Introduction: Classification

of Materials
Lecturer:

Mr. H J Uananisa
Office: 247/206
Consultation: WEDs; 09:00-16:00Hrs
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MMB 312 Teaching Plan:

Week Beginning on

First Semester Aug., Dec., 2016

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31 July 06 August,
2016

Introduction: Classification of materials;

metals (ferrous & non-ferrous) and nonmetals (polymers, ceramics, etc).
Crystal Structures & Imperfections of Ionic
Materials: BCC and FCC structures,
overview
on
dislocations
&
surface
defects.
Principles of solidification: Introduction to
the steel production line (Ingot casting &
processing),
nucleation,
growth
mechanism; solidification defects.
Phase diagrams: Overview, solubility, lever
rule,
iron-carbon
system.
Hardening
mechanisms:
Strain
hardening
and
annealing.

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07 13 August, 2016
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14 20 August, 2016

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21 27 August, 2016

Solid solution strengthening: Overview on

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phase
equilibrium,
solute
solubility,
28 Aug 03 Sept., 2016
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segregation.

MMB 312 Teaching PlanCont:

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04 10 Sept., 2016
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11 17 Sept., 2016
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18 24 Sept., 2016
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25 Sept. 01 Oct. 2016

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02 08 Oct., 2016
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09 15 Oct., 2016
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16 22 Oct., 2016
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23 29 Oct. 2016
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30 Oct. 05 Nov, 2016
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06 12 Nov., 2016

Properties of Materials: Mechanical properties;

and physical properties of materials.
Test 1
Mechanical testing and properties: Hardness
test, impact test, fatigue test, creep test.
Mid Semester Break
Heat treatment of steels: Quenching, tempering,
effect of alloying elements, surface treatments
and weldability of steels.
Failure mechanisms: Brittle fracture, Ductile
Failure, Fatigue, Creep; Detection and prevention.
Metallographic
techniques:
Equipment
and
technology
(grinding,
polishing,
etching,
microscopy).
Corrosion
and
wear:
Chemical
and
Electrochemical corrosion; electrode potential
and polarization; wear and erosion; Prevention &
Control.
Test 2

Revision

MMB 312 Assessment Mode:

Assessment SHALL consist of;
A CA component (40%):
o A minimum of two (2) Semester Tests (CAT #1 and CAT
#2) 20%.
o A minimum of two (2) Quizzes (Q #1 and Q #2) 10%.
o About three (3) Laboratory Experimental Repots (Lab #1,
Lab #2 & Lab #3) 10%.

An Examination component (60%):

A 2 hrs End of Semester Examination.

Classification of Materials:
o What is materials science
and engineering?
o Important: To understand the
goals of a materials engineer;

Make existing materials better.

Invent or discover new
materials, phenomena, devices,
and applications.
Appreciate variety of fields
reliant on a materials engineer
[bio-medical, physics (NASA),
IT].

Classification of Materials:
Interdisciplinary
field.
Manipulates
composition
&
structure
of
materials

Control properties
through synthesis
& processing.
Materials drive our
society;
Stone age.
Bronze age.
Iron age.
The materials science and engineering tetrahedron;
adopted from D R Askeland, 2014, 7th Edition.

From Stone Digital Age:

[Image extracted from the web].

Classification of Materials:
There are several ways of classifying materials;
Standard Major Groups;
o Metals and Alloys.
o Ceramics & Glasses.
o Polymers (plastics).
o Composites.

Functional classification of materials.

Structural classification of materials.
Classification based on response to
environmental effects.
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Classification of Materials:

[Image extracted from the web].

Metal Properties:
Good electrical & thermal
conductivity.
High
strength
&
high
stiffness.
Higher
ductility/formability
(good toughness).
Good for structural and loadbearing applications.
Alloys
provide
improved
properties.

[Image extracted from

the web].

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Ferrous Materials:
o Mostly contain Iron
(Fe).
o May contain small
amounts of other
(alloying) elements.
o Magnetic.
o Limited resistance
to corrosion.

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Ferrous Materials - Steels:

Steels alloys of Iron (Fe) and
Carbon (C). May contain trace
amounts of other elements.
Several steel grades available
(depending on application).
Low Alloy (<10 wt% Cr):
Low Carbon (<0.25 wt% C).
Medium Carbon (0.25 0.60 wt%
C).
High Carbon (0,60 1.4 wt% C)

High Alloy (>11 wt% Cr):

Stainless steels.
Tool steels.

Cast Iron (2,1 4.5 wt% C + Si)

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Ferrous Materials - Steels:

Low Carbon Steels:

Medium Carbon Steels:

Plain carbon steels - very low content

of alloying elements and small
amounts of Mn.
Most abundant grade of steel is low
carbon steel greatest quantity
produced; least expensive.
Not responsive to heat treatment;
cold working needed to improve the
strength.
Good Weldability and machinability.
High Strength, Low Alloy (HSLA)
steels - alloying elements (like Cu, V,
Ni and Mo) up to 10 wt %; have
higher strengths and may be heat
treated.

Carbon content in the range of 0.3

0.6%.
Can be heat treated (austenitizing,
quenching, tempering).
Most often used in tempered condition
tempered martensite.
Medium carbon steels have low
hardenability.
Addition of Cr, Ni, Mo improves the
heat treating capacity.
Heat treated alloys are stronger but
have lower ductility.
Typical applications Railway wheels
and tracks, gears, crankshafts.
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Classification of Materials:
High Carbon Steels:

Stainless Steels:

A group of steels containing at least 11% Cr.

