CHAPTER 1: MATERIALS SCIENCE & ENGINEERING

Early History
Stone Age (Paleolithic, ~2.5 Million BC) Flint: cutting edge easily formed by chipping Copper Age (~8000 5000 BC) Pottery kilns hot enough to melt Cu from ore (Cu Tm = 1085C) strength y = 70 MPa (10,000 lb/in2) Bronze Age (~3500 BC) Alloying: add tin to copper (Sn Tm = 232C) strength y = 125 MPa (18,000 lb/in2) Iron Age (~1500 BC) Reduce Fe ore at high T with charcoal to capture O2, release Fe metal (Fe Tm = 1538C) strength y = 275 MPa (40,000 lb/in2) Add carbon to Fe
K. M. Flores Materials Science & Engineering

Improve material properties, Increase design flexibility!

Steel! y > 1500 MPa (200,000 lb/in2)

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Power Generation Fuel cells, batteries Renewable energy collector/converter

Computers/Electronics Microchips Data storage

Automotive & Aerospace Engines Frames

What do Materials Scientists and Engineers make?

Recreation Athletic equipment Sportswear

Biomedical Implants, tissue scaffolding Drug delivery devices Food Processing Chocolate Ice cream
K. M. Flores Materials Science & Engineering

Environmental Recycled/recyclable materials Pollutant/chemical/biohazard sensors

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Materials enable all products from candy bars to rockets

Starting Salaries, 2004* BS: $50,025 MS: $56,150 PhD: $71,600

* www.engineersalary.com

$$$$
Median Salaries, Columbus OH # BS, entry level: $55,217 BS+, experienced: $94,540
#

What do Materials Scientists and Engineers make?

$$$$
K. M. Flores Materials Science & Engineering

salary.monster.com

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The essence of MATERIALS SCIENCE & ENGINEERING

K. M. Flores Materials Science & Engineering

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woven fibers

Crystalb 10-9 10-1 m

Grainc 10-9 10-2 m

0.5 mm
Engineered Composited 10-4 10-1 m

Atomica Up to 10-10 m

Structure

Properties
K. M. Flores Materials Science & Engineering

Processing

Natural Compositee

Images obtained from: (a) Fig. 3.3b, Callister 6e, (b) fluorapophylite, from http://www.gc.maricopa.edu/earthsci/imagearchive/apophylite.htm, downloaded Nov. 15, 2004, (c) Fig. K, color insert to Callister 4e, (d) D. Hull and T.W. Clyne, An Introduction to Composite Materials, 2nd ed., Cambridge University Press, New York, 1996, Fig. 3.6, p. 47, (e) https://courses.stu.qmul.ac.uk/smd/kb/microanatomy/bone/, downloaded Nov. 15 2004.

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Structure

Mechanicala (Strength, etc.)

Properties

Processing

Electricalb (Resistivity, etc.)

Deteriorativef (Galvanic Potential, etc.) Opticalc (Transmittance, etc.)

K. M. Flores Materials Science & Engineering

Thermald (Conductivity, etc.)

Magnetice (Permeability, etc.)

Images obtained from: (a) http://www.mcshane-enterprises.com/ASL/images/Mitchell/barbendatvastrong.jpg, downloaded Aug. 24, 2004, (b) http://www.netadmintools.com/cabletester/alltinned.jpg, downloaded Aug. 24, 2004, (c) Fig. 1.2, Callister 6e, (d) http://www.missilesandfirecontrol.com/our_products/spaceprograms/SHUTTLE/pic01-shuttle.html, downloaded Aug. 24, 2004, (e) Fig. 20.18, Callister 6e, (f) Fig. 17.0, Callister 6e.

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Structure

Properties

Processing

Photolithographyd

Drawinga Injection moldingc

Sinteringb
K. M. Flores Materials Science & Engineering
(a) Adapted from opening picture in Ch. 11, Callister 6e. PEPSI is a registered trademark of PepsiCo Inc., (b) Adapted from Fig 13.14, Callister 6e, (c) Fig. 15.23, Callister 6e, (d) www.just2good.co.uk/ cpuSilicon.htm downloaded Dec. 21, 2004.

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STRUCTURE, PROCESSING, & PROPERTIES

Processing can change structure
ex: structure vs cooling rate of steel
(d)

600

Hardness (BHN)

500 400 300 200

30 m 30m

(c) (a) (b)

4m

30 m
Data obtained from Figs. 10.21(a) and 10.23 with 4wt%C composition, and from Fig. 11.13 and associated discussion, Callister 6e. Micrographs adapted from (a) Fig. 10.10; (b) Fig. 9.27;(c) Fig. 10.24; and (d) Fig. 10.12, Callister 6e.

