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UNIT - I Introduction to Mechanical Engineering

1.0 Introduction To Mechanical Engineering:

Mechanical engineering is the study, design, development, construction, and testing

of mechanical and thermal sensors and devices, including tools, engines, and machines.
Mechanical engineering careers centre on creating technologies to meet a wide range of
human needs.

1.1 Role of Mechanical Engineering in Industries and Society:

Mechanical Engineer will play a vital role in the sustainable development of the
industry and the society. Starting from the conceptualization of the product to the
design, manufacturing, sales and service to the end of life of a product i.e, recycling
mechanical engineer will play his role.
To start with, for a design a product mechanical engineer has to conceptualize the
product, draw the preform of the product, then apply the mechanical design and
will build the product for its strength.
Mechanical engineer role as a manufacturing Engineering is a huge. Studying the
design, laying out the tooling for the production and optimize the raw material
consumption in the manufacturing a component requires huge skills as a
mechanical Engineering.
Mechanical Engineer also places a vital role in the logistics. Procuring the materials
for the production, maintaining the adequate material in the stores, dispatching the
finished products to the Consumer is the role of a Logistic Engineer.
Mechanical Engineer also works as a safety Engineer in an Industry. Taking care
of the human resources, machineries, equipment’s and planning out the safer
working conditions and ensuring the safety of the operations is the responsibility
of the safety engineer.
Mechanical Engineer plays a vital role in the overall growth of the economy as well
as the Society. Meeting the demand for a product to the optimum utilization of
the resources taken care by the mechanical Engineer. Designing a product for
longer product life cycle and reutilization/ recycling the product reduce the
dependency of the materials by the industry. Also, developing newer equipment’s,
devices for harnessing the renewable sources energy reduces the dependencies on
the fossil fuels. This in turn contributes the green energy, low or no emission of
carbon and its compounds.

Areas where in Mechanical Engineer play his role in an industry:

1. Design Engineer 2. Production Manager 3. Safety Engineer

4. QA Engineer 5. Logistic Manager 6. Data analyst
7. Drafts man 8. Sales Executive 9. Customer Service

1.1 Emerging Trends and Technologies in energy sector

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Renewable energy infrastructure development, power generation, storage, and efficiency
drive innovations in the sector with numerous emerging companies developing low-cost
renewable energy technology.

a. Renewable:
Renewable is one of the emerging trends in energy sector. This Renewable energy
trend helps to safeguard the environment by emitting little to no harmful pollutants. The
fundamental premise of renewable energy is to obtain it from a consistent source in the
environment, such as the sun, wind, or geothermal sources. The source is then converted
into useful power or fuel.
A variety of technologies that address various facets of generating power and heat
from renewable sources is one of the latest technology trends in renewable energy. This
involves lowering the cost of building renewable infrastructure and enhancing the
efficiency of power generation.

b. Energy Storage
Energy storage is one of the effective energy industry emerging trends. Energy
storage permits steady pricing by proactively maintaining demand from consumers in
response to shifting energy demands and technological advancements, the energy storage
business has evolved, adapted, and innovated during the last century. Energy storage
systems offer a diverse set of technological solutions for improving our power
supply to build more resilient energy infrastructure and save money for utilities and
customers.
The many methods of energy storage can be classified into five categories based on their
technology:
i. Batteries.
ii. Thermal
iii. Mechanical
iv. Pumped hydro
v. Hydrogen
It has the potential to save consumers money while also improving dependability and
resilience, integrating power sources, and reducing environmental impacts.
c. Blockchains:
Blockchains or distributed ledgers are emerging technology trends in the energy industry
that has drawn significant interest from energy supply firms, start-ups, financial institutions,
Governments, technology developers, and the academic community' Block chain technology
proposes to combine all energy stakeholders under a single decentralized system. Electricity
producers, metering operators, distribution network operators' and traders potentially avail
from utilizing smart contracts. These agreements ensure that all energy related transactions
are routed through a safe and immutable network, reducing the risk of losses. Block chain
also has the ability to achieve some degree of equity between energy generators and
consumers.
1.1.3 Emerging Trends and Technologies in manufacturing sector:

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Al, robots, 3D printing, and the like are all the latest manufacturing trends in
manufacturing technology - and have been for some time. 2021 is the year. Manufacturing
technology gets even smarter. Robots on the factory floor are growing at warp speed thanks
to their declining cost and increasing capabilities.

