Engineering Materials

20MTRN04C

Prof. Dr. Iman El-Mahallawi

TA Eng Sherif El-Seoudy
TA Eng Eman Zayed
 Aims
• The aim of this module
is to provide first year students with basic
knowledge of material engineering necessary for
all engineers in addition to selective topics of
significance to the Mechatronics and robotics
engineering specialisation.
 Indicative Content
• Material structure and microstructure;
• Phase equilibrium diagrams;
• Classification and applications of engineering materials;
• Mechanical properties;
• Destructive and non-destructive testing;
• Material characterisation;
• Material processing and treatment;
• Materials for electronics;
• Compliant material.
 Indicative Reading List
– William F. Smith, "Principles of Materials Science
and Engineering", McGraw-Hill, ISBN: 0070591695
(1990)
– W. Bolton, "Engineering Materials Technology",
Butterworth-Heinemann, ISBN: 0750639172
(1998)
– William D. Callister, "Materials Science and
Engineering: An Introduction ", Wiley, (2006)
– Donald R. Askeland and Pradeep P. Phule “The
Science and Engineering of Materials”
Part I: Introduction & Course
Information

• Course Objectives
• Course ILO
• Course Management
• Code of Conduct

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 Course ILOs
Knowledge and understanding:
1. Appreciate the relationship between material structure and its mechanical properties;
2. Recognise the different types of engineering material and their applications;

Subject-specific cognitive skills:

3. Analyse the results of destructive and non-destructive tests on engineering material;
4. identify the different types of structures found in engineering materials and relate
them to material behaviour;
5. Produce data from different material sources to obtain information to assisting in
materials selection;
 Course ILOs
Subject Specific Practical Skills
6. Conduct experiments on engineering materials to determine their properties;
7. Interpret material behaviour utilising phase equilibrium diagrams;

Transferable Skills
8. Select suitable material for mechatronics and robotics applications;
9. Appreciate how to use lab experiments to assess material properties.
 Assessments
Exam/
ILOs
Assessment Focus Weight % Assessment Type Exam Semester
Written Coursework
Assessed
Length
2 in-class 20% Class test a1, a2, b1, b2   50 min each
Assessments  
 
Designed to be based on open resources
on- or off- campus.
 
Group laboratory 20% Coursework b2, b3, c1, d2   5000 words and 20
min discussion
report (10%) and
individual discussion
(10%)
 
 
Unseen written exam 60% Final exam a1, a2, b1, c2,   2 hrs
d1
 20MTRN04C Attendance Policy
Dear Year One Students Please be informed that in
accordance to the University attendance policy the core
sessions are all lectures and all Tutorials/Labs.
Attendance will be recorded on all online sessions and will
be controlled by polls and ungraded quizzes.
Lab attendance will be recorded by TAs during the 4 weeks
assigned for each Lab session.
The students will be grouped in smaller teams of
approximately 6-7 students per group for conducting the
lab sessions.
Code of conduct:
 Conform to modesty (reserve) in attire (clothing).
 Adhere to BUE regulations.
 Respect rights of others.
 Refrain from obscene conversations.
No displays of ill-behavior
≠ Attempting to obtain unfair advantage
♦ Cheating, Plagiarism (Coping)
♦ falsifying information
♦ impersonating another person
♦ stealing, destroying resources
♦ offering bribes
≠ unauthorized access
≠ Aiding improper actions
≠ Effecting or encouraging any harm
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 Topics covered in lecture
• AVAILABLE ENERGY FOR BONDING,
FORMATION, TRANSFORMATION.
• ELECTRONIC CONFIGURATION
• ATOMIC BONDING
• CRYSTAL STRUCTURE
• MICROSTRUCTURE
• RELATION BETWEEN MICROSTRUCTURE AND
PROPERTIES
 Introductory Concepts
• The following Material is based on material
provided by:

Callister, Materials Science and

Engineering
 COURSE WEBSITES
Course Website: http://www. http://learn.bue.edu.eg
• Syllabus
• Lecture notes
• Answer keys
• Grades
•

Text Website: http://www.  connect.mheducation.com

• Study material
• Complete solutions to selected problems
• Links to other web resources
• Extended learning objectives
• Self-assessment exercises

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 Chapter 1 - Introduction
• What is materials science?
• Why should we know about it?

