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Metallurgy and Materials Engineering

(PRPC12, 3-0-0)
Section: A
3rd Semester
Production Engineering

Matruprasad Rout, PhD


Assistant Professor
Dept. of Production Engineering
National Institute of Technology Tiruchirappalli
Tamil Nadu- 620015, India
Email: matruprasad@nitt.edu
Course content
❖ Art and science of metallurgy-structure of metals and alloys-phase and structural
constitutions- Equilibrium diagrams.

❖ Ferrous metals and alloys-Fe-Fe3C diagram-Effect of alloying elements in steel,


Classification of ferrous alloys and their applications.

❖ Heat treatment of steel-CCT diagram-Surface hardening process-Non Ferrous Metals


Alloys- composition-properties and applications of copper, nickel, lead, tin, zinc,
aluminium, Mg and Ti alloys-Heat treatment of Non Ferrous alloy

❖ Metals and alloys-ceramic material- polymers-composite material – Nano-structured


materials.

❖ Testing of Materials-Non-Destructive Testing, Tensile testing, compression testing -


Hardness Testing, Impact testing, Fatigue testing, Creep, other related testing

❖ Different material characterization techniques: TEM, XRD, SEM.


MME (PRPC12)- July. 2024 2
Course outcome

✓ Interpret microstructure of engineering materials and explain


Equilibrium diagrams

✓ Understand iron-carbon equilibrium diagram

✓ Application of different ferrous and non-ferrous alloys

✓ Understand heat treatment processes for ferrous and non-ferrous

✓ Understand different material testing and material characterization


techniques

MME (PRPC12)- July. 2024 3


Books to Refer
1. Raghavan V, Physical Metallurgy - Principles and Practice, Prentice -
Hall of India, 2nd Edition, 2007.

2. Avner S.H., Introduction to Physical Metallurgy, Tata McGraw Hill, 2nd


edition, 2008

3. Dieter G. E., Mechanical Metallurgy, McGraw Hill Co- Koga, 1st


Edition, 2002

4. Callister W. D., Rethwisch D. G., Material Science and Engineering,


Willey & Sons, 8th edition, 2010

5. Suryanarayana AVK, Testing of Metallic Materials, BS Publications, 2nd


Edition, 2007
MME (PRPC12)- July. 2024 4
Course Assessment Methods
Mode of Week/Date Duration %
Assessment Weightage
Mid-semester 90 Minutes 30
Quiz test 15 Minutes 10
Wednesday: 8.30 to 9.20 am

Assignment --------- 20 Thursday: 9.20 to 10.10 am

Compensation 90 Minutes 30 Friday: 10.30 to 11.20 pm


Assessment
Final Assessment 180 Minutes 40
Assessment

Mid-Sem.
Final 30%
Assessment
40%

Room No. 116


Ground Floor, OJAS
Quiz test
10%
Assignment
20%
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METALLURGYis science and technology of metals.
Process or Extractive Metallurgy: the science of obtaining metals from their ores
which includes mining, concentration, extraction, and refining
Physical Metallurgy: the science concerned with structure and properties of metals
and alloys.
• Chemical composition/constituents
• Mechanical Metallurgy/Working: response of metals or alloys to force or load
• Engineering Metallurgy/Heat treatment
MATERIALS are inanimate substance used by an engineer in the practice of his/her
profession.
MATERIALS SCIENCE involves investigating the relationships that exist between
the structures and properties of materials.
MATERIALS ENGINEERING is, on the basis of these structure-property
correlations, designing or engineering the structure of a material to produce a
predetermined set of properties.
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Why to study the subject?
✓ Selecting the right material from the thousands of available materials
• rare occasions does a material possess the maximum or ideal combination of
required properties
• it may be necessary to trade one characteristic for another e.g. a material having a
high strength will have only a limited ductility
• a reasonable compromise between two or more properties may be necessary
✓ Selecting material considering any deterioration of material properties that may
occur during service operation
• reductions in mechanical strength may result from exposure to elevated
temperatures or corrosive environments
✓ Cost of the finished product
• a material may be found that has the ideal set of properties but is prohibitively
expensive, again, some compromise is inevitable.
✓ more familiar an engineer or scientist is with the various characteristics and
structure–property relationships, processing techniques of materials, the more
proficient and confident he or she will be in making judicious materials choices
based on these criteria
MME (PRPC12)- July. 2024 7
Evolution of material