1.1.4 Emerging Trends and Technologies in Automotive sector:

The automotive industry has been experiencing a great deal of change within the past
several years. More software is being added to vehicles, along with a greater number of electric
and autonomous vehicles are in production and on the road. Here are the most common
automotive trends of 2021.
 A Greater Amount of Al/Machine Learning and Connectivity
 An increase in Electric and Autonomous Vehicles.
 Software Security Has Become a Top Concern Electrification.
 Artificial intelligence (Al).
 Human-Machine interface.
1.1.5 Emerging Trends and Technologies in Aerospace sector

 Aerospace collectively refers to the atmosphere and outer space; it's a diverse
industry with a multitude of commercial, industrial, and military applications.
Aerospace engineering consists of aeronautics and astronautics and the research,
design, production, operation, or maintenance of aircraft and spacecraft involves
the work of numerous organizations.

Aerospace Engineering Technology Trends

1. Zero-Fuel Aircraft
2. Structural Health Monitoring (SHM)
3. Advanced Materials
4. Smart Automation and Block chain
5. Additive Manufacturing (3D Printing)
5. Supersonic Flights
7. More Resilient and Dynamic A&D Supply Chains
8. Utilizing Internet of Things (loT) to Anticipate Maintenance issues
9. Artificial intelligence (Al)
10. Autonomous Flight Systems.
1.1.6 Emerging technologies in the maritime industry

Advances in shipbuilding, propulsion, smart shipping, advanced materials, big data and
analytics, robotics, sensors and communications in conjunction with an increasingly skilled
workforce are all having monumental shifts in how the maritime industry are approaching
new challenges and opportunities.

The Indian Manufacturing sector currently contributes 16-17% to GDP and gives
employment to around l2o/o (201a) of the country's workforce. Various studies have
estimated that every job created in manufacturing has a multiplier effect in creating 2-3 jobs
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in the services sector. Manufacturing, value added (% of GDP) in India was reported at
12.96 % in 2020, according to the World Bank collection of development indicators,
compiled from officially recognized sources.

1.2 Ferrous and Non-Ferrous Metals

Ferrous metals, the base metal is iron. They compose a large part of the overall metals in
use today. This is made possible by their properties that suit many different industries and
use cases.
Non-ferrous metals, on the other hand, do not include iron. This distinction is made
because it brings along a certain characteristic change that non-ferrous metals do not
provide.
1.2.1 Properties of Ferrous Metals
Ferrous metals may include a lot of different alloying elements. Some examples are
chromium, nickel, molybdenum, vanadium, and manganese. Those give ferrous
steels material properties that make them widely used in engineering.
List of ferrous metal properties:
 Durable
 Great tensile strength
 Usually, magnetic
 A silver-like color
 Low resistance to corrosion
 Recyclable
 Good conductors of electricity
These qualities make them usable in the construction of long-lasting skyscrapers. On top
of that, they are utilised in making tools, vehicle engines, pipelines, containers,
automobiles, cutlery, etc.
Advantages
 High strength - weight ratio
 Weighs more than Aluminum and Titanium Alloys
 High quality and tough material
 Recyclable and eco friendly
Dis-advantages
 Tends to corrode by rusting
 Machine ability is affected by the magnetic field
 Requires more energy to form shapes or re-work

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CAST IRON:
The cast iron consists of 2 to 4% carbon and considerable amount of silicon. Also, it
contains smaller amounts of Sulphur, phosphorus and manganese. The usual composition
of cast iron is given below:
Carbon = 2.5 to 3.7%
Silicon = 1.0 to 3.0%
Manganese = 0.5 to 1.0%
Phosphorus = 90.1 to 0.9%
Sulphur = 0.07 to 0.1%

Advantages and limitations:

Cast iron is widely used for cast components which are not required to withstand
Impact or shock loads. It has many advantages over steel as a casting metal.

