Materials Science

Dr. K.E.D. Sumanasiri

1
Textbooks:
Callister W.D. Materials Science and Engineering, An
Introduction, John Wiley & sons (e-book posted in LMS)

Jones D.R.H., Michael F.A. Engineering Materials 1; An

Introduction to properties, Applications and design,
Butterworth - Heinemann Publishers

What is materials science?

Why should we know about it?
2
A Brief Introduction to
Materials Science and Engineering

3
Why the Study of Materials is Important?

• Production and processing of materials

constitute a large part of our economy.
• Engineers choose materials to suite
design.
• New materials might be needed for some
new applications.
• Modification of properties might be
needed for some applications.

4 of Mat. Sci. and Eng. W.Smith,

Foundations
ChapterJ.1- Hashemi, McGraw Hill
1-3 http://highered.mcgraw-hill.com/
 History of Materials Science & Engineering
• materials closely connected our culture
• the development and advancement of societies are dependent on the available
materials and their use
• early civilizations designated by level of materials development

• initially natural materials

• develop techniques to produce materials with superior qualities (heat treatments
and addition of other substances)

MATERIALS SELECTION!
5
 Materials Science and Engineering

structure • arrangement of internal components

• subatomic
• atomic
• microscopic
• macroscopic (bulk)

characterization
processing properties
• material characteristic
• method of preparing
• response to external
material
stimulus
• mechanical, electrical,
performance thermal, magnetic,
• behavior in a optical, deteriorative
particular application

6
 The world of materials – Year 2000

Steels
Cast irons
Al-alloys

Metals
Cu-alloys
Ni-alloys
Ti-alloys
PE, PP, PC
Alumina PA (Nylon)
Si-Carbide
Polymers,
Ceramics,
GFRP elastomers
glasses CFRP Butyl rubber
Soda-glass Neoprene
Pyrex Composites
KFRP
Plywood

Polymer foams Woods

Metal foams
Natural
Foams materials
Ceramic foams
Natural fibres:
Glass foams Hemp, Flax,
Cotton

Unit 1, Frame 1.4 © 2002, M.F. Ashby and D. Cebon

Classification of Materials

Metals Ceramics & Glasses Polymers

• good conductors of • thermally and • very large molecules
electricity and heat electrically insulating • low density, low weight
• lustrous appearance • resistant to high • maybe extremely
• susceptible to temperatures and flexible
corrosion harsh environments
• strong, but • hard, but brittle
deformable

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Classification of Materials: A Few Additional Catagories

Biomaterials Semiconductors Composites

• implanted in human • electrical properties • consist of more than
body between conductors one material type
• compatible with and insulators • designed to display
body tissues • electrical properties a combination of
can be precisely properties of each
controlled component

Intel Pentium 4 fiberglass surfboards

hip replacement

9
Why study materials?
• applied scientists or engineers must make material choices
• materials selection
– in-service performance
– deterioration
– economics

BUT…really, everyone makes material choices!

aluminum glass plastic

10
 Types of Materials
• Metals:
– Strong, ductile
– High thermal & electrical conductivity
– Opaque, reflective.

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

– Soft, ductile, low strength, low density
– Thermal & electrical insulators
– Optically translucent or transparent.

• Ceramics: ionic bonding (refractory) – compounds of metallic &

non-metallic elements (oxides, carbides, nitrides, sulfides)
– Brittle, glassy, elastic
– Non-conducting (insulators)

11
Chapter 1-
 structure

processing properties

performance

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Levels of Structure
structure

Sub-atomic, atomic, microscopic, bulk

processing properties

performance

STRUCTURE (length scale)

Sub-atomic
< 0.2 nm

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Metals

Metallic Bond + + + + “sea of electrons”

• one, two, or three valence electrons
• valence electrons free to drift through the + + + +
entire material forming a “sea of electrons”
surrounding net positive ionic cores + + + + ionic
• non-directional bond + + + +
cores

Properties
• good conductors of
electricity and heat
• lustrous appearance
• susceptible to
corrosion
• strong, but
deformable

