Material Science and Engineering

Materials science- Studies the relationship between the structures and properties of materials.
Materials engineering- designing or engineering the structure of a material to produce a predetermined
set of properties from a functional perspective.
Materials scientist- Role is to develop or synthesize new materials
Materials engineer- called upon to create new products or systems using existing materials and/or to
develop techniques for processing materials.
Importance of studying materials
Engrs. must make material choices!
Materials selection:
 In service performance- Ability to endure heights if dropped.
 Deterioration-
 Economics- Cheap
Given materials: Coke Bottle

Glass Aluminum Plastic

Performance: Mas masarap Hindi masarap
Deterioration: Madali mabasag Matagal madecompose Mag brittle
Economics: 2nd mura 3rd mura 1st mura

Consequences of Wrong Choice of materials

SPACE SHUTTLE CHALLENGER- Fuel leakage in the rocket booster caused by O-ring. The O-ring
lost elasticity at low temperature.

Brief History of materials

- Started with natural materials. Then we developed techniques to produce materials with superior
qualities.
- Development and advancement of societies are dependent on the available materials and their
use.
 Four Components of the discipline of material science and engineering and their interrelationship
1. Structure- arrangement of internal components
(Ex: Subatomic, atomic, microscopic, macroscopic)
2. Properties- Characteristic of material
-response to external stimulus
(Ex: Mechanical, electrical, thermal, magnetic, optical, deteriorative)
 Mechanical-Related deformation to an applied load or force

(elastic and shear modulus, hardness)

Overdue-Hindi na babalik
Like chess
sa original length Mababali na

Normal-babalik pa sa
original length
  Electrical-Electrical Conductivity and Dielectric Constant
(conductivity, resistivity, capacitance)

Formula- E= K ( )
Where
 E-electric field
 K-Coulomb constant
 Q-Charge of the object generating the field
 R2-Distance between the point charge and the test charge squared (Radius)

Terminologies
 Electric field-
 Electrical conductivity-
 Dielectric constant-

 Thermal- Heat Capacity and Thermal Conductivity.

(thermal expansion, heat capacity, thermal conductivity)
 Terminologies

 Heat Capacity
 Thermal Conductivity

 Magnetic properties- Magnetic Field

Terminologies
 Right hand rule-
 Magnetic field-

 Optical- Index of Refraction and Reflectivity

(Reflectivity, absorbance emission)

Terminologies

 Index of Refraction-
 Reflectivity-
 Convex mirror-
 Concave mirror-
  Deteriorative properties- Chemical Reactivity

 Combination-
 Combustion-
 Decomposition-

3. Processing- method of preparing material

-Series of operation that transforms raw industrial materials to finished product
4. Performance- behavior in a particular application
Levels of structure
Atomic Arrangement: Ordered vs. Disordered
1. Crystalline-atoms are uniformly arranged
-Have definite shape and structure
- made of regular repeating three-dimensional structure called crystal lattice
-When cut, it cleanly splits into two parts
2. Amorphous-Atoms are randomly arranged
- No characteristic of Geometry
- When cut, it gives irregular parts because of its uneven composition

Crystal lattices

Note- 8 corners
-Six faces
 Crystal Lattice: Unit Cell

Body-Centered Cubic (BCC) Face-Centered Cubic (FCC) Hexagonal Close-Packed

CIMNT ACGLNS BCMZ

Chromium Aluminum Beryllium
Iron Copper Cadmium
Molybdenum Gold Magnesium
Niobium Lead Zinc
Tungsten Nickel
Silver

Microstructure
1. Single Crystal- periodic arrangement of atoms that extends throughout the entire sample
-Difficult to grow, environment must be tightly controlled
(Anisotropic materials)

2. Polycrystalline-Many small crystals or grains

-Small crystals misoriented with respect to one another
-Several crystals are initiated and grow towards each other
(Isotropic materials)

Material properties Example Aluminum Oxide (Al2O3)

single-crystal polycrystalline, polycrystalline,

(transparent) fully dense 5% porosity
(translucent) (opaque)
 Classification of Materials

1. Metal-Composed of one or more metallic elements (aluminum, copper, iron, gold, nickel, titanium,) and
non-metallic elements (carbon, nitrogen, oxygen) in relatively small amounts.

Properties
 Good conductors-Both electricity and heat
 Appearance- Lustrous, opaque, reflective
 Susceptible to corrosion
 Stiff and strong, yet deformable, ductile
 High thermal and electrical conductivity

2. Ceramic and Glass-Compounds formed with metallic and non-metallic elements, most frequently oxides,
nitrides, and carbides.
Examples: aluminum oxide (alumina or Al2O3), silicon dioxide (silica or SiO2), silicon carbide (SiC), silicon
nitride (Si3N4), clay minerals (i.e., porcelain), cement, and glass.

Properties:
 Thermally and electrically insulating
 Resistant to high temperatures and harsh environments
 Strong and hard but brittle
 Optical characteristics – can be transparent, translucent, or opaque

3. Polymers-Organic compounds that are chemically based on carbon, hydrogen, and other nonmetallic
elements (O, N, and Si)
-Inorganic polymers also exist such as silicon rubber.