These advantages are:

1. Low melting point approximately 1200 0 C (melting point of steel is about
1380 0 C) and good machinability.
2. High fluidity and low shrinkage on cooling, enabling intricate shapes to be cast
with high accuracy.
3. Better corrosion and wear resistance than steel.
4. High compression strength and castings can withstand to heavy weights placed
upon them
5. Free graphite in cast iron can acts as a lubricant to reduce the friction between
sliding surfaces. This feature makes cast iron particularly suitable as a material for
machine tool slideways.
6. It is an inexpensive material.
7. High damping capacity.

Disadvantages:

- It is brittle.
- It cannot be forged or hardened.
- It is very weak in tension.

Non-Alloy Steels:

Non-alloy steels are also known as carbon steels because carbon is the alloying element
there. Yes, a little confusing as the name suggests one thing but that’s how it often is in
the world of metals. Although there are other elements also present, their content is low
enough to not make an impact on the material properties. Those elements are Sulphur,
phosphorus, silicon and manganese. Sulphur and phosphorus can actually have a
detrimental effect on the steel’s quality but again, not with such low-level content.

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Although the term “non-alloy steels” doesn’t get much mention in a typical engineering
company as such, our beloved structural steels like S235, S355, etc. belong to this group.
Non-alloy steels are classified by their carbon content as low, medium and high carbon
steel. Each has its own uses and the characteristics vary. Also, different treatment methods
are available accordingly.

Low Carbon Steel

Low carbon or mild steels contain 0.05…0.25% of carbon. They are pretty low-cost
and very well-suited for bending operations. The surface hardness can be increased
through carburizing.
The low-cost and malleability low-carbon steels are widely used. Some examples include
bolts and nuts, forgings, medium-loaded details, etc.
Examples of low carbon steels: C10E/1.1121, C15E/1.1141

Medium Carbon Steel

Medium carbon steels contain 0.25…0.6% of carbon. The higher carbon content
increases their strength and hardness compared to low-carbon steels. At the same time, the
ductility decreases. The increase of carbon and manganese allows tempering and
quenching.
Gears, shafts and axles – all ferrous metal medium carbon steels are mainly used for
making different automotive industry components like gears, axles, and shafts but also
bolts, nuts, screws, etc. Steels ranging from 0.4…0.6% are also suitable for everything
related to locomotives and rails.
Examples of medium carbon steels: C40E/1.1186, C60E/1.1221

High Carbon Steel

The carbon content numbers for high-carbon steels vary according to different sources.
Some have more sub-groups, while others stop with high carbon steels that start with
0.6% carbon content and end around 1%. We’ll go with the second interpretation.
These are the strongest of this group, making them suitable for applications where
resistance against mechanical material wear is needed. Another quality of high-carbon
steels is their tendency to keep a shape. This is why tool steels have a lot of different
applications in the field of engineering. As a downside, the weldability, ductility and
impact toughness are all inferior to steels with less carbon.

Steels are also classified by uses. Tool steels and high carbon steels overlap. The shape-
keeping quality makes them useful as springs. Other use-cases include blades, rail steels,
wire rope, wear-resistant plates, all kinds of tools etc.
Examples of high carbon steels: C70U/1.1520, C105U/1.1545

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UNIT - I Introduction to Mechanical Engineering
Alloy Steels and the Alloying Elements:

Alloys of iron and carbon containing other intentionally added elements are known as
alloy steels, and the elements added are called alloying elements. The most common
alloying elements added to steel are nickel, chromium, manganese, silicon, tungsten,
molybdenum, vanadium, copper and cobalt. Other elements which occur less commonly
include; aluminum, boran, titanium, niobium, zirconium and lead.

Alloying elements are added to steel for one or more of the following purposes:
1. Improvement of strength at elevated temperature.
2. Increase of hardenability and machinability.
3. Refinement of grain size and high toughness.
4. Increase of corrosion and fatigue resistance.
5. Increase of resistance to abrasion and wear.
6. Improvement of magnetic properties.

Effect Of Alloying Elements:

In addition of even small percentages of certain alloying elements imparts improved

mechanical and physical properties to steels. The effect of alloying elements on the
mechanical properties of steel is due to their influence on structure.
All alloying elements are classified as:
1. Graphitizing elements – Silicon, Nickel, Copper and Aluminum.
2. Carbide forming elements – Manganese, Chromium, Molybdenum, Tungsten,
Vanadium and Zirconium.
3. Neutral element – Cobalt.
The individual effects of these elements upon the properties of the steels are summarized
below.

