Subject: ENSC 027

(Materials Science & Engineering)

Properties of Engineering Materials

(Part 2)
April 11, 2023
10:30 am – 12:00nn
12:30 pm – 2:00pm
 Materials Science and Engineering
Components Material Science and Engineering

Above are the four components of the discipline of

materials science & engineering and their interrelationship.
 Materials Science and Engineering
Major classifications of engineering materials:
 Materials Science and Engineering
Major classifications of engineering materials:

1.Metallic
1.1. Ferrous
1.2. Non-Ferrous

2.Non Metallic
2.1. Polymers
2.2. Ceramics

3. Composites.
 Materials Science and Engineering
Major classifications of engineering materials:
1.Metallic
2.Non Metallic
2.1. Polymers
2.2. Ceramics
3. Composites.
 Materials Science and Engineering
Classifications of engineering materials:
• Ferrous Metals
• Ferrous metals are those which have iron as their main constituent.

• The ferrous metals commonly used in engineering practice are:

1. cast iron,
2. wrought iron,
3. steels and
4. alloy steels.

• The principal raw material for all ferrous metals is pig iron which is
obtained by smelting iron ore with coke and limestone, in the blast
furnace.
 Materials Science and Engineering
Classifications of engineering materials:

The principal iron ores with their metallic contents are shown in the
following table :
 Materials Science and Engineering
Classifications of engineering materials:
Cast Iron
• The cast iron is obtained by re-melting pig iron with coke and
limestone in a furnace known as cupola.
• It is primarily an alloy of iron and carbon.
• The carbon contents in cast iron varies from 1.7 per cent to 4.5 per
cent.
• It also contains small amounts of silicon, manganese, phosphorous
and sulphur.

• The carbon in a cast iron is present in either of the following:

1. Free carbon or graphite, and
2. Combined carbon or cementite.
 Materials Science and Engineering
Classifications of engineering materials:
Sample photos of Cast Iron
 Materials Science and Engineering
Classifications of engineering materials:
Types of Cast Iron
1. Grey cast iron.
• Its compositions :
Carbon = 3 to 3.5%;
Silicon = 1 to 2.75%;
Manganese= 0.40 to 1.0%;
Phosphorous = 0.15 to 1% ;
Sulphur = 0.02 to 0.15% ;
and the remaining is iron.

• The grey colour is due the presence of carbon is present in the form of *free
graphite.
• It has a low tensile strength, high compressive strength and no ductility.
• It can be easily machined.
 Materials Science and Engineering
Classifications of engineering materials:
Types of Cast Iron
2. White cast iron.
• Its compositions :
Carbon = 1.75 to 2.3% ;
Silicon = 0.85 to 1.2% ;
Manganese = less than 0.4% ;
Phosphorus = less than 0.2% ;
Sulphur = less than 0.12%,
and the remaining is iron.
• The white colour is due to fact that it has no graphite and whole of the
carbon is in the form of carbide (known as cementite) which is the
hardest constituent of iron.
• The white cast iron has a high tensile strength and a low compressive
strength.
 Materials Science and Engineering
Classifications of engineering materials:
Types of Cast Iron
3. Chilled cast iron.
• It is a white cast iron produced by quick cooling of molten iron.
• The quick cooling is generally called chilling and the cast iron so
produced is called chilled cast iron.
• All castings are chilled at their outer skin by contact of the molten
iron with the cool sand in the mould.
• But on most castings, this hardness penetrates to a very small
depth (less than 1 mm).
 Materials Science and Engineering
Classifications of engineering materials:
Types of Cast Iron
4. Mottled cast iron.
• A product in between grey and white cast iron in composition, colour
and general properties.
• It is obtained in castings where certain wearing surfaces have been
chilled.
5. Malleable cast iron.
• It is a cast iron-carbon alloy which solidifies in the as-cast condition in
a graphite free structure, i.e. total carbon content is present in its
combined form as cementite (Fe3C).
• Ductile and may be bent without breaking or fracturing the section.
• The tensile strength of the malleable cast iron is usually higher than
that of grey cast iron and has excellent machining qualities.
 Materials Science and Engineering
Classifications of engineering materials:
Types of Cast Iron
6. Nodular or spheroidal graphite cast iron.
• It is also called ductile cast iron or high strength cast iron.
• This type of cast iron is obtained by adding small amounts of
magnesium (0.1 to 0.8%) to the molten grey iron.
• It has high fluidity, castability, tensile strength, toughness, wear
resistance, pressure tightness, weldability and machinability.
• It is generally used for castings requiring shock and impact
resistance along with good machinability, such as hydraulic
cylinders, cylinder heads, rolls for rolling mill and centrifugally cast
products.
 Materials Science and Engineering
Classifications of engineering materials:
Alloy Cast Iron
• The alloy cast iron is produced by adding alloying elements like
nickel, chromium, molybdenum, copper and manganese in
sufficient quantities.
• These alloying elements give more strength and result in
improvement of properties.
• The alloy cast iron has special properties like increased strength,
high wear resistance, corrosion resistance or heat resistance.
• The alloy cast irons are extensively used for gears, automobile
parts like cylinders, pistons, piston rings, crank cases, crankshafts,
camshafts, sprockets, wheels, pulleys, brake drums and shoes,
parts of crushing and grinding machinery etc
 Materials Science and Engineering
Classifications of engineering materials:
Effect of Impurities on Cast Iron
The effect of these impurities on the cast iron are as follows:
1. Silicon.
• It may be present in cast iron upto 4%. It provides the formation of free graphite
which makes the iron soft and easily machinable. It also produces sound castings
free from blow-holes, because of its high affinity for oxygen.
2. Sulphur.
• It makes the cast iron hard and brittle. Since too much sulphur gives unsound
casting, therefore, it should be kept well below 0.1% for most foundry purposes.
3. Manganese.
• It makes the cast iron white and hard. It is often kept below 0.75%. It helps to
exert a controlling influence over the harmful effect of sulphur.
4. Phosphorus.
• It aids fusibility and fluidity in cast iron, but induces brittleness. It is rarely
allowed to exceed 1%. Phosphoric irons Phosphorus is a non-metallicare useful
for casting of intricate design and for many light engineering element. It must be
 Materials Science and Engineering
Classifications of engineering materials:
Wrought Iron
• Purest iron which contains at least 99.5% iron but may contain upto 99.9% iron.
• Its typical composition:
Carbon = 0.020%,
Silicon = 0.120%,
Sulphur = 0.018%,
Phosphorus = 0.020%,
Slag = 0.070%,
and the remaining is iron.
• The wrought iron is produced from pig iron by remelting it in the puddling
furnace.
• The wrought iron is a tough, malleable and ductile material.
• It cannot stand sudden and excessive shocks.
• Its ultimate tensile strength is 250 MPa to 500 MPa and the ultimate
compressive strength is 300 MPa.
• Easily forged or welded. Used for chains, crane hooks, railway couplings, water
and steam pipes.
 Materials Science and Engineering
Classifications of engineering materials:
Sample photos of Wrought Iron
 Materials Science and Engineering
Classifications of engineering materials:
Sample photos of Wrought Iron
 Materials Science and Engineering
Classifications of engineering materials:
Polarized light gives false-colour
image.

