MMEE 210

Materials Science

Prof EN OGUNMUYIWA
Associate Professor of Materials & Metallurgical Engineering
 A quick test on
previous lecture…
 How is/are engineering
material(s) different from all
other materials?
 Materials for Engineering:
Properties, Repertoire and Selection
 Issues to Address

➢ Functional classification of Materials

➢ Materials Properties: Classifications and Examples

➢ Materials repertoire and uses.

➢ Materials selection for engineering applications

Functional Classification of Materials
Materials for Engineering: Functional Classifications
➢ Structural materials – are those that bear load or stress. Their
primary function is to provide mechanical strength in an
engineered structure. Examples include metals (e.g. steel, Al
alloys, etc.), composites (e.g. concrete, woods), ceramics (e.g.
Al2O3, ZrO2), and plastics (e.g. phenolics, Teflon (PTFE),
UHMWPE, nylon).
➢ Biomaterials – are used in the body to replace diseased or
damaged body parts. Most important properties include
chemically inert (non-toxic) to the body, be compatible, have
good mechanical strength, good lubricity and high wear
resistance between articulating surfaces. Examples include
metals (e.g. stainless steel, Ti alloys), ceramics (Al2O3, ZrO2,
Si3N4), polymer (PLA, PGA, PLGA), and even composites.
➢ Electronic materials – employed specifically in the electric,
electronic, and the telecommunication industries. Used for their
electronic properties. Included in this category are conductors
and semiconductors. E.g. Cu, Al, Si, Ge, PZT, GaAs, BaTiO3, etc.
 Materials for Engineering: Functional Classifications
➢ Magnetic materials – used for their magnetic properties. Mostly
found in applications including computer HD, inductors,
components for wireless communications and transformer cores.
Examples include (Co-Pt-Ta-Cr) alloys, Fe, FeSi, NiZn, and MnZn
ferrites, γ-Fe2O3.
➢ Aerospace materials – are materials developed specifically for
the aerospace industry. Their main characteristics includes
lightweights, excellent strength, excellent heat and corrosion
resistance, high stiffness, and excellent fracture toughness.
Examples include Al alloys, composites (CFRP), ceramics
(e.g.SiO2) .
➢ Energy Technology and Environmental Technology – the
nuclear industry uses materials such as UO2 and plutonium as
fuel; glasses and stainless steels, are used in handling nuclear
materials and managing radioactive waste. Many membrane
technologies for purification of liquids and gases make use of
ceramics and plastics.
 Materials for Engineering: Functional Classifications
➢ Smart materials - A smart material can sense changes in their
environment and respond in a predetermined manner to such. The
changes include temperature, the application of a stress, change in
humidity or chemical environment. Usually a smart material-based
system consists of sensors (detects input signals) and actuators
(performs a responsive and adaptive functions). Four types of
materials are commonly used for actuators:
➢ Shape-memory alloys, (SMAs) – metals that, after having been
deformed, revert back to their original shape when temperature
is altered.
➢ Piezoelectric ceramics – expand and contract in response to an
applied electric field (or voltage). They also generate an electric
field when their dimensions are altered.
➢ Magnetostrictive materials – behaves similar to piezoelectric,
but are only responsive to magnetic fields.
➢ Electrorheological/Magnetorheological fluids – liquids that
experience dramatic changes in viscosity upon the application of
electric and magnetic fields.
 Materials for Engineering: Functional Classifications