Nickel:
1. Increases the tensile strength without sacrificing ductility.
2. Refine the grains and increases toughness.
3. Has the effect of lowering the temperature of transformation.
4. Makes the carbide unstable, i.e., promotes graphitization.
5. Lowers the co-efficient of thermal expansion.
6. Increases hardness slightly and decreases rusting

Chromium:
1. Increases strength and hardness without seriously affecting ductility.
2. Increases wear and corrosion resistance.
3. Has the effect of raising the critical temperature.
4. Carbide-forming element.
5. Improves hardenability and toughness.

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Manganese:
1. Increases the hardenability of steel.
2. Lowers the melting point of iron.
3. Forms carbide which tends to harden and strengthen steel.
4. Counter acts sulphur brittleness.
5. Decreases the critical temperatures.

Silicon:
1. Improves magnetic permeability and electrical resistivity.
2. Acts as a de-oxidizer and increases the resistance to oxidation.
3. Raises the ultimate strength without loss of toughness.
4. Intensifies the effect of molybdenum, manganese and chromium.
5. Act as a ferrite strengthener and makes the carbide unstable.

Tungsten:
1. Imparts red-hardness and hot-strength (strength at high temperature) to the steel.
2. Carbide-forming tendency is very high.
3. Inhibits grain growth, and considerably increases cohesive force.

Molybdenum:
1. Increases the hardenability.
2. Carbide-forming tendency is strong.
3. Imparts hot-strength, red hardness and toughness.
4. Increases corrosion and abrasion resistance.

Vanadium:
1. Increases the hardenability.
2. Promotes fine-grained structure.
3. Increases tensile strength, ductility and toughness.
4. Prevents softening at elevated temperature.
5. Carbide-forming tendency is very strong.

Copper:
1. Increases strength and hardness.
2. Lowers the ductility and impact resistance of cast steel.
3. Increases the corrosion resistance.

Cobalt:
1. imparts excellent magnetic properties.
2. Increases red-hardness in high-speed steels.
Aluminum:
1. Acts as a de-oxidizer.
2. Restricts grain growth and aids nitriding.
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Lead:
1. Increases machinability.
2. Does not imparts any unfavourable properties (hot - shortness) to steel.

Zirconium:
1. Used as an oxidizer; and produces a fine-grained steel.

Boran:
1. Imparts hardness to steel and increases plasticity.

Non-Ferrous Metal’s Properties:

Non-ferrous metals advantages make them usable in many applications instead or iron
and steel.

The properties of non-ferrous metals:

- High corrosion resistance
- Easy to fabricate – machinability, casting, welding, etc
- Great thermal conductivity
- Great electrical conductivity
- Low density (less mass)
- Colorful
- Non-magnetic

Advantages:
- Wide range of mechanical properties.
- Fabricated with relative ease.
- Economical to produce.
Disadvantages:
- Relative high density.
- Low electrical conductivity.
- Inherent susceptibility to corrosion.

Non-Ferrous Metals List:

Copper

When oxidized, copper turns green Copper is pretty widely spread in the industrial
sphere. Add the alloys brass (copper and zinc) and bronze (copper and tin), and you
may already see the many uses of copper. If not, we can help you out. For mechanical
engineers, slide bearings and bushings may be the most known uses.
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Still, copper and copper alloy properties allow more applications:

- High thermal conductivity – heat exchangers, heating vessels and appliances etc
- High electrical conductivity – used as an electrical conductor in wiring and motors
- Good corrosion resistance – beautiful but expensive roofing
- High ductility – makes the material very easily formable and suitable for making
statues

Aluminium:
In engineering terms, a very special and important metal. May not be so useful in everyday
applications because of the price but its combination of low weight and great
machinability make it the go-to metal in yachts, planes and many automotive parts.
Aluminium is also the base metal in many alloys. The best-known aluminum grades are
probably duralumin, Y-alloy and magnalium.

Aluminium properties include:

- Corrosion resistant
- Good conductor of heat and electricity (but less than copper) – in combination
with ductility and malleability replaces copper in some instances
- High ductility and lightweight
- Becomes hard after cold working, so needs annealing

Lead:
Properties of Lead:
For the average person, lead may ring a bell related to bullets (which are now without
lead) and gas. Although at first added to fuel to decrease motor knocks, it turned out to be
heavily unhealthy when vaporized into the atmosphere.
The same goes for bullets and shooting range employees who got health problems
because of it. Lead is the heaviest common metal. As it doesn’t react easily with other
substances, they are still used in batteries and power cables, acid tanks and water pipes.

