Masters of Engineering

(Mechanical Engineering)

MME501: Materials for Engineers

Tutorial

Topic 1
Introduction

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Topics
1. Introduction to materials engineering
2. Materials universe
3. Evolution of materials
4. Classification of materials: metals, ceramics and polymers.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Introduction to Materials Engineering

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Quiz 1
Deteriorative characteristics of a material is mainly related to its chemical
reactivity.

a) True
b) False

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Quiz 1
Deteriorative characteristics of a material is related to its chemical reactivity.

a) True
b) False

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Introduction to Materials Engineering
Case Study 1 – Liberty ship failure
• The following case study illustrates one role that materials scientists and
engineers are called upon to assume in the area of materials
performance:
– analyse mechanical failures
– determine their causes
– propose appropriate measures to guard against future incidents.
• The example shown is that of Liberty cargo ships that were mass-
produced by the United States to supply food and materials to the
combatants in Europe, during World war II.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Introduction to Materials Engineering

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Introduction to Materials Engineering
Case Study 1 – Liberty ship failure cont.
• The failure of many of the World War II Liberty ships is a well-known and
dramatic example of the brittle fracture of steel that was thought to be
ductile.
• Some of the early ships experienced structural damage when cracks
developed in their decks and hulls.
• Three of them catastrophically split in half when cracks formed, grew to
critical lengths, and then rapidly propagated completely around the ships’
girths.
• Following figure shows one of the ships that fractured the day after it was
launched.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Introduction to Materials Engineering
Case Study 1 – Liberty ship failure cont.
• Subsequent investigations concluded one or more of the following factors
contributed to each failure:
• When some normally ductile metal alloys are cooled to relatively low
temperatures, they become susceptible to brittle fracture—that is, they
experience a ductile-to-brittle transition upon cooling through a critical
range of temperatures.
• These Liberty ships were constructed of steel that experienced a ductile-
to-brittle transition.
• Some of them were deployed to the frigid North Atlantic, where the once
ductile metal experienced brittle fracture when temperatures dropped to
below the transition temperature.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Introduction to Materials Engineering
✓ The corner of each hatch (i.e. door) was square; these corners acted as
points of stress concentration where cracks can form.
✓ German U-boats were sinking cargo ships faster than they could be
replaced using existing construction techniques.
✓ Consequently, it became necessary to revolutionise construction
methods to build cargo ships faster and in greater numbers.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Introduction to Materials Engineering
✓ This was accomplished using prefabricated steel sheets that were
assembled by welding rather than by the traditional time-consuming
riveting.
✓ Unfortunately, cracks in welded structures may propagate unimpeded for
large distances, which can lead to catastrophic failure.
✓ However, when structures are riveted, a crack ceases to propagate once it
reaches the edge of a steel sheet.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Introduction to Materials Engineering
• Weld defects and discontinuities (i.e. sites where cracks can form) were
introduced by inexperienced operators.
• Remedial measures taken to correct these problems included the
following:
✓ Lowering the ductile-to-brittle temperature of the steel to an acceptable
level by improving steel quality (e.g. reducing sulfur and phosphorus
impurity contents).
✓ Rounding off hatch corners by welding a curved reinforcement strip on
each corner.
✓ Installing crack-arresting devices such as riveted straps and strong weld
seams to stop propagating cracks.
✓ Improving welding practices and establishing welding codes.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Introduction to Materials Engineering
• In spite of these failures, the Liberty ship program was considered a
success for several reasons, the primary reason being that ships that
survived failure were able to supply Allied Forces in the theater of
operations and in all likelihood shortened the war.
• In addition, structural steels were developed with vastly improved
resistances to catastrophic brittle fractures.
• Detailed analyses of these failures advanced the understanding of crack
formation and growth, which ultimately evolved into the discipline of
fracture mechanics.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Introduction to Materials Engineering
Case Study 1 – Liberty ship failure cont.
“An important thing to note is that the corners of windows and doors
for all of today’s marine and aircraft structures are rounded”.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Evolution of Materials

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Quiz 2
Which of these statements regarding carbon fiber–reinforced polymer
(CFRP) composite is true?

a) Contain carbon fibers embedded within a polymer

b) Stiffer and stronger than glass fiber–reinforced materials
c) Used in aircraft and aerospace applications
d) All of the above

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Quiz 2
Which of these statements regarding carbon fiber–reinforced polymer
(CFRP) composite is true?

