Materials Science and

Engineering, 6th ed., John Wiley and Sons, Inc.,Singapore
(2009).

[3] Shackelford, James F., Introduction to Materials Science for

Engineers, Pearson Education Inc., Upper Saddle River, NJ
(2004).

[4] Van Vlack, Lawrence H., Materials Science for Engineers, 4th
ed., Addison-wesley Publishing Co., Inc., Philippines (1980).