ME-2203

Engineering Materials
INTRODUCTION
Topics
• Historical perspective of engineering materials
• Various properties of engineering materials and advanced materials
• Materials cycle
• Materials Selection
 Introduction to Engineering Materials
• Material -> something tangible that goes into the makeup of
a physical object
• Engineering Materials-- construction of manmade structures
and components.
• Advanced Materials --- Nano composites, Kevlar , Carbon
Fiber
 Historical Perspective
• Stone Age (Paleolithic, ~2.5 Million BC)

Increase material Flexibility

Improve Material Properties

• Copper Age (~8000 – 5000 BC) ; Strength σy = 70 MPa

• Bronze Age (~3500 BC – 1200 BC) “Alloying”: add tin to copper

Strength σy = 125 MPa

• Iron Age (~1500 BC – 1900 AD)

Strength σy = 275 Mpa
• Steel Age (1900 AD – 1960 AD) Strength σy > 1500 Mpa

• Non-ferrous and Polymer Age (1970 AD – ) Aluminium, titanium and

nickel (super alloys) for aerospace applications Silicon for information
technology

• Plastics and composites  

• Exotic Materials Age (~1960 AD – )Nano materials and bio-materials

 Structure

Essence of
Processing Performance
Materials

Properties
 Metals : Distinguishing features

• Atoms arranged in regular repeating structure (crystal)

• Relatively strong and stiff
• Dense
• Malleable and ductile: high plasticity
• Resistant to shock and fracture : tough
• Excellent conductors of electricity and heat
• Opaque to visible light
• Shiny appearance
Metal (CON..)
Applications • Examples
• Electrical wiring
• Elements on the left side of the
• Structures: buildings, bridges
Periodic Table
• Automobiles: body, chassis, springs, engine
block • Pure metal elements (Al, Cu, Fe,
• Airplanes: engine components, fuselage, Zn, Ag, etc.)
landing gear assembly
• Alloys (Bronze (Cu-Sn alloy),
• Trains: rails, engine components, body,
wheels Brass (Cu-Zn alloy), Steels (Fe-C
• Machine tools: drill bits, hammers, alloy), Solder (Pb-Sn alloy))
screwdrivers, saw blades
• Magnets
Classification of Materials (Metals)

•Metals can be further classified as Ferrous & Non-Ferrous, some

examples include;
 Ceramics
Distinguishing features

• Most have a regular arrangement of atoms (exception: glasses)

• Composed of a mixture of metal and non-metal atoms
• Lower density than most metals
• Stronger and harder than metals
• Low resistance to fracture: low toughness or brittle
• Low ductility or malleability: low plasticity
• High melting point; high refractoriness
• Poor electricity and heat conductors; often
 Applications Examples

• White ware (e.g. porcelains) • Simple oxides (SiO2, Al2O3,

• Electrical ceramics (capacitors, Fe 2O3, MgO, etc.)
insulators, transducers)
• Abrasives (emery paper, grinding
• Mixed-metal oxides (BaTiO3,
wheel) • Nitrides (Si3N4, TiN, AlN, GaN,
• Thermal insulation and coatings BN)
• Glasses (e.g. soda-lime glass, crystal • Carbides (SiC, WC, TiC)
glass, optical fibers)
• Corrosion resistant applications
Polymer
• Organic materials, either natural or synthetic in nature
• Derived from two Greek words: “poly” means many
• “mer” means part (single hydrocarbon molecules)
• Long chained molecules composed of many “mer”s bonded together
by a process called polymerisation
Distinguishing features
• Composed primarily of C and H
(hydrocarbons)
• Low strength, light weight
• Low melting temperature
• Most are poor conductors of electricity
and heat
• Many have high plasticity
• A few have good elasticity
• Some are transparent, some are opaque
Applications
• Moldable products (computer
casings, telephone handsets)
• Clothing and upholstery material
(vinyl, polyester, nylon)
• Low-friction materials (teflon)
• Gaskets and O-rings (rubber)
• Container
 Polymers
• Natural
• Animal cellulose
• Plant

