Revision & Introduction

Materials Engineering

Dr. Mamdouh Salem

References: figures are from

• “The science and Engineering of Materials”, Askeland et al.
• “Materials Science and Engineering, An Introduction”, Callister et al.
Faculty of Engineering - Cairo University Dr. Mamdouh Salem 1
Main idea:

• For a given desired performance of any mechanical component, specific material

properties are targeted.

• The material properties are determined by its microstructure.

• The microstructure is affected by the processing processes through which the

component was manufactured.

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Crystal structure:
• You studied different types of crystal
structures, mainly FCC, BCC and HCP.

• You learned how to calculate linear and

planar densities.

• You learned that slip occurs on planes

having max planar density, in the directions
having max linear density.

Close-packed planes are Harder to slip

easier to slip
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Point defects

Vacancy Interstitial Substitutional

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 Dislocations
• Dislocations motion is the
mechanism through which plastic
deformation occurs.
• The incremental dislocation motion
enables slip at much lower shear
stress, in comparison to a perfect
crystal.
• Increasing the material strength
requires blocking dislocations
motion.
• When the dislocation density
increases, dislocations block the
motion of themselves (strain
hardening).

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Strengthening mechanisms
• Strain hardening: increasing the
dislocation density.
• Solid solution strengthening:
Introducing point defects.
• Grain-size strengthening: Reducing
the grain size.

• All these processes make the dislocation

motion more difficult, and therefore
increase the strength.

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Strengthening mechanisms

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Mechanical properties
• When loading a sample
under tension, unloading
it, machining a new
sample out of it and then
loading the new sample,
the yield strength
increases due to strain
hardening.
• Many mechanical
properties can be obtained
through
tension/compression test.

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 Annealing

After cold working After recovery

After recrystallization After grain growth

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Diffusion
• Diffusion is material transport through atomic motion.
• The driving force for diffusion is “Concentration difference”.
• Diffusion of interstitial atoms is easier than substitutional atoms.

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Diffusion
• Diffusion rate increases with temperature.

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Ferrous alloys classification

Commercially pure Steel contains between Cast iron contains

iron contains less than 0.008 and 2.14 wt% C between 2.14 and 6.7 wt%
0.008 wt% C (practically less than 1.0 C (practically less than 4.5
wt % C) wt % C)

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Hypoeutectoid Alloys
• These alloys having carbon content between 0.022
and 0.76 wt% C.
• In cooling to point d, both 𝛼 and 𝜸 phases will
coexist.
• Most of the small 𝛼 particles will form along the
original 𝜸 grain boundaries.
• As cooling continues, significant change in the
austenite composition happens.
• At temperature Te, austenite will have the eutectoid
composition, and will transform into pearlite when
cooled.
• The ferrite that is present in the pearlite is called
eutectoid ferrite, while that formed before Te is
called proeutectoid ferrite.
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 Hypoeutectoid Alloys
• How to determine the relative amount of
eutectoid and proeutectiod ferrite?
• At Te the fraction of pearlite is

• The fraction of proeutectoid ferrite is

• The fractions of both total ferrite and

cementite are determined using the lever
rule and a tie line that extends across the
entirety phase region, from 0.022 to 6.70
wt% C.
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Hypereutectoid Alloys
• When cooling from point g and reaching point h,
proeutectoid cementite phase will begin to form
along the initial austenite grain boundaries.
• During further cooling, the cementite composition
will remain unchanged, while the austenite
composition will change along PO line.
• When crossing , Te all remaining austenite of
eutectoid composition is converted into pearlite.
• The amount of pearlite and proeutectoid cementite
can be calculated as

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Adding other alloying elements
• The addition of other alloying elements will change the eutectoid composition
and temperature.

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 Course plan zqualza
Week number
Tuesday (8:00-9:30) Wednesday (2:00-3:30) Tutorial
(Sunday date) Blue: Dr. Ehab El-Danaf
1 (11/2) Revision – Solidification-1 Impact toughness -1 NDT Yellow: Dr. Emad El-Kashif
2 (18/2) Solidification-2 Impact toughness -2 Solidification Orange: Dr. Mamdouh Salem
Green: Dr. Sherif Ali
3 (25/2) Phase transformations-1 Creep-1 Impact toughness
Phase transformations-2
4 (3/3) Creep-2 Phase transformations
Heat treatments-1
5 (10/3) Heat treatments-2 Powder Metallurgy-1 Creep
6 (17/3) Polymers-1 Powder Metallurgy-2 Heat treatments
7 (24/3) Midterms week Grades distribution
Final Exam 75
8 (31/3) Polymers-2 Polymers-1 Midterm 25
9 (7/4) Polymers-3 & Composites -1 ‫ﻋﯾد اﻟﻔطر اﻟﻣﺑﺎرك‬ Assignments 10
Quizzes 15
10 (14/4) Composites -2 Polymers-2
11 (21/4) Composites-3 Composites-1
12 (28/4) Fatigue-1 Composites-2
13 (5/5) Fatigue-2 Fatigue-1
14 (12/5) Fracture Mechanics Fatigue-2
15 (19/5) Final revision week
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Learning outcomes
1. Explain the solidification mechanisms and the phase transformation diagrams, and
accordingly select the proper heat treatment processes for steel alloys.
2. Analyze the behavior of engineering materials under creep deformation and
impact loading.
3. Explain the basic concepts and applications of powder metallurgy.
4. To identify the basic concepts regarding the structure, properties and
manufacturing of polymers.
5. To describe the types of composites, their main characteristics and the evaluation
of their mechanical properties.
6. Identify the basics of fatigue loading, and carry out the design of mechanical
components subjected to fatigue.

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