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CLASSIFICATIONS AND SELECTION

OF ENGINEERING MATERIALS

Dr. Madan Lal Chandravanshi


Assistant Professor
Mechanical Engineering
Department, IIT(ISM) Dhanbad

Chapter 1 -
Course Objectives...
To introduce students to a wide range of modern
materials engineering topics.

You will learn about:

• Material structure
• How structure dictates properties
• The impact of materials on society

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?

Chapter 1 -
History of Materials Science & Engineering
• Materials closely connected our culture
• The development and advancement of societies are
dependent on the available materials and their use
• Early civilizations designated by level of materials
development

• Initially natural materials develop techniques to produce


materials with superior qualities (heat treatments and
addition of other substances)
MATERIALS SELECTION! Chapter 1 -
Chapter 1 -
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Chapter 1 -
Materials Science and Engineering
• arrangement of internal
structure components
• subatomic
• atomic
• microscopic
• macroscopic (bulk)
characterization
processing properties
• material
• method of
characteristic
preparing
• response to external
material
performance stimulus
• behavior in a • mechanical,
particular electrical, thermal,
application magnetic, optical,
Chapter 1 -
deteriorative
Chapter 1 -
Types of Materials
• Metals:
– Strong, ductile
– High thermal & electrical conductivity
– Opaque, reflective.
• Polymers/plastics: Covalent bonding sharing of e’s (electrons)
– Soft, ductile, low strength, low density
– Thermal & electrical insulators
– Optically translucent or transparent.

• Ceramics: ionic bonding – compounds of metallic &


non-metallic elements (oxides, carbides, nitrides,
sulfides)
– Brittle, glassy, elastic
– Non-conducting (insulators) Chapter 1 -
Classification of Materials
Metals Ceramics & Polymers
• good conductors of Glasses • very large
electricity and heat • thermally and electrically molecules
• lustrous appearance insulating • low density, low
• susceptible to • resistant to high
corrosion weight
temperatures and harsh
• strong, but environments • maybe extremely
deformable • hard, but brittle flexible

Chapter 1 -
Classification of Materials: A Few Additional
Catagories
Biomaterials Semiconductors Composites
• implanted in • electrical properties • consist of more
human body between conductors than one
• compatible and insulators material type
with body • electrical properties • designed to
tissues can be precisely display a
controlled combination of
properties of
each component

Hip replacement Intel Pentium 4 Fiberglass surfboards


Chapter 1 -
Why study materials?
• Applied scientists or engineers must make material choices
• Materials selection
– In-service performance
– Deterioration
– Economics

BUT…really, everyone makes material choices!


Aluminum Glass Plastic

Chapter 1 -
Bar-chart of room temperature density values

Glass Fiber Reinforced Concrete.


Carbon fibre reinforced carbon (CFRC)

Atoms in metals and their alloys are arranged in a very orderly manner
and in comparison to the ceramics and polymers, are relatively
Chapter 1 -dense
Bar-chart of room temperature Stiffness
Ceramics: Ceramics are compounds between metallic and
nonmetallic elements; they are most frequently oxides, nitrides,
and carbides. For example, some of the common ceramic

Chapter 1 -
Bar-chart of room temperature strength

Ceramics are typically very hard. On the other hand, they are
extremely brittle (lack ductility), and are highly susceptible to
fracture

Chapter 1 -
Bar-chart of room-temperature resistance to
fracture

Chapter 1 -
Bar-chart of room temperature electrical
conductivity

Chapter 1 -
Metal Applications
Metal Applications
• Electrical wire: aluminum, copper, silver
• Heat transfer fins: aluminum, silver
• Plumbing: copper
• Construction beams (bridges, sky scrapers,
rebar, etc.): steel (Fe-C alloys)
• Cars: steel (Fe-C alloys)
• Consumer goods:
– soup cans
– appliances (stainless steel sheet metal)
– utensils
– tools
– Many, many, many more…

Chapter 1 -
Advanced Applications Metals
• Hydrogen-absorbing metal alloys for energy transportation
or batteries
– Electorlyzed hydrogen from water (fuel cell technology) can be
stored in tanks fabricated from Hydrogen-absorbing metal alloys
(HAMA)
– Nickel Metal Hydride (Ni-MH) batteries use the same principle, but
to improve battery self discharge
– Volume density is significantly higher for gaseous hydrogen; more
hydrogen per tank
• Typical alloys consist of Mn-Ti-V, Mg-Ni, Zr-Mn/Ti/V, Mn-Ni,
La-Ni.
• BCC metals show higher storage and desorption
properties
• Some metals can absorb a gas densities equivalent to
liquid hydrogen densities
Chapter 1 -
Polymer Clay (Sculpey, FIMO)
• Polyvinyl chloride (PVC) long chain or high
molecular weight polymer
• Thermoplastic: polymer that melts to a liquid
when heated and freezes to a brittle, glassy state
when cooled
• as-purchased a plasticizer is added to keep clay
malleable
• heating the clay decomposes the plasticizer
hardening the clay

