CHAPTER

1
Introduction to Materials
Science and
Engineering

1-1

LEARNING OBJECTIVES
By the end of this chapter, students will be able to:
1. Describe the subject of materials science and
engineering as a scientific discipline
2. Cite the primary classification of solid materials.
3. Give distinctive features of each group of materials.
4. Cite one material from each group. Give some
applications of different types of materials.
5. Evaluate how much you know, how much you do not
know about materials.
6. Establish the importance of materials science and
engineering in selection of materials for various
application

What are Materials?

Materials may be defined as
substance of which something is
composed or made.

We obtain materials from earth crust

and atmosphere.

Examples : Silicon and Iron constitute 27.72 and 5.00

percentage of weight of earths crust respectively.

Nitrogen and Oxygen constitute 78.08 and 20.95

percentage of dry air by volume respectively.

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Table 1.1

Materials are...
engineered structures...not blackboxes!
Structure...has many dimensions...
Structural feature
atomic bonding
missing/extra atoms
crystals (ordered atoms)
second phase particles
crystal texturing

Dimension (m)
< 10-10
10-10
10-8 -10-1
10-8 -10-4
> 10-6

Materials Science and Materials Engineering

Materials Science
and Engineering
Materials
Science
Basic
knowledge
of materials

Resultant
knowledge of the
structure,
properties,
processing,
performance of
engineering
materials

Material
Engineering
Applied
knowledge of
materials

Figure 1.4: This diagram illustrates how materials

science and engineering form a bridge of
knowledge from the basic sciences to the
engineering disciplines (Reprinted with
permission from National Academy of sciences,
courtesy of National Academic Press.)

Materials Science and

Engineering
Materials science deals with basic
knowledge about the internal
structure, properties and processing
of materials.

Materials engineering deals with the

application of knowledge gained by
materials science to convert materials
to products.

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Structure, Processing, & Properties

Properties depend on structure
ex: hardness vs structure of steel

Hardness (BHN)

(d)

600
500
400

(a)

(b)
4m

300
200

30m

(c)

30m

100
0.01 0.1

30m

Data obtained from Figs. 10.21(a)

and 10.23 with 4wt%C composition,
and from Fig. 11.13 and associated
discussion, Callister 6e.
Micrographs adapted from (a) Fig.
10.10; (b) Fig. 9.27;(c) Fig. 10.24;
and (d) Fig. 10.12, Callister 6e.

1
10 100 1000
Cooling Rate (C/s)

Processing can change structure

ex: structure vs cooling rate of steel

The Materials Selection Process

1. Pick Application

Determine required Properties

Properties: mechanical, electrical, thermal,

magnetic, optical, deteriorative.

2. Properties

Identify candidate Material(s)

Material: structure, composition.

3. Material

Identify required Processing

Processing: changes structure and overall shape

ex: casting, sintering, vapor deposition, doping
forming, joining, annealing.

ELECTRICAL

Electrical Resistivity of Copper:

(1 0 -8 O h m -m )

R e s is tiv ity ,

6
5
Adapted from Fig. 18.8, Callister 6e.
(Fig. 18.8 adapted from: J.O. Linde,
Ann Physik 5, 219 (1932); and
C.A. Wert and R.M. Thomson,
Physics of Solids, 2nd edition,
McGraw-Hill Company, New York,
1970.)

4
3
2
1
0

-200

-100

T (C)

Adding impurity atoms to Cu increases resistivity.

Deforming Cu increases resistivity.

THERMAL
Space Shuttle Tiles:
Thermal Conductivity
--Silica fiber insulation
offers low heat conduction.

T h e rm a l C o n d u ctiv ity
(W /m -K )

Fig. 19.0,
Callister 6e.
(Courtesy of
Lockheed
Missiles and
Space
Company, Inc.)

of Copper:
--It decreases when
you add zinc!

Adapted from
Fig. 19.4W, Callister
6e. (Courtesy of
Lockheed Aerospace
Ceramics Systems,
Sunnyvale, CA)
(Note: "W" denotes
fig. is on CD-ROM.)

100m

400
300
200
100
0

0
10 20 30 40
Composition (wt%Zinc)

Adapted from Fig. 19.4, Callister 6e.

(Fig. 19.4 is adapted from Metals
Handbook: Properties and Selection:
Nonferrous alloys and Pure Metals, Vol.
2, 9th ed., H. Baker, (Managing Editor),
American Society for Metals, 1979, p.
315.)

MAGNETIC
Magnetic Storage:

vs. Composition:
--Adding 3 atomic % Si
makes Fe a better recording
medium!

M agnetization

--Recording medium
is magnetized by
recording head.

Magnetic Permeability

Fig. 20.18, Callister 6e.

