PowerPoint Lecture Slides

for
Foundations of Materials
Science and Engineering
Sixth Edition

William F. Smith
Javad Hashemi

© 2019 McGraw-Hill Education. All rights reserved. Authorized only for instructor use in the classroom. No reproduction or further distribution permitted without the prior written consent of McGraw-Hill Education.
 CHAPTER 1

Introduction to Materials
Science and Engineering

© 2019 McGraw-Hill Education

 The Mars Rovers - Spirit and Opportunity

Orion spacecraft and NASA’s manned Mars to mission will

require intelligent use of Materials in all classes including metals
ceramics, composites * polymers * and semiconductors.
Class Discussion Topic: Discuss examples of materials that are
used in the structure and for functionality of the Orion capsule.
© 2019 McGraw-Hill Education (left photo) NASA; (right photo) Daniel Casper/NASA
 What are Materials?
What are “materials”? According to Webster’s dictionary,
materials may be defined as substances of which something is
composed or made. Although this definition is broad, from an
engineering application point of view, it covers almost all relevant
situations.
Where do materials come from?
Earth’s crust: metals, ceramics, and electronic materials are mined in the form
of ores and processed to produce pure metals, nonmetals, alloys, and
compounds.
Laboratory or Factory: Polymers and composites are mostly manmade and are
synthesized in laboratories using chemical and thermal/mechanical processes.

Examples: Silicon (electronic material) and Iron (structural materials)

constitute 27.72 and 5.00 percentage of weight of earths crust, respectively.
PVC (polymer) and fiberglass (a composite) is made is a laboratory or a factory.
© 2019 McGraw-Hill Education
 Why the Study of Materials is Important?
Products (cars, planes, etc.) are made of materials
Production and processing of materials constitute a large part of
our economy
Engineers choose materials to fit a specific product or a specific
application
New materials might be needed for some new applications -
example NASA’s X-planes
• Needs advanced alloys for engine environment
(metals and ceramics)
• Needs lighter materials to be weight less (composites)
• Needs stronger materials to be safe, (composites)
• Needs corrosion resistant materials
• Needs advanced electronics, (electronic materials)
• Needs comfortable and aesthetic airline seat and
other furniture (polymers)
© 2019 McGraw-Hill Education NASA
 Materials Science and Engineering
Materials science deals with basic knowledge about the
internal structure, properties and processing of
materials.
Materials engineering deals with the application of
knowledge gained by materials science to convert
materials to products.

© 2019 McGraw-Hill Education

 Classes of Materials 1

Three main or fundamental classes (volume)

• Metals
• Example:- Iron, Copper, Aluminum.
• Ceramics
• Example:- Silicon carbide, Alumina, Clay.
• Polymers
• Example:- Polyethylene, Polyvinyl Chloride.

Two processing or application classes (application)

• Composite Materials
• Example:- Fiberglass, Graphite Epoxy, Wood.
• Electronic Materials
• Example:- Silicon, Gallium, Boron.
Class Discussion Topic: Discuss the main reason composite materials
and electronic materials are not classified as fundamental.
© 2019 McGraw-Hill Education
 Classes of Materials 2

Metals
• Inorganic
• Composed of one or more metallic elements (Fe, Al, Cu, …)
• May contain nonmetals (C, N, Si, …)
• Possess a crystal structure in solid form
• Good to excellent thermal and electrical conductors.
• Are strong and stiff both at room temps
• Some are strong at high temperatures
• Generally possess high density
• Can be shaped or cast into different shapes – are malleable
• Some metals are very hard (difficult to indent)
• Are chemically active (form oxides and corrode)
© 2019 McGraw-Hill Education
 Classes of Materials 3

Metals, continued
• Two major classes: Ferrous and Non-Ferrous
• Ferrous alloys contain iron as the major element – cast iron, steel
• Non-Ferrous alloys contain little or no iron – aluminum alloys

Nickel- based super

alloys, a non-ferrous
alloy, used in turbine
edgings

The distinction is made because of the significantly higher usage

and production of steels and cast irons when compared to other
alloys.
© 2019 McGraw-Hill Education (a) © SteveMann/123RF; (b) © MISS KANITHAR AIUMLA-OR/Shutterstock
 Types of Materials 1

Polymers
• Organic (carbon is the main building block)
• Synthetic (man made)
• Generally non crystalline (some are semicrystalline)
• Composed of long molecular chains or networks
• Poor thermal and electrical conductors; good electrical
insulators
• In general, not very strong (not good for high-load bearing)
• Low melt or decomposition temperature
• Generally possess low density
• Can be formed into different shapes
• Are chemically stable
© 2019 McGraw-Hill Education (a) © PhotoDisc/Getty Images; (b) © THIERRY ZOCCOLAN/AFP/Getty Images
 Types of Materials 2

