Introduction to Materials Science

& Engineering
Course Objective...
Introduce fundamental concepts in Materials
Science & Engineering
You will learn about:
• material structures
• how structure dictates properties
• how processing can change structure
This course will help you to:
• use materials properly
• realize new design opportunities
with materials

Chapter 1 - 1
 COURSE MATERIALS
Required text:
• Materials Science and Engineering: An Introduction,
W.D. Callister, Jr. and D.G. Rethwisch, 8th edition, John Wiley
and Sons, Inc. (2010).

Moodle:
• Syllabus
• PowerPoint lectures

Chapter 1 - 2
 Chapter 1 - Introduction
• What is materials science?
• Why should we know about it?

• Materials drive our society

– Stone Age (2.5 million BC)
– Bronze Age (3500 BC)
– Iron Age (1000 BC)
– Now?
• Silicon Age?
• Polymer Age?

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Chapter 1 - 9
(short for reinforcing bar)

Chapter 1 - 10
 Types of Materials
• Metals (and metal alloys):
• Examples …
• Made of …
• General properties …

• Polymers/plastics:
• Examples …
• Made of …
• General properties …

• Ceramics:
• Examples …
• Made of …
• General properties …

• Composites
• Semiconductors
• Biomaterials Chapter 1 - 11
 Types of Materials
• Metals (and metal alloys):
– Strong, ductile
– High thermal & electrical conductivity
– Opaque, reflective.

• Polymers/plastics: Covalent bonding à sharing of e’s

– Soft, low strength, low density
– Thermal & electrical insulators
– Optically translucent or transparent.
• Ceramics: ionic bonding – compounds of metallic & non-
metallic elements (oxides, carbides, nitrides, sulfides)
– Brittle, glassy, refractory
– Non-conducting (insulators)
• Composites
• Semiconductors
• Biomaterials Chapter 1 - 12
Chapter 1 - 13
Familiar objects that are made of metals and metal alloys
Common objects that are made of ceramic
materials

common objects that are made of polymeric materials

Chapter 1 - 14
 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. Material Identify required Processing

Processing changes structure and overall shape.
ex: casting, sintering, vapor deposition, doping
forming, joining, annealing.

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 Example – Hip Implant
• With age or certain illnesses joints deteriorate.
Particularly those with large loads (such as hip).

Adapted from Fig. 22.25, Callister 7e. Chapter 1 - 19

 Example – Hip Implant

• Requirements
– mechanical
strength (many
cycles)
– good lubricity
– biocompatibility

Adapted from Fig. 22.24, Callister 7e.

Chapter 1 - 20
Example – Hip Implant

Adapted from Fig. 22.26, Callister 7e. Chapter 1 - 21

 Hip Implant
• Key problems to overcome
– fixation agent to hold Ball
acetabular cup
– cup lubrication material
– femoral stem – fixing agent
Acetabular
– must avoid any debris in cup Cup and Liner

Femoral
Stem
Adapted from chapter-opening photograph,
Chapter 22, Callister 7e.

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Property-Definition:
A material’s reaction to an externally
imposed stimulus. It is independent of
material shape and size.

Six different categories: Mechanical,

electrical, thermal, magnetic, optical and
deteriorative (Chemical reactivity of
materials).

The structure of a material will depend on how it is processed. And a

materials performance will be a function of its properties.
=> Processing → Structure → Properties → Performance

Chapter 1 - 25
 Example – Develop New Types of
Polymers
• Commodity plastics – large volume ca. $0.50 / lb
Ex. Polyethylene
Polypropylene
Polystyrene
etc.

• Engineering Resins – small volume > $1.00 / lb

Ex. Polycarbonate
Nylon
Polysulfone
etc.

Can polypropylene be “upgraded” to properties (and price) near

those of engineering resins?

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 Structure, Processing, & Properties
• Properties depend on structure
ex: hardness vs structure of steel

(d)
600
Hardness (BHN)

30 µm
500 (c)
Data obtained from Figs. 10.30(a)
400 (b) and 10.32 with 4 wt% C composition,
(a) and from Fig. 11.14 and associated
4 µm discussion, Callister & Rethwisch 8e.
300 Micrographs adapted from (a) Fig.
10.19; (b) Fig. 9.30;(c) Fig. 10.33;
30 µm and (d) Fig. 10.21, Callister &
200 30 µm
Rethwisch 8e.

