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Workshop 1 – ENGINEERING MATERIALS

Jeimmi Katerin Bastidas Rodriguez 5801490

Pablo Mendoza Neira 5801428

Dana Zharick Garzón torres 5801374

Department of Engineering, Universidad Militar Nueva Granada

11501: Engineering Materials

Pedro Nel Martínez Henao

February 02, 2024

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Summary

In this workshop, the different types of materials that we find in our environment and that are

part of our daily activities are explained. Their variety and classification are examined, as

understanding them well is critical to solving various problems, such as creating quality products

in the industry. All industrial products must consider materials, as these affect their durability,

quality, usefulness, and profit. To meet the needs of society, it is crucial to know the

composition, strength, and other factors of materials, as detailed in this questionnaire. In

addition, it is essential to constantly consider the environmental impact that certain materials

can have on the ecosystem. Using them improperly can have negative consequences for the

environment. Therefore, it is necessary to analyze the properties of the materials before use to

find the most suitable one for our needs.

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Questionnaire

1. What is Materials Science and Engineering?

Materials science and engineering (MSE) is an interdisciplinary field that studies and

It manipulates the composition and structure of materials on length scales to control

material properties through synthesis and processing.

Materials scientists and engineers don't just deal with

materials development, also with the synthesis and processing of materials and

manufacturing processes related to the production of components.

Materials science focuses on the basic relationships between synthesis and processing,

structure, and properties of materials.

Materials engineering concentrates on ways to convert or transform materials into useful

devices or structures.

2. Define the following terms:

(a) composition; It is the chemical constitution of a material.

(b) structure; It means the arrangement of atoms, i.e. how it is observed at different

levels of detail.

(c) synthesis; It refers to how materials are made from natural or man-made chemicals.

(d) processing; It involves how materials are transformed into useful components to

bring about changes in the properties of different materials.

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(e) microstructure; It is the very small-scale configuration of a material, defined as the

structure of the prepared surface of a material shown by an optical microscope at high

magnification.

3. Classification of materials

3.1. Metals and alloys; Metals include aluminum, magnesium, zinc, iron, titanium,

copper, and nickel. An alloy is a metal that contains additions of one or more metals or

nonmetals.

Properties of Metals

Metals have good electrical and thermal conductivity. They have relatively high

strengths, high stiffness, ductility or formality and impact resistance.

They are particularly useful for structural or load-bearing applications.

Alloys can enhance a specific desirable property or allow for better combinations of the

properties.

Table 1

Metal Sorting

copper Electrical Conductive Wire High electrical conductivity,

good workability

Grey Placed Iron Automotive Engine Blocks Moldable, machinable,

vibration dampening.

Alloy steels Wrenches, car chassis Significant hardening by heat

treatment.

Note. This table shows the classification of metals taking into account their properties.
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3.2. Ceramics, glass, and glass-ceramics; Ceramics are inorganic crystalline materials.

The sand on the beach and the rocks are an example of ceramics in their natural state.

Advanced ceramics are materials prepared through the refining of natural-state ceramics

and other special processes, used in substrates that house computer chips, sensors and

activators, capacitors, wireless communications, spark generators, inductors, and electrical

insulators.

Properties of Ceramics

Ceramics do not conduct heat well and must be heated to very high temperatures before

melting. They're tough and tough, but they're also brittle.

Ceramic Processing. Fine powders from ceramics are prepared and converted into

various forms. New processing techniques make it possible to manufacture ceramics that are

sufficiently resistant to fracture that can be used in load application, such as impellers in turbine

engines. Glass is an amorphous material; Often, but not always, derived from a molten liquid.

Amorphous refers to materials that do not possess a regular, periodic arrangement of atoms.

Applications. They are used in homes, cars, computer screens, televisions,

smartphones, and hundreds of other atom applications.

Processing. Glass can be heat-treated (tempered) to make it stronger. The formation of

glasses and the nucleation (formation) of small crystals within them by means of a special

thermal process create materials known as glass-ceramics. The Zerodur™ is an example of a

glass-ceramic material used to construct mirror substrates for large telescopes. Glass-ceramics

are processed by melting and casting.