14
Ceramics and Glasses
Coulombic bonding force
Ionic Bond
• composed of metallic and non-metallic elements + +
• metallic elements give up valence electrons to
+ +
non-metallic elements
• all atoms have filled “inert gas” configuration + +
• ionic solid
• non-directional bond + +

Ceramics & Glasses

• thermally and
electrically insulating
• resistant to high
temperatures and
harsh environments
• hard, but brittle

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Polymers
shared electron H
Covalent Bond shared electron
from hydrogen
• electrons are shared between adjacent from carbon
atoms, each contributing at least one
electron H C H
• shared electrons belong to both atoms
• directional bond

H methane (CH4)

Polymers
• very large molecules
• low density, light
weight materials
• maybe extremely
flexible

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Levels of Structure
structure

processing properties

performance

STRUCTURE (length scale)

Sub-atomic Atomic
< 0.2 nm 0.2-10 nm
1 nm = ?

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Atomic Arrangement: Ordered vs. Disordered
Crystalline:
atoms are arranged in a 3D, periodic array giving the material “long range order”

• stacking can effect

properties (i.e.
ductility)
• anisotropic materials

hexagonal close-packed

Non-crystalline or amorphous:
atoms only have short-range, nearest neighbor order
• viscous materials (generally complex formulas) or rapid
cooling
• isotropic materials

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Levels of Structure
structure

processing properties

performance

STRUCTURE (length scale)

Sub-atomic Atomic Microscopic

< 0.2 nm 0.2-10 nm 1-1000 mm
1 nm = ?

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Microstructure

Single Crystal Polycrystalline

• the periodic arrangement of • many small crystals or grains
atoms extends throughout the • small crystals misoriented with
entire sample respect to on another
• difficult to grow, environment must • several crystals are initiated and
be tightly controlled grow towards each other
• anisotropic materials • anisotropic or isotropic materials

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Levels of Structure
structure

processing properties

performance

STRUCTURE (length scale)

Sub-atomic Atomic Microscopic Bulk

< 0.2 nm 0.2-10 nm 1-1000 mm > 1 mm
1 nm = ?

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Bulk Properties
Mechanical: Electrical:
elastic modulus conductivity
shear modulus resistivity
hardness capacitance

+ -

Thermal:
Optical: thermal expansion
reflectivity heat capacity
absorbance thermal conductivity
emission

22
Processing Structure Properties Performance
Performance Goal: increased strength from a metallic material

In actuality, crystals are NOT perfect. There are defects!

In metals, strength is determined by how easily defects can move!

OFF

slow cooling

quenching

23
Processing Structure Properties Performance

Aluminum Oxide (Al2O3)

single-crystal polycrystalline, polycrystalline,

(transparent) fully dense 5% porosity
(translucent) (opaque)

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Characterization Techniques
structure

characterization
processing properties

performance

STRUCTURE (length scale)

Sub-atomic Atomic Microscopic Bulk

< 0.2 nm 0.2-10 nm 1-1000 mm > 1 mm
1 nm = ?

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Optical Microscopy
• light is used to study the microstructure
• opaque materials use reflected light,
where as transparent materials can use
reflected or transmitted light

26
 Electron Microscopy
• beams of electrons are used for imaging
• electrons are accelerated across large voltages
• a high velocity electron has a wavelength of about 0.003 nm
• the electron beam is focused and images are formed using magnetic lenses
• reflection and transmission imaging are both possible

Scanning Electron Microscopy (SEM) Transmission Electron Microscopy (TEM)

• an electron beam scans the surface and • an electron beam passes through the
the reflected (backscattered) electrons material
are collected • thin samples
• sample must be electrically conductive • details of internal microstructure
• material surface is observed observed
• 200,000x magnification possible • 1,000,000x magnification possible

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Scanning Probe Microscopy (SPM)
• 3D topographical map of material
surface
• probe brought into close proximity of
material surface
• probe rastered across the surface
experiencing deflection in response to
interactions with the material surface
• useful with many different types of
Animation of SPM on epitaxial silicon.
materials

SPM image of 70 nm photoresist lines.

