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MODULE 06
Introduction to Materials
• Pure Metals
– Elements which come from a particular area of the
periodic table.
• Alloys
– Contain more than one element
– Their properties can be changed by changing the
elements present in the alloy
– Ex: Steel (Fe+C), Stainless Steel (Fe+C+Cr+Ni), Gold
Jewellery (Au+Cu)
Contd..
Metals
• Very brittle
Composites
Bonding
Primary Secondary
Types of Bonds
• Point defects
• Planar defects
• Bulk defects
Point Defects
• Defects related to a single atom
– Screw dislocation
Edge Dislocation
Screw Dislocation
Edge Dislocation Vs Screw Dislocation
Planar Defects
e
• Force-Extension curve is then converted to a Stress-
Strain curve.
ε
Stress – Strain Curve
Typical Engineering Stress – Strain Curve
Stress-Strain Diagram of Steel
Stress-Strain Diagram for Brittle Materials
Elasticity
• All materials show temporary deformation to a certain
extent – Elastic deformation.
• E of steel is 2x1011 Pa
Plasticity
• Ductile Materials
– Materials that exhibit plastic deformation (Most
metals are ductile)
• Brittle Materials
– Materials that do not have plasticity (glass, cast iron)
Ductility
– Percentage elongation L f Lo
x 100%
Lo
L b
3PL
MOR 2
2bd
Compression Test
Proof Stress
?
Proof Stress Contd...
ε=0.002
Work Hardening
O
P
Necking
75
Steels
• Iron-Carbon alloys that may contain appreciable
concentrations of other alloying elements.
• The mechanical properties are sensitive to the content
of carbon, which is normally less than 2.0 wt%.
• More common steels are classified according to carbon
concentration (low, medium, and high carbon types).
• Subclasses also exist within each group according to the
concentration of other alloying elements.
• Plain carbon steels contain only residual concentrations
of impurities other than carbon and a little manganese.
• For alloy steels, more alloying elements are intentionally
added in specific concentrations.
Stainless Steels
82
Gray Cast Iron
• C and Si contents vary between 2.5 and 4.0 wt% and 1.0
and 3.0 wt%, respectively.
• For most of these cast irons, the graphite exists in the
form of flakes (similar to corn flakes)
• Because of these graphite flakes, a fractured surface
takes on a gray appearance, hence its name.
• Mechanically, gray iron is comparatively weak and brittle
in tension.
Gray Cast Iron
• Light in mass
• Soft and ductile
• High resistance to corrosion
• No coloured salts are formed to stain surfaces.
• Good electrical and thermal conductivities
• Nontoxic (used for cooking utensils)
• Lose part of their strength at elevated temperatures.
Aluminium Alloys
• Heat treatable
– Treatments include solution heat treatment,
quenching and precipitation or age hardening.
Wrought Aluminium and Aluminium Alloy
Designation System
Copper 2xxx
Manganese 3xxx
Silicon 4xxx
Magnesium 5xxx
Magnesium and Silicon 6xxx
Zinc 7xxx
Other elements 8xxx
• 2nd digit is usually zero.
Non zero numbers are used to indicate some
modification to the original alloy.
– If 2nd digit is zero – Indicate original alloy
– If 2nd digit is 1-9 – intentionally introduced impurities.
• Main properties
– High strength to weight ratio
– Excellent machinability
• Wrought Mg alloys
• Tensile strenghts upto about 360 Mpa
• Yield strengths upto about 300 Mpa
• The Yield strength, tensile strength and hardness of Mg
alloys decrease with Rising temperature.
Titanium Alloys
• High strength to weight ratio.
– Capable of operating at temperatures from sub zero to 600°C.
• For aero-engines
– Blades, shafts and casings from the front fan to the last stage
of the high pressure compressor.
• Airframes
– Ti Alloys with strength up to 1200MPa
– Landing gears and large wing beams.
Corrosion on Aircraft Materials
Corrosion on Aircraft Materials
• Cladding
• Anodising
• Chromating
• Exterior Cleaning
• Surface Cleaning
Cladding
• Cu and Zn commonly alloyed with Al for high
strength skin and component parts.
Rivets
• Flat Head
• Round Head
• Universal Head
• Flush Rivets
Flat Head (AN442)