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Table 2

Properties of ceramics

𝑆𝑖𝑂2 − 𝑁𝑎2 𝑂 − 𝐶𝑎𝑂 Window glass Optically transparent,

thermally insulating

𝐴𝑙2 𝑂3 , 𝑀𝑔𝑂, 𝑆𝑖𝑂2 Refractories (i.e., furnace Thermal insulators, withstand

color resistant coatings) to high temperatures, relatively

contain molten metal inert to molten metal

Barium Titanate Capacitors for High Cargo Storage Capacity

microelectronics

Silica Optical fibers for information Low optical losses

technology

Note: Shows physical properties of ceramic materials, which vary depending on their bonds.

3.3 Polymers (plastics); Polymers are organic materials. They are produced by a

process known as polymerization. Polymeric materials include rubber (elastomers) and many

types of adhesives.

Thermoplastic polymers are those in which large molecular chains are not rigidly

connected, have good ductility and formability. Thermoset polymers are stronger, but more

brittle, because the molecular chains are cross-linked.

Properties of Polymers

They are good electrical and thermal insulators, although there are exceptions. Even

though they possess a lower strength than metals or ceramics. Polymers have a very good

strength-to-weight ratio. Cannot be used at high temperatures. They have very good resistance

to corrosive chemicals.
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Applications

Compact discs (CDs), strings and liquid crystal displays (LCDs), clothing and coffee

cups.

Table 3

Properties of polymers

Polyethylene Food Packaging Easily convertible into thin,

flexible and airtight films

Epoxy Integrated Circuit Electrically insulating and

Encapsulation moisture-resistant

Phenolic Adhesives for bonding layers Strong, moisture-resistant

of laminated timber

Note: The properties of polymers and their applications are evident.

3.4. Semiconductors; silicon-based semiconductors. Germanium and gallium arsenide,

such as those used in computers and electronic devices, are part of a broad class of materials

known as electronic materials. The electrical conductivity of semiconductor materials is between

that of ceramic insulators and that of metal conductors.

Applications

Semiconductors have enabled the information age. The level of conductivity can be controlled to

produce electronic devices, such as transistors and diodes, that are used to build embedded

ones.
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Production

Many applications require large single crystals of semiconductors that are produced from

molten materials. Thin films of semiconductor materials are also often manufactured using

specialized processes.

Table 4

Examples of semiconductors

Silicon Transistors and Integrated Unique electrical behavior

Circuits

Gas It converts electrical signals

Optoelectronic systems into light, is used in lasers,

laser diodes, etc.

Note: Application on electronic devices.

3.5. Composite materials; The main idea behind the development of composites is to

combine properties not found in any simple material. Composite materials are formed from two

or more materials, resulting in properties not found in any single material. Concrete, laminated

timber, and fiberglass are examples of composite materials.

Processing/Production

Fiberglass is prepared by dispersing glass fibers in a polymer matrix. These fibers give greater

rigidity to the polymer, but do not significantly increase its density.

Applications

Composites can be used to produce lightweight, strong, ductile and temperature-

resistant materials, or rigid cutting tools, but resistant to impact that would otherwise break

them. Advanced aircraft and aerospace vehicles rely on composite materials. Certain sports
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equipment such as bicycles, golf plates, tennis rackets, and the like also use different types of

composite materials that are lightweight.

Table 5

Composite Materials

Graphite-epoxy Aircraft Components Strength-to-weight ratio

Tungsten-cobalt carbide Carbide Cutting Tools for High hardness, but good

(WC-CO) Walking impact resistance

Titanium-coated steel Reactor Containers Low Cost and High Steel

Strength with Titanium

Corrosion Resistance

Note: Two or more materials with different properties are combined.

4. Make a Functional Classification of Materials

Aerospace Materials

Biomedical Materials

Electronic Materials

Energy Technology Materials and Environmental Technology

Magnetic Materials

Photonic or optical materials

Smart materials (a smart material can sense and respond to an external stimulus, such

as a change in temperature, the application of stress, or a change in humidity or the chemical

environment).

Structural materials (these materials are designed to withstand some type of stress.
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5. Explain the difference between crystalline and amorphous materials. Give an example

of each one you use in your daily life.

Crystalline: The atoms of the material are ordered in a periodic manner, for example, ice.

Amorphous: The arrangement of the atoms of the material does not have a far-reaching

order, for example, glass.

6. Do a Structure-Based Material Classification

Structure refers to the arrangement of atoms in a material.