SPM image of a butterfly wing. SPM image of silica coated
gold nanoparticles.

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 X-ray Diffraction
• x-rays are a form of light that has high
energy and short wavelength
• when x-rays strike a material a portion of
them are scattered in all directions
• if the atoms in the material is crystalline
or well-ordered constructive interference
can order

Bragg’s Law: 2d sin q = nl

Intensity

Diffraction angle 2q

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 Material Properties

• Mechanical
– E.g. Modulus of elasticity, strength
• Electrical
– Electrical conductivity, dielectric constant
• Thermal
– Thermal expansion, thermal conductivity, heat capacity
• Magnetic
– Flux density, susceptibility
• Optical
– Index of refraction, reflectivity
• Chemical (deteriorative)
– Oxidation, corrosion
• Physical Properties
– Density,
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 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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 ELECTRICAL PROPERTIES
• Electrical Resistivity of Copper:
6 Adapted from Fig. 18.8, Callister 7e.
(Fig. 18.8 adapted from: J.O. Linde,
5 Ann Physik 5, 219 (1932); and
C.A. Wert and R.M. Thomson,
Physics of Solids, 2nd edition,
Resistivity, r

4 McGraw-Hill Company, New York,

(10-8 Ohm-m)

1970.)

3
2
1
0
-200 -100 0 T (°C)
• Adding “impurity” atoms to Cu increases resistivity.
• Deforming Cu increases resistivity.
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33
 Types of Materials
❑Metals:
Metallic bonding;
Cu, Al, Ni, Fe, Au, bronze (Cu-Sn), steel (Fe-C) etc.
They are groupped as ferrous (steels) and non-ferrous (copper, magnesium,
titanium and so on) metals
Properties: strong, ductile, high density, good conductors of heat and
electricity (free valance electrons)

Jet engine containing

mainly titanium
alloys

Copper electric wires Aluminum cup

Drawback:
Corrosion of
some metals,
Car body panel: low carbon steel i.e. Steel,iron
Engine composed of steel and cast iron
parts 34
Chapter 1-
• Metals
– Pure metals
• Iron [Fe]
• Copper [Cu]
• Aluminium [Al]
– Alloys
• Steel [Fe+C]
• Brass [Cu+Zn]
• Bronze [Cu+Sn]
• Duralumin [Al+Cu]
• Stainless steel [Fe+C+Cr+Ni],
• Cast iron [Fe+C]
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 Types of Materials
• Polymeric (Plastic) Materials
➢ Organic giant molecules and mostly noncrystalline.
➢ Some are mixtures of crystalline and noncrystalline
regions.
➢ Poor conductors of electricity and hence used as
insulators.
➢ Strength and ductility vary greatly.
➢ Low densities and decomposition temperatures.

➢ Examples :- Poly vinyl Chloride (PVC),

Polyester, PTFE, Nylon
➢ Applications :- Appliances, DVDs, Fabrics etc.

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1-6
❑Polymers:

Organic compounds based on C, H and other nonmetallic elements.

Large molecular structures
(e.g. Epoxy, Nylon, PVC, Polystyrene, Plastics and rubber)
Properties: weak, low density, ductile, extremely flexible,insulators.

Natural Polymers Synthetic Polymers

Rubber, cotton, wool, leather, PP, PS, PVC, PE
silk

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Chapter 1-
Recyclable plastics

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 Types of Materials

• Ceramic Materials
➢ Metallic and nonmetallic elements are chemically bonded
together.
➢ Inorganic but can be either crystalline, noncrystalline or
mixture of both.
➢ High hardness, strength and wear resistance.
➢ Very good insulator. Hence used for furnace lining for heat
treating and melting metals.
➢ Also used in space shuttle to insulate it during exit and reentry
into atmosphere.
➢ Other applications : Abrasives, construction materials,
utensils etc.

➢ Example:- Porcelain, Glass, Silicon nitride.

