Engineering Materials

Introduction
Engr. Aisha Kousar

B.E. Chemical Engineering MUET Jamshoro

M.E. Environment Engineering MUET Jamshoro
Syllabus and Notes:
 Review the Syllabus
 Attendance is your job – come to class!
 Final is Common Time
 Or our regularly scheduled time
 Tests and homework/Assignments – (20% of your grade!)
 Don’t copy from others; don’t plagiarize – its just the right
thing to do!!
 Course Notes:
Lecture notes and review recommended books
Materials Science and
Engineering
 It all about the raw materials and how
they are processed
 That is why we call it materials
ENGINEERING
 Minor differences in Raw materials or
processing parameters can mean
major changes in the performance
of the final material or product
Our Text:
Material Science and Engineering
An Introduction
by William D. Callister, Jr

Seventh Edition, John Wiley & Sons, Inc.

Materials Science and
Engineering
 Materials Science
 The discipline of investigating the relationships that exist
between the structures and properties of materials.
 Materials Engineering
 The discipline of designing or engineering the structure of a
material to produce a predetermined set of properties based
on established structure-property correlation.
 Four Major Components of Material Science
and Engineering:
 Structure of Materials
 Properties of Materials
 Processing of Materials
 Performance of Materials
And Remember: Materials
“Drive” our Society!
 Ages of “Man” we survive based on the materials we control
 Stone Age – naturally occurring materials
 Special rocks, skins, wood
 Bronze Age
 Casting and forging
 Iron Age
 High Temperature furnaces
 Steel Age
 High Strength Alloys
 Non-Ferrous and Polymer Age
 Aluminum, Titanium and Nickel (superalloys) – aerospace
 Silicon – Information
 Plastics and Composites – food preservation, housing, aerospace and higher
speeds
 Exotic Materials Age?
 Nano-Material and bio-Materials – they are coming and then …
Doing Materials!
 Engineered Materials are a function of:
 Raw Materials Elemental Control
 Processing History
 Our Role in Engineering Materials then is to
understand the application and specify the
appropriate material to do the job as a function of:
 Strength: yield and ultimate
 Ductility, flexibility
 Weight/density
 Working Environment
 Cost: Lifecycle expenses, Environmental impact*
* Economic and Environmental Factors often are the
most important when making the final decision!
Example of Materials Engineering
Work – Hip Implant

 With age or certain illnesses joints deteriorate.

Particularly those with large loads (such as
hip).
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.

Example – Hip Implant

Adapted from Fig. 22.24, Callister 7e.

Solution – Hip Implant
Acetabular
 Key Problems to Cup and
Liner
overcome:
 fixation agent to hold Ball
acetabular cup
 cup lubrication material
 femoral stem – fixing
agent (“glue”)
 must avoid any debris in
cup
 Must hold up in body Femoral
chemistry Stem
 Must be strong yet
flexible
Introduction
 List the Major Types of MATERIALS
That You Know:
 METALS
 CERAMICS
 POLYMERS
 COMPOSITES
 ADVANCED MATERIALS
Introduction, cont.
 Metals  Polymers
 Steel, Cast Iron,  Plastics, Wood,
Aluminum, Copper, Cotton (rayon,
Titanium, many nylon), “glue”
others  Composites
 Ceramics  Glass Fiber-
 Glass, Concrete, reinforced polymers,
Brick, Alumina, Carbon Fiber-
Zirconia, SiN, SiC reinforced polymers,
Metal Matrix
Composites, etc.
Thoughts about these
“fundamental” 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)
 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.
But: Properties depend on Structure
(strength or hardness)

(d)

600
Hardness (BHN)

30 m
500 (c)
400 (b)
(a)
4 m
300
30 m
200 30 m

100
0.01 0.1 1 10 100 1000
Cooling Rate (ºC/s)