Structure on a microscopic scale is known as a microstructure. It is possible to observe

these arrangements at different scales, ranging from a few angstrom units to a millimeter.

Crystalline materials that assume the form of a crystal are called monocrystalline.

Materials that consist of many crystals or grains are known as polycrystalline.

7. What Environmental and Other Effects Occur in Material Handling

Temperature

Temperature changes drastically change the properties of materials. Metals and alloys

that have been hardened by certain heat treatments or deformation techniques lose their

strength when heated.

High temperatures modify the structure of ceramics and cause polymers to melt or

carbonize. Very low temperatures can cause a metal or polymer to crack or crack, even when

the applied loads are low.

Corrosion

Most metals and polymers react with oxygen and other gases in particles at high

temperatures.
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Metals and ceramics can disintegrate, and polymers and rust-free ceramics can rust.

Materials are also attacked by corrosive liquids, leading to premature failure.

Fatigue

Fatigue failure is when material is loaded and unloaded thousands of times, even small loads,

small cracks can begin to occur, and material fails as these cracks grow.

8. Design and Material Selection: What is the difference between physical and

mechanical properties? List three examples for each.

The material must acquire the desired physical and mechanical properties. It must be

able to be processed or manufactured in the way it is intended and offers an economical

solution to the design problem. In the design and selection, the density of the material, or its

weight per unit volume, must be considered. Strength-to-weight ratios of various materials.

Physical Properties:

These properties refer to characteristics that can be observed or measured without

changing the composition of the material.

Examples:

Density is the amount of mass per unit volume of a material.

-Copper is a good thermal conductor, that's why it's used in electrical cables.

-The melting point of water is 0°C.

Mechanical Properties:

These properties refer to the behavior of a material when subjected to external forces or

load.

Examples:
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Structural steel has a high tensile strength.

Diamond is extremely hard due to its crystalline structure.

Carbon steel has high toughness and is used in structural applications.

9. What material properties do you think an engineer should consider when selecting a

material for this application? Be as specific as possible.

When considering a material for a specific application, an engineer must consider

properties such as strength, thermal conductivity, electrical conductivity, density, durability, and

compatibility in the environment in which it will be used. It is also important to evaluate the

economic factors and availability of the material.

10. What benefits do you think carbon fiber epoxy composites have compared to

aluminum alloys? What limitations or potential drawbacks might there be when using a carbon

fiber epoxy compound?

Carbon fiber epoxy composites tend to be lighter and offer an excellent strength-to-

weight ratio compared to aluminum alloys. In addition, carbon fiber composites are strong and

have high specific strength, making them ideal for applications that require rigidity and tensile

strength.

However, some limitations of carbon fiber epoxy composites include their lower

compressive strength compared to aluminum alloys. In addition, the fabrication and repair of

carbon fiber components can be more complex and costly. In addition, their fatigue and impact

resistance may be lower compared to certain types of aluminum alloys. The choice between the

two materials will depend on the specific characteristics required for the application and

economic considerations.
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11. You are an engineer working for an onshore gas turbine manufacturer. These

turbines are similar to jet engines but are used onshore to provide power for electricity

generation and gas compression piping applications. Suppose you want to apply a ceramic-

based thermal barrier coating to the turbine blades on the first stage turbine to increase the

operating temperature and efficiency of the engine.

(a) What difficulties might engineers experience in trying to design a ceramic coating to

be applied to a superalloy metal blade?

Engineers could face challenges such as the difference in coefficients of thermal

expansion between ceramic and metal, which can lead to thermal stresses. In addition, the

adhesion of the coating to the metal surface and resistance to erosion and corrosion are major

concerns.

(b) What properties should be taken into account when choosing a suitable ceramic

material for a coating? Be as thorough as possible.

When choosing a ceramic material for coating, it is crucial to consider properties such as

thermal conductivity to ensure efficient heat distribution, chemical stability to withstand

aggressive environments, thermal expansion compatible with the base metal.

and low porosity to prevent the infiltration of corrosive agents. In addition, thermal shock

resistance and the ability to maintain its mechanical properties at high temperatures are

essential to ensure long-lasting performance under demanding operating conditions.

12. If you were given a material and asked to determine whether it is crystalline or

amorphous, how would you determine it?

-Examine visually: The crystalline ones have an orderly structure, while the amorphous

ones are more disordered.

