BBM 10103 Material Technology

CHAPTER 1:
INTRODUCTION
#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
Introduction to material science and

engineering
Materials science and engineering is an multidisciplinary field
concerned with inventing new materials and improve previously
known materials by developing a deeper understanding of the
microstructure-composition-synthesis-processing relation ship.
Material Science:The emphasis is on underlying relationship between the synthesis and
processing. Structure and properties of material.
Material Engineering:The focus is on how to translate or transform materials to useful device
or structure.
The modern materials scientist plays three major roles in the

development of technology
1) Material Selection
In order to produce working machines from engineering design, each
part of the machine must fill a number of criteria, for example high
strength, high ductility, good electrical properties, low weight, or
low cost. The materials scientist responsible for recommending
materials to best fit these criteria
2) Materials research
The materials scientist determines the strength, wear resistance, and
other properties of materials as well as studying the microscopic,
electronic and atomic structures that give rise to these properties.
This enable both proper use of materials by engineers as well as the
possibility of designing new materials to fulfill specific needs
Materials development
By applying the knowledge gained by studying the structure of
materials, the materials scientist can design materials with
specific properties by varying composition and processing.
Such work often results in materials which can be used in
applications that would have been impossible before.
Generic Product development flow

diagram
Factors that influences the material

selection process
Function dictates the choice of
material and shape.
Function
Material
Process is influenced by
material
Shape restricts the

choice of material
and process.
Shape
Process
Process interacts with

shape.
Material selection and process cannot be separated from the shape and the
function of the product, two way interaction.
Material Properties
Properties are the way the material responds to the environment
and external forces.
Materials Properties
Mechanical
Physical
Chemical
Optical
Mechanical Properties
Deformation and fracture as a response to applied
mechanical forces
Strength
Hardness
Ductility
Stiffness
Physical Properties (Thermal)

Affected by heat fluxes and temperature changes
Thermal Capacity Heat storage capacity of a
material
Thermal Conductivity Capacity of a material to
transport heat
Thermal Expansion How a material expands or
contracts if the temperature is raised or lowered
Physical Properties (Electrical)

Material response to electromagnetic fields
Electrical Conductivity Insulators, dielectrics,
semiconductors, semimetals, conductors,
superconductors
Thermoelectric Electrical stimuli provoke thermo
responses; thermo stimuli provoke electrical responses
Chemical Properties
Response and impact of environment on material
structures
Oxidation and Reduction Occur in corrosion and
combustion
Toxicity The damaging effect a material has on other
materials
Flammability The ability of a material to ignite and
combust
Example
Material
Properties
Engineering Materials Classification

Materials
Metals
Plastics
Ceramics
Glass
Composites
13
Materials Classification Cont

Materials
Metals
Ferrous
Non-ferrous
Plastics
Thermoplastics
Thermosets
Elastomers
Steel
Aluminum
Acrylic
Phenolic
Rubber
Stainless steel
Copper
Nylon
Polymide
Polyurethane
Die & tool steel
Zinc
ABS
Epoxies
Silicone
Cast iron
Titanium
Polyethylene
Polyester
Tungsten
Polycarbonate
PVC
14
Materials Classification Cont

Materials
Metals
Plastics
Ceramics
Glass
Carbides
Nitrides
Graphite
Diamond
Glasses
Composites
Reinforced
plastics
Metal-Matrix
Ceramic-Matrix
Laminates
Glass ceramics
15
Classifications & Specifications of Metallic

Materials
Major characteristics of metallic materials are crystalline,
conductivity to heat and electricity and relatively high strength
& toughness.
Classification: systematic arrangement or division of materials into
group on the basis of some common characteristic
Generally classified as ferrous and nonferrous
Ferrous materials-iron as the base metal,
range from plain carbon (>98% Fe) to high alloy steel
(<50% alloying elements)
Nonferrous materials consist of the rest of the metals
and alloys
Eg. Aluminum, magnesium, titanium & their alloys
16
Within each group of alloy, classification can be made

according
(a) chemical composition, e.g. carbon content or alloys
content in steels;
(b) finished method, e.g. hot rolled or cold rolled;
(c) product form, e.g. bar, plate, sheet, tubing, structural
shape;
(d) method of production, e.g. cast, wrought alloys.
17
In most eng. application, selection of metallic is usually based on the

following considerations:
1) Product shape: a) sheet, strip, plate, (b) bar, rod, wire, (c)
tubes, (d) forging (e) casting
2) Mechanical properties-tensile, fatigue, hardness, creep,impact
test
3) Physical & chemical properties-specific gravity, thermal &
electrical conductivity, thermal expansion
4) Metallurgical consideration-anisotrophy of properties,
hardenability of steel, grain size & consistency of properties
5) Processing castability-castability, formability, machinability
6) Sales appeal-color, luster
7) Cost & availability
18
Classifications & Specifications of Polymers
Polymer low density, good thermal & electrical insulation,

high resistance to most chemicals and ability to take colours
and opacities.
But unreinforced bulk polymer are mechanically weaker,
lower elastic moduli & high thermal expansion coefficients.
Improvement
Reinforced variety of fibrous materials
Composites (PMC).
19
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.
20
Thermoset & thermoplastic