• Synthetic-
• Thermoplastics
• Thermosets
Composites: Distinguishing features

Physical mixture of two or more different materials (e.g.,

metal/ceramic, ceramic/polymer, polymer/polymer)
• Particulate composites (cermets, duralumin)
• Laminate composites (golf club shafts, tennis rackets)
• Fiber reinforced composites (e.g. fiberglass)
• One of the common composites is fiberglass, in which small glass
fibers are embedded within a polymeric material
• Glass Fiber -> Strong + Stiff + Brittle
• Polymer -> Ductile + Weak + Flexible
Glass-Fiber Reinforced Polymer
COMPOSITES (contd…)
• CFRP -> carbon fibers that are embedded within a polymer
• These materials are stiffer and stronger than the glass fiber-reinforced
materials, thus they are more expensive
• CFRPs are used in some aircraft and aerospace applications, as well as
high-tech sporting equipment
CFRP microstructure
 Examples
Applications
• Sports equipment (golf club shafts, • Wood (cellulose-fibre-reinforced lignin)
tennis rackets, bicycle frames) • Concrete (aggregate composite of cement,
rock and sand)
• Aerospace materials (Space shuttle,
• Fiberglass (glass fibres in a polymer: GFRP,
heat shields) CFRP)
• Thermal insulation • Metal matrix composites (MMCs) (SiC in
• Concrete aluminium)
• Ceramic matrix composites (CMCs) (ZrO2 in
• "Smart" materials (sensing and alumina)
responding)
• Ceramic metal composites (Cermets) (Ag in
• Brake materials alumina
Classification of Materials (Smart Materials)

•A smart material can be described as a material that has a useful

response to external influences or stimuli.

There are many examples of smart materials in everyday use that are not
modern developments they include;
•Metal springs
•Light bulbs self regulate because as
The filament temperature increases
their resistance rises
•Ancient civilisations have long used
porous ceramics for self regulating cooling
Wine Cooler
Classification of Materials (Smart Materials)
•Other more modern examples of smart materials include;

•Shape memory polymers and alloys

Heat shrink tubing and packaging
Automatic actuators – open/close greenhouse windows
Thermostats for heating control

•Piezoelectric Materials
Sensors, musical cards, motors, actuators, clocks
Comparison Chart - 1
Comparison Chart - 2

Bar-chart of room temperature stiffness (elastic modulus)

Comparison Chart - 3

Bar-chart of room temperature strength (tensile strength)

Comparison Chart - 4

Bar-chart of room temperature resistance to fracture (fracture toughness)

Comparison Chart - 5

Bar-chart of room temperature electrical conductivity ranges

 Sources of Materials
• Primary sources (Natural Resources)
• Minerals
• obtained by mining, drilling or digging in the earth.
• inorganic, naturally occurring, crystalline, and of definite composition.
• Rocks
• matter of which the earth’s crust is comprised.
• tends to be mixtures of two or more minerals.
• need not to be crystalline nor of a fixed composition. 
• Fossil Fuels
• coal, oil or natural gas from the decomposition of organic materials (i.e., plants and
animals).
 Secondary sources

• Industrial Scrap
• damaged/defective products

• Products After Use

• recycling
 Life Cycle of Engineering Materials

• Raw materials extracted from their natural earthly habitat

• Synthesized, possessed to bulk form
• Further synthesis, possessing to engineering material
• Design, manufacture, assemble to final product
• Use in different applications
• Degrade to waste or recycle.
Materials Cycle: Energy Considerations

• The earth’s materials are a closed system, not an infinite reservoir

• Each step in the materials cycle consumes energy

• In order of increasing energy consumption:

• Reduce amount of material used
• Reuse existing material
• Recycle existing material
• Produce new material from natural resources
• Application:
Agriculture,Construction,Defense,Information,Environmental,Energy,
Health and Transportation.
Materials Cycle: Environmental Considerations

Each step in the materials cycle produces byproducts

• Solid waste: litter; landfills
• Liquid waste: water pollution
• Gaseous waste: air pollution 
Health impact
• Control of toxic materials (Pb in solders; Cr; volatile organics; … )