Slabs of impure
iron

Iron is hammered to remove

impurities
A close look at cast iron

Wrought Iron
 Materials Science and Engineering
Classifications of engineering materials:
The ocean floor contains huge amounts of
manganese (a metal used in steel and
industrial processes). The manganese is in the
form of round lumps called nodules, mixed
with other elements, such as iron and nickel.
The nodules are dredged up by ships fitted
with hose lines which scrape and suck at the
ocean floor.

Suction line
Dredging rake

Nodules look rather like

hailstones.The minerals
are washed into the
sea by erosion of the
land. About one-fifth of
the nodule is
manganese.
 Materials Science and Engineering
Classifications of engineering materials:
Steel
• It is an alloy of iron and carbon, with carbon content up to a
maximum of 1.5%.
• The carbon occurs in the form of iron carbide, because of its ability
to increase the hardness and strength of the steel.
• Other elements e.g. silicon, sulphur, phosphorus and manganese
are also present to greater or lesser amount to impart certain
desired properties to it.
• Most of the steel produced now-a-days is plain carbon steel or
simply carbon steel.
• A carbon steel is defined as a steel which has its properties mainly
due to its carbon content and does not contain more than 0.5% of
silicon and 1.5% of manganese.
 Materials Science and Engineering
Classifications of engineering materials:
Sample photos of Steel
 Materials Science and Engineering
Classifications of engineering materials:
Steel
• Plain carbon steels varying from 0.06% carbon to 1.5% carbon are
divided into the following types depending upon the carbon
content.

1. Dead mild steel — up to 0.15% carbon

2. Low carbon or mild steel — 0.15% to 0.45% carbon
3. Medium carbon steel — 0.45% to 0.8% carbon
4. High carbon steel — 0.8% to 1.5% carbon
 Materials Science and Engineering
Density Values of engineering materials:

Bar chart of room temperature density values for various metals,

ceramics, polymers, and composite materials.
 Materials Science and Engineering
Elastic Modulus of engineering materials:

Bar chart of room temperature stiffness (i.e., elastic modulus) values

for various metals, ceramics, polymers, and composite materials.
 Materials Science and Engineering
Tensile Strength of engineering materials:

Bar chart of room temperature strength (i.e., tensile strength) values

for various metals, ceramics, polymers, and composite materials.
 Materials Science and Engineering
Toughness of engineering materials:

Bar chart of room-temperature resistance to fracture (fracture toughness)

for various metals, ceramics, polymers, and composite materials
 Materials Science and Engineering
Electric Conductivity of engineering materials:

Bar chart of room-temperature electrical conductivity ranges for

metals, ceramics, polymers, and semiconducting materials.
 Materials Science and Engineering

Assignment:
1. Watch You tube video about the four (4)
ways/method of determining Hardness of
Eng’g Materials
2. Show and report them next meeting by group.
3. I will be the one which method the group will
present.
 Materials Science and Engineering

Take Aways and Assignment:

1. Relax and Enjoy Studying
2. Don’t hesitate to ask questions
3. Solve Assignment Problems
4. Advanced Reading for next Topic
5. Pray……
6. Ingatz….
 Materials Science and Engineering

That’s all for today class,

God bless
and see you next meeting…