100
a) a ferrite with cementite
0.01 0.1 1 10 100 1000 c) Tempered martensite
Cooling Rate (ºC/s) d) martensitic microstructure

• Processing can change structure

ex: structure vs cooling rate of steel
Chapter 1 - 32
 ELECTRICAL
• Electrical Resistivity of Copper:
6 Adapted from Fig. 18.8, Callister &
N i
at% Rethwisch 8e. (Fig. 18.8 adapted
5 3.3 2 from: J.O. Linde, Ann Physik 5, 219
+ (1932); and C.A. Wert and R.M.
Cu Ni
Resistivity, r

Thomson, Physics of Solids, 2nd

4 a t% i
(10-8 Ohm-m)

.1 6 %N edition, McGraw-Hill Company, New

u +2 1 2 at York, 1970.)

3
C
u + 1.
m e dC
defo
r
t % Ni
2 1 .12 a
+
Cu
1 e ” Cu
r
“P u
0
-200 -100 0 T (ºC)
• Adding “impurity” atoms to Cu increases resistivity.
• Deforming Cu increases resistivity.
Chapter 1 - 33
 THERMAL
• Space Shuttle Tiles: • Thermal Conductivity
-- Silica fiber insulation of Copper:
offers low heat conduction. -- It decreases when
Adapted from chapter- you add zinc!
opening photograph,
Chapter 17, Callister &
400

Thermal Conductivity
Rethwisch 3e. (Courtesy
of Lockheed
Missiles and Space
Company, Inc.) 300

(W/m-K)
200

100
0
0 10 20 30 40
Composition (wt% Zinc)
Adapted from Adapted from Fig. 19.4, Callister & Rethwisch
Fig. 19.4W, Callister 8e. (Fig. 19.4 is adapted from Metals Handbook:
6e. (Courtesy of Properties and Selection: Nonferrous alloys and
Lockheed Aerospace Pure Metals, Vol. 2, 9th ed., H. Baker,
Ceramics Systems, (Managing Editor), American Society for Metals,
Sunnyvale, CA) 1979, p. 315.)
(Note: "W" denotes fig.
100 µm is on CD-ROM.) Chapter 1 - 34
 MAGNETIC
• Magnetic Storage: • Magnetic Permeability
-- Recording medium vs. Composition:
is magnetized by -- Adding 3 atomic % Si
recording head. makes Fe a better
recording medium!

Magnetization
Fe+3%Si

Fe

Magnetic Field
Adapted from C.R. Barrett, W.D. Nix, and
Fig. 20.23, Callister & Rethwisch 8e. A.S. Tetelman, The Principles of
Engineering Materials, Fig. 1-7(a), p. 9,
1973. Electronically reproduced
by permission of Pearson Education, Inc.,
Upper Saddle River, New Jersey.

Chapter 1 - 35
 OPTICAL
• Transmittance:
-- Aluminum oxide may be transparent, translucent, or
opaque depending on the material’s structure (i.e.,
single crystal vs. polycrystal, and degree of porosity).
polycrystal: polycrystal:
single crystal no porosity some porosity

Adapted from Fig. 1.2,

Callister & Rethwisch 4e.
(Specimen preparation,
P.A. Lessing; photo by S.
Tanner.)

Chapter 1 - 36
 DETERIORATIVE
• Stress & Saltwater... • Heat treatment: slows
-- causes cracks! crack speed in salt water!

10 -8 “as-is”
“held at

crack speed (m/s)

160ºC for 1 hr
before testing”
10 -10 Alloy 7178 tested in
saturated aqueous NaCl
solution at 23ºC

increasing load

Adapted from chapter-opening photograph, Adapted from Fig. 11.20(b), R.W. Hertzberg, "Deformation and
Chapter 16, Callister & Rethwisch 3e. Fracture Mechanics of Engineering Materials" (4th ed.), p. 505, John
(from Marine Corrosion, Causes, and Wiley and Sons, 1996. (Original source: Markus O. Speidel, Brown
Prevention, John Wiley and Sons, Inc., 1975.) Boveri Co.)

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 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.

Chapter 1 - 41
 Further Reading

Materials Science and Engineering: an Introduction", by

W. D. Callister - Chapter 1

Chapter 1 - 42