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PowerPoint Lecture Slides

for

Foundations of Materials
Science
and
Engineering
Forth Edition

William F. Smith
Javad Hashemi

CHAPTER

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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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

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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.

1-4

Materials Science

Materials Science and

Engineering

Basic
Knowledge
of
Materials

Resultant
Knowledge
of Structure and
Properties

Materials Engineering
Applied
Knowledge
of Materials

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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.
* mineral, not
biological origin

Metals and Alloys

Ferrous
Eg: Steel,
Cast Iron

1-5

Nonferrous
Eg:Copper
Aluminum

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Metallic Materials

Section 01 stops here 12/5/2011

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

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Metallic Materials

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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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Plastic resin producers are developing ultrapure, high-flow grades of

polycarbonate plastic for DVDs

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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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(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

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Types of Materials
Section 02 stops here 18/5/2011

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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Composite materials

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Composite materials - concrete

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Composite materials

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Composite materials

Overview of the wide variety of composite parts used in the Air Forces
C-17 transport. This airplane has a wingspan of 165ft and uses 15,000Ib
of advanced composite

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Composite materials

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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, Sattelites etc.
1-9

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Competition Among Materials

Materials compete with each
other to exist in new market

Example:1600

lb/Car

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

1400
1200

Aluminum
Iron
Plastic
Steel

1000
800
600
400
200
0

1985

1992

1997

Model Year

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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Competition Among Materials

Breakdown of weight percentage of major materials used in the average 1985

U.S. automobile

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Competition Among Materials

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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

Forging
1-11

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Future Trends

Powder Metallurgy

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 FiberglassEpoxy 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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Crystal/Grain

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Case Study Material Selection

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

Wood

Low cost but

Heavy. Less
Corrosion
resistance

Light and
strong. But
Cannot be
shaped

Carbon fiber
Aluminum
Reinforced
alloys
plastic

Ti and Mg
alloys

Very light and Light, moderately Slightly better

strong. No
Strong. Corrosion
Than Al
corrosion.
Resistance.
alloys. But much
Very expensive
expensive
expensive

Cost important? Select steel

Properties important? Select CFRP