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28 views45 pages

EM Chapter1

Uploaded by

drsrajakumar
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© © All Rights Reserved
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MIME2204

Engineering Materials
Semester No. 1/Academic Year: 2018-19

Dr.P.SENTHIL
Lecturer in Mechanical Engineering
MIE Section

Office:ME212
Engineering Materials

“Material” means “object composed of matter”.


Matter is composition of small physical particles called atoms

“Engineering” means application of scientific knowledge


in the development of useful products to human beings

“Engineering Materials” means that the materials used


for engineering applications
CHAPTERS

CHAPTER 1: CLASSIFICATION OF MATERIALS

CHAPTER 2: PROPERTIES OF MATERIALS

CHAPTER 3: STRUCTURE OF MATERIALS

CHAPTER 4: SELECTION OF MATERIALS FOR DESIGN

CHAPTER 5: STANDARDS, SPECIFICATIONS AND CODES


CLASSIFICATION OF MATERIALS
METALS

Metals can be classified into two types:


Pure Metals
Alloys

Pure Metals may not be suitable for many Engineering


applications.
Alloys are mixture of two or more metals. Alloys with
suitable alloying elements have better properties than
pure metals.
Properties/Characteristics of Metals

 High melting points


 High density
 High strength
 Ductility - They can be easily made into wires
 Malleability- They can be easily made into sheets
 Formability-They can be easily made into different
shapes
 Good conductivity for heat and electricity
FERROUS METALS/ALLOYS
STEELS

Steel is Ferrous alloy with less than 2% carbon


(1) Plain Carbon Steel
An alloy of iron and carbon, however it also contains
lesser amount of other elements like silicon, manganese,
sulphur, phosphorus, nickel ,etc

Depending upon the carbon content, it can be classified


into three types.
 Low-carbon steels
 Medium-carbon steels
 High-carbon steels
Low-carbon steel has carbon content less than 0.3% and
also known as mild steel
 Relatively soft and weak
 Can be formed to different shapes easily
 Can be welded easily
 Cannot be hardened appreciably by heat treatment

Applications: structural shapes (I-beams, channel, and


angle iron) used in buildings, bridges, automobile body, etc
Applications: structural shapes (I-beams, channel, and
angle iron) used in buildings, bridges, automobile body, etc
Medium-Carbon Steels have carbon content between
0.3% and 0.8%.
 High strength
 High hardness
Applications: railway wheels, railway tracks, gears,
crankshafts, and other machine parts.
High-Carbon Steels have carbon content greater than
0.8%.
 hardest and strongest among the carbon steels
 least ductile (i.e., more brittle) among the carbon steels
Applications: knives, razors, hacksaw blades, springs, high-
strength wire Cutting tools and dies.
(2) Alloy Steel

Steel with suitable alloying elements in addition to


carbon.
Alloying elements could be any one or a combination of
other metals like chromium, nickel, molybdenum,
vanadium, tungsten, cobalt, boron, and copper

Examples: High Speed Steel (HSS) and Stainless Steel


High Speed Steel
Composition: 18% tungsten, 4% Chromium, 1% Vanadium,
0.7% carbon and the rest is Iron.
Suitable for cutting tools because of high hardness, high
strength, high toughness and low cost
Stainless Steel is an alloy of iron, carbon, chromium, and other
elements that resist corrosion from many environments.
Chromium remains as a predominant element for corrosion
resistant. It is also known as corrosion-resistant steel.
CAST IRON

 Cast Iron is Ferrous alloy with greater than 2% carbon


 Also contains small amounts of silicon, sulphur,
manganese, phosphorus, etc.
(i) Gray Cast Iron
 Graphitic microstructure
 Gray color due to graphite
• excellent compressive strength
• good torsional strength
• shear strength
Applications: engine cylinder, break drum, cam shaft,
pipes, rolling mills etc.
(ii) White Cast Iron
 white or silvery appearance
 very hard and brittle
 high abrasion resistance
 high tensile strength
 low compressive strength
Applications: rolls, wear plates, and pump linings, etc
(iii) Malleable Cast Iron
 significant ductility and malleability
 good castability, shock-resistance, and machinability

Applications: brake-shoes, pedals, levers, wheel-hubs,


axle-housings, connecting rods, transmission gears, and
door hinges
(iv) Spheroidal Graphite Cast Iron
 Also known as Ductile iron, nodular
cast iron, spheroidal graphite iron
and SG iron
 more impact and fatigue resistance
due to its nodular graphite
inclusions
Applications: Ductile iron pipe used
for water and sewer lines.
NON-FERROUS METALS