➢ 4000 – 2000 BC Copper Age


➢ 2000 – 1000 BC Bronze Age, i.e. (Cu, Sn) alloys, invention of metallurgy
➢ 1000 – 1 BC Iron Age
➢ ~ 1650 Classical physics – Mechanics
➢ ~ 1800 Metallography / Crystallography
➢ ~ 1900 Physical Metallurgy, Crystal Physics, Statistical Physics, Modern Physics,
Sold State Physics
➢ 1947 invention of transistor at Bell Labs (Ge),
➢ ~ 1950 Materials Science and Engineering
➢ ~ 1955 Silicon (electronic materials, information technology) Age
➢ 21st century Nanoscience and Technology
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Evolution of engineering materials in Products

MME (PRPC12)- July. 2024 10


Container for carbonated beverages

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The material used for container for carbonated beverages must satisfy the
following constraints:

a) Provide a barrier to the passage of carbon dioxide, which is under pressure in


the container;

b) Be nontoxic, unreactive with the beverage, and, preferably be recyclable;

c) Be relatively strong, and capable of surviving a drop from a height of several


feet when containing the beverage;

d) Be inexpensive and the cost to fabricate the final shape should be relatively
low;

e) If optically transparent, retain its optical clarity; and

f) Capable of being produced having different colors and/or able to be adorned


with decorative labels.

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ALUMINIUM ALLOY:
• RELATIVELY STRONG (BUT EASILY DENTED),
• IS A VERY GOOD BARRIER TO THE DIFFUSION OF CARBON DIOXIDE,
• IS EASILY RECYCLED,
• BEVERAGES ARE COOLED RAPIDLY,
• LABELS MAY BE PAINTED ONTO ITS SURFACE,
• OPTICALLY OPAQUE, AND
• RELATIVELY EXPENSIVE TO PRODUCE

GLASS:
• IS IMPERVIOUS TO THE PASSAGE OF CARBON DIOXIDE,
• RELATIVELY INEXPENSIVE MATERIAL,
• MAY BE RECYCLED,
• IT CRACKS AND FRACTURES EASILY, AND
• GLASS BOTTLES ARE RELATIVELY HEAVY

PLASTIC:
• IS RELATIVELY STRONG,
• MAY BE MADE OPTICALLY TRANSPARENT,
• IS INEXPENSIVE AND LIGHTWEIGHT,
• IS RECYCLABLE, AND
• IT IS NOT AS IMPERVIOUS TO THE PASSAGE OF CARBON DIOXIDE AS THE ALUMINUM AND GLASS
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TYPES OF ENGINEERING MATERIALS

All the materials used for the engineering applications can be put into six basic:

➢ Pure substances (including metals)


➢ Alloys (ferrous and non-ferrous)

➢ Polymers (plastics and rubber or elastomers)


➢ Ceramics

➢ Composites
➢ Some recent advances: shaper memory materials, nano-materials

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Basic Sub Sub-sub Typical
Category Category Category Examples
PURE SUBS- Metals Ductile: Face Centered Al, Cu, Ni, Pb, Ag, Au, Ca, Pt,
TANCES Cubic (FCC) Austenite ( - Iron)
Hard: Body Centered Cr, V, Mn, Ferrite (-Iron),
Cubic (BCC) Refractory Metals: Mo, Nb (or
Columbium), Ta, W
Hexagonal Ti, Be, Cd, Co, Mg, Zn, Zr
Close-Packed
(HCP)
Non-Metals Carbon, Graphite
Semi Intrinsic Si, Ge
Conductors Extrinsic n-type Doped with FIFTH-column
[Hard and elements, i.e., P, As, Sb
brittle]
p-type Doped with THIRD-column
Elements, i.e., B, Al, Ga, In

