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ECE CC2
Materials Science
- is primarily concerned with the search for basic
knowledge about the internal structure, properties
and processing of materials.
Materials Engineering
- is mainly concerned with the use of fundamental
and applied knowledge of materials.
2
ENGINEERING MATERIALS
Materials
Metals Polymers
3
ENGINEERING MATERIALS
Materials
Ceramics
Metals Polymers Glass Composites
Carbides Reinforced
plastics
Nitrides
Metal-Matrix
Glasses
Ceramic-Matrix
Glass ceramics
Laminates
4
METALS
- are inorganic substances that are composed of one
or more metallic elements and may also contain
some nonmetallic elements
Useful properties:
- Strength
- Ductility
- High melting points
- Thermal and electrical conductivity
- Toughness
5
TWO CLASSES:
Ferrous metal and alloys – contain a large percentage
of iron
Nonferrous metal and alloys – do not contain iron, if
they contain iron, it is only in relatively small
percentage.
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POLYMER
- Can be thought of a material that contains many
chemically bonded parts or units which themselves are
bonded together to form a solid. The word polymer
literally means “many parts”.
.
Properties:
- are less dense that metals and ceramic
- Resist atmospheric and other form of corrosion
- Exhibit excellent resistance to the conduction of electrical
current
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Types:
1. Plastics – are a large and varied group of synthetic materials
which are processed by forming or molding into shapes.
Classes:
1.1 Thermoplastics – these materials melt on heating and may
processed by a variety of molding and extrusion techniques
- polyethylene – packaging, plastic bag, film
- polypropylene – ropes, carpets
- polysterene – CD and DVD case
- PVC – electrical cable
1.2. Thermosetting plastics – cannot be melted or remelted
- epoxies, alkyds, polyesters
2. Elastomers or rubbers – can be elastically deformed a large
amount when a force is applied to them and return to their original
shape (or almost) when force is released.
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CERAMICS
A ceramic has traditionally been defined as inorganic,
nonmetallic solid that is prepared from powdered
materials, is fabricated into products through the
application of heat and displays such characteristic
properties as hardness, strength, low electrical
conductivity and brittleness.
Broad categories:
Structural clay products – bricks, floor tile
White wares - dinnerware
Glass – window (flat glass), bottle (container glass)
Cements
Advanced ceramics
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COMPOSITES
A composite is commonly defined as a combination of
two or more distinct materials, each of which retain its
own distinctive properties, to create a new material
with properties that cannot be achieved by any of the
components acting alone.
Common classifications:
- Metal – matrix composites
- Ceramic – matrix composites
- Polymeric – matrix composites
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RECENT ADVANCES:
IONIC BONDS
hard
good insulators
brittle
high melting point
ATOMIC BONDS
COVALENT BONDS
Where a compound only contains nonmetal
atoms, a covalent bond is formed by atoms
sharing two or more electrons.
An important feature of this bond is that the electrons are tightly held
and equally shared by the participating atoms.
ATOMIC BONDS
hard
good insulators
brittle
transparent
ATOMIC BONDS
METALLIC BONDS
• Coordination # = 8
• Coordination # = 12
In the fcc structure (and the hcp structure) the atoms can
pack closer together than they can in the bcc structure. The
atoms from one layer nest themselves in the empty space
between the atoms of the adjacent layer. The packing factor
(the volume of atoms in a cell per the total volume of a cell)
is 0.74.
extensometer specimen
gauge
length
Modulus of Elasticity
Yield Strength at 0.2% offset
Ultimate Tensile Strength
Percent of Elongation at Fracture
Percent Reduction in Area at Fracture
Modulus of Elasticity or Young’s Modulus
- the properties of a material as it undergoes
stress deforms and then return to its original
shape after the stress is removed.
