(Bia- 0) ering Materials; Types, Properties Engineering Mater Engincering materials refers to the group of materials that are used in the construction of manmade structures and components. The primary function of an engineering materi withstand applied loading without breaking and without exhibiting excessive deflection. Specify the needs of lea ification of engineering materials: rning cl Material enginecring helps in the understanding of the composition of materials, their best applications and how to combine them for improved performance. These discaveries have real- life value in healthcare, manufacturing, transport, defense and a wide range.of other industries. ‘There area lot of materials and elements found in otir environment some of them are natural and some others are laboratory prepared. There are a lot of similarities and differences between ceach of them on the basis of several factors. But itis hard for anyone-to study the structure, behavior and properties of each one of them individually and also to remember them for chemical use. So, for the convenience and to make the study of different materials easier.and convenient we group the materials on the basis of different properties. The grouping or the élassification of materials makes the study easier and also saves our time and energy. Development of new materials has followed a number of different pathways, depending on both the nature of the problem being pursued and the means of investigation, Breakthroughs in the discovery of new materials have ranged from pure serendipity, to trial-and-error approaches, to design by analogy to existing systems. These methodologies will remain important inthe development of materials but as the challenges and requirements for new materials become more complex, the need 0 design and develop new materials from the molecular scale through the macroscopic final product will become inereasingly important. The use of molecular modeling and ilo useable forms or devi the engineering of new materials i .es are of patticular importance. 1 Page Md. Tarek Ur Rahman Crin Assistant Professor (Mechanical) cree ww ! Module 1 - ; : d og (Engineering Matera: 16 101) Regioo i Module I 1, Materials: Basie ( Basically: Engineering Materials Can be classified into two ealegories- 1. Metals Non-Metals Metal Metals are polycrystalline bodies which are having number of differentially oriented fine exystals. Normally major metals atv in solid states at normal temperature. However, some metals are having high thermal such as mereury are also in liquid state at normal temperature. All metal: and electrical conductivity, All metals are having positive temperature coefficient of resistance. sases with incre temperature. Metals ean be further divided Means resistance of metals in chemical element that possesses metallic luster and into bso groups- A metal may bedefined as jive charge that is liberated at the cathode. Most nonmetallic which, in electrolysis, pos is the nonmetals earry negative charges elements do not possess melallic luster, and in electroly that are liberated at the anode. OF all the natural chemical elements, about 70 are metals and, of these, about 39 are used commercially ample: Iron, Gold, Silver. Metals can be further divided into two groups- 1. Ferrous Metals = All ferrous metals are having iron as common element. All ferrous materials are having very high permeability which makes these materials suitable for construetion of core of electrical machines. Examples: Cast Iron, Wrought Iron, Steel, Silicon Steel, High Spe: Steel, Sprin; 2 is Metals ~ ferrous metals are having very low permeability. Example: Silver, Copper, Gold Aluminum ete. 21 Ma farek We tahModule 1 CCngnccring Materia 101) Rego Non-Metal materials are non-erystalline in nature. ‘These exists in amorphic or mesomorphic forms. These are available in both solid and gaseous forms at normal temperature. Normally all non-metals are bad conductor of heat and electricity. Pla Example ties, Rubber, Leathers, Asbestos etc, As these non-metals are having very high resistivity which makes them suitable for insulation purpose in electrical machines. nple: Carbon, Sulphur, Phosphorous. Other classification of engineering materials: iginecring materials can also be classified as below- 1. Alloys 2. Ceramic Materials 3. Organic Materials Alloy: Analloy is a metallic substance, but itis not a single chemical clement. An alloy is formed by the union or mixture of two or more metals; in some cases, it may consist of one or more metals and a nonmetal, In short, an alloy is a mixture of chemical elements where the primary component