INTRODUCTION TO MATERIALS

SCIENCE AND ENGINEERING

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A Historical Notes
• The interaction between man and material
starts since stone age
• By the 1500 BC Hittites were already
experimenting with iron
• In Egypt, people were enjoying the benefits of
the Copper and early Bronze ages
• In China they already start melting iron and
start alloying (bronze, a copper—tin alloy that
is stronger and easier to cast than pure copper)

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Advancement in material processing
• The advancement was too slow!
• One of the most important mechanical figures to improve is Strength
to Weight ratio takes until 1800 AD to increase

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Advancement in material processing – Cont.
• This figure shows the significant
improvements made in abrasive
‫مكشطه‬and cutting tool materials due
to the improvement of the materials
used

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Materials Cycle

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Materials Cycle – Cont.
• The “Recycle” process means to reprocess the already
processed Engineering Material and convert it again to
Engineering material
• The “Reuse” process means to reuse the extracted goods
“out of junk” in its shape without reprocessing

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Materials Cycle – Cont.
• Where should we put the “Reuse” operation in this cycle?

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The interaction of Materials, Energy, and the
Environment
• Usually to get materials we consume energy
and affect the environment (interaction)
• We want to get materials without consuming
energy or harming the environment
• If the there is no control from governments on
the way we use the resources catastrophic
consequences are waiting!

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The interaction of Materials, Energy, and the
Environment – Cont.
• Examples
Great “Temper Famine” in the middle ages (1450-1600)
due to the use of Charcoal ‫فحم النباتي او الحيواني‬
 Building huge wooden ships
 Huge demand for books and paper
 High level standards requires extra energy which they get from
burning charcoal
 Producing iron requires huge amount of energy (charcoal), e.g.
1 ton requires 200 cords of wood
As a result deserts created and spread out across Europe
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The interaction of Materials, Energy, and the
Environment – Cont.
• Examples – Cont.
To produce ~1.7 x 106 tons of refined copper (the annual
need) USA needs:
 About one billion tons of rock must be excavated
 About 0.2% of the total US energy is required
 3.3x106 tons of slag ‫ خبث‬and 3.5x106 tons of SO2 gas are
produced (toxic gas), adversely affecting the environment and
public health
As a result the concentration of copper in exploitable ores in the
USA has fallen to less than 0.6%, let alone the health problems
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The interaction of Materials, Energy, and the
Environment – Cont.
• Examples – Cont.
 Global Warming due to excess CO2 emissions
 The Ozone hole due to excess ChloroFluoroCarbons
(CFCs) emissions which breaks down to chlorine which
reacts with Oxygen atoms of ozone layer and destroy it

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The interaction of Materials, Energy, and the
Environment – Cont.
• For each category
the sum must be
100%
• This table lacks the
info about the
material
concentration in
space, like moon,
comets, etc. !

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Recycling and The Interaction
• Recycling can affects positively on the interaction reducing
the side of effects on environment
• Example: What is the minimum energy required to melt 1
ton of recycled aluminum beverage cans?
Answer: it is ~8.98x105 kJ/ton
If we extract Al from Al2O3 we need 264x105 kJ/ton

29 times
recycle !!!!
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Producing Energy Consumes Energy!
• Example: The energy required to produce a complete solar
cell module is estimated to be 2170 kWh per square meter.
How long will it take to recover this energy if an average of 1
kW/m2 assuming that it operates only 5 hours a day, is 12%
efficient, and has an area of 1 m2
Answer: In 1 day the amount of solar energy converted into
electrical energy is 1 kW X 5 h X 0.12 = 0.6 kWh. Therefore, the
number of days required is 2170 kWh/0.6 kWh/day = 3617 days
The module must operate almost 10 years before it recovers the
energy used for its production
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Materials-Design-Processing
• If your product fails, think in one of those in the figure
• Good designs of components and systems are defeated if
fabrication is impractical or if the wrong materials are
selected

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Materials-Design
• Example: During WW-II 5000
welded steel merchant ships
sunk and the cause was not
the enemy but the engineers
themselves!
• Some of them broken in 2 halves
• Most because of the cracks when
they pass a very cold water

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Structure, Properties, Processing, Performance
Structure-Properties
• People realizes difference between materials via different properties,
e.g. hardness, mechanical strength, malleability ‫القابلية للطرق‬, and color
• Though these properties roughly describe the material
• Deep understanding of materials requires deep knowledge about
their atom crystalline structure and properties

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Structure, Properties, Processing, Performance
Processing
• Different processes include: mechanical shaping of metals,
melting, firing, alloying, etc.

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Structure, Properties, Processing, Performance
Performance
• If there are no design flaws, it is up to the materials to meet
performance requirements
• Processing influences the structure of the material and their
properties so testing the performance of the material is a
must

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Material Selection
• Here are the most important aspects in material selection
Essential property or properties of interest (e.g. conductor
or not)
Fabricability (e.g. can I make a wire of it)
Availability
Cost
• Prices will vary depending on size, shape, and quantity purchased.
• The increased value of a number of materials due to additional processing
• Subsequent labor, production, and assembly costs, associated with use of a
particular material
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Engineering material and their applications
Metals
• Basic properties: High reflectivity, thermal conductivity,
malleability, low electrical resistance, strong (high tensile
strength), stiff (large modulus of elasticity), and tough
(resistant to fracture)
• Examples: irons, steels, aluminum, copper, nickel, titanium,
zinc, tin, lead, manganese, chromium, tungsten, and the
precious metals gold, silver, and platinum
• Application: look around!

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Engineering material and their applications
Ceramics
• Ceramics are composed of metallic and nonmetallic elements
• They have extreme hardness, high-temperature strength (good
thermal insulator), good electrical insulator
• Examples include metal oxides (AI2O3, TiO2, ZrO2, SiO2, Na2O K2O, Li2O,
etc.)

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Engineering material and their applications
Polymers
• Their low cost and density, coupled with ease in processing and
durability, have been key reasons for the substitution of polymers for
metals, glasses, and natural products
• It has widespread use in clothing, fabrics, food and beverage
containers, packaging of all kinds, furniture
• The use of polymer in cars industry halved the weight of USA cars
from 4000 lb to 2000 lb which decreases the energy used to drive
them

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Engineering material and their applications
Semiconductors
• Semiconductors are the basic element in our telecommunication
revolutions nowadays
• Applications: whatever electric device you imagine!

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Thanks

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