Contain a metal other than iron as their main


constituent
Examples: Copper, Aluminum, Lead, Magnesium,
Nickel, Tin, Titanium, Zinc, etc.
 Light-weight
 High thermal and electrical conductivity
 Excellent corrosion resistance
 Non-toxic
 Soft and ductile for ease of fabrication
ALUMINUM

 Light-weight (one-third the weight of steel)


 High thermal and electrical conductivity
 Excellent corrosion resistance
 Non-toxic
 Soft and ductile
 Low specific gravity
 High strength-to-weight ratio
Applications: parts of airplane, cooking utensils, electric
wires, window frames, glazing bars, corrugated sheets,
foils, posts, furniture, precision surveying instruments,
surgical instruments, automobile frames, engines, etc.
COPPER

 Light-weight (one-third the weight of steel)


 Very high electrical conductivity
 Very high thermal conductivity
 Excellent resistance to corrosion
 Very soft, ductile and malleable

The important copper alloys are:


 Brass (copper-zinc alloy)
 Bronze (copper-tin alloy)
 Gun-metal (copper-tin-zinc alloy)
Applications: used for manufacturing power cables,
motor winding, car radiators, printed circuit boards,
cooking utensils etc.
POLYMERS

 Compounds of carbon, hydrogen, oxygen or other non


metallic molecules joined together in long chains.
 Formed by polymerization reaction

Properties of Polymers
 Good insulators of heat and electricity
 Have moderate strength
 Corrosion resistant
 Light in weight
 Ductile and malleable
 Have low melting points
Types of Polymers
Thermoplastics
Thermosetting Plastics
Elastomers

(i) Thermoplastics
 Can be easily softened and reshaped again and again by
heating.
 Examples: Polyethylene, Nylon, PVC etc.
Applications: cable covers, polyethylene carry bags,
PVC pipes, bottles, gears, etc.
Applications of Thermoplastics
(ii) Thermosetting Plastics
Cannot be softened and reshaped by re-heating once set
into shape by heating and curing.
Examples: Polyester, Bakelite etc.
Applications: Furniture, Switches, electric plugs etc.
(iii) Elastomers
 Highly elastic in nature
 Stretched upto twice their original length and on
releasing the force they regain their original shape and
size.
Example: Rubber
Applications: Automobile tyres and tubes
CERAMICS

Ceramics are metallic and non-metallic oxides, carbides


or nitrides
 Very hard compared to other engineering materials
 Brittle materials
 Heat resistant materials / Refractory Materials
 Very high melting points
 Corrosion resistant
 Insulators of heat and electricity

Examples: Aluminum Oxide (Alumina), Silicon


Nitride, Tungsten Carbide, Glass, Cement, Sand.
Types of Ceramics

(i) Domestic Ceramics


Clay: Aluminum silicate can be mixed with water and
then the water will be dried off and then heated to high
temperature.
Cement: Calcium Oxide, silica and alumina. It becomes
very hard when treated with water.
(ii) Engineering Ceramics
Oxides: Alumina has high thermal and electrical
resistance used as a cutting tool and high
quality thermal and electrical insulation
Carbides: Tungsten and Titanium carbides are very
hard materials used for cutting tools
Nitrides: Silicon nitrides and Boron nitrides used in
engine parts and cutting tools
(iii) Natural Ceramics
Available in the nature as a result of biological or
geological processes. Two types of Natural ceramics are
as under:

Carbonaceous materials: Chalk, Lime stone and marble


Silicaceous materials : Granite and Basalt
COMPOSITES
Composed primarily of matrix i.e. a continuous phase,
which is protected with reinforcement (secondary phase),
i.e. a discontinuous phase
Classification of Composites
Advantages of Composites
higher strength, toughness, stiffness, but also a higher
resistance to creep, corrosion, wear or fatigue
compared to conventional materials

Disadvantages of Composites
difficult in workability and relatively higher price

Application of Composites
aircraft, military aircraft, missiles, helicopters, space
hardware, automobile and trucks, electrical and
electronics, marine applications, etc
SEMICONDUCTORS
The electronic components like, diodes, transistors,
capacitors etc. are made by using semiconducting
materials
Examples: Silicon and Germanium
ADVANCED MATERIALS

Materials used in "High-Tec" applications, usually


designed for maximum performance, and normally
expensive.

Examples:
 Titanium alloys for supersonic airplanes
 Magnetic alloys for computer disks
 Special ceramics for the heat shield of the space
shuttle

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