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Basic Sub- Sub-sub Typical
Category Category Category Examples
ALLOYS Ferrous Cast Irons (CI) Gray, White, Malleable, Nodular (SG),
Alloys and Compacted
Homogen Plain Carbon Steels Low (Mild Steel), Medium, and High
ous Carbon Steels
Mixture
of two or Alloy Steels Constructional and High-Strength Low
more than Alloy (HSLA) or Micro-Alloyed
two Stainless Steels Ferritic, Martensitic, Austenitic, and
elements Duplex
Tool Steels Seven Basic Families Including HSS
Non- Cu-based Alloys Brasses, Cupronickel, Bronzes,
Ferrous Constantan etc.
Alloys Al-based Alloys Duralumin, Hindalium, Magnalium
Ni-based Alloys Monel, Nichrome
Ti-based Alloys , , and -Type
Co-based Alloys Stellite
Super- Ni-based Inconel, Rene, Hastelloy, Waspaloy,
alloys Udimet
Co-based Haynes
Fe-Ni Based Illium, Incoloy etc.
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Basic Sub Sub-sub Typical
Category Category Category Examples
POLYMERS PLASTICS Thermoplastics ABS (Acrylonitrile-butadiene-
[Natural or (Flexible and Styrene), Acetal, Nylon, Vinyl,
[Long-Chain Synthetic Resins Tough) Fluorocarbons (Teflon), Acrylics
Molecules or or their (Plexiglass or Lucite),
Macro- Compounds] Polyethylene, Polypropylene,
molecules Polystyrene, Polycarbonate, etc.
Formed by Thermosetting Plastics, Epoxies, Bakelite,
Linking and (Strong and Phenolics, Melamines, Polyester,
Cross-linking Brittle) Silicone, Urea,
of Different
Monomers] ELASTOMERS Natural Natural rubber
OR Artificial or EDPM (Ehtylene Propylene),
RUBBER Synthetic Styrene Butadiene (SBR),
[Special Class of Urethanes, Silicone Rubber,
Linear Polymers] Neoprene, Polyacrylate,
Polyisoprene, Polybutadiene,
Polysulfide, Fluoroelastomers,
Ebonite

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Basic Sub Sub-sub Typical
Category Category Category Examples
CERAMICS Crystalline Refractories Acidic Silica (SiO2), and Alumina (Al2O3)
structure type based
Compounds Basic type Magnesite (MgO), Olivine (Mgo-
of Metallic SiO2) based
and Non-
Metallic Neutral Chromite (Cr2O3), and Chromite-
Elements in type magnesite
the form of Abrasives Natural Diamond, Quartz, Emery, Garnets,
Carbides, Sand, Corundum
Oxides,
Nitrides Artificial Aluminum Oxide, Silicon Carbide
(SiC), Silicon Nitride (Si3N4),
Cubic Boron Nitride (CBN), Boron
Carbide, Poly Crystalline Diamond
(PCD)
Structural Ceramics Artificial Abrasives, Sialon,
Zirconia, Titanium Diboride
Insulators Porcelain
Precious Mineral Ruby, Sapphire, Topaz, Emerald,
Stones Coral, Agate, Mother of Pearl etc.
Sheet Structure Mica (Muscovite)
Double chain Structure Asbestos (Tremolite)
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Basic Sub Sub-sub Typical
Category Category Category Examples
CERAMICS Amorphous or Glasses Silica, Borosilicate, Soda-lime,
(Contd.) Non-crystalline Magnesia, Vycor-type glasses etc.
Structure
Crystalline and Glass Ceramics Pyroceram
Amorphous Cermets Ceramics in Metallic Binder
both

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Basic Sub Sub-sub Category Typical
Category Category Examples
COMPOSITES Laminar or Laminates Plywood, Safety Glass,
layered type ARALL, Formica, etc.
[Heterogeneous [having distinct Bimetallic Strips Alclad, US coinage etc.
Solid of Two or layers of materials
More Materials bonded together] Sandwich Materials Corrugated Cardboard,
Bonded Together Honeycomb Structures
Mechanically or Particulate type Coarse Particles Cemented or Sintered
Metallurgically] [Discrete particles Carbides
of one material Concrete, Asphalt
surrounded by
matrix of another] Dispersion TD-nickel, Sintered
Strengthened Aluminum Powder (SAP)
Materials
Fiber-Reinforced Wood, Bamboo, Steel-
Composites Reinforced Concrete, Glass
(FRC) Fiber Reinforced Plastics
(GFRP), Fiberglass