Exhibits extraordinary corrosion resistance due
to formation of a very thin layer of Cr2O3 on the
surface.
Categories of stainless steels:
Ferritic Stainless Steels Composed of ()
ferrite (BCC) phase.
Martensitic Stainless Steels Can be heat
treated.
Austenitic Stainless Steels Austenite ()
phase (FCC) field is extended to room
temperature. Most corrosion resistant.
Duplex Stainless Steels Ferrite +
Austenite.

High carbon steels Carbon content

0.6 1.4%
High C content provides high
hardness and strength.
Hardest and least ductile.
Used in hardened and tempered
condition
Strong carbide formers like Cr, V, W
are added as alloying
elements to from carbides of these
metals.
Used as tool and die steels owing to
the high hardness and

wear resistance property.

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Metal Properties Compared

with Other Materials:

[Image extracted from the web].

[Image extracted from the web].

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Functional Classification of
Materials:

[Image extracted from the web].

[Image extracted from the web].

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Non-Ferrous Metals:

[Image extracted from the web].

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Copper Alloys:
Brass:

Bronze:

Copper alloys containing tin, lead, aluminium,

silicon and nickel are classified as bronzes.
Cu-Sn Bronze is one of the earliest alloy to
be discovered as Cu ores invariably contain
Sn.
Stronger than brasses with good corrosion
and tensile properties; can be cast, hot
worked and cold worked.
Wide range of applications: ancient Chinese
cast artifacts,
Skate-board ball bearings, surgical and
dental instruments.

Brass is the most common alloy of Cu

Its an alloy with Zn.
Brass has higher ductility than
copper or zinc.
Easy to cast - Relatively low melting
point and high fluidity.
Properties can be tailored by varying
Zn content.
Some of the common brasses are
yellow, naval and cartridge.
Brass is frequently used to make
musical instruments (good ductility
and acoustic properties).

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Ceramic Materials:

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Refractory Ceramics:
Refractory - retains its strength at high temperatures > 500C.
Must be chemically and physically stable at high temperatures.
Need to be resistant to thermal shock, & should be chemically inert,
and have specific ranges of thermal conductivity and thermal
expansion.
Are used in linings for furnaces, kilns, incinerators, crucibles and
reactors.
Aluminium oxide (alumina), silicon oxide (silica), calcium oxide
(lime) magnesium oxide (magnesia) and fireclays are used to
manufacture refractory materials.
Zirconia - extremely high temperatures.
SiC and Carbon also used in some very severe temp conditions,
but not in oxygen environments oxidizes.
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Glass Ceramics:

Glass - inorganic, non-crystalline (amorphous) material.

Range: soda-lime silicate glass for soda bottles to the extremely high purity silica
glass for optical fibers.
Widely used for windows, bottles, glasses for drinking, transfer piping and
receptacles for highly corrosive liquids, optical glasses, windows for nuclear
applications.
The main constituent of glass is silica (SiO2). The most common form of silica used
in glass is sand.
Sand fusion temp to produce glass - 1700 C. Adding other chemicals to sand can
considerably reduce the fusion temperature.
Sodium carbonate (Na2CO3) or soda ash, (75% SiO2 + 25% Na2O) will reduce the
fusion temperature to 800 C.
Other chemicals like Calcia (CaO) and magnesia (MgO) are used for stability.
Limestone (CaCO3) and dolomite (MgCO3) are used for this purpose as source of
CaO and MgO.
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Abrasive Ceramics:
Abrasives are used in cutting and
grinding tools.
Diamonds - natural and synthetic, are
used as abrasives, though relatively
expensive. Industrial diamonds are hard
and thermally conductive. Diamonds
unsuitable as gemstone are used as
industrial diamond.
Common abrasives SiC, WC, Al2O3
(corundum) and silica sand.
Either bonded to a grinding wheel or
made into a powder and used with a
cloth or paper.

Silicon Carbide extracted from the web.

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Image

Polymer Materials:
Polymers Chain of H-C molecules. Each repeat unit
of H-C is a monomer e.g. ethylene (C2H4),
Polyethylene (CH2
CH2)n.
Polymers: Thermosets Soften when heated and
harden on cooling totally reversible. Thermoplasts
Do not soften on heating.
Plastics moldable into many shape and have
sufficient structural rigidity. Are one of the most
commonly used class of materials.
Are used in clothing, housing, automobiles, aircraft,
packaging, electronics, signs, recreation items, and
medical implants.
Natural plastics hellac, rubber, asphalt, and
cellulose.
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Characteristics & Applications of some

common Thermoplastics:

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Characteristics & Applications of some

common Thermosetting polymers:

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Elastomers:
Elastomer a polymer with rubber-like
elasticity.
Each of the monomers that link to form the
polymer is usually made of carbon, hydrogen,
oxygen and/or silicon.
Cross-linking in the monomers provides the
flexibility.
Glass transition temperature, Tg, is the
temperature at which transition from
rubbery to rigid state takes place in polymers.
Elastomers are amorphous polymers existing
above their Tg. Hence, considerable
segmental motion exists in them.
Their primary uses are in seals, adhesives and
molded flexible parts.

Typical Elastomers extracted from the web.

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Image

Characteristics & Applications of some

commercial Elastomers:

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The Material Selection Process:

o Pick
Application
Properties.

Determine

required

[Properties: mechanical, electrical, thermal, magnetic,

optical, deteriorative].

o Properties Identify candidate materials.

o [Materials: structure and composition].

o Material Identify required Processing.

o [Processing: changes structure and overall shape (ex:
casting, sintering, vapor deposition, doping
forming,
joining, annealing)].

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SUMMARY:
The fundamental points to remember here
are;
Ability to use the right material for any
application.
Understanding the relationship between;
properties, structure and processing.
Recognize
new
design
opportunities
offered by good material selection.

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