Properties:
 Very large molecules, often chain-like
 Low density, low weight, soft, ductile
 Extremely flexible
 Thermal and electrical insulators
 Optically translucent or transparent

4. Composites-Combination of two or more individual materials formed from metals, ceramics, and/or
polymers.
Design goal- To achieve a combination of properties that is not displayed by any single material
-To incorporate the best characteristics of each of the component materials

Example: fiberglass- made of small glass fibres embedded within a

polymeric material (epoxy). Thus, it is stiff, strong (from the glass) and
flexible and ductile (from polymer)
 5. Semiconductors-electrical properties are intermediate between the electrical conductors (metals and
metal alloys) and insulators (ceramics and polymers).
Examples: gallium arsenide, germanium.

6. Biomaterial-components implanted into the human body for replacement of diseased or damaged body
parts.
Biocompatible-not cause adverse biological reactions.
Example- metals, ceramics, polymers, composites, or semiconductors.

Hip replacement

7. Nanomaterials-sizes of below 100 nm (1 nm = 10-9m).

-At these dimensions materials can acquire novel properties (i.e. optical, mechanical, thermal).
Example: Bulk silver and silver nanoparticles.

Crystal structure

Materials and Packing

 Crystalline Materials-Atoms are pack in dense periodic, 3d array

-Typically occur in metals, ceramics, and some polymers.

 Amorphous materials-Non crystalline

-Atoms have no periodic packing
-Typically occurs in complex and rapid cooling
Energy and Packing

Non dense, random packing Dense, ordered packing

 Crystal structure-manner in which atoms, ions, or molecules are spatially arranged within the unit cell.

Can be simple like in metal to complex like in some ceramic and polymeric materials.

 Unit cell-Smallest repetitive entity in the crystal.

- basic structural unit or building block of the crystal structure.
-defines the crystal structure by virtue of its geometry and the atom positions within.

 Crystal lattice-Three-dimensional array of points coinciding with atom positions.

 Atomic hard sphere model-Atoms are represented by spheres
-Nearest-neighbor atoms touch one another.

Kinds of crystal structure

1. Metallic Crystal Structures- simplest crystal structure!

Metals-tend to be densely pack

 Since only 1 element is present, all atomic radii are the same
 Metallic bonding-Non directional
 Nearest neighbor distances tend to be small in order to lower bond energy
 Electron clouds shields cores from each other
 2. Simple Cubic Structure (SC)-Rare due to low packing density (Only Po has this structure)

SIMPLE CUBIC

Coordination Number = 6 (the number of nearest neighbors or touching atoms)

Atomic Packing Factor

Volume of atom

APF for a simple cubic structure = 0.52

3. Body Centered Cubic Structure (BCC) - Atoms touch along cube diagonals
Examples- (Cr, W, Fe (a), Tantalum, Molybdenum)

BCC

Coordination No = 8
 Atomic Packing Factor: BCC

APF for a body-centered cubic structure = 0.68

4. Face Centered Cubic Structure (FCC)- Atoms touch along face diagonals
Examples-(Al, Cu, Au, Pb, Ni, Pt, Ag)

Coordination No = 12
 Atomic Packing Factor: FCC

APF for a face-centered cubic structure = 0.74

maximum achievable APF

5. Hexagonal Close-Packed Crystal Structure)- Examples include Co, Cd, Zn, Ti

Coordination number = 12
APF = 0.74
 No. Atom Atom volume Unit cell volume APF
Simple cube 1
0.52
Body centered cube 2
0. 68
Face centered cube 4
0.74
Hexagonal close 6 -------------- ---------------
packed 0.74

Densities of Material Classes

 Metals-close packing (Metallic bonding)

 Large atomic masses

 Ceramic- less dense packing

 Lighter elements

 Polymers-low packing density (often amorphous)

 Lighter elements (C,H,O)

Polymorphism-Two or more distinct crystal structures for the same material (allotropy/polymorphism)
 IMPERFECTIONS

1. Point defects
(a) Vacancies-vacant lattice site, from which atom is missing
-The number of vacancies increases exponentially w/ temperature
-Occur in all solids

Example (vacancies in iron)

Consider 10 g of iron
Atomic mass: 55.85 g/mol

(b) Self Interstitials -atom crowded into an interstitial site, a small void space that under ordinary
circumstances is not occupied.
-Introduces relatively large distortions, because the atom is substantially larger than the interstitial
position
-Formation of this defect is NOT highly probable
-Exists in significantly lower concentrations than vacancies.

2. Linear defects-dislocations; one-dimensional defects which atoms are misaligned

(a) Edge dislocation-extra half plane of the atoms inserted in a crystal structure

-An extra portion of a plane of atoms, or half-plane, the edge of which terminates within the crystal
-The atoms above the dislocation line are squeezed together while those below are pulled apart.

