1 MBB3023 Course Outcomes

At the end of the course, the students should be

able to:

1 Identify the appropriate material testing standards.

2 Interpret and analyze materials testing data.

3 Select suitable materials for a given engineering application.

4 Apply knowledge of materials properties for engineering

design and applications.
2

Metals and
Alloys Wire-
Steel-cord reinforced
tyres cement
(Cermet)
Composites

CFRP GFRP Ceramics

Polymers
Filled polymers and Glasses
 3 Role of Materials in Product Success
 Failure of products:
1. Insufficient design
2. Insufficient properties Insufficient properties is a materials
engineering issue.
Properties: characteristic that
distinguish and identify a material.
“Design flaws Originate in the nature of material
occurs because at the atomic or molecular level.
the designers and
tool fabricators Material properties
never use the
product - common
Chemical Mechanical Physical
in large
corporations.”
4 Material properties

Chemical Mechanical Physical Thermal

•Material •The •Characteristics
characteristics that
•The properties
characteristics of of materials that of a material
relates to the a material that relate to the change with
structure of
are displayed interaction of temperature,
materials, its
formation from the when a force is these materials usually for worst.
elements, and its applied to the with various Start to creep or
reactivity with material. forms of energy oxide/degrade.
chemicals, other and with human
materials, and senses.
environment.

Procurement/Manufacturing considerations are not listed in property handbooks

and not even legitimate category by most standards. However the available shapes,
sizes, surface Texture, tolerances on materials are often the most important selection
factors.
 5 Materials Property Spectrum
Procurement/
CHEMICAL PHYSICAL MECHANICAL Manufacturing
considerations
Tensile/compressive
Composition Available Shapes,
• Specific heat Toughness
Microstructure
METALS

Ductility Sizes, Surface

Phases • Coefficient of
Fatigue Texture
Grain Size Thermal Hardness Manufacturing
Corrosion Resistance Expansion Tolerances
Creep resistance
Inclusions • Thermal Shear strength
Composition conductivity Tensile/compressive Manufacturing tolerances,
POLYMERS

Fillers, Crystallinity • Heat Stability, Available Sizes,

Heat distortion
Molecular weight distortion moldability, surface
Pressure-velocity limit
Flammability texture
temp Toughness, Stress
Spatial configuration
Chemical resistance • Glass Rupture, Creep
transition
Composition Tensile/compressive Available Shapes,
temp
CERAMICS

Porosity Fracture toughness Sizes, Surface Texture

Grain size • Magnetic Transverse rupture Manufacturing
Crystal Structure • Electrical Hardness Tolerances, Stability
Corrosion Resistance • Optical
• Acoustic Tensile/compression
Composition Available shape and Sizes
COMPOSITES

Matrix/reinforcement bond; • Gravimetric Fracture toughness Manufacturing tolerances

Volume fraction of • Color Creep resistance Stability
reinforcement; Reinforcement orientation
Reinforcement nature
6 “Properties-Product Design Relationship”
Properties

INTRINSIC ATTRIBUTIVE  How the

Bulk Price and properties of
mechanical Availability engineering
properties materials
affect the way
Production in which
Bulk non- properties: ease
mechanical of mfg,
products are
properties fabrication, designed.
joining, finishing

Surface Aesthetic
properties properties:
appearance,
texture, feel
7 “Properties-Product Design Relationship”
 How the Mechanical Properties of engineering materials affect the
way in which products are designed.

•“Elastic” means it springs

back when released;
•Elastic stiffness – resistance
to bending is set partly by its
shape – thin strips are easy to
bend – partly by a property of
the material itself - its Elastic
Modulus, E.
•Materials with high E, like
steel, are intrinsically stiff;
those with low E, like PE, are
not.
8 “Properties-Product Design Relationship”
 How the Mechanical Properties of engineering materials affect the
way in which products are designed.
•Permanent deformation is related
to strength not stiffness.
•Permanent bent depends on its
shape and its Yield Strength , y.
•Large y (Ti) is hard to deform
permanently, even E is not high
•Low y like lead is deformed easily
•When metals deformed they
getting stronger („work
hardening‟) but there is limit called
Tensile strength, ts after this limit
the materials fails (the amount of
stretches before it breaks is called
“ductility”.
9 “Properties-Product Design Relationship”
 How the Mechanical Properties of engineering materials affect the
way in which products are designed.

•Fracture suddenly before it

acquires a permanent bend.
•No permanent deformation -
y is not the right property.
•Resistance of materials to
cracking and fracture is
measured instead by Fracture
Toughness, K1c.
•Steels are tough – have high
K1c; glass is brittle – low K1c
10 “Properties-Product Design Relationship”
 How the Mechanical Properties of engineering materials affect the
way in which products are designed.
Inadequate Stiffness
(E too low)
Inadequate
Strength (y low)

Inadequate
Inadequate Density
Fracture & ( too high)
Toughness
(K1c too low)
11 “Properties-Product Design Relationship”
 How the Thermal Properties of engineering materials affect the way in
which products are designed.

