Adapted by Clinton Bemont from McGraw-Hills Foundations of Materials Science and Engineering by Smith and Hashemi

CHAPTER

1
Introduction to Materials Science and Engineering
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The Mars Rovers - Spirit and Opportunity

Spirit and Opportunity are made up of materials such as * Metals * Ceramics * Composites * Polymers * Semiconductors
www.nasa.gov

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SMA force-weight ratio compared

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What are Materials?

Materials may be defined as substance of which things are composed or made. We obtain materials from earths crust and atmosphere.

Examples : Silicon and Iron constitute 27.72 and 5.00 percentage of weight of earths crust respectively. Nitrogen and Oxygen constitute 78.08 and 20.95 percentage of dry air by volume respectively.

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Why the Study of Materials is Important?

Production and processing of materials constitute a large part of our economies. Engineers choose materials to suite application and design. New materials might be needed for some new applications.
Example :- Highly temperature resistant materials. Space station and Mars Rovers are designed according to conditions in space. * High pressure, low temperature, strong but light.

Modification of properties are needed for some applications.

Example :- Heat treatment to modify properties.

Weve even named mankinds history by our ability to manipulate materials (stone, copper, iron ages)
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Materials progress in engineering

Mechanical engineers: Lighter, higher temperature, stronger Electrical engineers: Energy efficiency, energy storage, high temperature Electronic engineers: Faster chips, cooling, higher temperature operation Civil engineers: Cheaper, higher strength, lighter, more design compliant Chemical engineers: Corrosion resistance, catalysts

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Materials Science and Engineering

Materials science deals with fundamental knowledge about the internal structure, properties and processing of materials. Materials engineering deals with the application of knowledge gained by materials science to convert materials into products.
Materials Science Materials Science and Engineering Materials Engineering

Fundamental Knowledge of Materials

Resultant Knowledge of Structure and Properties

Well engineered & competitive products

Applied Knowledge of Materials

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Types of Materials - Metals

Metallic Materials (Metallic bonds, electron sharing)
Composed of one or more metallic elements.
Example:- Iron, Copper, Aluminum.

Metallic materials may contain nonmetallic elements.

Example:- Carbon, nitrogen, silicon.

Inorganic and have crystalline structure. Good thermal and electric conductors.
Metals and Alloys

Ferrous Eg: Steel, Cast Iron 1-5

Nonferrous Eg:Copper Aluminum

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Metal alloys
An alloy is a combination of two or more metals (eg.
stainless steel = iron + chromium, 7075 Aluminium = Al + Zn + Mg + Cu + Cr),

or a metal with a small amount of a non-metal (eg. steel = Fe + <2% carbon). Alloys are nearly always impure and have elements (particularly non-metals) included unintentionally. Alloying changes a materials properties,
strength, ductility, hardness, toughness, corrosion resistance, electrical & thermal conductivity and others.

Shock resistance, strength and formability are usually good in metals.

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Types of Materials - Polymers Polymeric Materials (Plastics)

(primarily covalent bonds, also Van Der Waals)

Organic (carbon backbone) giant molecules and mostly noncrystalline. These are produced through the process of polymerisation. Some are mixtures of crystalline and noncrystalline regions. Poor conductors of electricity and hence used as insulators. Low melting points. Strength and ductility vary greatly. Low densities and decomposition temperatures. Thermoplastics (recyclable) and thermosets (not easily recyclable Examples :- Poly Vinyl Chloride (PVC), Polyester, Epoxy, Rubber, Phenolics, Polyethylene, Polystyrene Applications :- Appliances, DVDs, Fabrics, Packaging etc.

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Types of Materials polymers

Additives are often added to plastics (thermosets and thermoplastics). Fillers such as glass, clay, sawdust and limestone are used.

Type

Properties

Thermoplastics
Thermosets Elastomers

Hot = soft, Cold = hard Permanently hardened Structure between Thermopolymer and thermoset Large recoverable strains

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Types of Materials - Ceramics

Ceramic Materials (ionic bonds)
Metallic and nonmetallic elements are chemically bonded together (usually ionic but sometimes covalent) in molecules. Inorganic but can be either crystalline, noncrystalline or mixture of both. High hardness, strength and wear resistance but brittle Very good thermal (& electrical) insulators and very high melting points. Hence used as inert refractories for furnace linings for heat treating and melting metals inside. Also used in space shuttle to insulate it during exit and reentry into atmosphere. Other applications : Abrasives, construction materials, crockery, piezoelectrics etc. Example:- Porcelain, Glass, China, Silicon nitride, Silicon carbide,
tungsten carbide, cement 1-7

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Types of Materials ceramics

Ceramics are mostly carbides, nitrides or oxides.

Ceramic glasses are usually a combination of silicon, sodium and lime. There is no definite transition between solid and liquid in glasses, which gives glass its particular forming capabilities.

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Types of Materials ceramics

Glass ceramics are a combination of glass and other ceramic. Fine ceramic particles are held together by crystallised glass, giving high thermal shock resistance. Eg. porcelain and Pyrex-type cookware. Bricks, tiles and other shapes are formed from moist natural clay dried and fired at high temperatures. Cements are ceramics such as lime, plaster of paris and cement that harden at room temperature Also abrasives such as silicon carbide and tungsten carbide. These are hard but also relatively tough and fracture resistant. Advanced ceramics include several classes such as those that are highly wear resistant, corrosion resistant, temperature resistant and light. Used in car engines, jet and rocket engines, armour plating. Also superconductors.