And: Processing can change structure! (see

above structure vs Cooling Rate)
Another Example: Rolling of Steel

 At h1, L1  At h2, L2
 low UTS  high UTS
 low YS  high YS
 high ductility  low ductility
 round grains  elongated grains

Structure determines Properties but Processing determines

Structure!
Optical Properties of Ceramic are
controlled by “Grain Structure”

Grain Structure is a function of

“Solidification” processing!
Electrical Properties (of Copper):
6 i
%N
at
5 3 .32
+ i Electrical Resistivity of
Cu t% N i
a N
Resistivity, 

4 2.1 6 t % Copper is affected by:

(10-8 Ohm-m)

+ 1 2 a
Cu +1 .
3 C u • Contaminate level
e d
efo rm % Ni
d 2 a t • Degree of deformation
2 . 1
u +1
C • Operating temperature
” C u
1 r e
“Pu
0
-200 -100 0 T
Adapted from Fig. 18.8, Callister 7e.
(Fig. 18.8 adapted from: J.O. Linde, (°C)
Ann Physik 5, 219 (1932); and
C.A. Wert and R.M. Thomson,
Physics of Solids, 2nd edition,
McGraw-Hill Company, New York,
1970.)
THERMAL Properties
• Space Shuttle Tiles: • Thermal Conductivity
--Silica fiber insulation of Copper: --It decreases when
offers low heat conduction. you add zinc!

400

Thermal Conductivity
300

(W/m-K)
200

100
0
0 10 20 30 40
Composition (wt% Zinc)
Adapted from Adapted from Fig. 19.4, Callister 7e.
Fig. 19.4W, Callister (Fig. 19.4 is adapted from Metals Handbook:
6e. (Courtesy of Properties and Selection: Nonferrous alloys and
Lockheed Aerospace Pure Metals, Vol. 2, 9th ed., H. Baker,
Ceramics Systems, (Managing Editor), American Society for Metals,
Sunnyvale, CA) 1979, p. 315.)
(Note: "W" denotes fig.
100 m is on CD-ROM.)
 MAGNETIC Properties
• Magnetic Permeability
• Magnetic Storage: vs. Composition:
--Recording medium
--Adding 3 atomic % Si makes Fe a
is magnetized by
better recording medium!
recording head.

Magnetization
Fe+3%Si

Fe

Magnetic Field

Adapted from C.R. Barrett, W.D. Nix, and

Fig. 20.23, Callister 7e. A.S. Tetelman, The Principles of
Engineering Materials, Fig. 1-7(a), p. 9,
(Fig. 20.23 is from J.U. Lemke, MRS Bulletin, 1973. Electronically reproduced
Vol. XV, No. 3, p. 31, 1990.) by permission of Pearson Education, Inc.,
Upper Saddle River, New Jersey.
 DETERIORATIVE Properties
• Heat treatment: slows
• Stress & Saltwater... crack speed in salt water!
--causes cracks! 10-8 “as-is”
“held at

crack speed (m/s)

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

increasing load
Adapted from Fig. 11.20(b), R.W. Hertzberg, "Deformation and Fracture Mechanics of
Engineering Materials" (4th ed.), p. 505, John Wiley and Sons, 1996. (Original source:
Markus O. Speidel, Brown Boveri Co.)

4 m
--material:
7150-T651 Al
"alloy"
Adapted from chapter-opening photograph,
Chapter 17, Callister 7e. (Zn,Cu,Mg,Zr)
(from Marine Corrosion, Causes, and Adapted from Fig. 11.26,
Prevention, John Wiley and Sons, Inc., 1975.) Callister 7e. (Fig. 11.26 provided courtesy of G.H.
Narayanan and A.G. Miller, Boeing Commercial
Airplane Company.)
 Course Goal is to make you aware of the
importance of Material Selection by:

• Using the right material for the job.

one that is most economical and
“Greenest” when life usage is considered

• Understanding the relation between

properties, structure, and processing.

• Recognizing new design opportunities offered

by materials selection.