Chapter one

INTRODUCTION TO
FUNDAMENTALS OF
ENGINEERING MATERIALS
AT THE END OF CHAPTER ONE, YOU ARE
EXPECT TO KNOW

 Historical perspective
 Differentiate materials science & materials
Engineering
Know different type(classification) of
Engineering materials.
Know the application of this Engineering
materials.
 Atomic structure and bonding
 Crystal structures and defects
INTRODUCTION

o Materials play an important role for our existence,

for our day to day needs.
o Knowledge of material science and engineering
will make a better engineer and designer.
o In order to be a good designer, you must learn
what material will be appropriate for specific
purpose to use different applications.
 HISTORICAL PERSPECTIVE
 Materials are so important in the development of civilization that we
associate Ages with them.
 In the origin of human life on Earth, the Stone Age, people used only
natural materials, like stone, clay, skins, and wood for the purposes
like to make weapons, instruments, shelter, etc.
 The increasing need for better quality tools brought forth exploration
that led to Bronze Age, followed by Iron Age.
 In fact, early civilizations of human being have been designated by the
level of their materials development:
 Stone Age → Bronze Age → Iron Age → Advanced Materials
WHAT ARE MATERIALS?
-are substances which is something is
composed or made of.
e.g.:-wood(timber), concrete, brick,
steel, plastic, glass, rubber, al, cu,
paper…etc
WHAT IS THE DIFFERENCE BETWEEN MATERIAL
SCIENCE AND MATERIAL ENGINEERING?
MATERIALS SCIENCE” is primarily concerned with
the search for basic knowledge about the internal
structure, properties and processing of materials.
-involves investigating the relationships that exist
between the structures and properties of materials.
“MATERIALS ENGINEERING” : is mainly
concerned with the use of fundamental and applied
knowledge of materials so that the materials can be
converted into necessary products that are desired by the
society.
 is on the basis of these structure–property correlations,
designing or engineering the structure of a material to
produce a predetermined set of properties.
-From a functional perspective, the role of a materials
scientist is to develop or synthesize new materials,
-whereas a materials engineer is called upon to create
new products or systems using existing materials,
and/or to develop techniques for processing
materials.
Most graduates in materials programs are trained to
be both materials scientists and materials engineers
WHY YOU ARE LEARNING ENGINEERING MATERIALS?

To select the most suitable material for the

application and to develop the best processing methods
Create new materials or modify the properties of
existing materials
*To do so, Engineers should be knowledgeable
about the internal structure and properties of materials.
Engineers in all disciplines should have basic and
applied knowledge of Engineering material so that they
will able to do so their work more effectively when
using materials.
CONT…
 The term composition means the chemical make-up of
a material.
 The term structure means a description of the
arrangement of atoms, as seen at different levels of
detail.
 The term “synthesis” refers to how materials are made
from naturally occurring or man-made chemicals.
 The term “processing” means how materials are
shaped into useful components to cause changes in
the properties of different materials.
ORIGIN & CLASSIFICATION OF ENGINEERING
MATERIALS
Based primarily on chemical makeup
/composition and atomic structure
Materials in this group are composed of one or more
metallic elements (such as iron, aluminium, copper, titanium,
gold, and nickel).
All metals are solid except mercury, which is liquid
CONT…
 Ferrous alloys—those of which iron(Fe) is the prime constituent—are produced
in larger quantities than any other metal type.
 Steels are iron–carbon alloys that may contain appreciable concentrations
of other alloying elements
 Cast irons are a class of ferrous alloys with carbon contents above 2.14
wt%
 Some cast irons are very brittle, and casting is the most convenient fabrication
technique .


PROPERTIES OF METALLIC SOLIDS
. Posses metallic properties such as malleability,
ductility, lustrous appearance
CONT’D
However ,the product of today technology are dependent on part
made of metal.
Metals form the most important group of engineering material
because they have desirable mechanical and physical properties,
can be easily fabricated in various shapes and are readily
available.
Metals also accounts for about 2/3 of the elements and about 24% of the
mass of planet.
CONT…

 The key feature that distinguish metals from non-

metal is their bonding.
 Metallic material have free electron that are free
to move easily from one atom to the next.
 The existence of these free electron has a number
of profound consequence for the properties of
metallic materials
 CERAMICS
• The word ceramic comes the from Greek word
"keramikos", which means “burnt stuff."
• They are typically crystalline in nature and are compounds
formed between metallic and nonmetallic elements such
as aluminum and oxygen (alumina-Al2O3), calcium and
oxygen (calcia - CaO), and silicon and nitrogen (silicon
nitride-Si3N4).
• Depending on their method of formation, ceramics can
be dense or lightweight.
• Typically, they will demonstrate excellent hardness
properties; however, they are often brittle in nature.
CONT…
 *Ceramics can also be formed to serve as
electrically conductive materials or insulators.
 *Some ceramics, like superconductors, also
display magnetic properties. They are also more
resistant to high temperatures and harsh
environments than metals and polymers.
 Performance-500ºC-2000ºC
 Corrosion resistant at high temperature
 *Due to their wide range of properties, ceramic
materials are used for a multitude of applications
MECHANICAL APPLICATIONS

 Refractory materials
 Ceramics that have been designed to provide mechanical or
chemical properties at high temperatures.
In 3 categories.
 Acidic, basic, and neutral conditions
 Abrasives
 Ceramics have high hardness.
 Can be used in grinding applications
 Diamond and cubic boron nitride are superabrasives
 Ceramics may be used for electrical and
magnetic applications.
CONT…

