Materials Science

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 Organizatorial Aspects
Instructor: Jan Schroers, jan.schroers@yale.edu
TA: Sebastian Kube, David Ritzer

22 Classes
Two exams
Grading: Homework (40%), class participation (10%), midterm
(20%), final (30%)
Weekly homework
Text book: Callister, 9th edition, Materials Science and
Engineering, An Introduction, Wiley
Discussion session
Lab excursion
Your instructor
My background
-bigger picture, see the forest for the trees
-less is more
-interactive
-learn with you 2
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 What is materials science?

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 What is materials science?
Wikipedia: Materials science, also commonly known as materials
science and engineering, is an interdisciplinary field which deals
with the discovery and design of new materials. This relatively
new scientific field involves studying materials through the
materials paradigm (synthesis, structure, properties and
performance). It incorporates elements of physics and chemistry,
and is at the forefront of nanoscience and nanotechnology
research. In recent years, materials science has become more
widely known as a specific field of science and engineering.

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 Historical
Materials (access and master in fabrication) plays crucial role for
societies
-wins wars (and races)
-wealth
-food
-health

-Stone Age (2.5 Million BC - 3500 BC)

-Bronze Age (3500 BC - 1000 BC)
-Iron Age (1000 BC -)
-(Plastic Age) 1950)
-Silicon Age (1950)

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 Materials Selection Process

Need
Mankind, Society
Problem (Application) -Energy, Cancer, Earthquakes, warfare ..
Scientists, Engineers Scientific Communities
Other Communities
Required Properties Companies

Materials Materials Scientists

Develop Combine Optimize Existing

Materials Materials Material Material

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Ashby Maps

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 Materials Selection Process

Need
Mankind, Society
Problem (Application) -Energy, Cancer, Earthquakes, warfare ..
Scientists, Engineers Scientific Communities
Other Communities
Required Properties Companies

Materials Materials Scientists

Develop Combine Optimize Existing

Materials Materials Material Material

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Examples

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Materials enable us to do new things:
Surfboards
100 pounds redwood board (1930)

Fiberglass surfboard < 10 pounds

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 Surfboards
Fiberglass surfboard < 10 pounds, ~6,
(Anderson, 1972)

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Materials Insight Us

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 Example Hip Implant
With age or certain illnesses joints deteriorate.
Particularly those with large loads (such as hip).

good bad

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 Example Hip Implant

Requirements
mechanical
strength (many
cycles)
Same stiffness
than bone
good lubricity
biocompatibility

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Example Hip Implant

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Example Develop New Types of
Foams
Stiffness mismatch a serious problem for implants
Bone ~20 GPA, Titanium ~100 GPa
Only 20% of foam should be titanium

Light and stiff materials, transportation

a: porosity 25%, precursor

B: porosity 38%, 60 sec
C: porosity 49%, 120 sec
D: porosity 70%, 180 sec 20
Seek for help in Nature

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 Example-Biomimetics:
Imitation of Nature
Trust evolution to have arrived at best design/material

Leonardo Da Vinci

burs Velcro

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 Materials win
Britta Steffens,2008,
5 x world records 100 meter!

2008:
13 out of 35 world records with the magic suit

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Lotus Effect

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 Limitation of Biomimetics Approach

Often design optimized for many properties/functions

e.g., shark skin
-reduces drag,
-maintain clean,
-prevents growth of seeweed,..
-prevent fouling
-

If only drag reduction desired, perhaps not best choice

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Bring in some structure!

Can we categorize materials into classes?

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 Material Classes
Various categorization schemes, e.g.:
Metal, non-metal,
Metals, semiconductor, insulators
Organic, inorganic
For general practical (structural) applications:

Solid Materials

Metals Polymers Ceramics (semiconductors)

Also: composites
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 Metals
What is going on with metals?

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MOORES LAW

Doubles
every ~year

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Metals Law

8000 Years 30
Metals Law

Figure of Merit?

8000 Years 31
Metals Law

Strength

8000 Years 32
Metals Law

Strength x Toughness

8000 Years 33
 Metals Law

*KIC
BMGs
100,000 Steels
Doubles every 600 years
Ni alloy or Ti
alloy

Cu alloy W alloy
10000

Au alloy Al alloy
Cast Mg
1000 iron alloy
6000BC 3000 BC 1000 BC 16002000 34
Year
Metals vs Moores Law
%increase/year

Microelectronics
Metals

8000 Years 35
 METALS
Most versatile structural material
Application range (10 nm 100 m)
Historically important
(warfare, Guns germs and steels
Long used material, Iron age 1200 BC
bronze 3000 BC

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 Metals
Most metals are chemically reactive with oxygen, oxidation
-big issue, ~5% of an industrial nations income is spend on
corrosion prevention and replacement
-disadvantageous in service but advantageous in refinement
-Na, Ca, Al are the most reactive
-Noble metals, Au, Pd, Pt, (Ta) do not react with oxygen
-some metals oxidize fast but form a pacifying oxide layer on surface (Al, Ti, SS)