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Microscope: The crystalline lens show a regular arrangement under the microscope,

while the amorphous ones are more random.

-X-ray diffraction: Clear patterns indicate crystallinity; fuzzy patterns, amorphity.

-Optical properties: The crystalline lens produces definite patterns; the amorphous ones

do not.

-Mechanical properties: Crystalline fractures are more regular than amorphous ones.

13. List six material performance issues that can lead to component failure.

13.1 Fatigue: occurs due to repetitive loads, leading to the formation and propagation of

cracks, especially in components subjected to charge-discharge cycles.

13.2 Corrosion: caused by chemical reactions with the environment, weakens materials

and can lead to failure, especially in aggressive environments.

13.3 Wear: the repetitive friction between surfaces, causing loss of material and

eventually affecting the integrity of the component.

13.4 Creep: Slow and continuous deformation under constant loads and high

temperatures, known as creep, can cause permanent deformation and eventual material failure.

13.5 Hydrogen Embrittlement: Hydrogen absorption can cause embrittlement,

weakening the material and leading to the formation of catastrophic cracks and failures.

13.6 Excessive Plastic Deformation: High loads can result in excessive plastic

deformation, causing irreversible changes in the shape of the material and eventually leading to

failure.
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14. Steel is often coated with a thin layer of zinc if it is to be used outside. What

characteristics do you think zinc provides to this coated or galvanized steel? What precautions

should be considered when producing this product? How will the recyclability of the product be

affected?

Beneficial Features:

-Corrosion protection, longer service life and self-healing properties.

Precautions When Producing Galvanized Steel:

Thickness control, temperature regulation, avoid contaminants to prevent the presence

of contaminants on the surface of the steel before galvanizing to ensure proper adhesion of the

zinc coating.

Impact on Product Recyclability:

Galvanized steel is recyclable. However, the recycling process must consider the

removal of zinc, as it does not mix easily with steel during melting. This may require special

treatment to recover and recycle the zinc.

15. The relationship between structure and material properties can be influenced by

service conditions (environmental conditions). Name two engineering disasters that have had

tragic results and why they occurred.

Space Shuttle Challenger disaster (1986): The disaster occurred due to the failure of an

O-ring in one of the space shuttle's solid thrusters. Cold temperatures on launch day

compromised the elasticity of the elastomer-made O-ring material, resulting in a gas leak and

eventually the destruction of the shuttle.

Tacoma Narrows Bridge Accident (1940): The collapse of the Tacoma Narrows Bridge

was caused by wind resonance that matched the natural frequency of the bridge. The bridge
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structure was susceptible to wind-induced vibration due to its slim, streamlined design.

Environmental conditions, combined with a lack of understanding of the effects of wind on the

structure, led to the collapse of the bridge.

16. You want to select a material for the electrical contacts in an electrical switching

device that opens and closes frequently and forcefully. What properties should the contact

material have? What kind of material could you recommend? Would Al2O3 be a good choice?

Explain.

Key properties for electrical contact material in a switching device that operates

frequently and forcefully include:

Good electrical conductivity: To ensure low electrical resistance and efficient current

conduction through the contacts.

Wear resistance: Since the device switches frequently, the material must resist the wear

associated with repetitive motion.

Chemical stability: To prevent the formation of oxides or other layers that can affect

electrical conductivity.

Ability to withstand mechanical loads: The material must be strong enough to withstand

the forces applied during switching.

As for Al2O3 (aluminum oxide), although it is a good electrical insulator and has decent

mechanical properties, it is not an ideal choice for electrical contacts due to its low electrical

conductivity. A conductive material is preferred to ensure an efficient electrical connection.

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17. You would like to be able to identify different materials without having to resort to

chemical analysis or lengthy testing procedures. Describe some possible testing and

classification techniques you could use based on the physical properties of the materials.

Density: Use density as a way to identify materials. Density can be determined by

measuring the mass and volume of the material.

Thermal conductivity: The ability of a material to conduct heat. You can use a thermal

conductivity measuring device to determine this attribute. Metals, for example, tend to have high

thermal conductivity compared to plastics.

Magnetism: Using a magnet to see if the material is attracted to it. Ferromagnetic

materials such as iron and nickel will be attracted, while other materials will show no magnetic

response.

Brightness: The reflection of light can provide clues about the type of material. Some

materials have a characteristic metallic sheen, while others may be more opaque or translucent.