(Fig. 20.18 is from J.U. Lemke, MRS
Bulletin,
Vol. XV, No. 3, p. 31, 1990.)

Fe+3%Si
Fe

Magnetic Field

Adapted from C.R. Barrett, W.D. Nix, and

A.S. Tetelman, The Principles of
Engineering Materials, Fig. 1-7(a), p. 9,
1973.Electronically reproduced
by permission of Pearson Education, Inc.,
Upper Saddle River, New Jersey.

 Transmittance:

OPTICAL

--Aluminum oxide may be transparent, translucent, or

opaque depending on the material structure.
single crystal

polycrystal:
low porosity

polycrystal:
high porosity

Adapted from Fig.

1.2,
Callister 6e.
(Specimen
preparation,
P.A. Lessing; photo
by J. Telford.)

DETERIORATIVE

--causes cracks!

Heat treatment: slows

crack speed in salt water!

c r a c k s p e e d ( m /s )

Stress & Saltwater...

10-8

10-10

Adapted from Fig. 17.0, Callister 6e.

(Fig. 17.0 is from Marine Corrosion,
Causes, and Prevention, John Wiley and
Sons, Inc., 1975.)

as-is
held at
160C for 1hr
before testing

Alloy 7178 tested in

saturated aqueous NaCl
solution at 23C

increasing load

Adapted from Fig. 11.20(b), R.W. Hertzberg,

"Deformation and Fracture Mechanics of Engineering
Materials" (4th ed.), p. 505, John Wiley and Sons, 1996.
(Original source: Markus O. Speidel, Brown Boveri Co.)

--material:
7150-T651 Al "alloy"
(Zn,Cu,Mg,Zr)

Adapted from Fig. 11.24,

Callister 6e. (Fig. 11.24 provided courtesy of
G.H.
Narayanan and A.G. Miller, Boeing Commercial
Airplane Company.)

4m

Classification of Materials
* Metals
* Polymer
* Semiconductor
* Advanced Materials
* Smart Materials
* Nanotechnology

* Composite
* Ceramics
* Biomaterials

Materials
Metal

Properties

Examples

Good conductivity of heat and electricity

Not transparent to visible light
Polished surface has lustrous appearance
Strong
Deformable (machinable)
Extensive use in structure

Ferrous Iron and

Steels
Non ferrous
Aluminum,
aluminum
alloy, Titanium
alloy etc

Polymer

Large molecular structure

Low densities
Flexible (compare to other material)
Low electrical and thermal conductivity

Plastic
Rubber
Adhesive

Ceramics
/ glasses

Strong and hard

Low thermal conductivity and electrical conductivity
(extensive use as refractory material)
Brittle
Resistant to harsh environment
Resistant to high temperature

Clay
Cement
Glasses

Material

Properties

Composite

Combination of more than one material type

and displays combination of the best
characteristics
Light weight
Hard, strong, very stiff
high temperature resistance materials

Semiconductor Electrical properties are intermediate

/ electronic
between insulator and conductor
Able to convert electrical signal

Biomaterials

Components implanted into the human body

for replacement of disease or damaged body
parts
Non-toxic
Biocompatible with body tissues

Example
Fiberglass
Concrete
Plywood

Germanium;
Silicon;
Gallium
arsenide
Metal
Ceramics
Polymer
Composite
Semiconductor

Ch
apt
er
120

Types of Materials

Metallic Materials

Composed of one or more metallic elements.

Example:- Iron, Copper, Aluminum.

Metallic element may combine with nonmetallic

elements.

Example:- Silicon Carbide, Iron Oxide.

Inorganic and have crystalline structure.

Good thermal and electric conductors.
Metals and Alloys
Ferrous
Eg: Steel,
Cast Iron

Nonferrous
Eg:Copper
Aluminum

Metallic Materials

The aircraft turbine engine shown is made principally of metal alloys. The latest hightemperature, heat resistant, high-strength nickel-base alloys are used in this engine. This
engine has many advanced, service-proven technologies to enhance operational performance
and durability. These include second-generation single-crystal turbine blade materials, powder
metal disks, and an improved full authority digital electronic control

 Polymeric (Plastic) Materials

Organic giant molecules and mostly noncrystalline.
Some are mixtures of crystalline and noncrystalline
regions.

Poor conductors of electricity and hence used as

insulators.

Strength and ductility vary greatly.

Low densities and decomposition temperatures.
Examples :- Poly vinyl
Chloride (PVC), Polyester.

Applications :- Appliances,
DVDs, Fabrics etc.

 Ceramic Materials
Metallic and nonmetallic elements are chemically
bonded together.

Inorganic but can be either crystalline, noncrystalline

or mixture of both.

High hardness, strength and wear resistance.

Very good insulator. Hence used for furnace lining for
heat treating and melting metals.