Structure&properties:
Large number of non-localized electrons (metallic bonds, isotropic) results in:
-Highly ordered and dense (fcc, hcp, bcc)
-Very good thermal&electrical conductor
Electrons too
-limited use at high temperatures slow to screen
-Not transparent to visible light
-Stiff,strong,ductile, tough, highest damage tolerance
(thats why metals are used as structural materials)
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Processing of Metals

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 Metals processing
Alloying and casting
High temp., >1600C steel

Pre-shapes

TprocTm0.6
forging
casting rolling

extrusion
Also powder metallurgy
MIM
TprocTamb
drawing stamping SPF

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 Ceramics

Wide range of applications

Traditionally less expensive than metals
Often do not require complex extraction&synthesis process like
metals
Widely used material in early civilizations (10,000 years ago!)
Almost any shape possible (Sintering)
Mainly used in different applications than metals 40
 Ceramics

Ceramic: (keramos; Greek)

Def: The American Society of Testing and Materials (ASTM) defines a ceramic article
as an article of crystalline or partly crystalline structure, or of glass, which body is
produced from essentially inorganic, non-metallic substances and either is formed
from a molten mass which solidifies on cooling,
or is formed and simultaneously or subsequently matured by the action of the heat.

Properties: Due to strong covalent and ionic bonding characteristic

Stiff&strong, large E0
Very hard, extremely brittle (no dislocations)
Very low fracture toughness
Poor electrical and (thermal) conductor (localized electrons)
Low thermal expansion coefficient => high thermal shock resistance (large E0)
Good at high temperature and harsh environment (do not oxidize)
Optical, whole range transparent-opaque
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 Ceramics Processing
Sintering:
-Bricks
-compact powder of ceramic
-heat and bake, diffusion bonding
-almost any shape possible
-porosity a problem

Top:
A: pressure,
Green compact
B:sintering
(temperature&pressure) Ceramic injection
molding
Bottom:
A&B: reduction in surface area

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 Ceramics Processing
Glass Processing:
-melt
-cool and vitrify (to avoid crystallization)
-form under heat (close to glass transition), gradual softening
-can be crystallized which changes properties, glass ceramics

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 Polymers (Synthetic Plastics)

-young Material class, ~100 years old

-fantastic to process (thermoplastics), also easy to 3D print
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-limited strength
Properties vs. Processing of Polymers

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 Polymers

Organic compounds based on carbon and hydrogen

Very large molecule (macromolecule) composed of repeating structural unites.
Units are connected through covalent bonds.

C-H groups form typically long chains with weak interchain bonds
(Van der Waals bonding)

Properties:
Low density (weak bonds and filling of space, spaghetti)
Low stiffness and strength (low bond energy)
But good specific strength, strength/density (comparable to metals)
Very ductile (only break van der Walls bonds, loosely packed)
Can not withstand temperature well (low bond energy
Poor electrical and thermal conductor (localized electrons)

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Properties by Classes of Materials

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Not only the material but also how we
process it is critical!

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 Carbon
Graphite

Diamond

Graphene

Fullerene

Carbon Nanotubes 49
 Manipulation of Materials:
Structure, Processing, & Properties
Properties depend on structure
ex: hardness vs structure of steel
Processing can change structure
ex: structure vs cooling rate of steel

(d)
600
Hardness (BHN)

30 m
500 (c)
400 (b)
(a)
4 m
300
30 m
200 30 m

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0.01 0.1 1 10 100 1000
Cooling Rate (C/s) 50
 Goals-relationship properties and
microstructure-Imperfections
Imperfections:
-always present, can be significantly reduced or controlled
-utilized

Imperfection often define materials properties

-impurities=> nucleation => grain size(microstructure) => mechanical properties
-semiconductors, doping, e.g. Si with boron (10-8 ), create p-n junction
-Dislocation, structural defects, control mechanical properties of metals

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 Imperfections-Impurities
-effect of rimp on solidification, impurities act as crystal seeds

=>impurity density can be utilized to control microstructure of materials

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 Imperfections-Doping

Si doping with boron (10-8 ), band gap reduces from 1.12 eV

to 0.045 eV.
 Relevant Properties

Mechanical
Electrical
Magnetic
Thermal
Optical
Deteriorative

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From here

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From Quantum Mechanics to Materials Properties

Electronic configuration
QM
Valence electrons
Electro negativity

Bonding characteristics
(metallic, covalent, ionic (primary) Van der Waals (secondary)

Properties

Physical Mechanical Electrical Optical Thermodynamic

density strength resistivity Characteristic Melting
Spectrum temperature
reflectivity
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 Class Outline
Motivation/Overview
Bonds (Quantum Mechanics origin of material classes)
Structure (Crystal Structure)
Defects (in structure, important concepts of thermally activated
processes)
Diffusion
Mechanical Properties
Strengthen Mechanism of Metals, Dislocation
Failure (Fracture Toughness, Fatigue)
Phase Diagrams
Development of Microstructure (Phase Diagrams,
Nucleation&Growth)
Polymers
Ceramics
Metallic Glasses
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 SUMMARY

Materials Science focuses on relationship of properties

and microstructure (and processing)

Material classes are metals, ceramics, polymers

Property classifications are: mechanical, optical, electrical,

magnetic, thermal, deteriorative

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