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Types of Materials - Composites Composite Materials

Mixture of two or more materials (phases or constituents) - Resulting in a unique combination of properties. Consists of a dispersed filler material (/reinforcing / fibers / particles) and a continuous binding (/matrix) material. Materials only bond, will not dissolve in each other. Matrix can be metal, ceramic or polymer Primarily two broad types of composite:o Fibrous: Fibers in a matrix o Particulate: Particles in a matrix Properties are a function of the constituents, their relative amounts and the filler phase geometry. Thus toughness, strength and stiffness can potentially all be optimised. Can be made temperature resistant. Properties are usually anisotropic (different in different directions), not isotropic like eg. polymers. Composites are not easily recyclable.
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Types of Materials composites

Categories: o Particle reinforced composites: dispersed phase dimensions approximately the same in all directions. o Fibre reinforced composites : dispersed phase fiber shaped large length-to-diameter ratio. o Structural composites: combination of composites and homogeneous materials which are either laminar or sandwich panels. Examples: o Fiber Glass (Reinforcing material in a polyester or epoxy matrix) o Wood (Organic fibers in resin) o Concrete (Gravels or steel rods reinforced in cement and sand) Applications: Aircraft structures and engines, bicycles, canoes, construction.

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Types of Materials composites

90 layup:

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Types of Materials Electronic (/Electric) Materials

Semi-conductors
Low volume but very important. Silicon is a common electronic (semi-conductor) material. Its electrical characteristics are changed by adding impurities (doping). 100nm feature resolution Examples:- Silicon chips, transistors Applications :- Can you think of any?!

Others:
Capacitors & super-capacitors Batteries Circuit boards Transformer cores MEMS (Micro Electro-Mechanical Systems) Motors, inductors & magnets
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Competition Among Materials

Materials compete with each other to exist in new markets
1600

Example:1400 1200 1000 800 600 400

Over a period of time usage of different materials changes depending on cost and performance.

Aluminum Iron Plastic Steel

New, cheaper or better materials replace the old materials when there is a breakthrough in technology

lb/Car

200 0 1985 1992 1997 Model Year

Predictions and use of materials in US automobiles.

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After J.G. Simon, Adv. Mat. & Proc., 133:63(1988) and new data

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Future Trends
Metallic Materials
Production follows economic data closely. Alloys are continually improved by better chemistry and process control. New alloys are always being researched, eg:
o Example: Nickel based high temperature super alloys. o Aim: To improve both temperature and corrosion resistance while retaining high strength

New processing techniques are investigated.

o Example: Isothermal forging, Powder metallurgy. o Aim: To improve product life and fatigue properties and reduce cost.

Metals for biomedical applications

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Future Trends
Polymeric (Plastic Materials)
Fastest growing basic material (9% per year average from 1930 to 1995). After 1995 rate of growth decreased due to partial application saturation. Different polymeric materials can be blended together to produce new plastic alloys. Search for new plastics continues to be successful.

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Future Trends
Ceramic Materials
New families of engineering ceramics have been produced in the last decade New materials and applications are constantly found. Now used in Auto and Biomedical applications. Processing of ceramics is usually expensive and costs must be reduced. Often easily damaged as they are brittle. Better processing techniques and high-impact (high fracture toughness, less brittle) ceramics must be found.
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Future Trends
Composite Materials
Fiber reinforced plastics are the most widely used products. On an average 3% annual growth. Annual growth rate of 5% is predicted for composites such as Fiberglass-Epoxy and Graphite-Epoxy combinations. Commercial aircraft use a greater and greater proportion of composite materials.

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Future Trends
Electronic Materials
Use of electronic materials such as silicon has increased rapidly since 1970. Electronic materials are expected to play vital role in Factories of the Future. Use of computers and robots will increase, resulting in extensive growth in use of electronic materials. Aluminum for interconnections in integrated circuits might be replaced by copper resulting in better conductivity.

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Future Trends

Smart Materials : Change their properties by

sensing external stimulus. Shape memory alloys: Strained material reverts back to its original shape above a critical temperature.
Used in heart valves and to expand clogged arteries.

Used to open satellite collectors. Used in unbreakable reading glasses / sun-glasses Piezoelectric materials: Produce electric field when

exposed to force and vice versa.

Used in actuators and vibration reducers.

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MEMS and Nanomaterials

MEMS: Microelectromechanical systems.
Miniature devices Micro-pumps, sensors

Nanomaterials: Characteristic length < 100 nm

Examples: ceramics powder and grain size < 100 nm Nanomaterials are inherently harder and stronger than bulk materials due to their nano-sized features. Some have biocompatible characteristics (as in Zirconia) Transistors and diodes are developed on nanowires. Carbon nanotubes, etc.

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Case Study Material Selection

Problem: Select suitable material for a bicycle frame and fork.
Steel and alloys Wood Carbon fiber Aluminum Reinforced alloys plastic Ti and Mg alloys

Low cost but Heavy. Less Corrosion resistance

Light and strong. But Cannot be shaped

Very light and Light, moderately Slightly better strong. No Strong. Corrosion Than Al corrosion. Resistance. alloys. But much Very expensive Expensive, fatigue expensive

Cost important? Select steel Mechanical properties important? Select CFRP