MET REVIEWER

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involves investigating the relationships that
MATERIALS SCIENCE exist between the structures and properties
of materials.
On the basis of these structures-property
correlations, designing or engineering the
MATERIALS ENGINEERING
structure of a material to produce a
predetermined set of properties
PROCESSING, PERFORMANCE, PROPERTIES, STRUCTURE FOUR COMPONENTS OF MATERIAL SCIENCE
material that exhibit electrical and thermal
METALLIC
conductivity
include wood, stone, brick, cement, resins
NON-METALLIC (plastics), rubber, leather, ceramics and so
forth
- normally combinations of one or more
metallic element and often also nonmetallic
elements
- crystalline structure in which the atoms are
METALS
arranged in orderly manner
- relatively strong and ductile at room
temperature and maintain good strength
even at high temperature
steel, cast iron, wrought iron, malleable cast
FERROUS
iron and iron-base metal
copper, tin, zinc, aluminum, magnesium and
NON-FERROUS
titanium
- compounds between the non-metallic and
non-metallic elements chemically bonded
together
- comes from the Greek word "ºµÁ±¼¹ºÌÂ"
(keramikos), "of pottery" or "for pottery",
from "º-Á±¼¿Â"
keramos),( "potter's clay,
tile, pottery"which is said to derive from the
CERAMICS Indo-European word *cheros (unattested),
meaning heat.
- are relatively stiff and strong—stiffnesses
and strengths are comparable to those of
the metals
- exhibited extreme brittleness (lack of
ductility) and are highly susceptible to
fracture
- derived from the Greek words À¿»Í-polymeaning
-
"many"; and ¼-Á¿Âmeros-
meaning "part".
POLYMERS - familiar plastics and rubber materials
- Chemically based on carbon, hydrogen and
another non-metallic element
- Low density and may be extremely flexible
NATURAL POLYMERS Cellulose
synthetic rubber, Bakelite, neoprene, nylon,
SYNTHETIC POLYMERS PVC, polystyrene, polyethylene,
polypropylene, polyacrylonitrile, silicone

- Mixture of two or more materials (metal,

ceramics and polymers)
COMPOSITE - design goal of a composite is to achieve a
combination of properties that is not
displayed by any single material and also to

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incorporate the best characteristics of each
of the component materials
- Solid or liquid material which is able to
conduct electricity at room temperature
more readily than an insulator but less
easily than a metal
SEMICONDUCTOR MATERIALS - Have electrical properties that are
intermediate between the electrical
conductors and insulator
- At low temperatures, pure semiconductors
behave like insulator
- Employed in components into the human
body for replacement of diseased or
BIOMATERIAL damage body parts
- does not produce toxic substances and
must be compatible with body tissues
- materials of which a single unit is sized (in
at least one dimension) less than 100
NANOMATERIAL nanometers
- have unique optical, electronic, or
mechanical properties
- atoms pack in periodic, 3D arrays
CRYSTALLINE MATERIALS - Typical of: -metals, many ceramics, some
polymers
- atoms have no periodic packing
NONCRYSTALLINE MATERIALS
- Occurs of: complex structures, rapid cooling
AMORPHOUS Noncrystalline
- tend to be densely packed.
METALLIC CRYSTALS
- have the simplest crystal structure
- Typically, only one element is
present, so all atomic radii are the
same.
REASONS FOR DENSE PACKING (METALLIC) - Metallic bonding is not directional.
- Nearest neighbor distances tend to
be small in order to lower bond
energy
- Rare due to poor packing (only Po has this
structure)
SIMPLE CUBIC STRUCTURE (SC)
- Close-packed directions are cube edges.
- Coordination Number: 6
- Close packed directions are face diagonals.
FACE CENTERED CUBIC STRUCTURE (FCC) - All atoms are identical;
- Coordination Number: 12
- Close packed directions are cube diagonals.
BODY CENTERED CUBIC STRUCTURE (BCC)
- Coordination Number: 8
HEXAGONA; CLOSE-PACKED STRUCTURE
- ABAB... Stacking Sequence
(HCP)
the same atoms can have more than one
POLYMORPHISM
crystal structure.
- close-packing (metallic bonding)
METALS (DENSITY)
- large atomic mass
- less dense packing (covalent bonding)
CERAMICS (DENSITY)
- often lighter elements
- poor packing (often amorphous)
POLYMERS (DENSITY)
- lighter elements (C,H,O)