is a metal, Bronze, Gunmetal, Invar. Super Alloys ete. amples: Steels, Bras: 3]Page Md. Tarek Ur Rahman Erin Assistant Professar (Mechanica CTEC pyModule | ‘ C (Engineering Materials; IPE 101) 3 Carbon silver Gold Sulphur Red Phosphorous Figure : Non-Metals ] ) ( \ Bronze 18K Gold Brass eomper (a wll eprint ins) copper: Mme) sir Sterling Silver her carbone conse (758 Figure: Alloy [14k Gold: 14k gold is 58.5% gold, usually with silver, copper, and zine, Alloying gold makes it harder and stronger 18k Gold: 18k gold is 75% gold, usually with copper, nickel, or zinc, ‘The alloy retains the color and luster of gold, but is harder and stronger than the pure element. at Md. Tarek Ur Baharan teDifference Between Metals & Non-Meta Module 1 (Pingineering Materials; IPE. 101) They have lustre (shine) They are malleable {they can be broken into thin sheets) They are good conductor of electricity (electricity can pass through them) They do not have lustre(shine) They are non malleable {they cannot be broken into thin sheets) They are bad conductor of electricity {electricity cannot pass through them) They are good conductor of heat (heat can pass through them) They are bad conductor of heat (heat cannot pass through them) They are ductile (they can be drawn into wires) They are non ductile {they cannot be drawn into wires) They are sonorous {they produce ringing sound) They are non sonorous (they do not preduce sound)” The Difference Between Alloys anid Composites (and Compound Terms & Definitions combitiation of elements (at least 1 metal) in solid-solution, ~ with overall metallic properties Alloy coinbination of othet materials, wirere the mixed materials remain physically distinct Composite combination of eletents with chemical bonds, with very different properties from its base elements Compound Md. Tarek Ur Rahman Erin Assistant Professor (Mechanical) cTEC 5IPaneModule 1 Ceramic Mat Is are non-metallic solids. These aire made of inorganic compounds such Ceramic mat as Oxides, Nitrides, Silicates and Carbides. Ceramic materials possess exceptional Structural, Electrical, Magnetic, Chemical and Thermal properties. These ceramic materials are now extensively used in different engineering fields. Examples: Silica, glass, cement, concrete, garnet, MgO, CdS, ZO, SiC ete. Organic Material terials carbon ‘All organic materials are having carbon as a common element. In organi is chemically combined with oxygen, hydrogen and other non-metallic substances: Generally organic materials are having complex chemical bonding. Example: Plasties, PVC, Synthetic Rubbers ete. 6 [Pane Md Tarek Uy Babman fron Assistant Protesser (Mechanical creeModule t Metalloids: Some products show properties of both metals and onmetals, They are called metalloids. cemesian Example: Silicon, Germanium, Arsent Selection of Materials for Enginee The best material is one which serve the desired objective at the minimum cost, > Availability of the materials ® Suitability of the materials for the working conditions in ser > The cost of the materials Properties of Materials: Properties give a material suitable or unsuitable for particular use in industry. Different material properties: > Mechanical properties: ¢ > Thermal properties > Electrical properties v Magnetic properties > Chemical properties > Physical properties, TIPane Md. Tarek Ur Rahman Erin Assistant Professor (Mechanical) cTECModule 1 Mechanical Properties: Mechanival propei s determnine the behaviour of en load > Strength ‘The strength of a material is the property of resistance to external loads or stresses while not causing structural damage icine 1. sane, Ano cesmanscivE (a) Tensile Strength, (b) Shear Strength, (c) Compressive Strength, > 2 asticity Elasticity is the ability of material 0 retum to its original size, shape, and dimensions after _ being deformed. a, The elastic limit is the point at which permanent deformation begins b. The yield point is the point at which a definite deformation occurs with litte or no increase in load, > Ductility | 7 Ductility is the capacity of a material, such as copper, to be drawn or stretched | under tension loading and permanently deformed without rupture or fracture. > Malleability Malleability is the property of a metal to be deformed or compressed permanently ‘without rupture or fracture, BLP age Md. Tarek Us Rahman frin Assistant Pro cre ssor (Mechanicallree Module 1 Plasticity Plasticity is the ability of a metal, such as gold, silver, or lead, to be deformed extensively without rupture, Toughny 8 Toughness is a combination of high strength and medium ductility. Toughnes is the ability of a mate