1. The strength of materials fails, it starts to „creep‟

(to sag slowly over time), it may oxidize, degrade or
decompose (figures).
This means that there is a limiting temperature called
the Maximum Service Temperature, Tmax, above which
its use is impractical.
12 “Properties-Product Design Relationship”
 How the Thermal Properties of engineering materials affect the way in
which products are designed.

2. Most materials expand when they are heated, but by

different amount depending on their Thermal
Expansion Coefficient,.
The expansion is small but its consequences can be
large. E.g. buckling of the rod. (the rod is constrained
and then heated – the expansion forces the rod against
the constraint, causing it to buckle). E.g: railway
tracks.
13 “Properties-Product Design Relationship”
 How the Thermal Properties of engineering materials affect the way in
which products are designed.

High Conductivity,

3. Some materials-metals-feel cold; others-wood-feel warm. This feel has to do with

two thermal properties of materials: Thermal Conductivity,  and Heat Capacity. -
measures the rate at which heat flows through the material when one side is hot and
the other cold: High  is needed in conducting heat from one place to another
(cooking pans, radiators, heat exchangers). Low  is useful in insulate homes,
reduce energy consumptions of refrigerators and freezers and enable space vehicles
to re-enter the earth’s atmosphere.
When time is limited, Heat Capacity, Cp is matter. It measures the amount of heat
that it takes to make the temp. of material rise by a given amount.
 14 The Price & Availability of Materials
Consider how the materials used for building bridges in Cambridge
have changed over the centuries. Fig. 1.2 (Queens’ Bridge) suggests,
until 150 years or so ago wood was commonly used for bridge
building. It was cheap, and high-quality timber was still available in
large sections from natural forests. Stone, too, as the picture of Clare
Fig. 1.2
Bridge (Fig. 1.3) shows, was widely used. In the 18th century the
ready availability of cast-iron, with its relatively low assembly costs,
Fig. 1.3 led to many cast-iron bridges of the type exemplified by Magdalene
Bridge (Fig. 1.4). Metallurgical developments of the later 19th century
allowed large mild-steel structures to be built (the Fort St. George
Footbridge, Fig. 1.5). Finally, the advent of cheap reinforced concrete
Fig. 1.4 led to graceful and durable structures like that of the Garret Hostel
Lane bridge (Fig. 1.6).
“This evolution clearly illustrates how availability influences the
choice of materials. Nowadays, wood, steel and reinforced concrete
are often used interchangeably in structures, reflecting the relatively
small price differences between them. The choice of which of the
three materials to use is mainly dictated by the kind of structure the
Fig. 1.5 architect wishes to build: chunky and solid (stone), structurally
efficient (steel), slender and graceful (pre-stressed concrete.”
15 Mechanical Properties of Materials

Learning Objectives: students should be able to:

1. Achieve an understanding of the difference between

strength and toughness.
2. Gain a secure knowledge of tensile testing and its
product.
3. Learn how to use mechanical properties in materials
selection and failure analysis.
 16 Spectrum of Mechanical Properties

Mechanical
properties
Strength Formability Toughnes
Stiffness Durability
s
Tensile
Yield % elongation; Modulus of Impact
elasticity strength; Hardness;
Compressi % reduction Wear
area; Flexural Notch
on resistance;
modulus sensitivity; Fatigue
Flexural Bend radius
Critical strength
Shear stress
Creep intensity
factor
Stress
rupture
17 Tensile Testing
 What is tensile testing?
 What is it used for?
 How does it work?
 Important parts on a tensile tester:
– Specimen‟s pulling/pushing mechanism
– Grips
– Extensometer
– Fixtures
 Type of loading
 Definition of elastic modulus
 Yield strength
 Tensile strength
 Determining percent elongation
 True stress and strain
 Poisson‟s ratio
18 Tensile Test

The key mechanical properties obtained from a Tensile Test:

1-Modulus of Elasticity (E);
2-Yield Strength (Y.S).
3-Tensile Strength (TS);
4-Ductility, 100xєfailure (elastic recovery occurs after fracture);
5-Toughness (measured under load; hence the dashed line is
vertical)
19 The tensile test is the most common test for determining such
mechanical properties of materials as strength, ductility, toughness,
elastic modulus, and strain-hardening capability.
 20 Significance of Stress-Strain Data
Parameter Description
Modulus of Used to measure the relative stiffness of materials.
elasticity
Yield strength(YS) Design stresses must be lower than the YS to ensure
that a part does not fail by plastic deformation. Shear
strength may be estimated from this YS.
Ultimate tensile The ultimate tensile stress is the maximum stress
strength (UTS) observed in a tensile test. Necking begins when the
value is reached.
UTS/YS ratio The ratio provides an indication of the degree of work
hardening that has occurred.
% elongation Indication of material ductility and toughness
% reduction in area Indication of material ductility and toughness
General shape of Area under the curve provides a relative indication of
curve material toughness. Interstitial activity in the material
can be observed. Relative level of work hardening are
assessed.