100 0.01 0.1 1 10 100 Cooling Rate (C/s)

1000

Properties depend on structure

K. M. Flores Materials Science & Engineering

ex: hardness vs structure of steel

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STRUCTURE, PROCESSING, & PROPERTIES

Electrical Resistivity of Copper:
6 5
(10 -8 Ohm-m)
i %N 2 at .3 +3 i Cu t%N i 16 a %N 2. 2 at u+ C 1.1 u+ dC i rme %N defo 2 at 1 + 1. Cu u re C Pu
Adapted from Fig. 18.8, Callister 6e. (Fig. 18.8 adapted from: J.O. Linde, Ann Physik 5, 219 (1932); and C.A. Wert and R.M. Thomson, Physics of Solids, 2nd edition, McGraw-Hill Company, New York, 1970.)

Resistivity,

4 3 2 1 0

-200

-100

T (C) Adding impurity atoms to Cu increases resistivity. Deforming Cu increases resistivity. K. M. Flores
Materials Science & Engineering

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STRUCTURE, PROCESSING, & PROPERTIES

Thermal Conductivity of Copper, :
--It decreases when you add zinc!
400 Thermal Conductivity (W/m-K) 300 200 100 0 0 10 20 30 40 Composition (wt%Zinc)

Magnetic Permeability
vs. Composition:
--Adding 3 atomic % Si makes Fe a better recording medium!

Magnetization

Fe+3%Si Fe

Magnetic Field
Adapted from C.R. Barrett, W.D. Nix, and A.S. Tetelman, The Principles of Engineering Materials, Fig. 1-7(a), p. 9, 1973. Electronically reproduced by permission of Pearson Education, Inc., Upper Saddle River, New Jersey.

Adapted from Fig. 19.4, Callister 6e. (Fig. 19.4 is adapted from Metals Handbook: Properties and Selection: Nonferrous alloys and Pure Metals, Vol. 2, 9th ed., H. Baker, (Managing Editor), American Society for Metals, 1979, p. 315.)

K. M. Flores Materials Science & Engineering

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THE MATERIALS SELECTION PROCESS

1. Application Determine required Properties
Properties: mechanical, electrical, thermal, magnetic, optical, deteriorative.

2. Properties Identify candidate Material(s)

Material: composition, structure.

3. Material Identify required Processing

Processing: changes structure and overall shape ex: casting, sintering, vapor deposition, doping, forming, joining, annealing.
K. M. Flores Materials Science & Engineering

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STRUCTURE, PROCESSING, & PROPERTIES

Processing Property trade-offs! (e.g. strength tends to be inverse to ductility)
tensile strength (MPa) 600 strength 500 400 ductility

Brass

yield strength (MPa)

60 ductility (%EL) 50 40 30

Cu
400 300 200 100 0 20 20

strength
40

20 300 100 300 500 700 Annealing Temperature (C)

Adapted from Fig. 7.20, Callister 6e. (Fig. 7.20 is adapted from G. Sachs and K.R. van Horn, Practical Metallurgy, Applied Metallurgy, and the Industrial Processing of Ferrous and Nonferrous Metals and Alloys, American Society for Metals, 1940, p. 139.)

ductility
0 40 60

% Cold Work
Adapted from Fig. 7.17, Callister 6e. (Fig. 7.17 is adapted from Metals Handbook: Properties and Selection: Iron and Steels, Vol. 1, 9th ed., B. Bardes (Ed.), American Society for Metals, 1978, p. 226; and Metals Handbook: Properties and Selection: Nonferrous Alloys and Pure Metals, Vol. 2, 9th ed., H. Baker (Managing Ed.), American Society for Metals, 1979, p. 276 and 327.)

K. M. Flores Materials Science & Engineering

ductility (%EL)
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60

MSE 205 HIGHLIGHTS

Material Classes Metals Ceramics Polymers Composites Material Processing
K. M. Flores Materials Science & Engineering

Material Properties Mechanical Electrical Thermal/Magnetic/Optical Deteriorative

Phase Diagrams/Transformations Strengthening Mechanisms

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SUMMARY
Course Goals:
Use the right material for the job. Understand the relation between properties, structure, and processing. Recognize new design opportunities offered by materials selection.

K. M. Flores Materials Science & Engineering

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