without plasticizer: polymer clay is brittle at room temperature

with plasticizer: polymer clay is malleable at room temperature


- the plasticizer acts as a lubricant putting space between chains and Chapter 1 -
allowing them to slide passed each other
Polymer Applications
• Car tires: vulcanized polymer (added sulfur)
• Ziploc bags
• Food storage containers
• Plumbing: polyvinyl chloride (PVC)
• Kevlar
• Aerospace and energy applications: Teflon
• Consumer goods:
– calculator casings
– TV consuls
– shoe soles
– cell phone casings
– Elmer’s Glue (adhesives)
– contact lenses
– Many, many. many more…
Chapter 1 -
Advanced Applications Polymers
• Self-decontaminating polymers
– medical, military, security and environmental
applications
– current applications: look for attachment to textiles for
self toxin cleaning fabrics (that is, chemical scavenging
and cleaning clothing)
• Sulphonated polyether polyetherketone (SPEEK)
and
• polyvnvyl alcohol (PVA) aqueous solutions
• Excite solutions with light to form strong reducing
benzophenyl ketyl (BPK) radicals; helps break
down organic toxic chemicals
Chapter 1 -
Ceramic Applications

• Window glass: Al2O3 – SiO2 – MgO – CaO


• Aerospace, energy and automotive industry
– heat shield tiles
– engine components
– reactor vessel and furnace linings

• Consumer products:
– pottery
– dishes (fine china, plates, bowls)
– glassware (cups, mugs, etc.)
– eye glass lenses
Chapter 1 -
Composites
• A mixture of two different materials to create a new material
with combined properties
• Types of composites:
– Particulate reinforced – discontinuous type with low aspect ratio
– Whisker/rod reinforced - discontinuous type with high aspect ratio
– Fiber reinforced - continuous type with high aspect ratio (naturally)
– Laminated composites - layered structures (surf boards, skate
boards)
• Bonding: depends on type of composite (strong-covalent,
medium-solid solution, weak-tertiary phase layer)
• Properties: Depends on composites
– High melting points with improved high temperature strength:
ceramic-ceramic
– High strength and ductile with improved wear resistance: metal-
ceramic
– High strength and ductile: polymer-polymer Chapter 1 -
Composites: Applications

• Wood: naturally occurring biological material


consists of very strong fibers imbedded in a
soft matrix

• Plywood: laminated wood for buildings

• Concrete: basements, bridges, sidewalks

• Fiberglass: boats

• Carbon fiber resins: bicycle frames Chapter 1 -


Advanced Applications Ceramics &
Composites
Structural materials for use in hypersonic aircraft Next-generation re-
entry vehicles
Why is the space shuttle shaped the
way it is?

To reduce the amount of heat


generated upon re-entry.

Chapter 1 -
Materials of the Future
Smart (or intelligent) materials are a group of new and state-of-the-art materials now
being developed that will have a significant influence on many of our technologies.

Biomaterials are employed in components implanted into the human body for
replacement of diseased or damaged body parts.

Shape memory alloys are metals that, after having been deformed, revert back to
their original shapes when temperature is changed

Piezoelectric materials, Electro rheological and Magneto rheological fluids


Chapter 1 -
The Materials Selection Process
1. 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.

Chapter 1 -
ELECTRICAL
• Electrical Resistivity of Copper:
6 Adapted from Fig. 18.8, Callister &
Rethwisch 8e. (Fig. 18.8 adapted
from: J.O. Linde, Ann Physik 5, 219
5 (1932); and C.A. Wert and R.M.
Resistivity, r

Thomson, Physics of Solids, 2nd


(10-8 Ohm-m)

edition, McGraw-Hill Company, New


4 York, 1970.)

3
2
1
0
-200 -100 0 T (ºC)
• Adding “impurity” atoms to Cu increases resistivity.
• Deforming Cu increases resistivity.
Chapter 1 -
THERMAL
• Space Shuttle Tiles: • Thermal Conductivity
-- Silica fiber insulation of Copper:
offers low heat conduction. -- It decreases when
you add zinc!

Thermal Conductivity
400

300

(W/m-K)
200

100
0
0 10 20 30 40
Composition (wt% Zinc)

Adapted from Fig. 19.4, Callister & Rethwisch


100 mm 8e Chapter 1 -
MAGNETIC
• Magnetic Permeability
• Magnetic Storage: vs. Composition:
-- Recording medium -- Adding 3 atomic % Si
is magnetized by makes Fe a better
recording head. recording medium!

Magnetization
Fe+3%Si

Fe

Magnetic Field

Fig. 20.23, Callister & Rethwisch 8e.

Chapter 1 -
OPTICAL
• Transmittance:
-- Aluminum oxide (Al2O3) 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 & Rethwisch 8e.
(Specimen preparation,
P.A. Lessing; photo by S.
Tanner.)

Chapter 1 -
DETERIORATIVE
• Stress & Saltwater... • Heat treatment: slows
-- causes cracks! crack speed in salt water!

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
4 mm
-- material:
7150-T651 Al "alloy"
(Zn,Cu,Mg,Zr)

Adapted from chapter-opening photograph, Chapter 16, Callister &


Rethwisch 3e. Chapter 1 -
Example/Demo: Environmental
Stress Cracking

Chapter 1 -
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.

Chapter 1 -

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