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COMPOSITES (DENSITY) have intermediate values
the investigation of the relationship among
MATERIALS SCIENCE processing, structure, properties, and
performance of materials.
denote the physical state of materials that
PHYSICAL PROPERTIES are exclusive of their chemical or
mechanical components
implies the weight of a material, with higher
DENSITY
density rates implying heavier materials
minimum required temperature for a solid
MELTING POINT
material to change into liquid
COLOR reflective property of a material
- minimum required temperature for a liquid
material to change into gas
BOILING POINT
- boiling point of water in standard condition
is 100C or 212F
- Dimension of any metal reflect shape and
size of material, length, width, height, depth
SIZE AND SHAPE etc
- determines specific rectangular, circular,
spherical, or any other section
represents quantity of voids in solid
POROSITY OF MATERIALS
materials
defined as ratio of density of material with
SPECIFIC GRAVITY OF MATERIALS respect to density of reference material or
substance
response to mechanical forces, strength,
MECHANICAL PROPERTIES
etc.
response to electrical and magnetic fields,
ELECTRICAL AND MAGNETIC PROPERTIES
conductivity, etc.
related to transmission of heat and heat
THERMAL PROPERTIES
capacity
includes absorption, transmission and
OPTICAL PROPERTIES
scattering of light
in contact with the environment-corrosion
CHEMICAL STABILITY
resistance
- Adding "impurity" atoms to Cu increases
ELECTRICAL resistivity.
- Deforming Cu increases resistivity
- Space Shuttle Tiles: Silica fiber insulation
offers low heat conduction.
THERMAL
- Thermal Conductivity of Copper: It
decreases when you add zinc!
- Magnetic Storage: Recording medium is
magnetized by recording head.
MAGNETIC - Magnetic Permeability vs. Composition:
Adding 3 atomic % Si makes Fe a better
recording medium!
Transmittance: Aluminum oxide may be
OPTICAL transparent, translucent, or opaque
depending on the material structure.
- Stress & Saltwater: causes cracks!
DETERIORATIVE - Heat treatment: slows crack speed in salt
water!

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These are size-independent measures of
STRESS AND STRAIN
load and displacement, respectively
Stress is defined as the instantaneous load
ENGINEERING STRESS (Ã) divided by the original specimen
cross-sectional area
gradually increasing tensile load is applied
TENSION TEST
uniaxially along the long axis of a specimen
conducted in a manner similar to the tensile
test, except that the force is compressive
COMPRESSION TEST
and the specimen contracts along the
direction of the stress
SHEAR TEST performed using a pure shear force
variation of pure shear in which a structural
TORSION TEST
member is twisted
- transverse beam testing
FLEXURAL BENDING TEST - measures the behavior of materials
subjected to simple beam loading
change in length (in the direction of load
ENGINEERING STRAIN (õ)
application) divided by the original length
The degree to which a structure deforms or
STRESS-STRAIN BEHAVIOR strains depends on the magnitude of an
imposed stress.
- This reversible behavior often shows a
linear relation between stress and strain.
ELASTIC BEHAVIOR
- To minimize deformation, select a material
with a large elastic modulus (E or G).
- the deformation in which stress and strain
are proportional
ELASTIC DEFORMATION - nonpermanent, which means that when the
applied load is released, the piece returns to
its original shape
POISSON'S RATIO (½) ratio of the lateral and axial strains
This permanent deformation behavior
PLASTIC BEHAVIOR occurs when the tensile (or compressive)
uniaxial stress reaches Ã
y.
occur when the stress is removed, the
material does not return to its previous
PLASTIC DEFORMATION
dimension, it is a permanent, irreversible
deformation
region in the strain curve which obeys
hooke's law i.e. within elastic limit the stress
PROPORTIONAL LIMIT
is directly proportional to the strain
produced in the material
point in the graph up to which the material
ELASTIC LIMIT returns to its original position when the load
acting on it is completely removed
point at which the material starts to deform
YIELD POINT OR YIELD STRESS POINT
plastically
the point corresponding to the maximum
ULTIMATE STRESS/TENSILE STRENGTH stress that a material can handle before
failure.
point in the stress strain curve at which the
FRACTURE OR BREAKING POINT
failure of the material takes place