Polymers, continued
• Two major classes: Plastics and Elastomers
• Plastics are polymers that can be molded and shaped into different
forms while soft and have good but limited deformability when set
into a solid form
• Plastics may be either a thermoplastic (can be reheated or reshaped)
or a thermoset (can not be reheated and reshaped)
• Elastomers are polymers that have outstanding elastic properties, can
elongate significantly and return to original shape

Polycarbonate,
the materials for Rubber, the
a common CD is material for tire
a thermoplastic is an elastomer

© 2019 McGraw-Hill Education (a) © PhotoDisc/Getty Images; (b) © THIERRY ZOCCOLAN/AFP/Getty Images
 Types of Materials 3

Ceramic Materials
• Inorganic
• Consist of metallic and nonmetallic
elements, chemically bonded together
Ceramic bearings
• Can be either crystalline (alumina) or non-
crystalline (clay)
• Possess, high hardness and strength
• Are highly wear resistant
• Very good to excellent insulators of heat
and electricity
• High melting temperature, refractory.
• Low friction materials Variety of ceramic parts
© 2019 McGraw-Hill Education (top photo) © Editorial Image, LLC/Alamy; (bottom photo) Courtesy of Kyocera Industrial Ceramics Corp.
 Types of Materials 4

Composite Materials
• A mixture of two or more materials (phases or constituents)
integrated to form a new one.
• Consists of a reinforcing filler material and a binding material.
• The constituents only bond, will not dissolve in each other;
there is a clear interface.
• The constituents keep their original properties
• Mainly two types :-
• Fibrous: Fibers in a matrix
• Particulate: Particles in a matrix
Examples :-
• Fiber Glass ( glass fiber in epoxy matrix)
• Concrete ( Gravels or steel rods in
cement and sand)
© 2019 McGraw-Hill Education Advanced Composites, May/June 1988, p. 53.
 Types of Materials 5

Electronic Materials
• Not Major by volume but very important.
• Silicon is a common electronic material.
• Its electrical characteristics are modified by adding impurities.

Examples:-
• Silicon, Gallium

Applications :-
• Computer electronics,
Integrated Circuits,
Satellite electronics, etc.
© 2019 McGraw-Hill Education © IMP/Alamy RF
 Competition Among Materials 1

Example:-
The per capita consumption of
all materials is projected to rise
due to increase in population
Materials compete with each
other for existing and new
market In 1970, the average U.S. auto weighed
Over a period of time usage of 1100 kg and consisted of about 79% cast
iron, steel, and other metals, 8% plastics
different materials changes and rubber, and 14% other materials
depending on cost and (composites and ceramics).
performance. For comparison, in 2010, the average
New, lighter, cheaper or better vehicle weight is 1400 kg (due to larger
cars) and consists of about 61% metals,
materials replace the heavier, 22% plastic and rubber, and 20% other
more expensive materials materials.
© 2019 McGraw-Hill Education
 Competition Among Materials 2

Note the rapid rise in production

of cement and polymers Note the average per person use of
different materials in US, western
Europe, and world average

Prediction of future use of

materials in US automobiles

© 2019 McGraw-Hill Education (top) (a) Source: J.P. Birat et al. Revue de Metallurgie 110, 95-129 (2013); (b) Source: Grida.; (bottom) Source: AG Metal Miner, 2013.
 Recent Advances and Future Trends 1

Smart Materials – Shape Memory Alloys

• Have the ability to sense external environmental stimuli
(temperature, stress, light, humidity, and electric and magnetic
fields) and respond to them by changing their properties
(mechanical, electrical, or appearance), structure, or functions.
• Examples:- Shape memory alloys – used in the artery stents.

The stent expands inside the partially clogged artery

to push the plaque aside and allow blood flow
© 2019 McGraw-Hill Education (a) © Czgur/Getty Images; (b) © GJLP, CNRI/Science Source
 Recent Advances and Future Trends 2

Nano materials
• Materials that have a characteristic length scale (particle
diameter, grain size, layer thickness, etc.) that is smaller than
100 nm
• Examples:- Carbon nanotubes, nanoscale graphite (bottom middle
image)

Various nanomaterials with nano scale features or length scales.

© 2019 McGraw-Hill Education Nature.com
 Case Study – Material Selection
Problem: Select suitable material for
bicycle frame and fork.

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