E=modulus of elasticity or
Young’s modulus (GPa or psi)
F
s= Note:
(s < 0)
Ao
Shear and torsional stress
Shear stress:
Smaller indents
D d mean larger
hardness.
increasing hardness 58
Commonly used materials for indenters:
Hardened steel
Tungsten carbide
Diamond
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TYPES OF HARDNESS TESTS
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SUPERFICIAL ROCKWELL HARDNESS SCALES
62
A - Cemented carbides, thin steel and shallow case
hardened steel
B - Copper alloys, soft steels, aluminum alloys, malleable
iron.
C - Steel, hard cast irons, pearlitic malleable iron, titanium,
deep case hardened steel and other materials harder than
B 100
D - Thin steel and medium case hardened steel and pearlitic
malleable iron
E - Cast iron, aluminum and magnesium alloys, bearing
metals
F - Annealed copper alloys, thin soft sheet metals
G - Phosphor bronze, beryllium copper, malleable irons
H - Aluminum, zinc, lead
K, L, M, P, R, S, V - Bearing metals and other very soft or
thin materials, including plastics.
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BRINELL HARDNESS TESTS, HB
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CREEP
67
STAGES OF CREEP
69
70
3 Variables that have a profound influence on the toughness of a
material.
2.) temperature
As temperature is lowered, the ductility and toughness also decrease.
71
TOUGHNESS PROPERTIES
1) Impact Toughness
The impact toughness (AKA Impact strength) of a material can be
determined with a Charpy or Izod test. These tests are named
after their inventors and were developed in the early 1900’s.
72
PREPARED BY:- MRS. NORAZEAN SHAARI (UNISEL) 73
The impact toughness of a metal is determined by
measuring the energy absorbed in the fracture of the
specimen.
3) Fracture toughness
KI = Yσ(πa)1/2
Where:
KI = stress-intensity factor in MPa(m) ½ or psi(inch) ½
σ = applied nominal stress in MPa or psi
a= edge-crack length or half the length of an internal through
crack in meters or inches
Y = dimensionless geometric constant on the order of 1
78
Example Problem
A structural plate component of an engineering design must
support 207MPa in tension. If aluminum alloy 2024-T851 is
used for this application, what is the largest internal flaw
size that this material can support?(Use Y=1; KI = 26.4
MPa(m) ½)
Solution:
KI = Yσ(πa)1/2
Using Y=1 and KI = 26.4 MPa(m) ½
a = 1/π(KI/σ)2 = 1/ π(26.4 MPa(m) ½/207MPa)2
a = 5.18 mm
Thus, the largest internal crack size that this plate can
support is 2a, or (2)(5.18mm) = 10.36 mm. 79
FUNDAMENTAL OF FRACTURE
Fracture: separation of a body into pieces due to stress.
Steps in fracture:
crack formation
crack propagation
Ductile fracture :
Extensive plastic deformation
Main cause for their occurrence is overloading of the component
Crack is “stable”: resists further extension unless applied stress is
increased
Brittle fracture :
Relatively little plastic deformation
Crack is “unstable”: propagates rapidly without increase in applied
stress
80
DUCTILE VS BRITTLE FAILURE
• Classification:
Fracture Very Moderately
Brittle
behavior: Ductile Ductile
81
EXAMPLE: FAILURE OF A PIPE
• Ductile failure:
--one piece
• Brittle failure:
--many pieces
82
MODERATELY DUCTILE FAILURE
• Evolution to failure:
void void growth shearing
necking and linkage fracture
nucleation at surface
s
• Resulting 50
50mm
mm
fracture
surfaces
(steel)
100 mm
particles
serve as void
nucleation
sites. 83
DUCTILE VS. BRITTLE FAILURE
84
FATIGUE FAILURE
s max s min
Mean _ stress : s m =
2
Range _ of _ stress : s r = s max s min
sr s max s min
Stress _ amplitude: s a = =
2 2
s min
Stress _ ratio : R =
s max
Remember the convention that tensile stresses are positive,
compressive stresses are negative
87
Fatigue properties of a material (S-N curves) are tested in rotating-bending tests in fatigue
testing apparatus.