Solubility: Some materials are soluble in certain solvents and others are not. Performing

solubility testing can help identify specific compounds within a material.

Melting point: Heating the material in a controlled manner, observing its melting point

can help identify it. Each material has a characteristic melting point.

18. You would like to be able to physically separate different materials in a scrap metal

recycling plant. Describe some possible methods that could be used to separate materials such

as polymers, aluminum alloys, and steels from each other.

Magnetic separation: Ferrous metals, such as steel, can be separated using strong

magnets.

Density separation: Materials can be separated using differences in their density.

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Crushing and sieving: Materials can be crushed and then sifted to separate particles of

different sizes. This can help separate materials such as plastics, aluminum, and steel based on

their size and shape.

Optical induction separation: This method uses optical sensors to identify and separate

materials based on their optical properties. It can be useful for separating materials such as

polymers, aluminum alloys, and steel in a waste stream.

19. Some pistons for automobile engines can be produced from a composite material

containing small, hard particles of silicon carbide in an aluminum alloy matrix. Explain what

benefits each material in the composite can provide to the overall part. What problems can the

different properties of the two materials cause when producing the part?

Benefits of Each Material in the Composite

Aluminum Alloy:

-Low Density: Aluminum is lightweight, which contributes to reducing the overall weight

of the piston and, therefore, the engine, improving fuel efficiency.

-Good Thermal Conductivity: The high thermal conductivity of aluminum helps to

dissipate the heat generated during the operation of the motor, preventing overheating.

Silicon Carbide:

-Hardness and Wear Resistance: Silicon carbide particles are hard and wear-resistant,

which increases piston life and reduces wear, especially under high load and speed conditions.

Improved Mechanical Strength: The addition of silicon carbide improves the

mechanical strength of the material, allowing the piston to handle higher forces and pressures.
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Potential Problems When Producing the Part

Manufacturing Challenges: The uniform distribution of silicon carbide particles in the

aluminum matrix can be a challenge during the manufacturing process.

Machinability: The presence of silicon carbide can make the material more difficult to

machine. This can increase complexity and costs in the manufacturing phase.

Costs: The addition of silicon carbide can increase the production costs of the composite

material compared to conventional aluminum alloys.

20. Investigate the origins and applications of a material that has been invented or

discovered since birth or investigate the development of a product or technology that has been

invented since birth that was made possible by the use of a novel material. Write a paragraph

about this material or product. Provide a list of the references or websites you used. You must

use at least three references.

Graphene is a material that is extracted from graphite and is composed of pure carbon,

one of the most important elements in nature and found in everyday objects such as the lead of

a pencil.

Graphene was discovered in 2004 by Russian-born scientists Andre Geim and

Konstantin Novoselov, but it was in 2010, the year in which these researchers received the

Nobel Prize in Physics, that the "graphene fever" began.

Applications

Graphene, a material composed of a single layer of carbon atoms, has a variety of

applications. It is used in electronics, medicine, composites, batteries, and more due to its
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unique properties, such as high electrical and thermal conductivity, as well as its strength and

lightness.

Conclusions:

-The different types of materials present in our environment have been explored and

categorized according to their properties and uses.

-It is important to choose materials carefully to ensure the durability and quality of

industrial products, as well as to minimize their environmental impact.

-It seeks to optimize efficiency and sustainability in the development of industrial

products, finding a balance between functional needs and environmental considerations.

Continuous research in the field of materials is essential to make more informed and

responsible decisions in product development.

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References

Graphene, a material that will change our world. (2013-04-17). Obtained from Graphene:

https://www.inmesol.com/blog/el-grafeno-un-material-que-cambiara-nuestro-mundo/

The era of graphene. Usage and applications today. (2020, 05/19). Obtained from Graphene:

https://planetagrafeno.com/es-esta-la-era-del-grafeno-usos-y-aplicaciones-en-la-

actualidad/

Guidebook: The Science and Engineering of Materials

Chemical and physical properties of ceramics. (n.d.). Obtained from ceramics:

https://www.zschimmer-schwarz.es/noticias/propiedades-fisicas-y-quimicas-de-la-

ceramica/#:~:text=Las%20propiedades%20f%C3%ADsicas%20de%20los,tomar%20infi

nitas%20formas%20y%20tama%C3%B1os