Also used in space shuttle to insulate it during exit and

reentry into atmosphere.

Other applications : Abrasives, construction materials,

utensils etc.

Example:- Porcelain, Glass,

Silicon nitride.

(a) Examples of a newly developed

generation of engineered ceramic
materials for advanced engine
applications. The black items
include engine valves, valve seat
inserts, and piston pins made of
silicon nitride. The white item is a
port-manifold liner made of an
alumina ceramic material

(b) Potential ceramic component

applications in a turbocharged
diesel engine

High-performance ceramic ball bearings and races are

made from titanium and carbon nitride feedstocks through
power metal technology

 Composite Materials
Mixture of two or more materials.
Consists of a filler material and a binding material.
Materials only bond, will not dissolve in each other.
Mainly two types :o Fibrous: Fibers in a matrix
o Particulate: Particles in a matrix
o Matrix can be metals, ceramic or polymer

Examples : Fiber Glass ( Reinforcing material in a polyester or epoxy

matrix)

Concrete ( Gravels or
steel rods reinforced in
cement and sand)

Applications:- Aircraft wings

and engine, construction.

Composite materials

Composite materials

 Electronic Materials
Not Major by volume but very important.
Silicon is a common electronic material.
Its electrical characteristics are changed by adding
impurities.

Examples:- Silicon chips,

transistors

Applications :- Computers, Integrated Circuits,

Satellites etc.

3
2

Competition Among
Materials
Materials compete with
each other to exist in new
market

Example:-

Over a period of time

usage of different
materials changes
depending on cost and
performance.

New, cheaper or better

materials replace the old
materials when there is a
breakthrough in
technology

Figure 1.14
Predictions and use of
materials in US automobiles.

Competition Among
Materials

Breakdown of weight percentage of major materials used in the average 1985 U.S.
automobile

Recent Advances and

Future Trends
Nanomaterials
Smaller than 100 nm particle size.
Materials have special properties.
Very hard and strong characteristics.
Research in progress.
Example: Carbon nanofiber reinforced plastic: very
light but stronger than metals.

http://farm4.static.flickr.com/
www.ml.afrl.af.mil/stories/mlb-00378.html

Recent Advances and

Future Trends

Smart Materials
React to environment Stimuli.
Change their properties by sensing

external stimulus.
Examples: Shape memory alloys used in the
artery stents.

Microelectromechanical systems (MEMS)

devices.

Future Trends
Polymeric (Plastic Materials)
Fastest growing basic material (9%
per year).

After 1995 growth rate decreased due

to saturation.

Different polymeric materials can be

blend together to produce new plastic
alloys.

Search for new plastic continues.

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Future Trends
Ceramic Materials
New family of engineering ceramics are
produced last decade

New materials and applications are constantly

found.

Now used in Auto and Biomedical

applications.

Processing of ceramics is expensive.

Easily damaged as they are highly brittle.
Better processing techniques and high-impact
ceramics are to be found.

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Future Trends
Composite Materials
Fiber reinforced plastics are primary
products.

On an average 3% annual growth from

1981 to 1987.

Annual growth rate of 5% is predicted

for new composites such as FiberglassEpoxy and Graphite-Epoxy combinations.

Commercial aircrafts are expected to

use more and more composite materials.

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Future Trends
Smart Materials : Change their

properties by sensing external stimulus.

Shape memory alloys: Strained material
reverts back to its original shape above a
critical temperature.
Used in heart valves and to expand arteries.

Piezoelectric materials: Produce electric

field when exposed to force and vice
versa.
Used in actuators and vibration reducers.

Future Trends
Electronic Materials
Use of electronic materials such as silicon
increased rapidly from 1970.

Electronic materials are expected to play

vital role in Factories of Future.

Use of computers and robots will increase

resulting in extensive growth in use of
electronic materials.

Aluminum for interconnections in integrated

circuits might be replaced by copper
resulting in better conductivity.

1-15

Recent Advances and

Future Trends
Nanomaterials
Smaller than 100 nm particle size.
Materials have special properties.
Very hard and strong characteristics.
Research in progress.
Example: Carbon nanofiber reinforced plastic: very
light but stronger than metals.

Case Study Material

Problem:Selection
Select suitable material
for bicycle frame and fork.
Steel and
alloys

Low cost but

Heavy. Less
Corrosion
resistance

Wood

Carbon fiber
Reinforced
plastic

Aluminum
alloys

Light and
strong. But
Cannot be
shaped

Very light and

strong. No
corrosion.
Very expensive

Light, moderately
Strong. Corrosion
Resistance.
expensive

Cost important? Select steel

Properties important? Select CFRP

Ti and Mg
alloys

Slightly better
Than Al
alloys. But much
expensive

The End
Thank You