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Engineering Materials in simple

The Study of Engineering Materials usually includes: Testing, specifications, microstructure,


methods of extraction, and heat treatment.

Engineering Materials Classifications:

Metallic Materials:
a) Ferrous Metals:
Which are composed of Iron and carbon plus a number of other elements. (As raw materials, added
alloying).

b) Non-Ferrous Metals:
Which include:
-

Heavy metals such as Copper, Nickel,. ets.

Light Metals such as Aluminum, Magnesium ets.

Soft Metals such as tin, leadetc.

Non-Metallic Materials:
Include many types of materials that are used in every day activity.

a) Building materials:
Include stones, cement, lime, bricks, timberetc.

b) Energy Materials:
They are used for energy generation. They May include water, oil, coal, fuels..etc.

c) Miscellaneous Materials:
They include rubber, cork, plastics..etc.

Mechanical Properties of Materials


They are their behavior under action of external loads or forces or their ability to resist failure.
Most of mechanical properties are expressed in terms of stress, strain or both.

Types of Mechanical Properties of Materials:


1. Elasticity:
The ability of a metal to return to its original shape and size after removing loads.

Steel has a wide range of elasticity.

2. Plasticity:
The ability of a metal to undergo permanent deformation (without fracture) after removing loads.

Lead has good plasticity even at room temperature, while Cast iron does not possess any
appreciable plasticity even when red hot.

3. Ductility:
The ability of the materials to undergo cold plastic deformation by tension and can be drawn into
wires before rupture.

The following common metals have ductility in the decreasing order:


Gold, Platinum, Silver, Iron, Copper, Aluminum, Tin, Lead

4. Brittleness :
The ability of materials to fracture without plastic deformation. It is opposite to ductility.

Cast Iron, Glass and Concrete are example of brittle materials.

5. Hardness:
The ability of metal to resist abrasion, deformation, penetration scratching or indentation by harder
bodies, it is measured by the resistance of metal to scratching.

As Diamond, Quartz, Calcite and Gypsum.

6. Toughness :
The Capacity of material to withstand (absorb) shock loads without fracture (Toughness of most
materials falls with the rise in Temperature).

7. Stiffness :
The ability of a metal to resist deformation
Modulus of elasticity (stress/strain below elastic limit) is a measure of Stiffness.

8. Resilience:
The ability of a metal to store energy and resist shocks or Impacts.

9. Creep :
The ability of metal to deform continuously under steady loads. Creep occurs in steel at high
temperatures.

It is important in designing I.C Engines, Boilers, and Turbines.

10. Endurance :
The ability of a metal to withstand varying stresses (same or opposite nature).
Endurance limit is the maximum stress that can be applied for indefinite times without causing
failures.

11. Strength:
The ability of the material to resist applications of forces without rupture.
Types of Strength:
a- Elastic Strength:
The value of load corresponding to transition from elastic to plastic range.
b- Plastic Strength:
The value of load corresponding to plastic range & rupture.
Factor of safety =
Ultimate Stress / Working Stress

Factors Affecting Mechanical Properties of


Materials
1- Grain Size.
2- Temperature.
3- Heat Treatments.
4- Atmospheric Exposure.

Types of Technological Properties of Materials


It determine behavior of materials in fabrication process
A. Malleability:
Metal ability to be deformed with cold deformation in all directions into thin sheets by
squeezing rolling or hamming without rapture

Examples:
Gold, Silver, Aluminum, Copper, Tin, Lead, Platinum, Iron and Nickel.

B. Machinability:
Metal ability to be cut by turning, drilling, boring () , milling.etc.

Examples:
White Cast Iron, wrought iron low alloy steel, Copper, Aluminum, and Grey Cast Iron.

C. Weldability:

Metal ability to be joint two similar or dissimilar metals by welding.


Examples:
Iron carbon Steel cast, Iron Low alloy steels & Stainless steel.

D. Formability :

Metal ability to be formed (pressed by forging i.e.) into different shapes and sizes.
Examples:
Low carbon steels, medium carbon steel.

E. Castability:

Metal ability to be formed into different shapes and sizes from its liquid state.
Examples:
Most of metals have good Castability: Aluminum, Cast iron, Copper, Brass, Leadetc.

Hook's Law and Modulus of Elasticity


Hook's law states: "When a material is loaded with in its elastic limit the stress is
proportional to strain"

Modulus of elasticity = stress / strain = constant

Mechanical Testing of Materials


Mechanical tests are done to determine mechanical properties by deformation or by
destruction.
i.

Tensile Test:
The results obtained by tensile test are widely used in the design of materials for structures and other
purposes.

ii.

Compression Test:
It is opposite of the tensile test and performed for ductile and brittle materials. Difficulties in
performing the test are:

Non-parallel top and bottom faces of specimen leads to difficult axial loading.

Specimen Length is short (about twice of its diameter) to avoid buckling.

Friction Between ends of specimen and machine affects test results.

iii.

Hardness Test:
Hardness test is done to know metal resistance against indentation, penetration and abrasion.

iv.

Fatigue Test:
Fatigue failure is caused by repeated stress cycles (reversal of direction of bending or torsion or
alternating compressive and tensile stresses application and removal of stresses). A fatigue crack
starts at some point of stress concentration. The Stress that produces fatigue failure is smaller than
the ultimate tensile stress.

v.

Creep Test:
Materials loaded for long periods may gradually deform, and fracture at a stress that is well below the
ultimate tensile stress. This continuous gradual extension under a steady load or steady stress is
known as Creep. Creep is critical at high temperatures and for low-melting-point metals at room
temperature.

Examples for Materials with its properties


a. Non-Ferrous Materials

Metal
Aluminum
Copper
Lead
Magnesium
Zinc
Chromium
Manganese

b.

Properties and Uses


Is a white and light metal. Is used in many applications such as aero
planes, home cooking,.,etc.
Is a reddish-brown metal. It is used as a pure or alloyed material.
Is very malleable, ductile, weak, heavy, resists corrosion and is a good
insulator against nuclear radiation.
It is a weak, silvery-white, very light. It is used as base for many light
alloys.
It is very weak, moderately ductile and malleable and extremely
corrosion resistant. It is used as protective coating for iron and steel and
as die-casting metals.
It is steel-grey in color, very hard, corrosion resistance, heat resisting
alloys.
It is present in all steels and cast iron as useful impurity because it
offsets the ill effect of sulphur.

Non- Metallic Materials:

Material
Asbestos
Ceramics
Cement
Concrete
Diamond
Plastics
Rubber

Properties and Uses


A group of minerals spun or woven into fabrics. It is fire electrical and heat
resisting, chemically inert, and, free from decay. It is used in roofing cement,
tiles, fireproof paints, building sheets, insulating material, brake linings and
clutch facings. Is use was restricted due to its cancer effects.
Used as cutting tool materials as extrusion dies, and as a refractory coating in
rocket casings.
Have two types: Portland and high alumina. It is composed of calcium
carbonate, silica, alumina, and iron oxide (clay). The mix is heated and clinker
is ground to form a powder.
Made by mixing cement, aggregate and water to produce an artificial stone.
Is the purest form of crystallized carbon, and is the hardest known material. It is
used as a cutting toll material, as a spindle bearing material, and as a stylus
material for sound reproduction.
Are used extensively in engineering.
Is used for shock absorbers, engine mountings, road tires, transmission belting,
hose, and electrical insulation.

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