Lead properties are:

1. Very heavy
2. Resistant to corrosion – doesn’t react with many chemicals
3. Soft and malleable

Zinc:
Zinc on its own doesn’t mean much to the average person. As an alloying element, on
the other hand, it has a wide range of purposes. It is mainly used for galvanizing steel in
all kinds of fields. Galvanizing makes materials more durable against corrosion.

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UNIT - I Introduction to Mechanical Engineering
COMPOSITE MATERIALS

A composite material is a material that consists of one or more discontinuous components

(particles/fibres/reinforcement) that are placed in a continuous medium (matrix). In a
fibre composite the matrix binds together the fibres, transfers loads between the fibres and
protects them from the environment and external damage.

Composite materials, or shortened to composites, are microscopic or macroscopic

combinations of two or more distinct engineered materials with a recognizable interface
between them in the finished product. For structural applications, the definition can be
restricted to include those materials that consist of a reinforcing phase such as fibers or
particles supported by a binder or matrix phase. Wood composites are commonly seen
examples of composite materials.

Classification of Composites:
• Matrices:
1. Organic Matrix Composites (OMCs)
2. Polymer Matrix Composites (PMCs)
3. Carbon‐carbon composites
4. Metal Matrix Composites (MMCs)
5. Ceramic Matrix Composites (CMCs)
• Reinforcements:
1. Fibres reinforced composites
2. Laminar composites
3. Particulate composites

Properties of Composite Materials:

1. High Strength to Weight Ratio: Fibre composites are extremely strong for their
weight. By refining the laminate many characteristics can be enhanced.
2. Lightweight: A standard Fiberglass laminate has a specific gravity in the region of
1.5, compared to Alloy of 2.7 or steel of 7.8
3. Fire Resistance: The ability for composites to withstand fire has been steadily
improving over the years.
4. Electrical Properties: Fiberglass Developments Ltd produced the Insulator Support
straps for the Tranz Rail main trunk electrification.
5. Color: Almost any shade of any color can be incorporated into the product during
manufacture by pigmenting the gelcoat used. Costs are therefore reduced by no
further finishing or painting.
6. Translucency: Polyester resins are widely used to manufacture translucent
moulding and sheets. Light transmission of up to 85% can be achieved.
7. Design Flexibility: Because of the versatility of composites, product design is only
limited by your imagination.

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8. Low Thermal Conductivity: Fiberglass Developments has been involved in the
development and production of specialized meat containers which maintain prime
cuts of chilled meat at the correct temperature for Export markets.
9. Manufacturing Economy: Fiberglass Developments produces several models of
fuel pump covers for Fuel quip.
10. Design Flexibility: Because of the versatility of composites, product design is only
limited by your imagination.

Advantages:
1. Lighter than most materials – Composite materials are less heavy compared to
most other materials, making them ideal for applications where weight is a
concern, like in aircraft.
2. Strong and durable – They are known for their strength and durability, which
allows them to withstand high pressures and resist wear and tear.
3. Resistant to corrosion – These materials are also resistant to corrosion, meaning
they don’t easily rust or degrade, making them useful in harsh environments.
4. Easily molded into shapes – They can be easily shaped into various forms,
providing flexibility in design and usage.
5. Good thermal and electrical insulation – They offer good insulation against heat
and electricity, making them safe for use in electrical appliances and high-
temperature environments.
Disadvantages:
1. Expensive to produce – Composite materials can be costly to manufacture due to
the high price of raw materials and the complex production process.
2. Difficult to repair – Repairing these materials can be challenging because damage
is often hidden and not easily detected.
3. Not resistant to UV light – Exposure to UV light can degrade composite
materials over time, which affects their durability and lifespan.
4. Can’t withstand high temperatures – These materials may not perform well under
high temperatures, which can lead to deformation or even failure.
5. Limited material recycling options – The recycling options for composite
materials are limited, making them less environmentally friendly compared to
other materials.
Applications
1. Aerospace.
2. Building & Civil Engineering
3. Design, Furniture and Home.
4. Equipment & Machinery.