88
89
FATIGUE LIMIT, FATIGUE STRENGTH, FATIGUE LIFE
90
FATIGUE LIFE CALCULATIONS
Where:
Nf = fatigue life in cycles
af = critical crack size
ao = initial crack size
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EXAMPLE:
92
CLASSIFICATIONS OF METAL ALLOYS
heat
Name plain HSLA plain plain tool stainless
treatable
Cr,V Cr, Ni Cr, V,
Additions none none none Cr, Ni, Mo
Ni, Mo Mo Mo, W
They are relatively low in cost since they do not contain nickel.
They are used mainly as general construction materials in which
their special corrosion and heat resistance is required.
Austenitic stainless steels
Austenitic stainless steels usually contain 18% Cr and 8%
Ni in addition to other minor alloying elements. Other
alloying additions include Ti, Nb, Mo (prevent weld decay),
Mn and Cu (helps in stabilizing austenite).
101
TYPES OF CAST IRON
Gray cast iron
graphite flakes
weak & brittle in tension
stronger in compression
excellent vibrational dampening
wear resistant
Typical applications include: base structures, bed
for heavy machines, etc.
Ductile or nodular cast iron
add Mg and/or Ce
graphite as nodules not flakes
matrix often pearlite – stronger but less ductile
Typical applications include: pump bodies, crank
shafts, automotive components, etc.
102
White cast iron
< 1 wt% Si
pearlite + cementite
very hard and brittle
their use is limited to wear resistant applications
such as rollers in rolling mills.
103
Compacted graphite iron
relatively high thermal conductivity
good resistance to thermal shock
lower oxidation at elevated
temperatures
• Steels
• Cast Irons
Chief alloying elements include: Cu, Si, Mn, Mg, Zn. Recently,
alloys of Al and other low-density metals like Li, Mg, Ti gained
much attention as there is much concern about vehicle weight
reduction. Al-Li alloys enjoy much more attention especially as
they are very useful in aircraft and aerospace industries.
Noble metals:
These are eight all together: Ag, Au, Pt, Pa, Rh, Ru, Ir
and Os. All these possess some common properties
such as: expensive, soft and ductile, oxidation resistant.
Ag, Au and Pt are used extensively in jewelry, alloys are
Ag and Au are employed as dental restoration
materials; Pt is used in chemical reactions as a catalyst
and in thermocouples.
Fabrication of Metals
114
Investment casting (lost wax casting)
115
Investment casting (lost wax casting)
117
Continuous casting
molten
solidified
Metal forming
stationary die
tf Vf Vf
to to tf
Vo
Vo
rolling die
thread rolling machine
Drawing: It is pulling of material though die orifice using
tensile forces. Again a reduction in cross-section results with
corresponding change in length.
F (pulling force)
Extrusion: In this technique a piece of material is forced
though a die orifice by a compressive force. Final product
emerging from die will have the desired shape and reduced
cross sectional area, and will constant cross-section over very
long lengths.
chamber die
extruded shape
hydraulic
stock
piston
chamber
Machining
synthetic polymers
NATURALLY OCCURRING POLYMERS
Properties of plastics :-
strong
malleable
inert to chemical
insulators of electricity
and heat
PLASTICS
example of plastics are :-
polythene (polyethylene)
polyvinylchloride (PVC)
polypropene (polypropylene)
polystyrene
Perspex
Bakelite
FIBERS
long chain polymers that withstand stretching
example of fibers are :-
polyamide nylon,
terylene
phenol-formaldehyde (PF)
acrylic polymers
ELASTOMERS
polymer that can regain its original shape after
being stretched or pressed
example of elastomers are :-
Styrene-butadiene rubber(SBR)
Polyisoprene (IR)
Polybutadiene (BR)
Chloroprene Rubber (CR)
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