ial or metal to resist fracture, plus thi ‘ist failure after the 2 2 damage has begun, Britt ‘The term "brittleness" implies sudden failure. It is the property of breal without warning; that is, without visible permanent deformation. Corrosive Resistance Corrosive resistance is the resistance to eating away or wearing by the atmosphere, moisture, or other agents, such as acid » Abrasion resistance is the resistance to wearing by friction. Fatigue When metal is subject to frequent repetitions ofa stress, it will ultimately rupture and fail, even though the stress may not, be sufficient to prodiice permanent deformation if continuously applied for a relatively brief time. Machinabilit Machinability is the ease or difficulty with which a material lends itself to being machined. Hardness Hardness is the ability of a material to resist penetration and wear by another material. 9|Page Md. Tarek Ur Rahman Erin Assistant Professor (Mechanical) CTEModule t ical Prop Shiny appearance; they show a metallic luster. Harder to cut vvy This property is n be beaten into thinner sheets. On being hammered ca called Malleability, Most metals are malleable. Gold and Silver metals are the most malleable metals. > Most metals are ductile. > Good conductors of electricity & heat. sing sound when struck. Metals are generally sonorous. That is, they make a I Metals such as iron are very strong. Therefore, it is therefore, widely used in the ~ construction of buildings, bridges, railway lines, carriages, vehicles anc machinery. > All metals except Mercury, exist in the solid form at room temperature. Therefore, they retain their shapes under normal conditions. > High melting points. > High tensile strength, that is they can be stretched to some degree without breaking, Metals ile strength. ike tungsten has high ter General Chemical Properties of the Met > Metals when bummed i the presence of oxygen, they combine with oxygen to fo oxides which are basic in nature. Metal hydroxide changes red litmus blue which shows ils basic characterist vi Most metals corrode when they are exposed to atmosphere. v Metals differ in their reactivity with acids. Most metals react with acids to produce sa m and hydrogen. : ‘The Physical and Chemical Properties of Ceramics: > High melting points (so they're heat resistant). > Great hardness and strength ty (they're long-lasting and hard-wearing) Considerable dural > Low electrical and thermal conductivity (they're good insulators). > Chemical inertness (they're unreactive with other chemicals). 10] Page Md. Tarek Us Rahman Prin Assistant Professor (Mechanical) creeModule 1 (Bngineering Materials; 1PE 101) > High dimensional stability. > Good wear resi lance. nish between fatigue and creep: a it loading lefined as time dependent deformation when material is under constant loading ile fatigue is defined Creep i is occurred due to variation in grain structure of the material whi Generally, as failure of material due to rapidly stress (variation of stresses). Fatigue * failure occurs in components that are subjected to cyclic variation of stresses- aircraft wing struts, pistons, crankshafts, etc continuously suffer forces in opposing directions in a rhythmic pattern * can cause components to fail at a fraction of its.real tensile strength Creep * creep failure happens in situations where forces involved cause less than the limiting stresses on components. + the premature deformation of materials at'stress levels that are otherwise safe, but in elevated temperature conditions wi eee ‘The Physical and Chemical Properties of Polymers: A polymer is any of a class of natural or synthetic substances composed of very large molecules, called macromolecules, which are: multiples of simpler chemical units called monomers. Polymers make up many of the materials in living organisins ind are the basis of many minerals and man-made materials. Some of the useful properties of various engineering polymers are high strength or modulus ‘o weight ratios (light weight but comparatively stiffand strong), toughness, resilience, resistance 11] Page Md. Tarek Ur Rahman Erin Assistant Professor (Mechanical) creModule 1 (Engineering Materi to corrosion, lack of conductivity (heat and electrical), color, transparency, processing, and low cost. Stress: Engineering Stress (o) is the quotient of load (F) and area (A). The units of stress are normally pounds per square ineh (psi). © isthe stiess (psi) F is the force that is loading the object (Ib) A is the cross sectional area of the object (in”) where: When stress is applied to a material, the material will deform. Elongation is defined as the