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PowerPoint Lecture Slides

for

Foundations of Materials
Science
and
Engineering
Fourth Edition

William F. Smith
Javad Hashemi
 CHAPTER
1
Introduction to
Materials Science
and
Engineering
1-1
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The Mars Rovers - Spirit and Opportunity

Spirit and Opportunity are made up of materials such as

* Metals * Ceramics * Composites * Polymers * Semiconductors

www.nasa.gov
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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.

1-2
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Why the Study of Materials is Important?

• Production and processing of materials constitute a
large part of our economy.
• Engineers choose materials to suite design.
• New materials might be needed for some new
applications.

 Example :- High temperature resistant materials.

 Space station and Mars Rovers should sustain
conditions in space.
* High speed, low temperature, strong but light.
• Modification of properties might be needed for some
applications.

 Example :- Heat treatment to modify properties.

1-3
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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.

Materials Science and

Materials Science Engineering Materials Engineering
Basic Resultant Applied
Knowledge Knowledge Knowledge
of of Structure and of Materials
Materials Properties

1-4
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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 Nonferrous
Eg: Steel, Eg:Copper
Cast Iron Aluminum
1-5
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Types of Materials

• 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.

1-6
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Types of Materials

• 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.

1-7
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Types of Materials

• 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.

1-8
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Types of 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.

1-9
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Competition Among Materials

• Materials compete with each
other to exist in new market Example:- Aluminum
1600
Iron
1400 Plastic
• Over a period of time usage 1200
Steel
of different materials changes 1000

lb/Car
depending on cost and
800
performance.
600
400
• New, cheaper or better 200
materials replace the old 0
1985 1992 1997
materials when there is a
Model Year
breakthrough in technology
Figure 1.14
Predictions and use of
materials in US automobiles.
1-10 After J.G. Simon, Adv. Mat. & Proc., 133:63(1988) and new data
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Future Trends

• Metallic Materials
 Production follows US economy closely.
 Alloys may be improved by better chemistry and
process control.
 New aerospace alloys being constantly
researched.
o Aim: To improve temperature and corrosion
resistance.
o Example: Nickel based high temperature super
alloys.
 New processing techniques are investigated.
o Aim: To improve product life and fatigue
properties.
o Example: Isothermal forging, Powder metallurgy.
 Metals for biomedical applications
1-11
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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.

1-12
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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.

1-13
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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 Fiberglass-
Epoxy and Graphite-Epoxy
combinations.
 Commercial aircrafts are expected to
use more and more composite materials.

1-14
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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
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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.
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MEMS and Nanomaterials

• MEMS: Microelectromechanical systems.

 Miniature devices
 Micro-pumps, sensors

• Nanomaterials: Characteristic length < 100 nm

 Examples: ceramics powder and grain size < 100
nm
 Nanomaterials are harder and stronger than bulk
materials.
 Have biocompatible characteristics ( as in
Zirconia)
 Transistors and diodes are developed on a
nanowire.
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Case Study – Material Selection

• Problem: Select suitable material for bicycle

frame and fork.
Carbon fiber
Steel and Aluminum Ti and Mg
Wood Reinforced
alloys alloys alloys
plastic

Low cost but Light and Very light and Light, moderately Slightly better
Heavy. Less strong. But strong. No Strong. Corrosion Than Al
Corrosion Cannot be corrosion. Resistance. alloys. But much
resistance shaped Very expensive expensive expensive

Cost important? Select steel

Properties important? Select CFRP