(b) Screw dislocation-spiral planar ramp resulting from shear deformation

 The atomic distortion associated with a screw dislocation is also
linear and along a dislocation line

Extra half plane

3. Planar defects- One case is a twin boundary (plane).

-Essentially, a reflection of atom positions across the twin plane. There is specific mirror lattice symmetry
 Impurities in Solids

Fact! Pure metal consisting of only one type of atom simply does not exist.
-Most familiar metals are not highly pure, but are alloys!
-Impurity atoms have been added intentionally to impart specific characteristics to the material.
- mechanical strength
- corrosion resistance
2 types of impurities in solid
1. Substitutional – solute or impurity atoms substitute for the host atoms

2. Interstitial –impurity atoms fill the voids among the host atoms
Note! The atomic diameter of an interstitial impurity must be substantially smaller than that of the host atoms.

Imperfections in solids
1. Solidification-
2 steps:
1st Nuclei formation
2nd Nuclei growth to form crystals

2. Dislocation-visible in electron microscopy.

A transmission electron micrograph of a titanium alloy in which the dark lines are dislocations.

Dark lines (Dislocations)

 3. Grain boundaries-are the regions between crystals, from which the transition from lattice of one region
to that of the other is slightly disordered
-Low density in grain boundaries

METALS TYPES

1. Metal alloys (Ferrous and Nonferrous)

2. Steels
3. Ferrous Alloys –Iron based alloys (Steels and cast irons)

Limitation of ferrous alloy

o Relatively high densities
o Relatively low electrical conductivities
o Generally poor corrosion resistance

AISI-American Iron and Steel Institute

 Cast irons
o Low melting-relatively easy to cast
o Generally brittle
o Metastable- Cementite decomposes to ferrite and graphite (a slow process)
 Types of cast iron

 Gray iron
o graphite flakes
o weak and brittle in tension, stronger in compression
o excellent vibrational dampening and wear resistance

 Ductile Iron
o Graphite as nodules
o Matrix often pear lite-stronger but less ductile

 White iron
o pearlite + cementite
o very hard and brittle

 Malleable Iron
 heat treat white iron at 800–900°C
 graphite in rosettes
 reasonably strong and ductile

 Compacted Graphite Iron

o relatively high thermal conductivity
o good resistance to thermal shock
o lower oxidation at elevated temperatures
 COMPOSITE

-Composed of two or more individual materials to produce a better combination of properties

COMPOSITE MATERIALS
matrix- two phases which compose simplest composite materials
The continuous phase. Fills the volume, provides shape. Transfers stress to other phase and protect
phases from the environment.

Dispersed phase- continuous and surrounds the other phase

-Enhances matrix properties May increase E, sy, TS or creep resistance.
Concrete- most prevalent building material used today due to widespread availability, cost-effectiveness,
structural characteristic, and ability to be molded into limitless geometries.

Concrete Properties

o High compressive strength, but significantly lower tensile strength

o elasticity of concrete is relatively constant at low stress levels but starts decreasing at higher stress levels
as matrix cracking develops.
o very low coefficient of thermal expansion; as it matures, concrete shrinks.
o All concrete structures will crack to some extent, due to shrinkage and tension

Types of Concrete
Based on weight
o Ultra-lightweight (1200 kg/m3)
o Lightweight (<1800 kg/m3)
o Normal weight (2400 kg/m3)
o Heavy weight (>3200 kg/m3)

Based on strength
o Low strength (<20 MPa compressive strength)
o Moderate strength (20-50 MPa compressive strength)
o High strength (50-200 MPa compressive strength)
o Ultra-high strength (>200 MPa compressive strength)

ADVANTAGE OF CONCRETE DISADVANTAGES OF CONCRETE

 More economical • Low tensile strength
• Ability to be cast • Low ductility; brittle
• More energy efficient • Volume instability
• Water-resistant • Formwork is needed
• High temperature-resistant • Long curing time
• Fire resistant

COMPOSITION OF CONCRETE
1. PORTLAND CEMENT -most common hydraulic cement, a type of cement that hardens by reacting with water
to form a water-resistant product.
- produced by pulverizing clinkers consisting of hydraulic calcium silicates

Hydration - chemical reaction between cement powder and water

COMPONENTS OF PORTLAND CEMENT

a. Iron oxide: gives color
b. Silica: gives strength
c. Lime- sufficient quantity forms dicalcium silicate and tricalcium silicate
d. Alumina: sets cement quickly; lowers clinkering temperature
e. Magnesia: helps in color
f. Gypsum: increases the setting of cement

2.AGGREGATES- granular material such as sand, gravel, crushed stone, crushed blast-furnace slag, or
construction and demolition wastes that is used with a cementing medium to produce either
concrete of mortar
- should be inert and strong. Essentially, it must be free of silt and/or organic matter

TYPES OF AGGREGATE

FINE AGGREGATE COARSE AGGREGATE

• Size more than 4.75 mm
• Size less than 4.75 mm • Includes gravel and crushed
• Includes natural sand or stones
crushed stone with most • Obtained by crushing
particles passing through a various types of granites,
sieve hard lime stones and sand
 Obtained from pits, lake, stones
river, or seashore