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- property of a solid material which indicates
that how easily a material gets deformed
DUCTILITY under tensile stress
- ability of material to get stretched into a wire
by pulling or drawing
ability of material to absorb the energy when
it is deformed elastically by applying stress
RESILIENCE
and release the energy when stress is
removed
ability of material to absorb the energy and
TOUGHNESS
gets plastically deformed without fracturing
ability of material to resist to permanent
HARDNESS
shape change due to external stress
ability of material to oppose the
SCRATCH HARDNESS scratch to outer surface layer due to
external force
ability of material to oppose the dent
INDENTATION HARDNESS due to punch of external had and
sharp object.
- also called as dynamic hardness
- determined by the height of "bounce"
REBOUND HARDNESS of a diamond tipped hammer
dropped from a fixed height on the
material.
ability of a material to attain the hardness by
HARDENABILITY
heat treatment processing
indicates that how easily it gets fractured
BRITTLENESS
when it is subjected to a force or load
- how easily a material gets deformed under
compressive stress.
MALLEABILITY
- ability of material to be formed in the form of
a thin sheet by hammering or rolling
tendency of material to move slowly and
CREEP deform permanently under the influence of
external mechanical stress
SLIP plane with high density of atoms
weakening of material caused by the
FATIGUE
repeated loading of material
AISI American Iron and Steel Institute
1xxx (AISI DESIGNATION) Carbon Steels
2xxx (AISI DESIGNATION) Nickel Steels
3xxx (AISI DESIGNATION) Nickel-Chromium Steels
4xxx (AISI DESIGNATION) Molybdenum Steels
5xxx (AISI DESIGNATION) Chromium Steels
6xxx (AISI DESIGNATION) Chromium-Vanadium Steels
7xxx (AISI DESIGNATION) Tungsten Steels
8xxx (AISI DESIGNATION) Nickel-Chromium-Vanadium Steels
9xxx (AISI DESIGNATION) Silicon - Manganese Steels
DESIGN UNCERTAINTIES means we do not push the limit

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- Prolonged endurance testing under
the most severe operating
conditions, continued until the
component, equipment, or product
specimen fails (is broken or
destroyed).
DESTRUCTIVE TESTING - Purpose: determine service life and
to detect design weaknesses
- tests are carried out to the
specimen's failure, in order to
understand a specimen's
performance or material behavior
under different loads.
the simplest and
POLDI HARDNESS TEST most economical device for measuring
hardness
measures the depth of
ROCKWELL HARDNESS TEST penetration of an indenter under a large load (major load) com-
pared to the penetration made by a preload (minor load)
hardness scale
ROCKWELL SCALE based on indentation hardness of a
material.
used to determine internal weld quality
BEND TEST
coupons.
(face of the weld is
FACE BEND tested) - places the greatest amount
of stress on the weld face.
(root of the weld is
ROOT BEND tested) - places the greatest amount
of stress on the weld root
(sides of the weld are
SIDE BEND tested) - places the greatest amount
of stress along the weld axis.
used to compare the weldment to the base
TENSILE TEST metal mechanical values and specification
requirements.
the point
ULTIMATE STRENGTH
at which the weld fails under tension
point at which
the weld yields or stretches under
YIELD STRENGTH
tension and will not return to its
original dimensions.
amount of stretch
ELONGATION
that occurs during the tensile test
- method used to quantify a material's ability
to withstand an impact with a flaw present in
the material.
- measures the amount of energy a material
NOTCH TOUGHNESS TEST
can absorb.
- define the ability of welds to resist cracking
or crack propagation at low temperatures
under loads.
- determine the internal quality of a weld with
regard to porosity, lack of fusion, and slag.
NICK-BREAK TEST - A SECTION OF THE WELD TO BE
TESTED IS REMOVED FROM THE WELD
AND PREPARED