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❑Ceramics:
Combinations of metals or with oxygen, nitrogen, carbon and boron
(oxides, nitrides, carbides, borides) CaO, Al2O3, BN, SiC, TiB2
Properties: hard but very brittle, Insulators of heat and electricity,
resistant to high temperature and harsh environments,
1-TRADITIONAL CERAMICS
Pottery, porcelain, brick, glass

Whiteware
2-ADVANCED CERAMICS
Structural: bioceramics, cutting tools, engine components, armour.
Electrical: Capacitors, insulators, magnets and superconductors

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Cutting tools
Chapter 1-
Brake disc SiC engine SiC body armour
 Types of Materials
Composite Materials
– Mixture of two or more materials.
– Consists of a filler material and a binding material.
– Materials only bond, will not dissolve in each other.
– Mainly two types :-
• Fibrous: Fibers in a matrix
• Particulate: Particles in a matrix
– Matrix can be metals, ceramic or polymer
– Examples :
• Fiber Glass ( Reinforcing material in a polyester or
epoxy matrix)
• Concrete ( Gravels or steel rods reinforced in cement
and sand)
– Applications:- Aircraft wings and engine, construction.
41 of Mat. Sci. and Eng. W.Smith,
Foundations
ChapterJ.1-
Hashemi, McGraw Hill
http://highered.mcgraw-hill.com/
 Types of Materials

Electronic Materials
• Not Major by volume but very important.
• Silicon is a common electronic material.
• Its electrical characteristics are changed by
adding impurities.
• Examples:- Silicon chips, transistors
• Applications :- Computers, Integrated Circuits,
Satellites etc.

42 of Mat. Sci. and Eng. W.Smith,

Foundations
ChapterJ.1- Hashemi, McGraw Hill
http://highered.mcgraw-hill.com/
Smaller and thinner than a
dime, this tiny silicon chip
contains millions of
transistors that work
together

43
Chapter 1-
 SEMICONDUCTORS

Solar Cells

OLED
Technology

44
Chapter 1-
 BIOMATERIALS
Example – Hip Implant
• With age or certain illnesses joints deteriorate. Particularly
those with large loads (such as hip).

45
Chapter 1-
Adapted from Fig. 22.25, Callister 7e.
 Example – Hip Implant

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

Adapted from Fig. 22.24, Callister 7e.

46
Chapter 1-
Example – Hip Implant

47
Adapted from Fig. 22.26, Callister 7e. Chapter 1-
 Hip Implant
• Key problems to overcome
– fixation agent to hold Ball
acetabular cup
– cup lubrication material
– femoral stem – fixing agent (“glue”)
Acetabular
– must avoid any debris in cup Cup and Liner

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

48
Chapter 1-
 Competition Among Materials
Example:- Aluminum
• Materials compete with each 1600
Iron
other to exist in new market 1400 Plastic
Steel
1200
1000
• Over a period of time usage

lb/Car
800
of different materials
600
changes depending on cost
400
and performance.
200
0
• New, cheaper or better 1985 1992 1997

materials replace the old Model Year

Figure 1.14
materials when there is a
Predictions and use of
breakthrough in technology
materials in US automobiles.
49
Chapter 1-
After J.G. Simon, Adv. Mat. & Proc., 133:63(1988) and new data
50
 Advanced Materials
• High tech Materials-(intricate and sophisticated principles)
– Materials used for laser Technology
– Integrated circuits
– Magnetic information storage
– Liquid crystal displays
– Fiber optics
– Aerospace applications
• Smart Materials-(Material properties change with the
environment in a predetermined manner) used in sensors
and actuators
– Shape memory alloys
– Piezoelectric ceramics
– Magnetostrictive materials
– Electrorhelogical/magnetorhelogical fluids

• NanoTechnology
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Sustainable city concept
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 57
Ref: www.slintec.lk
58
BIOMIMETICS
Some paints and roof tiles have
been engineered to be self-cleaning
by copying the mechanism from the
lotus