a) Contain carbon fibers embedded within a polymer

b) Stiffer and stronger than glass fiber–reinforced materials
c) Used in aircraft and aerospace applications
d) All of the above

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Evolution of Materials
Evolution of materials in the car industry:
• The introduction of new materials into automotive manufacturing has
often been dictated by how fast such materials can be processed in the
production line.
• Right from the first cars until the present, steel has been the preferred
option for structural components requiring high strength.
• But, with the need to produce lighter cars being driven by the CO2
emission regulations imposed for new car builds, this is likely to change.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Evolution of Materials
• The first commercialised car was designed in 1885 by Karl Benz.
• The tubing was made of steel and a driver compartment was created
using panels of wood (although there was no bodywork as we now
understand it).
• The car was powered by a 0.75 hp petrol engine connected to three steel
wheels and solid rubber tyres.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Evolution of Materials
• Benz was also responsible for the first production car (1200 units) in 1894
and a new generation of commercialised cars was born.
• Crucially, the process of varnishing wooden bodywork to make it
sufficiently resilient was both time-consuming and expensive.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Evolution of Materials
• In 1912, Budd, a US metal and die-stamping company, fabricated the first
all-steel car which quickly resulted in an order for 70,000 cars from Dodge
Brothers.
• These cars were less expensive to manufacture, required considerably
less production time and were stronger than the wood/steel
combination.
• And the introduction of the integrated moving production line by Henry
Ford in 1913 meant that cars could be produced in far greater volume
than previously.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Evolution of Materials
• The first experiments with light weight materials were made during the
First World War when cast aluminum was introduced by the American
automobile manufacturer Marmon and was widely used for building
aircraft.
• From the beginning, motorsport was an important vehicle for
popularizing innovations and showcasing the performance capabilities of
automobiles.
• Indeed, fiberglass composites were first used on Bill Tritt’s Lancer sports
car in 1951.
• Shortly afterwards, Lotus developed its first dedicated production car, the
Elite, in 1959 which featured both lightweight fiberglass body and
structure and weighed only 773 kg.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Evolution of Materials
The Lotus Elite featured a lightweight fiberglass body and structure

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Evolution of Materials
• The Stout Scarab was the first “minivan” made with fiberglass panels.
• However, its production volume was always intended to be low, and it
was far too expensive to be accessible to the general public.
• In today’s high-mass production, conventional steel alloys have partly
been replaced by high strength steel which makes steel still a leader in
the construction of car bodies.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Evolution of Materials
• However, since the oil crisis of the 1970s, followed by the global pressure
on fossil fuel resources, manufacturers have been increasingly aware of
the need to build lighter vehicles in order to enjoy better fuel efficiency.
• The use of aluminum alloy started to become more widespread but, in
most cases, it costs more than steel.
• OEMs searching for cheaper alternatives realised plastics have a
significant role to play in relation to sacrificial parts, such as bumpers,
rather than metal.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Evolution of Materials
• Even though the correlation of lightweight components with better fuel
efficiency has been understood for decades, the development of new
electronics, safety features and entertainment requirements has meant
that overall the reduction of weight from new materials has been more
than countered by the addition of more technology.
• This therefore implies that more effort will have to be expended in order
to make the weight savings required, while still meeting safety and
environmental regulations as well as consumer expectations.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Evolution of Materials
• Taking a concrete example of car mass, Ford’s Model T, launched in 1908,
weighed 544-680 kg for 3.4m length and 1.68 m width.
• Today, a similar size car such as the Ford KA, weighs 870 kg for 3.6 m
length and 1.6 5 m width.
• Nevertheless, with environmental studies showing a correlation between
lower weight vehicles and lower CO2 emissions, there is considerable
impetus to pursue the lightweighting trend.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Evolution of Materials
• Today, to counteract the problems associated with finding a material
lighter than steel but really strong for body parts, carbon fiber composites
might seem to be the obvious choice.
• Ten times stronger than steel and eight times stronger than aluminum, it
is much lighter than both metals.
• In 2013, BMW launched the i series which is its first production electric
car with a body made of carbon fibre composite.
• The Korean automotive manufacturer, Hyundai, also presented a concept
car in 2014 at the Geneva Motor Show; the Intrado, a hydrogen fuel cell
car with a carbon fibre body.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Evolution of Materials
The electric BMW i3 is manufactured from carbon fiber composite