ference between loaded and unloaded length AL=L-Lo where: Al is the elongation (ft) Lis the loaded length of the cable (ft) Zs is the unloaded (original) length of the cable (ft) Strain is the concept used to compare the elongation of a material to its original, undeformed length. Strain (¢) is the quotient of elongation (e) and original length (L0). Engineering Strain has no units but is often given the units of in/in or fUft. 32} Page Md. Tarek Ur Rahman Crin Assistant Professor (Mechanical) cTEC.Module 1 (Engineering Materials; IPE and Material Behavior: Stress and strain are calculated from easily measurable quantities (normal load, diameter, as in Figure. Such Sire int it is loaded until it breaks. Strain elongation, original length) and can be plotted against one another diagrams are used to study the behavior of a material from the poi ach material produces a different stress-strain diagram. uts| s Fracture oy Ss . t r e s Pinstic Region s — Elastic Region 1 Figure: Stress/Strain Diagram ; Al a Lo where: & is the strain in the cable (Aft) Al is the elongation (ft) « Z, is the unloaded (original) length of the cable (ft) Point 1 on the diagram represents the original undeformed, unloaded condition of the material. As the material is loaded, both stress and strain increase, and the plot proceeds from Point 1 to Point 2. If the material is unloaded before Point 2 is reached, then the plot would proceed back down the same line to Point 1. Md. Tarek Ur Rahman Erin Assistant Professor (Mechanical) cTEc 13 [PageModule 1 ‘e (Engineering Materials; IPE 101) UW the material is unloaded anywhere between Points | and 2, then it will return to its I shape, like a rubber band. This type of behavior is termed Elastic and the region between Poi 's Land 2 is the Elastic Region. region stress The Stres cin eurve also appears linear between Points 1 and 2. Int lastic Modulus or and strain are proportional, The constant of proportionality is called the Young's Modulus (FE). The relationship between stress and strain in this region is given by Equation, i @ = or o=Ee where is the stress (psi) is the Elastic Modulus (psi) is the strain (in/in) ome Point 2 is called the Yield Strength (o;). If it is passed, the material will no longer return to its original length. It will have some permanent deformation. This area beyond Point 2 is the along the curve from Point 2 Plastic Region. Consider, for example, what happens if we con mn increases with increasing strain, If the to Point 3, the stress required to continue deformat material is unloaded the curve will proceed from Point 3 to Point 4, The slope (Elastic Modulus) will be the same as the slope between Points 1 and 2, The difference between Points 1 and 4 represents the permanent strain of the material, . the curve will proceed from Point 4 to Point 3 with the same If the material is loaded agai Slastic Modulus will be unchanged, but the Yield Strength will be Plastic Modulus (slope). increased. Permanently straining the material in order to increase the Yield Strength is called Strain Harden If the material is strained beyond Point 3 stress decreases as non-uniform deformation and necking occur. The sample will eventually reach Point 5 at which it fractures, called the Tens ‘The largest value of stress on the diagram le Strength ('8) or Ultimate ‘Tensile Strength (UTS). This is the most stress the material can support without breakin, 14] Page Mid. Tarek Ue Rahman Erin Assistant Professor (Mechanical) teModule f (Engi Materials; IPE 101) Brittle a Figure: Ductile and Brittle Behavior Mathematical Problem: QA hollow cylinder 2 m long has an outside diameter of 50 mm and inside diameter of 30 mm. Ifthe cylinder is carrying a load of 25 KN. Find the stress in the cylinder. Also find the deformation modulus of elasticity is 200 GPa, of the cylinder, Solution: 100 GPa=200 x 10° N/mm? L=2m=2 X 10%mm, D= 50mm, d=30mm, P= 25 KN= 25000 N, Stress in the cylinder ; <(D? ~d*) 21257 mm? = 19.9 N/mm? Deformation of the cylinder a PL AE =0.4mm Md. Tarek Ur Rahman Erin Assistant Professar (Mechanical) crec 15 [PaneModule 1 ( ncring Materials; IPF. 101) a tensile load of 400 kN. ad inside diameter of 100 mm must carry imited to 120 MNh Q.2. A hollow stee! tube with a Determine the outside diameter of the tube if the stress Solution: 400 x 107 P “@ * 120 «108 Q.3. What force is required to punch a 20 mm diameter hole in a plate that is 25 mm thick? The shear strength is 350 MN/m. Solution: Az red = 1*.02%.025 m? P. Shear strength, Tt =— me Force, P= tx A P= 350x108 x 1x,02x.025 = 550 KN . Mad. larek Ur @ahman tein Assistant Peatessor (Mechanical cree