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Ceramics:
A ceramic is an inorganic non-metallic solid made up of either metal or non-
metal compounds that have been shaped and then hardened by heating to high
temperatures. In general, they are hard, corrosion-resistant and brittle.

Defining ceramics:
Dr Ian Brown, a senior research scientist with Industrial Research Limited, explains how
the term ‘ceramics’ now has a more expansive meaning. Traditional ceramics are clay-
based, but high-performance or advanced ceramics are being developed from a far wider
range of inorganic non-metal materials. Advanced ceramics have the properties of high
strength, high hardness, high durability and high toughness.

Properties:
The properties of ceramics, like those of any material, depend on the types of atoms
involved, the bonds between them, and their arrangement. This atomic structure
determines the material’s characteristics. Ceramic materials tend to be:
1. Harder and more brittle than metals
2. Wear-resistant
3. Refractory
4. Good thermal and electrical insulators
5. Nonmagnetic
6. Oxidation-resistant
7. Chemically stable

Mechanical Properties
The mechanical properties of ceramics include:
1. Poor impact strength
2. High compressive strength
3. Extremely stiff and rigid structure with little or no yielding
4. The presence of microcracks can cause local stress concentrations and brittle
fracture
5. Hardness and strength in compression, with a high softening temperature
6. Poor thermal shock resistance
7. Brittle nature

Types Of Ceramics:
Ceramics typically fall under two categories:
1. Traditional Ceramics: These are made from natural materials like feldspar, quartz,
or clay. Their structure depends on the composition of the clay which makes them
more imperfect compared to the uniform microstructure of advanced ceramics.
Traditional ceramics are manufactured by wet molding. They are mainly used in
daily-use items and building materials.
2. Advanced Ceramics: These use synthetic powders such as aluminum oxide, silicon
carbide, and silicon nitride. They are designed and engineered to have specific
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properties for high-performance applications. Advanced ceramics are typically
made from a mixture of high-purity powders that are processed using specialized
techniques to give the final product unique properties such as high strength,
toughness, wear resistance, high-temperature stability, and chemical inertness. Each
of these ceramics is known for its ability to serve specific purposes, such as
permeability, magnetism, insulation, and conductivity.

Advanced Ceramics
Some common types of advanced ceramics are listed below:
1. Silica
Silica (SiO2) is a material widely recognized for its remarkable thermal shock resistance
and leachability. It is a popular choice for aerospace and energy applications for the
production of investment casting shells and cores.
2. Tungsten Carbide
Tungsten carbide items are composed of tungsten carbide particles bonded with a metal
binder. The material is known for its ability to maintain its properties at high
temperatures. Tungsten carbide often gets mixed with high percentages of cobalt or nickel
as a second metallic phase to form materials known as "cermets." Pure tungsten carbide
can also be produced as an advanced technical ceramic using a high-temperature hot
isostatic pressing process. This extremely hard and wear-resistant material is used in
cutting tools, abrasive water jet nozzles, and other applications where strength and
toughness are critical. However, its weight can limit its use in certain applications.
3. Fire Bricks
Fire bricks are made from a refractory material and get used to line high-temperature
furnaces, fireboxes, fireplaces, and kilns. They are typically made from a mixture of clay
and other materials and are designed to withstand extreme heat without cracking or
breaking down. They also exhibit low thermal conductivity so they naturally save energy.
The refractory nature of these bricks makes them ideal for applications that focus on heat
resistance and durability. Fire bricks are used in a wide variety of industrial applications,
including steelmaking, glassmaking, and ceramics production.
4. Bone China
Bone china, also referred to as fine china, is a porcelain variety renowned for its strength,
chip resistance, and translucency. The material is composed of bone ash, kaolin, and
feldspathic material. It was first created by Josiah Spode, an English ceramicist, in the
1800s. Due to its superior durability, bone china can be molded into thinner shapes than
porcelain. It undergoes vitrification during production, but its transparency results from
differences in mineral properties. Bone china is often used for fine dinnerware and
decorative objects because of its elegant appearance and durability.
5. Silicon Carbide
Silicon carbide (SiC) is an advanced ceramic material known for its high wear resistance
and exceptional thermal conductivity. It is composed of silicon and carbon atoms. It is
typically produced by heating a mixture of sand (silicon dioxide) and petroleum coke
(carbon) at high temperatures. Due to its outstanding chemical resistance and high
strength, SiC is an ideal choice for thermal processing applications. This material is
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specifically used in advanced ceramic applications that need a highly durable material with
exceptional thermal conductivity. Specific examples include cutting tools, abrasives, and
semiconductor devices.
6. Titanium Carbide
Titanium carbide is a type of advanced ceramic that is used in cutting tools, wear-resistant
coatings, and other applications that require extreme strength and hardness. It is composed
of titanium and carbon atoms and is typically produced by heating a mixture of titanium
dioxide and carbon at high temperatures. Titanium carbide is known for having stable
properties even at high temperatures and in harsh environments.
7. Glass Ceramics
Glass-ceramics are composite materials with crystals embedded in a glassy matrix. These
advanced ceramics are made by heating glass to a high temperature and then cooling it
rapidly to form a crystalline material. This unique combination of amorphous and
crystalline states makes for customizable properties. Many varieties are especially known
for their high strength, toughness, and resistance to thermal shock.
They were initially developed for the mirrors and mounts of astronomical telescopes.
Glass ceramics have gained wider popularity, though, and are now found in everyday
products such as cooktops, cookware, bakeware, and high-performance reflectors for
digital projectors.