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Evolution of Materials
• The principle of carbon fibre composites seems to be accepted.
• But, in order to see carbon fibre in everyone’s cars tomorrow, effort
needs to be made to reduce its cost.
• R&D companies and universities are working on this challenge and are
also trying to solve the issue of recycling.
• Carbon fibre composite life cycle analysis suggests that without recycling,
this material won’t be a green alternative.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Evolution of Materials
• Also, the size of the vehicle can have a greater impact on the materials
selected for manufacturing.
• Bigger vehicles such as aero planes and buses where the power to weight
ratio is crucial, is an area where advanced lightweight materials will play a
key role.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Classification of Materials: Metals, Ceramics
and Polymers

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Quiz 3
Which of these is not a characteristic of polymers?

a) Highly ductile
b) Lightweight with low densities
c) Highly reactive to corrosive environments
d) Low melting point

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Quiz 3
Which of these is not a characteristic of polymers?

a) Highly ductile
b) Lightweight with low densities
c) Highly reactive to corrosive environments
d) Low melting point

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Classification of Materials: Metals, Ceramics and Polymers
SMC
Sheet molding
Compound:
Polyester resin and
chopped glass

Polyester resin and glass

mat preform
with RTM resin transfer
molding

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Classification of Materials: Metals, Ceramics and Polymers

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Classification of Materials: Metals, Ceramics and Polymers
Case Study 2: Automotive Ceramic Coating Application on Jeep Cherokee:
• Tracy Hall and her husband John are owners of a boat yard in Pompano,
FL.
• They got a Glidecoat ceramic coating application carried out on a 2017
Robalo in July 2018.
• Satisfied with the results, they wanted to get their 2016 Black Jeep Grand
Cherokee SRT coated with Glidecoat's automotive ceramic coating.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Classification of Materials: Metals, Ceramics and Polymers
• Living near the ocean, the salt in the air takes its toll on everything,
especially the paint on your car.
• The major problem with owning a black vehicle is that it shows every
little imperfection and spec of dirt.
• Because Tracy is always around the water, her vehicle suffered from water
marks and salt deposits on the surface, which were very visible on the
black paint.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Classification of Materials: Metals, Ceramics and Polymers
Vehicle covered with dirt, salt, and water marks

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Classification of Materials: Metals, Ceramics and Polymers
Visible water marks on the surface of the driver side door

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Classification of Materials: Metals, Ceramics and Polymers
Rims are the toughest area of a vehicle to keep clean, as they are constantly covered in dirt
and brake dust

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Classification of Materials: Metals, Ceramics and Polymers
• The first step in the Glidecoat ceramic coating application was to wash
the entire vehicle to remove all dirt, salt and break dust from the surface
and rims.
• Once the vehicle was clean, the next step was to polish the paint to
remove the light surface scratches and water marks.
• This step restores a deep shine to the paint, preparing the surface to be
protected and enhanced with Glidecoat's ceramic coating.
• Immediately before applying the ceramic coating, the paint was sterilised
with surface wipe.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Classification of Materials: Metals, Ceramics and Polymers
• The final step of the application process is applying two coats of
Glidecoat's ceramic coating.
• Once the coating is applied on the surface, microfiber towels are used to
buff the coating into the pores of the paint, while removing any excess
coating.
• This is repeated across the entire vehicle, again applying two coats to
ensure the best possible results and that showroom shine!

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Classification of Materials: Metals, Ceramics and Polymers

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Classification of Materials: Metals, Ceramics and Polymers
Case Study: Outcome:

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Classification of Materials: Metals, Ceramics and Polymers
• The gloss and shine of the paint can be seen.
• The jeep is now properly protected from the elements and making the
vehicle super easy to clean.
• Glidecoat's Automotive Ceramic Coating fills in the pores of the paint,
bonding directly with the surface and creating a hard barrier.
• This prevents UV damage and doesn't allow dirt, salt or other
contaminants to penetrate the surface.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Classification of Materials: Metals, Ceramics and Polymers
The coating is great for rims, helping keep them clean and shinny while making it easy to keep
them clean

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
References
• W. D. Callister, D. G. Rethwisch, Materials Science and Engineering
• https://www.oxfordsurfaces.com/resource/evolution-of-materials-in-the-
car-industry/
• https://www.glidecoat.com/case-study/automotive-ceramic-coating-
application/
• https://www.csuchico.edu/~jpgreene/itec104/m104_ch01-
02/m104_ch01-02.ppt

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
 End of Topic 1
Any questions or comments?

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971