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Basic Sub Sub-sub Typical
Category Category Category Examples
COMPOSITES Advanced Polymer Matrix Glass-epoxy, Boron-epoxy,
(Contd..) FRC Composites (PMC) Graphite-epoxy, Kevlar-epoxy
Or composites
Fiber Reinforced
Plastics (FRP)
Metal Matrix Aluminum reinforced with
Composites (MMC) graphite, Al2O3 , or SiC
Carbon Carbon Graphite fibers in carbon
Composites (CCC) matrix
Ceramic Matrix Silicon nitride reinforced with
Composites (CMC) silicon carbide

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Basic Sub Sub-sub Typical
Category Category Category Examples
MISCELLANEOUS Organic Paper
MATERIALS
Textiles
Leather Natural
Synthetic
Wood Maple, Oak, Pine, Spruce, Teak, Deal,
Aspen, Knot, Fir, Hickory etc.
Miscellaneous Delrin, Lexan, Mylar
Inorganic Rocks Granite, Gypsum, Limestone,
Sandstone, Plaster-of-Paris etc.
Cement
Miscellaneous Spinel

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SHAPE MEMORY MATERIALS

➢ DEFINITION: Shape memory materials (SMM) are those materials which, after
being deformed PLASTICALLY (i.e., PERMANENTLY) at the room temperature
into various shapes, return to their original shapes upon heating.

➢ EXAMPLES: Typical shape memory alloys are:


❖ 55% Ni-45%Ti
❖ Copper-Aluminum-Nickel
❖ Copper-Zinc-Aluminum
❖ Iron-Manganese-Silicon

➢ CHARACTERISTICS:
❖ SMM have good ductility, good corrosion resistance, high electrical conductivity
❖ Behavior of SMM can also be reversible i.e., shape can switch back and forth
upon heating

➢ APPLICATIONS:
❖ To generate motion and/or force in temperature-sensitive actuators
❖ Eyeglass frames, connectors, clamps, fastener, and in seals
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NANO-MATERIALS
➢ DEFINITION: Materials with grains, fibers, films, and composites having particle
size of the order of 1-100 nm.

➢ EXAMPLES: Any combination of chemical elements:


❖ Important compositions are carbides, oxides, nitrides, metals and alloys, organic
polymers and various composites.

➢ ALTERNATIVE NAMES: Nano-crystalline materials, nano-structured materials,


nano-phase materials , nano-powders, nano-wires, nano-tubes, nano-films etc.

➢ CHARACTERISTICS:
❖ Since synthesis is done at atomic level, their purity and homogeneity (99.9999
%), and uniformity of their microstructure is Highly Controlled → Their
mechanical, physical, and chemical properties can be precisely controlled.
❖ Properties such as strength, ductility, hardness, wear resistance, corrosion
resistance, that frequently superior to traditional and commercially available
materials.
❖ Unique electrical, magnetic, and optical properties.

➢ APPLICATIONS:
Powders for Powder Metallurgy Processing, Cutting Tools and Inserts, Computer
Chips Using Nano-Crystalline Materials, Spark-Plug Electrodes, High-Sensitivity
Sensors, High Energy Density Batteries
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THE FOUR COMPONENTS OF THE DISCIPLINE OF MATERIALS SCIENCE AND
ENGINEERING AND THEIR INTERRELATIONSHIP

Aluminum Oxide

transparent translucent opaque


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Properties of Engineering Materials
• A property is a material trait in terms of the kind and magnitude of response to a
specific imposed stimulus.
• Generally, definitions of properties are made independent of material shape and size.
PROPERTY
➢ Mechanical Properties MODIFICATION
➢ Thermal Properties
STRUCTURE ➢ Chemical Properties ➢ Heat treatment
OF ➢ Electrical Properties ➢ Annealing
MATERIAL ➢ Optical Properties ➢ Tempering
➢ Normalizing
➢ Magnetic Properties ➢ Hardening
➢ Atomic bond: ➢ Mechanical Working
metallic, ionic, and ➢ Alloying
covalent ➢ Reinforcements
➢ Crystalline Structure of a material usually ➢ Composites
➢ Amorphous or relates to the arrangement of its ➢ Laminations
Non-crystalline ➢ Fillers
➢ Partly crystalline internal components. ➢ Surface treatment
➢ Polymer chains
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STRUCTURE OF MATERIALS

1. Atomic structure;
2. Short- and long-range atomic arrangements;
3. Nanostructure;
4. Microstructure; and
5. Macrostructure.