Advantages Of Ceramics:
 Most of them have high hardness hence they are used as abrasive powder
and cutting tools
 They have high melting point which makes them excellent refractory material
 They are good thermal insulators this is another reason to use them as refractory
material
 They are high electric resistivity which makes them suitable to be used an
insulator
 They have low mass density which results in lightweight components
 They are generally chemically inert which makes them durable

Disadvantages Of Ceramics:
 They are brittle in nature
 They have almost zero ductility
 They have poor tensile strength
 The show a wide range in the variation of strength, even for the identical
specimens
 They are difficult to shape and machine
Applications:
Advanced ceramics have a wide range of applications in various industries. Some
examples include:
1. Aerospace: Ceramics make up some high-temperature components such as
turbine blades, heat shields, and nose cones. Although these materials are hard to

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shape using conventional manufacturing methods, 3D printing is now being used
to build aerospace parts out of ceramics.
2. Biomedical: Ceramics show up in medical implants due to their biocompatibility,
strength, and wear resistance.
3. Electronics: Electronic devices receive ceramic components because of the
material’s electrical insulation properties and ability to dissipate heat.
4. Energy: Ceramic materials are important to energy applications such as fuel cells,
solar panels, and thermal insulation due to their thermal stability and temperature
resistance.
Smart Materials:
Smart materials are those materials that have the ability to change the shape or size
simply by giving a little amount of heat or to change from a liquid to semi-solid
instantly under an external magnetic field.
Types
There are a number of types of smart material, of which are already common. Some
examples are as following:

 Piezoelectric materials are materials that produce a voltage when stress is applied. Since
this effect also applies in a reverse manner, a voltage across the sample will produce
stress within sample. Suitably designed structures made from these materials can,
therefore, are made that bend, expand or contract when a voltage is applied.
 Shape-memory alloys and shape-memory polymers are materials in which large
deformation can be induced and recovered through temperature changes or stress
changes (pseudo elasticity). The shape memory effect results due to respectively
martensitic phase change and induced elasticity at higher temperatures.
Photovoltaic materials or optoelectronics convert light to electrical current.
 Electroactive polymers (EAPs) change their volume by voltage or electric fields.
 Magneto strictive materials exhibit a change in shape under the influence of magnetic
field and also exhibit a change in their magnetization under the influence of mechanical
stress.
 Magnetic shape memory alloys are materials that change their shape in response to a
significant change in the magnetic field.
 Smart inorganic polymers showing tunable and responsive properties.
 PH-sensitive polymers are materials that change in volume when the pH of the
surrounding medium changes.
 Temperature-responsive polymers are materials which undergo changes upon
temperature.
 Halochromic materials are commonly used materials that change their color as a result
of changing acidity. One suggested application is for paints that can change color to
indicate corrosion in the metal underneath them.
 Chromogenic systems change color in response to electrical, optical or thermal
changes. These include electrochromic materials, which change their colour or opacity
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on the application of a voltage (e.g., liquid crystal displays), thermochromic materials
change in colour depending on their temperature, and photochromic materials, which
change colour in response to light—for example, light-sensitive sunglasses that darken
when exposed to bright sunlight.
 Ferrofluids are magnetic fluids (affected by magnets and magnetic fields).
 Photomechanical materials change shape under exposure to light.
 Polycaprolactone (polymorph) can be moulded by immersion in hot water.
 Self-healing materials have the intrinsic ability to repair damage due to normal usage,
thus expanding the material's lifetime.
 Dielectric elastomers (DEs) are smart material systems which produce large strains (up
to 500%) under the influence of an external electric field.
 Magnetocaloric materials are compounds that undergo a reversible change in
temperature upon exposure to a changing magnetic field.
 Smart self-healing coatings heal without human intervention.
 Thermoelectric materials are used to build devices that convert temperature
differences into electricity and vice versa.
 Chemo responsive materials change size or volume under the influence of external
chemical or biological compound.
Smart materials have properties that react to changes in their environment. This means
that one of their properties can be changed by an external condition, such as temperature,
light, pressure, electricity, voltage, pH, or chemical compounds. This change is reversible
and can be repeated many times. There is a wide range of different smart materials. Each
offer different properties that can be changed. Some materials are very good and cover a
huge range of the scales.