Differ in the degree of their inter-molecular bonding
Thermoplastic-litle cross bonding between polymer,
soften when heated & harden when cooled
Thermoset-strong intermolecular bonding which
prevents fully cured materials from softening when
heated
Rubber are similar to plastic in structure and the difference
is largely based on the degree of extensibility or stretching.
21
Classifications & Specifications of Ceramic
Ceramics inorganic compounds of one or more metals with a

nonmetallic element. Eg Al2O3, SiC, Si2N3.
o Crystal structure of ceramic are complex
They accommodate more than one element of widely
different atomic size.
o The interatomic forces generally alternate between ionic &
covalent which leave few free electrons
usually heat & electrical insulators.
o Strong ionic & covalent bonds give high hardness, stiffness
& stability (thermal & hostile env.).
22
Structure:
(1) Amorphous or glass-short range order, (2) crystalline
(long range order) & (3) crystalline material bonded by
glassy matrix.
Clasiification:
Whitewares, glass, refractories, structural clay products
& enamels.
Characteristics:
Hard & brittleness,
low mechanical & thermal shock
High melting points
Thermal conductivities between metal & polymer
23
Design consideration for ceramics

Britle, low mechanical & thermal shock-need special
consideration
Ratio between tensile strength, modulus of rupture &
compressive strength ~ 1:2:10. In design, load ceramic parts in
compression & avoid tensile loading
Sensitive to stress concentration
Avoid stress raiser during design.
Dimensional change take place during drying and firing, should
be consider
Large flat surface can cause wrapping
Large changes in thickness of product can lead to nonuniform
drying and cracking.
Dimensional tolerances should be generous to avoid machining
24
Classifications & Specifications of Composites
Can be any type of mixture: polymer+metal, polymer+glass,

metal+ceramic, ceramic+ceramic
25
Characteristics of Composites
26
Design consideration for composites
Consider special characteristics and properties of

composites (why do you prefer them in the product?)
Composites combine the properties of different
materials and generate new properties
For example glass fibers are strong but brittle;
polymers are much tougher. A glass fiber reinforced
polymer is both tough and strong.
For conventional materials, the designer may consult a
handbook or manual to obtain a certain property
(strength, hardness, thermal conductivity- etc.)
For composite materials, the designer has to consult
performance charts or carpet plots representing a
particular property of a given composite system
27
Application of Most Commonly Used Materials

Component
Ken Youssefi
Material
SJSU, ME dept.
28

Component
Ken Youssefi
Material
SJSU, ME dept.
29

Component
Material
Ken Youssefi
SJSU, ME dept.
30
Application of composite materials in

Boeing 757-200
Source: Courtesy of Boeing Commercial Airplane Company

Example :Research impacts products (Nokia)

Power management
User experience
Battery life, charging,

thermal durability
Ergonomy, usability, user

interfaces, user behavior,
security
Materials
GSM/WCDMA
Structural, functional,
optical, decorative
Strong IPR portfolio
Mechanics
Software and
Applications
Structures, user interface,

mechanisms
Platforms, middleware,
architectures
Cameras and optics
Voice & Video codecs

Improved quality
Electronics
Semiconductors,
microelectromechanical
components
Proximity
Algorithms
Signal processing, image and
sound processing
WLAN, Ultra Wideband,

RFID, Bluetooth
Materials research in products

Nokia N90
Materials for
transformable
mechanics
High strength &
accuracy, low friction
Nokia 5140
Integrated soft-hard
cover
33
2005 Nokia YN
10.10.2006
Nokia 7280
laser patterned
decoration
half-mirror window
thin rotator plate
Multi-disciplinary research needed

Drivers for future
communication devices
Enhanced user experience,
new features/functions,
design look & feel
Small, compact, easy to
use, easy to carry/wear
Integration of electronics
and mechanics for
functionality and
production
Need research in multidisciplinary areas

Materials technology
Novel manufacturing
technologies
Examples:
Flexible/Printed
electronics
Nanotechnology

BBM 10103 Material Technology

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CHAPTER 1:

Introduction to material science and

The modern materials scientist plays three major roles in the

Generic Product development flow

Factors that influences the material

Shape restricts the

Process interacts with

Physical Properties (Thermal)

Physical Properties (Electrical)

Engineering Materials Classification

Materials Classification Cont

Die & tool steel

Materials Classification Cont

Classifications & Specifications of Metallic

Within each group of alloy, classification can be made

In most eng. application, selection of metallic is usually based on the

Classifications & Specifications of Polymers

Polymer low density, good thermal & electrical insulation,

Advantages : ease of manufacturing & versatility.

Thermoset & thermoplastic

Classifications & Specifications of Ceramic

Ceramics inorganic compounds of one or more metals with a

Design consideration for ceramics

Classifications & Specifications of Composites

Can be any type of mixture: polymer+metal, polymer+glass,

Design consideration for composites

Consider special characteristics and properties of

Application of Most Commonly Used Materials

Application of Most Commonly Used Materials

Application of Most Commonly Used Materials

Application of composite materials in

Source: Courtesy of Boeing Commercial Airplane Company

Example :Research impacts products (Nokia)

Battery life, charging,

Ergonomy, usability, user

Strong IPR portfolio

Structures, user interface,

Cameras and optics

Voice & Video codecs

WLAN, Ultra Wideband,

Materials research in products

Multi-disciplinary research needed

Need research in multidisciplinary areas

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