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- process of doing inspections, testing, or
evaluating materials, components or
assemblies for defects without destroying
the material or component.
NON-DESTRUCTIVE TESTING - use of noninvasive techniques to determine
the integrity of a material, component or
structure".
- "Inspect or measure without doing
harm."
- visual observation of the surface to evaluate
the presence of surface discontinuities such
as corrosion, misalignments, cracks etc.
- most commonly used test method in
VISUAL TESTING (VT) industry
- may be by direct looking, or may be by use
of optical instruments such as magnifying
glasses, mirrors, borescopes, and remote
viewing
- uses a liquid with high surface wetting
characteristics is applied to the surface and
allowed to seep into defects and then
LIQUID PENETRANT TESTING (PT) excess liquid is removed.
- the penetrant used is often loaded with a
fluorescent dye and the inspection is done
under UV light to increase test sensitivity
- detects anomalies in normal flux patterns
created by discontinuities in ferrous material
saturated by a magnetic field.
- can be used for piping and tubing
MAGNETIC FLUX LEAKAGE (MFL) OR
inspection, tank floor inspection and other
MAGNETIC PARTICLE INSPECTION
applications.
- can be done without removing the
insulation, resulting in a fast, economic way
to inspect long runs of pipe or tubing.
radiation used in radiography testing is a
higher energy (shorter wavelength) version
RADIOGRAPHY
of the electromagnetic waves that we see
as visible light
The part is placed between the radiation
FILM RADIOGRAPHY
source and a piece of film.
- High frequency sound waves are introduced
into a material and they are reflected back
from surfaces or flaws.
ULTRASONIC INSPECTION
- Reflected sound energy is displayed versus
(PULSE-ECHO)
time, and inspector can visualize a cross
section of the specimen showing the depth
of features that reflect sound.
High resolution images can be produced by
ULTRASONIC IMAGING plotting signal strength or time-of-flight using
a computer-controlled scanning system.
particularly well suited for detecting surface
cracks but can also be used to make electrical conductivity and
EDDY CURRENT TESTING
coating thickness
measurements
- subject a vessel, tank, piping, or tubing to
internal pressure.
PRESSURE TEST - HYDROSTATIC TEST - If a fluid is used
- During the test, the part will expand. This
expansion should not be restricted with
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tools, or undue stresses will build within the
part.
- determines the amount of magnetic ferrite in
an austenitic (nonmagnetic) weld.
FERRITE TEST
- Insufficient ferrite in a weld made under high
restraint is prone to cracking at red heat.
- Inspection of Raw Products
COMMON APPLICATION OF
- Inspection Following Secondary Processing
NON-DESTRUCTIVE TESTING
- In-Services Damage Inspection
- Forgings,
INSPECTION OF RAW PRODUCTS - Castings,
- Extrusions
- Machining
- Welding
INSPECTION FOLLOWING SECONDARY
- Grinding
PROCESSING
- Heat treating
- Plating
- Cracking
- Corrosion
INSPECTION FOR IN-SERVICE DAMAGE - Erosion/Wear
- Heat
- Damage
Periodically, power plants are shut down for
POWER PLANT INSPECTION
inspection
Electromagnetic devices and visual
inspections are used to find broken wires
WIRE ROPE INSPECTION and other damage to the wire rope that is
used in chairlifts, cranes and other lifting
devices
- Robotic crawlers use ultrasound to inspect
the walls of large above ground tanks for
signs of thinning due to corrosion.
STORAGE TANK INSPECTION
- Cameras on long articulating arms are
used to inspect underground storage tanks
for damage.
- Nondestructive testing is used extensively
during the manufacturing of aircraft.
AIRCRAFT INSPECTION - NDT is also used to find cracks and
corrosion damage during operation of the
aircraft
- Aircraft engines are overhauled after being
in service for a period.
JET ENGINE INSPECTION
- They are completely disassembled,
cleaned, inspected and then reassembled
- The failure of a pressure vessel can result in
the rapid release of a large amount of
energy.
PRESSURE VESSEL INSPECTION
- To protect against this dangerous event, the
tanks are inspected using radiography and
ultrasonic testing
Special cars are used to inspect thousands
RAIL INSPECTION of miles of rail to find cracks that could lead
to a derailment

- Bridges get a visual inspection about every

BRIDGE INSPECTION 2 years.
- Some bridges are fitted with acoustic

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emission sensors that "listen" for sounds of
cracks growing.
- NDT is used to inspect pipelines to prevent
leaks that could damage the environment.
- Visual inspection, radiography and
electromagnetic testing are some of the
NDT methods used.

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