Advantages of Smart Materials:

o Sensing and Actuating: Smart materials can function as both sensors (detecting
changes in their environment) and actuators (responding to external stimuli).
o Self-Repairing: Passively smart materials possess self-repairing capabilities,
enhancing durability.
o Feedback Utilization: Actively smart materials utilize feedback mechanisms,
adapting their behavior based on external conditions.
o Biological Replication: Some smart materials mimic biological functions in load-
bearing systems.

Disadvantages of Smart Materials:

o Delicacy: Smart materials can be fragile due to their specialized properties.
o Instability: Their behavior may be unpredictable under certain conditions.
o Diminished Performance over Time: Long-term use may lead to performance
degradation.
o Incorporation Difficulties: Integrating smart materials into existing structures can
be challenging.

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o Toxicity: Some materials may pose health risks.
o Costs: Developing and implementing smart materials can be expensive.

Applications:

1. Structural Engineering:
o Shape Memory Alloys (SMAs): These materials can “remember” their
original shape and return to it when heated. They are used in self-healing
structures, adaptive truss systems, and earthquake-resistant buildings.
o Piezoelectric Materials: These generate electricity when subjected to
mechanical stress. They are employed in sensors, actuators, and energy
harvesting devices for civil infrastructure health monitoring.

2. Aerospace and Aviation:

o Shape Memory Polymers (SMPs): Used for morphing aircraft wings,
allowing for improved aerodynamics during flight.
o Electroactive Polymers (EAPs): Used in artificial muscles, adaptive wing
surfaces, and vibration control.

3. Biomedical Applications:
o Biocompatible Smart Materials: Used for drug delivery, tissue engineering
and implantable medical devices.
o Smart Hydrogels: Respond to changes in pH, temperature, or other
environmental factors. They find applications in drug release systems and
wound healing.

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4. Consumer Electronics:
o Liquid Crystal Polymers (LCPs): Used in flexible displays, smart textiles,
and wearable devices.
o Electrochromic Materials: Change color in response to an electric field,
used in smart windows and displays.

5. Energy Harvesting and Storage:

o Thermoelectric Materials: Convert heat into electricity, suitable for
energy-efficient devices.
o Smart Fabrics with Energy-Generating Properties: Harvest energy from
body movements.

6. Automotive Industry:
o Magneto strictive Materials: Used in sensors for automotive safety
systems.
o Smart Tires: Embedded with sensors to monitor tire pressure and wear.

7. Environmental Monitoring:
o Chemo responsive Materials: Detect pollutants, gases, or chemical changes
in the environment.
o Self-Healing Concrete: Contains microcapsules that release healing agents
when cracks occur.
8. Sports and Recreation:
o Smart Textiles: Embedded with sensors for monitoring athletes’
performance and health.
o Impact-Responsive Materials: Used in protective gear to absorb impact
energy.

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Prepared by M. Rajesh (Ph. D), Dept. of Mech, JNTUACEP