Functional classification of materials. Notice that metals, plastics, and ceramics occur in different
categories. A limited number of examples in each category are provided.
 Materials Properties:
Classifications and Examples
 Materials Properties: Classifications and Examples
➢ Chemical – relates to material's structure, its formation, and reactivity
with chemicals. Usually measured in a chemical laboratory.
➢ Examples include composition, microstructure, phases, grains,
inclusion, crystal structure, corrosion resistance, chemical
reactivity, etc.
➢ Physical – pertains to the interaction of materials with various forms
of energy and human senses. Can be measured without destroying or
changing a material.
➢ Examples include magnetic, electrical, optical, acoustic,
gravimetric, color, thermal properties, conductivity, specific heat,
heat distortion temperature (plastics), thermal expansion,
transition temperature (glass), elastic modulus – measures
stiffness, Poisson's ratio, use temperature, etc.
➢ Mechanical – associated to a material’s response to an applied force.
Often requires damage or destruction to a material. They usually
relate to elastic or plastic behavior.
➢ Examples include toughness, ductility, formability, strength
(tensile, compressive, impact, fatigue, shear, yield, rupture),
hardness, creep resistance, etc.
 Materials Properties: Classifications and Examples
➢ Electrical – response to electrical signals. E.g. electrical
conductivity, electrical resistivity, dielectric strength.
➢ Thermal – relates to material response on application of heat
energy, e.g. heat capacity, thermal expansion, thermal
conductivity and resistivity, heat distortion temperature,
transition temperature, etc.
➢ Magnetic – to the response of a material to an applied magnetic
field.
➢ Optical – define how a material interacts with light, e.g.
refraction, reflection, diffraction, intensity, etc
➢ Deteriorative/environmental – relates to the state of interaction
of a material with the environment during service. E.g.
corrosion, wear, durability. Etc.
➢ Procurement/manufacturing consideration – relates to specific
consideration during procurement and or manufacturing of a
component e.g. available sizes and shapes, surface texture,
manufacturing tolerance, stability, moldability,
Materials: Properties Spectrum
Materials Repertoire
 Materials Repertoire: Importance

➢ Thousands of materials to choose from for different applications

– competitions amongst materials.
➢ Working knowledge of engineering materials.
➢ Need to identify an exact material by using a globally
recognized designation system and designated required material
treatments.
➢ Over 100,000 engineering materials to choose from; over 15,000
plastics are commercially available worldwide and even more
metals and ceramics.
➢ No designer or engineer can be familiar with all those or know
the designation number for all.
➢ Be familiar with the common ones, e.g. steel, Al, Cu, etc.
➢ A repertoire of material will meet most design needs.
➢ Examples includes handbooks and in the modern days we have
software.
➢ ASTM handbook of Materials
➢ Granta Edupack, formerly CES Edupack, etc.
 Materials Repertoire: Example

Strength vs. density (yield strength for metals and polymers, compressive strength for ceramics, tear strength
for elastomers, and tensile strength for composites). The guide lines are used in minimum weight, yield-
limited, design. © Materials Selection in Mechanical Design, Michael F. Ashby 4th Edition.
 Materials Repertoire: Example

Strength vs. relative cost per unit volume. The design guide lines help selection to maximize strength per unit
cost. © Materials Selection in Mechanical Design, Michael F. Ashby 4th Edition.
 Materials Repertoire: Example

The maximum service temperature—the temperature above which a material becomes unusable. ©
Materials Selection in Mechanical Design, Michael F. Ashby 4th Edition.
 Materials Repertoire: Example

Young’s modulus vs. strength. The design guide lines help with the selection of materials for springs, pivots,
knife-edges, diaphragms, and hinges. © Materials Selection in Mechanical Design, Michael F. Ashby 4th
Edition.
 Materials Repertoire: Example

Strength vs. density (yield strength for metals and polymers, compressive strength for ceramics, tear strength
for elastomers, and tensile strength for composites). The guide lines are used in minimum weight, yield-
limited, design. © Materials Selection in Mechanical Design, Michael F. Ashby 4th Edition.
Materials Selection for Engineering
Purposes
 Materials Selection Process: Overview
Materials selection, like other aspects of engineering design, is a decision-
making process. The steps in the process are as follows:

1. Analysis of the materials requirements. Determine the conditions of

service and environment that the product must withstand. Translate them
into material properties.
2. Screening for candidate materials. Compare the needed properties with
a large materials property database to select a few materials that look
promising for the application.
3. Analysis of candidate materials in terms of trade-offs of product
performance, cost, manufacturability, and availability to select the best
material for the application. This is done in the embodiment phase of
design.
4. Development of design data for critical systems or components*.
Determine experimentally the key material properties for the selected
material to obtain statistically reliable measures of the material
performance under the specific conditions expected to be encountered
in service.
 Materials Selection: Relationships

Interrelations of design, materials, and processing to produce a product.