• Materials drive our society

– Stone Age
– Bronze Age
– Iron Age
– Now?
• Silicon Age?
• Polymer Age?

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 Why study materials science?

• Engineers must understand the capabilities

and the limitations of materials.

• A lack of fundamental understanding of

materials, their properties and failure modes
can result in catastrophic failures.
Aloha Airlines, 28 April 1988
Challenger, 1986: temperature was outside of
acceptable limits for rubber seals
 Space Shuttle Columbia, 2003

Foam insulation hit the leading edge of one wing during takeoff.
The thermal tiles were broken in this area. During the return
through the atmosphere hot gasses penetrated the broken tiles and
melted the metal wing from the inside out.
 Why study materials science? Why study
materials engineering?
•An understanding of materials helps us to
design better components, parts, devices…
– How can we make something stronger, lighter
or more environmentally benign?
– Can we reduce costs by using a less expensive
material?
– Why is it that different classes of materials have
such vastly different properties?
– How can we produce Micro or nano scale
devices?
 The Materials Selection
Process
• 1. Application Determines required Properties
Properties: mechanical, electrical, thermal, chemical,
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.
 How to do well in this course:
Materials science and engineering is different from the other courses that
you will take for your engineering degree; it is highly
descriptive and theoretical. It requires a different approach
than your other subjects…simply solving example
problems will be inadequate. Instead you should:

Attend and take part in the lectures and tutorials: Ask

questions!
•Read the sections in the textbook as we go along: Add
details to the course notes as you read the textbook
•Do the sample problems on the website and discuss them
with another student.
 Types of Materials
Let us classify materials according to the way the atoms are bound
together

Metals: valence electrons are detached from atoms, and spread in an

'electron sea' that "glues" the ions together. Strong, ductile, conduct
electricity and heat well, are shiny if polished.

Semiconductors: the bonding is covalent (electrons are shared between

atoms). Their electrical properties depend strongly on minute
proportions of contaminants. Examples: Si, Ge, Ga and As.

Ceramics: atoms behave like either positive or negative ions, and are
bound by Coulomb forces. They are usually combinations of metals or
semiconductors with oxygen, nitrogen or carbon (oxides, nitrides, and
carbides). Hard, brittle, insulators. Examples: glass, porcelain.

Polymers: are bound by covalent forces and also by weak van der Waals
forces, and usually based on C and H. They decompose at moderate
temperatures (100 – 400 oC), and are lightweight. Examples: plastics
rubber.
 Example – Hip Implant
• With age or certain illnesses joints deteriorate.
Particularly those with large loads (such as hip).

Adapted from Fig. 22.25, Callister 7e.

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 Example – Hip Implant

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

Adapted from Fig. 22.24, Callister 7e.

29
Example – Hip Implant

Adapted from Fig. 22.26, Callister 7e. 30

 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.

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Example – Develop New Types of Polymers
• Commodity plastics – large volume ca. $0.50 / lb
Ex. Polyethylene
Polypropylene
Polystyrene
etc.

•  Engineering Resins – small volume > $1.00 / lb

Ex. Polycarbonate
Nylon
Polysulfone
etc.
 
Can polypropylene be “upgraded” to properties (and price) near
those of engineering resins?

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 Structure, Processing, & Properties
• Properties depend on structure
ex: hardness vs structure of steel

(d)

6 00
30 mm
5 00 (c)
Hardness (BHN)

Data obtained from Figs. 10.30(a)

4 00 (b) and 10.32 with 4 wt% C composition,
(a) and from Fig. 11.14 and associated
4 mm discussion, Callister 7e.
3 00 Micrographs adapted from (a) Fig.
10.19; (b) Fig. 9.30;(c) Fig. 10.33;
30 mm
30 mm and (d) Fig. 10.21, Callister 7e.
2 00
100
0.01 0.1 1 10 100 1000
Cooling Rate (ºC/s)
• Processing can change structure
ex: structure vs cooling rate of steel
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f01_01_pg4

f01_01_pg4
• Metals:
Types of Materials
– 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)

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 The Materials Selection Process
Pick Application Determine required Properties
1.
Properties: mechanical, electrical, thermal,
magnetic, optical, deteriorative.