59
Chapter 1-
Lotus leaf surface
60
Water strider

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63
64
65
66
cobweb

67
68
SOME CURRENT APPLICATIONS OF
NANOTECHNOLOGY

69
Chapter 1-
 SOLAR CELLS
Nanotechnology enhancements provide:
 Improved efficiencies: novel
nanomaterials can harness
more of the sun’s energy
 Lower costs: some novel
nanomaterials can be made
cheaper than alternatives
 Flexibility: thin film flexible
polymers can be manipulated
to generate electricity from
the sun’s energy

70
Chapter 1-
 COMPUTING
Nanotechnology enhancements provide:
 Faster processing speeds:
miniaturization allows more
transistors to be packed on a
computer chip
 More memory: nanosized features
on memory chips allow more
information to be stored
 Thermal management solutions for
electronics: novel carbon-based
nanomaterials carry away heat
generated by sensitive electronics

71
Chapter 1-
 CLOTHING
Nanotechnology enhancements provide:
 Anti-odor properties: silver
nanoparticles embedded in textiles kill
odor causing bacteria
 Stain-resistance: nanofiber coatings on
textiles stop liquids from penetrating
 Moisture control: novel nanomaterials
on fabrics absorb perspiration and wick
it away
 UV protection: titanium nanoparticles
embedded in textiles inhibit UV rays
from penetrating through fabric

72
Chapter 1-
 BATTERIES
Nanotechnology enhancements provide:
 Higher energy storage capacity and
quicker recharge: nanoparticles or
nanotubes on electrodes provide high
surface area and allow more current to
flow
 Longer life: nanoparticles on electrodes
prevent electrolytes from degrading so
batteries can be recharged over and over
 A safer alternative: novel nano-enhanced
electrodes can be less flammable, costly
and toxic than conventional electrodes
73
Chapter 1-
 SPORTING GOODS AND EQUIPMENT

Nanotechnology enhancements provide:

 Increased strength of materials:

novel carbon nanofiber or
nanotube-based
nanocomposites give the player
a stronger swing
 Lighter weight materials:
nanocomposites are typically
lighter weight than their
macroscale counterparts

74
Chapter 1-
 CARS
Nanotechnology enhancements provide:

 Increased strength of materials:

novel carbon nanofiber or
nanotube nanocomposites are
used in car bumpers, cargo liners
and as step-assists for vans
 Lighter weight materials:
lightweight nanocomposites mean
less fuel is used to make the car go

 Control of surface characteristics: nanoscale thin films can be

applied for optical control of glass, water repellency of
windshields and to repair of nicks/scratches
75
Chapter 1-
 FOOD AND BEVERAGE
Nanotechnology enhancements provide:

 Better, more environmentally

friendly adhesives for fast food
containers
 Anti-bacterial properties: Nano
silver coatings on kitchen tools
and counter-tops kill
bacteria/microbes

 Improved barrier properties for carbonated beverages or

packaged foods: nanocomposites slow down the flow of
gas or water vapor across the container, increasing shelf
life
76
Chapter 1-
 THE ENVIRONMENT

Nanotechnology enhancements provide:

 Improved ability to capture groundwater

contaminants: nanoparticles with high surface
area are injected into groundwater to bond
with contaminants
 Replacements for toxic materials

77
Chapter 1-
 BODY ARMOR
Nanotechnology enhancements will provide:
 Stronger materials for better protection:
nanocomposites that provide unparalleled
strength and impact resistance
 Flexible materials for more form-fitting
wearability: nanoparticle-based materials that
act like “liquid armor”
 Lighter weight materials: nanomaterials
typically weigh less than their macroscale
counterparts
 Dynamic control: nanofibers that can be flexed
as necessary to provide CPR to soldiers or
stiffen to furnish additional protection in the
face of danger 78
Chapter 1-
 DRUG DELIVERY
Nanotechnology enhancements will provide:

 New vehicles for delivery:

nanoparticles such as buckyballs or
other cage-like structures that carry
drugs through the body
 Targeted delivery: nano vehicles that
deliver drugs to specific locations in
body
 Time release: nanostructured
material that store medicine in
nanosized pockets that release small
amounts of drugs over time
79
Chapter 1-
 CANCER
Nanotechnology enhancements will provide:
 Earlier detection: specialized
nanoparticles that target cancer
cells only – these nanoparticles can
be easily imaged to find small
tumors
 Improved treatments: infrared light
that shines on the body is absorbed
by the specialized nanoparticles in
the cancer cells only, leading to an
increased localized temperature
that selectively kills the cancer cells
but leaves normal cells unharmed
80
Chapter 1-
 SENSORS
Nanotechnology enhancements will provide:

 Higher sensitivity: high surface area of

nanostructures that allows for easier
detection of chemicals, biological
toxins, radiation, disease, etc.

 Miniaturization: nanoscale fabrication

methods that can be used to make
smaller sensors that can be hidden
and integrated into various objects

81
Chapter 1-
 NEXT GENERATION COMPUTING

Nanotechnology enhancements will provide:

 The ability to control atomic
scale phenomena: quantum or
molecular phenomena that can
be used to represent data
 Faster processing speeds

 Lighter weight and miniaturized

computers
 Increased memory

 Lower energy consumption

82
Chapter 1-
 NANOROBOTICS
Nanotechnology enhancements will provide:
 Miniaturized fabrication of
complex nanoscale systems:
nanorobots that propel through
the body and detect/ cure
disease or clandestinely enter
enemy territory for a specific
task
 Manipulation of tools at very
small scales: nanorobots that
help doctors perform sensitive
surgeries

83
Chapter 1-
 WATER PURIFICATION
Nanotechnology enhancements will provide:
 Easier contamination removal:
filters made of nanofibers that can
remove small contaminants
 Improved desalination methods:
nanoparticle or nanotube
membranes that allow only pure
water to pass through
 Lower costs

 Lower energy use

84
Chapter 1-
 MORE ENERGY/ENVIRONMENT
APPLICATIONS…

Nanotechnology enhancements will provide:

 Improvements to solar cells

 Improvements to batteries

 Improvements to fuel cells

 Improvements to hydrogen storage

 CO2 emission reduction: nanomaterials that do a better

job removing CO2 from power plant exhaust
 Stronger, more efficient power transmission cables:
synthesized with nanomaterials

85
Chapter 1-
 Future Trends

• Smart Materials : Change their properties by sensing

external stimulus.
➢ Shape memory alloys: Strained material reverts back
to its original shape above a critical temperature.
➢ Used in heart valves and to expand arteries.

➢ Piezoelectric materials: Produce electric field when

exposed to force and vice versa.
➢ Used in actuators and vibration reducers.

86
 MEMS and Nanomaterials
• MEMS: Microelectromechanical systems.
➢ Miniature devices
➢ Micro-pumps, sensors

• Nanomaterials: Characteristic length < 100 nm

➢ Examples: ceramics powder and grain size < 100 nm
➢ Nanomaterials are harder and stronger than bulk
materials.
➢ Have biocompatible characteristics ( as in Zirconia)
➢ Transistors and diodes are developed on a nanowire.

87
Chapter 1-
 Modern Materials Needs
• In the field of Nuclear Energy
– Environmental issues
– Disposal of radioactive waste
• Transportation
– Energy and environmental issues
• Energy
– Advanced Solar cells
– Light emitting diodes - LEDs

• Pollution control
– Catalytic converter

• Recycling
88
 Case Study – Material Selection
• Problem: Select suitable material for bicycle
frame and fork.
Carbon fiber
Steel and Aluminum Ti and Mg
Wood Reinforced
alloys alloys alloys
plastic

Low cost but Light and Very light and Light, moderately Slightly better
Heavy. Less strong. But strong. No Strong. Corrosion Than Al
Corrosion Cannot be corrosion. Resistance. alloys. But much
resistance shaped Very expensive expensive expensive

Cost important? Select steel

Properties important? Select CFRP 89