Amorphous: Short-range atomic arrangements (1 to 10 Å)

Crystalline: Long-range atomic arrangements (from 10 nm to cm)

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Amorphous solids Crystalline solids
1. Lacks well-defined shape 1. Definite characteristic geometrical shape
2. Only short-range order 2. Long range order (arrangement of particles are
very regular)
3. Gradually soften over a range of 3. Melt at a sharp and characteristic temperature
temperature
4. They do not have definite heat of 4. They have a definite and characteristic heat of
fusion fusion (melts at a particular temp.)
5. Isotropic in nature 5. Anisotropic in nature

6. Pseudo solids or super-cooled 6. True solids (definite shape)


liquids

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ATOMIC ARRANGEMENTS: LONG-RANGE ORDER (LRO)

(10 nm to cm)

PIEZOELECTRIC PZT-BASED GAS IGNITERS. WHEN THE PIEZOELECTRIC MATERIAL IS STRESSED (BY
APPLYING A PRESSURE), A VOLTAGE DEVELOPS AND A SPARK IS CREATED BETWEEN THE ELECTRODES.

Lead-zirconium-titanate [Pb(ZrxTi1-X)O3] or PZT: When ions in this material


are arranged such that they exhibit tetragonal and/or rhombohedral crystal
structures, the material is piezoelectric (i.e., it develops a voltage when
subjected to pressure or stress). PZT ceramics are used widely for many
applications including gas igniters, ultrasound generation, and vibration control.

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ATOMIC ARRANGEMENTS: SHORT-RANGE ORDER (SRO)
(1 to 10 Å)

Optical fibres based on a form of silica that is amorphous

Ions in silica (SiO2) glass exhibit only a short-range order in which Si+4 and O-2 ions
are arranged in a particular way (each Si+4 is bonded with O-2 ions in a tetrahedral
coordination, with each O-2 ion being shared by two tetrahedra). This order, however,
is not maintained over long distances, thus making silica glass amorphous. Amorphous
glasses based on silica and certain other oxides form the basis for the entire fibre-optic
communications industry.
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NANOSTRUCTURE

(10-9 to 10-7 m, 1 to 100 nm)

FERROFLUID

Nano-sized particles (5–10 nm) of iron oxide are used in ferrofluids or


liquid magnets. An application of these liquid magnets is as a cooling
(heat transfer) medium for loudspeakers.

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MICROSTRUCTURE

(>10-7 to 10-4 m, 0.1 to 100 m)

Micrograph of stainless steel showing grains and grain boundaries

The mechanical strength of many metals and alloys depends very strongly on the
grain size. The grains and grain boundaries in this accompanying micrograph of
steel are part of the microstructural features of this crystalline material. In
general, at room temperature, a finer grain size leads to higher strength. Many
important properties of materials are sensitive to the microstructure.
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MACROSTRUCTURE

(>10-4 m, > 100,000 nm or 100 m)

A NUMBER OF ORGANIC AND INORGANIC COATINGS PROTECT THE


CAR FROM CORROSION AND PROVIDE A PLEASING APPEARANCE

Relatively thick coatings, such as paints on automobiles and other


applications, are used not only for aesthetics, but to provide corrosion
resistance.
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ATOMIC BONDING

There are four important mechanisms by which atoms are bonded in engineered
materials. These are:

1. Metallic bonds;
2. Covalent bonds;
3. Ionic bonds; and
4. Van der waals bonds.

The first three types of bonds are relatively strong and are known as primary
bonds (relatively strong bonds between adjacent atoms resulting from the transfer
or sharing of outer orbital electrons).

The van der waals bonds are secondary bonds and originate from a different
mechanism and are relatively weaker.

MME (PRPC12)- July. 2024 35


THE METALLIC BOND
❑ The metallic elements have electropositive
atoms that donate their valence electrons to
form a “sea” of electrons surrounding the
atoms.

❑ The valence electrons move freely within


the electron sea and become associated with
several atom cores.