Properties Identify candidate Material(s)

2.
Material: structure, composition.

Material Identify required Processing

3.
Processing: changes structure and overall shape
ex: casting, sintering, vapor deposition, doping
forming, joining, annealing.

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 ELECTRICAL
• Electrical Resistivity of Copper:

6 Adapted from Fig. 18.8, Callister 7e.

t% Ni (Fig. 18.8 adapted from: J.O. Linde,
5 3. 32 a Ann Physik 5, 219 (1932); and

Cu + C.A. Wert and R.M. Thomson,

a t % Ni Physics of Solids, 2nd edition,

4 Ni
Resistivity, r

(10-8 Ohm-m)

McGraw-Hill Company, New York,

2 . 1 6 t %
Cu + a 1970.)

+ 1.12
3 ed Cu
eform Ni
d a t %
2 1 . 1 2
Cu +
1 r e ” Cu
“Pu
0 T (°C)
-200 -100 0
• Adding “impurity” atoms to Cu increases resistivity.
• Deforming Cu increases resistivity.

37
 THERMAL
• Space Shuttle Tiles: • Thermal Conductivity
--Silica fiber insulation of Copper:
offers low heat conduction. --It decreases when
you add zinc!
Adapted from chapter-
opening photograph,
Chapter 19, Callister 7e.
(Courtesy of Lockheed 400

Thermal Conductivity
Missiles and Space
Company, Inc.)
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 6e. (Fig. 19.4 is adapted from Metals Handbook:
(Courtesy of Lockheed Properties and Selection: Nonferrous alloys and Pure
Aerospace Ceramics Metals, Vol. 2, 9th ed., H. Baker, (Managing Editor),
Systems, Sunnyvale, CA) American Society for Metals, 1979, p. 315.)
(Note: "W" denotes fig.
is on CD-ROM.)
100 mm 38
• Magnetic Storage:
MAGNETIC
• Magnetic Permeability
--Recording medium vs. Composition:
is magnetized by --Adding 3 atomic % Si
recording head. makes Fe a better
recording medium!

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
(Fig. 20.23 is from J.U. Lemke, MRS Bulletin, Engineering Materials, Fig. 1-7(a), p. 9,
Vol. XV, No. 3, p. 31, 1990.) 1973. Electronically reproduced
by permission of Pearson Education, Inc.,
Upper Saddle River, New Jersey.

39
• Transmittance:
OPTICAL
--Aluminum oxide may be transparent, translucent, or
opaque depending on the material structure.

polycrystal: polycrystal:
single crystal low porosity high porosity

Adapted from Fig. 1.2,

Callister 7e.
(Specimen preparation,
P.A. Lessing; photo by S.
Tanner.)

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 DETERIORATIVE
• Stress & Saltwater... • Heat treatment: slows
--causes cracks! crack speed in salt water!
10 -8

crack speed (m/s)

“as-is”
“held at
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
Adapted from chapter-opening photograph, Chapter Sons, 1996. (Original source: Markus O. Speidel, Brown Boveri Co.)
17, Callister 7e.
(from Marine Corrosion, Causes, and Prevention,
John Wiley and Sons, Inc., 1975.) 4 mm
--material:
7150-T651 Al "alloy"
(Zn,Cu,Mg,Zr)

Adapted from Fig. 11.26,

Callister 7e. (Fig. 11.26 provided courtesy of G.H.
Narayanan and A.G. Miller, Boeing Commercial
Airplane Company.) 41
 SUMMARY
Course Goals:
• Use the right material for the job.

• Understand the relation between properties,

structure, and processing.

• Recognize new design opportunities offered

by materials selection.

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