 Materials Selection: General Criteria
Materials are selected on the basis of four general criteria:

1. Performance characteristics (properties) – the process of matching

values of the properties of the material with the requirements and
constraints imposed by the design.
2. Processing (manufacturing) characteristics – means finding the
process that will form the material into the required shape with a
minimum of defects at the least cost.
3. Environmental profile – focused on predicting the impact of the
material throughout its life cycle on the environment. environmental
considerations are growing in importance because of the dual
pressures of greater consumer awareness and governmental
regulation.
4. Business considerations – cost of the parts that is made from the
material! This considers both the purchase cost of the material and the
cost to process it into a part. A more exact basis for selection is life-
cycle cost, which includes the cost of replacing failed parts and the
cost of disposing of the material at the end of its useful life.
 Materials Selection: General Procedure

Engineers are often required solve materials selection problems.

Procedure:

1. For a Specific Application Determine Required Properties

• Properties: mechanical, electrical, thermal,
magnetic, optical, deteriorative.

2. From List of Properties Identify Candidate Material(s)

3. Best Candidate Material Specify Processing technique(s)

• To provide required set of properties
• To produce component having desired shape and size
• Example techniques: casting, mechanical forming, welding,
heat treating
4. Consider the Cost Life–cycle Cost!
Materials Selection:
Simple Case Studies
 Materials Selection: Classes of Material 1

A certain application requires a material with the following

properties:

1. Lightweight,
2. Electrically non–conductive, and
3. Extremely stiff.

Suggest candidate class(es) of material suitable for such

application.
 Materials Selection: Classes of Material 2

A certain application requires a material with the following

properties:

1. Lightweight,
2. Electrically non–conductive, and
3. Extremely stiff.
4. Resistant to high temperatures.

Suggest candidate class(es) of material suitable for such

application.
 Materials Selection: Classes of Materials 3
A certain application requires a material with the following
properties:

Major requirement:
1. Very hard,
2. Corrosion resistant at room temperature and atmosphere
3. Extremely stiff.
Minor requirement:
1. Impact resistant

a. If you consider the major requirement, which class(es) of

materials would you suggest for such application?
b. If you consider both major and minor requirement, which
class(es) of materials would you suggest for such application?
c. Suggest a candidate material
 Materials Selection: Case Study
Artificial Hip Replacement

Anatomy of a human hip joint and adjacent skeletal features

 Materials Selection: Case Study
Artificial Hip Replacement
Hip joint problems can be painful and disabling
➢ Joint deterioration (loss of cartilage) as one ages
➢ Joint fracture

(a) (b)

Arrows point to
ends of fracture line

X-ray of (a) normal hip joint, and (b) fractured hip joint
 Materials Selection: Case Study

Artificial Hip Replacement

➢ Damaged and diseased hip joints can be replaced with

artificial ones!

➢ Materials requirements for artificial joints

➢ Biocompatible – minimum rejection by surrounding
body tissues
➢ Chemically inert to body fluids
➢ Mechanical strength to support forces generated
➢ Good lubricity and high wear resistance between
articulating surfaces.
 Materials Selection: Case Study

Artificial Hip Replacement

➢ Femoral stem — inserted into
Head
top of hip bone (femur) (Ball)
➢ Head (Ball) — affixed to
femoral stem
➢ Shell — attached to pelvis
➢ Liner — into which head fits Liner & Shell
(Acetabular)
Materials Used Femoral
Stem
➢ Femoral stem — Titanium or
CoCrMo alloy
➢ Head (Ball) —CoCrMo alloy
or Al2O3
➢ Shell — Titanium alloy © Photograph courtesy
of Zimmer, Inc.,
➢ Liner — PE or Al2O3. Warsaw, IN, USA.
 Materials Selection: Hip Replacement

Schematic diagram of an artificial

hip X-ray of an implanted artificial hip
Materials Selection: Incorrect Prediction Factors

➢ War – e.g., unrest, etc.

➢ In–service defects
➢ New major discovery
➢ Others?
 Summary

➢ Appropriate materials and processing decisions

require engineers to understand materials and their
properties.
➢ Materials' properties depend on their structures;
structures are determined by how materials are
processed.
➢ In terms of chemistry the classifications of materials
are metals, ceramics, and polymers.
➢ Most properties of materials fall into the following
categories: mechanical, physical, and chemical.
➢ An important role of engineers is that of materials
selection.
Ask the burning questions.