❑ The positively charged ion cores are held


together by mutual attraction to the
electrons, thus producing a strong metallic
bond.

❑ Because their valence electrons are not fixed


The metallic bond forms when atoms give up their
in any one position, most pure metals are
valence electrons, which then form an electron good electrical conductors of electricity at
‘sea’. The positively charged atom cores are bonded relatively low temperatures (t < 300 k).
by mutual attraction to the negatively charged
electrons.

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THE COVALENT BOND

❑ Materials with covalent bonding are characterized by bonds that are formed by sharing
of valence electrons among two or more atoms.

❑ Covalent bonds are very strong. As a result, covalently bonded materials are very
strong and hard. For example, diamond (C), silicon carbide (SiC), silicon nitride
(Si3n4), and boron nitride (BN) all have covalent bonds. These materials also exhibit
very high melting points, which means they could be useful for high-temperature
applications. The materials bonded in this manner typically have limited ductility
because the bonds tend to be directional.

❑ The electrical conductivity of many covalently bonded materials (i.e., Silicon,


diamond, and many ceramics) is not high since the valence electrons are locked in
bonds between atoms and are not readily available for conduction.

❑ With some of these materials such as Si, we can get useful and controlled levels of
electrical conductivity by deliberately introducing small levels of other elements
known as dopants.

❑ Conductive polymers are also a good example of covalently bonded materials that can
be turned into semiconducting materials. The development of conducting polymers
that are lightweight has captured the attention of many scientists and engineers for
MME (PRPC12)- July. 2024
developing flexible electronic components. 37
(a) Covalent bonding requires that electrons be shared between atoms in such a way
that each atom has its outer sp orbitals filled

(b) In silicon, with a valence of four, four covalent bonds must be formed.

(c) Covalent bonds are directional. In silicon, a tetrahedral structure is formed with
angles of 109.5° required between
MMEeach covalent
(PRPC12)- July. 2024bond. 38
EXAMPLE

How do oxygen and silicon atoms join to form silica?


Assuming that silica (SiO2) has 100% covalent bonding, describe how oxygen
and silicon atoms in silica (SiO2) are joined.

The tetrahedral structure of silica (SiO2), which contains covalent


bonds between silicon and oxygen atoms

MME (PRPC12)- July. 2024 39


THE IONIC BOND

❑ When more than one type of atom is present in a material, one atom may donate its
valence electrons to a different atom, filling the outer energy shell of the second
atom.

❑ Both atoms now have filled (or emptied) outer energy levels, but both have acquired
an electrical charge and behave as ions.

❑ The atom that contributes the electrons is left with a net positive charge and is called
a cation, while the atom that accepts the electrons acquires a net negative charge and
is called an anion.

❑ The oppositely charged ions are then attracted to one another and produce the ionic
bond.

❑ For example, the attraction between sodium and chloride ions produces sodium
chloride (NaCl), or table salt.

MME (PRPC12)- July. 2024 40


An ionic bond is created between two unlike atoms with different electro-
negativities. When sodium donates its valence electron to chlorine, each becomes
an ion, attraction occurs, andJuly.
MME (PRPC12)- the2024
ionic bond is formed. 41
Ionic Bonds: One big greedy thief dog! Covalent Bonds: Dogs of equal strength!

Metallic Bonds: Mellow dogs with plenty of bones to go around!

MME (PRPC12)- July. 2024 42


• The magnitude of this bonding energy
and the shape of the energy–versus–
interatomic separation curve vary from
material to material
• Both depend on the type of atomic
bonding.
• A number of material properties depend
on E0, the curve shape, and bonding
type.
• e.g. materials having large bonding
energies typically also have high
melting temperatures
MME (PRPC12)- July. 2024 43
Reference
1. Raghavan V, Physical Metallurgy - Principles and Practice, Prentice -
Hall of India, 2nd Edition, 2007.

2. Avner S.H., Introduction to Physical Metallurgy, Tata McGraw Hill, 2nd


edition, 2008

3. Dieter G. E., Mechanical Metallurgy, McGraw Hill Co- Koga, 1st


Edition, 2002

4. Callister W. D., Rethwisch D. G., Material Science and Engineering,


Willey & Sons, 8th edition, 2010

5. https://www.google.com/

MME (PRPC12)- July. 2024 44

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