 Glasses
 Soft and moldable when hot; easily shaped
 Strong in compression but brittle and weak in tension
 Excellent corrosion resistance

 Cermets are combinations of metals and ceramics

-found in Crucibles, nozzles, aircraft brakes
Advanced ceramics may be used as cutting tools
 Ceramic coatings
 Enamels, porcelains
 POLYMERS
 Polymer=poly(many)+mers (parts)
 Large molecules consisting of structural units
(monomers)
 Polymers include the familiar plastic and rubber
materials.
 Many of them are organic compounds that are
chemically based on C, H2, and other non-metallic
elements (viz. O, N, and Si).
 Some of the common and familiar polymers are
polyethylene (PE), nylon, polyvinyl chloride(PVC),
polycarbonate (PC), polystyrene (PS), and silicone
rubber.
Polymer – low density, good thermal & electrical
insulation, high resistance to most chemicals and
ability to take colors and opacities.
But unreinforced bulk polymer are mechanically weaker,
lower elastic moduli and high thermal expansion
coefficients.
Polymers are classified Thermoset & thermoplastic based on
their thermal behavior
Differ in the degree of their inter-molecular bonding
Thermoplastic-little cross bonding between polymer, soften
when heated & harden when cooled so they can be converted
into any shape by molding.
eg:- PE,PP,PS, PVC
Thermoset-strong intermolecular bonding which prevents
fully cured materials from softening when heated. Eg:-resins,
epoxy, polyester
Are polymers which change irreversibly into hard and rigid
materials on heating and can not be reshaped.
Polymers are also classified as Elastomers & Fibers based on
their molecular forces

1.Elastomers can be easily stretched by applying small

stress
Eg. Natural Rubbers which are similar to plastic in
structure and the difference is largely based on the
degree of extensibility or stretching.
2.Fibers which have strong intermolecular forces like
hydrogen bonds or dipole-dipole interactions between the
polymer chains. They are less elastic.
Advantages :
ease of manufacturing & versatility.
Can manufacture into complicated shapes in one step
with little need for further processing or surface
treatment.
Versatility : ability to produce accurate component,
with excellent surface finish and attractive color, at
low cost and high speed
Application: automotive, electrical & electronic products,
household appliance, toys, container, packaging, textiles
Basic manufacturing processes for polymer parts are
extrusion, molding, casting and forming of sheet.
APPLICATIONS OF PLASTICS
 Almost any color material is possible with plastics
 Used in packaging and containers
 Household appliances, clock cases, exteriors of
electronic products
 Cushioning materials
 Rigid foams are used in sheet metals for
compressive strength
 Gears, lenses, safety helmets and unbreakable
windows
 composite
Introduction
A composite material can be broadly defined as an assembly
two or more chemically distinct material, having distinct
interface between them and acting to produce desired set of
properties
The composite constituent divided into two
Reinforcement-material that provides strength to the
matrix
Matrix-material that holds the reinforcements in place
 Eg :-Fiberglass sheet – in which glass fibers are embedded
with in polymeric material.
 It display a combination of the best characteristics of each
of the components materials. Here fiberglass acquire
strength from glass and flexibility from polymer.
CONT…
Properties / behavior depends on properties, size &
distribution, volume fraction & shape of the constituents,
& the nature and strength of bond between constituents.
Mostly developed to improve mechanical properties i.e.
strength, stiffness, creep resistance & toughness.
FIBER-REINFORCED COMPOSITES
 Discontinuous thin fibers of one material are
embedded in a matrix
 Automobile tires
 Fibers of steel, rayon, Kevlar, or nylon to reinforce the rubber
 Bricks of straw and mud
 Ceramic fibers,
 Wood and bamboo are naturally occurring fiber composites
Common objective is high strength and lightweight
 Orientation of the fibers is important
*Designing with composite
A composite materials usually are more expensive on a
cost.
Used when weight saving is possible when the relevant
specific property (property/density) of the composite is
better than conventional material
E.g. specific strength (strength/density), specific
elastic modulus ( elastic modulus/density)
Efficient use of composite can be achieved by tailoring
the material for the application
E.g. To achieve max. strength in one direction in a
fibrous composite, the fibers should be well aligned in
that direction
 SEMI-CONDUCTORS
 Silicon, germanium, and gallium arsenide-based
semiconductors
 such as those used in computers and electronics
are part of a broader class of materials known as
electronic materials.
 The electrical conductivity of semiconducting
materials is between that of ceramic insulators
and metallic conductors.
 In some semiconductors, the level of conductivity
can be controlled to enable electronic devices
such as transistors,
FUNCTIONAL CLASSIFICATION OF MATERIALS
CLASSIFICATION OF MATERIALS BASED
ON STRUCTURE
 some materials may be crystalline (the material’s atoms are
arranged in a periodic fashion) or
 they may be amorphous (the arrangement of the material’s
atoms does not have long-range order).
 Some crystalline materials may be in the form of one crystal
and are known as single crystals.
 Others consist of many crystals or grains and are known as
polycrystalline.
 The characteristics of crystals or grains (size, shape, etc.)
and that of the regions between them, known as the grain
boundaries, also affect the properties of materials.
ENVIRONMENTAL AND OTHER EFFECTS

 The structure-property relationships in materials

fabricated into components are often influenced
by the surroundings to which the material is
subjected during use.
 This can include exposure to high or low
temperatures, cyclical stresses, sudden impact,
corrosion, or oxidation.
 These effects must be accounted for in design to
ensure that components do not fail unexpectedly
CONT…

 Temperature
 Corrosion

 Fatigue

 Strain Rate