Preliminaries

• Design in the English language has two usages:

• As a noun, “the design” refers to that actual
manifestation of a product, a tangible man-made object,
an idea, a concept, a pattern, an artificial process, the
way it looks, feels, and behaves, the result of a human
intention.
• As a verb, “designing” refers to the mental and other
processes that occur during this activity in order to
establish “the design”.
• Design is the process of translating a new idea or a
market need into the detailed information from which a
product can be manufactured.
• Each of its stages require decisions about the materials
of which the product is to be made and the process for
making it
Chapter 1 - 1
 Introduction
• What is materials science?
• Why should we know about it?
• What is materials engineering?
• What is the difference between materials science
and materials engineering?
• Why should mechanical engineers study
materials science/engineering?

Chapter 1 - 2
Evolution of Engineering Materials
• The ages man has lived have been named
after the dominant materials being used
– Stone Age
– Bronze Age
– Iron Age
– Now?
• Silicon Age?
• Polymer Age?
• People in certain cultures were buried with
prized possessions that represented state
of the art technology of the time, e.g.
swords, shields, household items
Chapter 1 -
Evolution of Engineering Materials
• If such a culture existed today, people
would be buried with titanium wrist
watches, carbon fiber racquets, Si-based
electronic gadgets/mobiles
• The evolution of engineering materials
increased in pace during the past century

Chapter 1 -
Evolution of Engineering Materials

Chapter 1 -
 Materials Science and
Engineering
• Materials Science
– Investigating relationships that exist between
the structure and properties of materials
• Materials Engineering
– On the basis of these structure-property
correlations, designing or engineering the
structure of a material to produce a pre-
determined set of properties

The four components of the discipline of materials science and engineering

and their interrelationship

Chapter 1 - 6
 Example – Hip Implant
• With age or certain illnesses joints deteriorate.
Particularly those with large loads (such as hip).

Adapted from Fig. 22.25, Callister 7e.

Chapter 1 - 7
 Example – Hip Implant

• Requirements
– mechanical
strength (many
cycles)
– good lubricity
– biocompatibility

Adapted from Fig. 22.24, Callister 7e.

Chapter 1 - 8
Example – Hip Implant

Adapted from Fig. 22.26, Callister 7e. Chapter 1 - 9

 Hip Implant
• Key problems to overcome
– fixation agent to hold Ball
acetabular cup
– cup lubrication material
– femoral stem – fixing agent
(“glue”) Acetabular
Cup and Liner
– must avoid any debris in cup

Femoral
Stem
Adapted from chapter-opening
photograph, Chapter 22, Callister 7e.

Chapter 1 - 10
Example – Develop New Types of
Polymers
• Commodity plastics – large volume ca. $0.50 / lb
Ex. Polyethylene
Polypropylene
Polystyrene
etc.

•  Engineering Resins – small volume > $1.00 / lb

Ex. Polycarbonate
Nylon
Polysulfone
etc.
 
Can polypropylene be “upgraded” to properties (and price) near
those of engineering resins?

Chapter 1 - 11
 Structure, Processing, & Properties
• Properties depend on structure
ex: hardness vs structure of steel

(d)

600
Hardness (BHN)

30 mm
500 (c)
Data obtained from Figs. 10.30(a)
400 (b) and 10.32 with 4 wt% C composition,
(a) and from Fig. 11.14 and associated
4 mm discussion, Callister 7e.
300 Micrographs adapted from (a) Fig.
10.19; (b) Fig. 9.30;(c) Fig. 10.33;
30 mm
and (d) Fig. 10.21, Callister 7e.
200 30 mm

100
0.01 0.1 1 10 100 1000
Cooling Rate (ºC/s)
• Processing can change structure
ex: structure vs cooling rate of steel
Chapter 1 - 12
 Types of Materials
• Metals:
– Strong, ductile
– high thermal & electrical conductivity
– opaque, reflective.

• Polymers/plastics: Covalent bonding  sharing of e’s

– Soft, ductile, low strength, low density
– thermal & electrical insulators
– Optically translucent or transparent.

• Ceramics: ionic bonding (refractory) – compounds of metallic

& non-metallic elements (oxides, carbides, nitrides, sulfides)
– Brittle, glassy, elastic
– non-conducting (insulators)

Chapter 1 - 13
 Types of Materials
• Composites:
– Consist of more than one material type
– Designed to display a combination of the best characteristics
of constituent materials.

• Semiconductors: Soft, ductile, low strength, low density

– Electrical properties intermediate between electrical
conductors and insulators
– These materials have made possible the advent of ICs

• Biomaterials:
– Must be bio-compatible
– Must not produce toxic substances
– Must not cause adverse biological reactions.
– Brittle, glassy, elastic
– non-conducting (insulators)
Chapter 1 - 14
 Types of Materials

Bar-chart of room temperature density values for various

metals, ceramics, polymers, and composite materials
Chapter 1 - 15
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Chapter 1 - 16
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Chapter 1 - 17
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Chapter 1 - 18
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Chapter 1 - 19
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Chapter 1 - 20
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p03_pg1 Chapter 1 - 21
 Materials of the Future

Smart Materials
Smart (or intelligent) materials are a group of new and
state-of-the-art materials
now being developed that will have a significant influence
on many of our technologies.
The adjective “smart” implies that these materials are able
to sense changes
in their environments and then respond to these changes in
predetermined manners—
traits that are also found in living organisms

Chapter 1 - 22
 Materials of the Future
Nano engineered Materials
With the advent of scanning probe microscopes (Section
4.10), which permit observation of individual atoms and
molecules, it has become possible to manipulate and move
atoms and molecules to form new structures and, thus, design
new materials that are built from simple atomic-level
constituents (i.e., “materials by design”).
This ability to carefully arrange atoms provides opportunities to
develop mechanical, electrical, magnetic, and other properties
that are not otherwise possible.
We call this the “bottom-up” approach, and the study of
the properties of these materials is termed nanotechnology”;
the “nano” prefix denotes that the dimensions of these
structural entities are on the order of a nanometer
(109 m)—as a rule, less than 100 nanometers
Chapter 1 - 23
 The Materials Selection Process
1. Pick Application Determine required Properties
Properties: mechanical, electrical, thermal,
magnetic, optical, deteriorative.

2. Properties Identify candidate Material(s)

Material: structure, composition.

3. Material Identify required Processing

Processing: changes structure and overall shape
ex: casting, sintering, vapor deposition, doping
forming, joining, annealing.

Chapter 1 - 24
 ELECTRICAL
• Electrical Resistivity of Copper:
6 Adapted from Fig. 18.8, Callister 7e.
t %Ni (Fig. 18.8 adapted from: J.O. Linde,
a
5 3 .32 Ann Physik 5, 219 (1932); and
+ C.A. Wert and R.M. Thomson,
Cu Ni
Resistivity, r

Physics of Solids, 2nd edition,

t%
4 16 a Ni
(10-8 Ohm-m)

McGraw-Hill Company, New York,

+ 2 . a t% 1970.)
Cu . 12
3 u +1
ed C
e f o rm % N i
d 2 a t
2 .1
u +1
C
1 r e” Cu
“Pu
0
-200 -100 0 T (°C)
• Adding “impurity” atoms to Cu increases resistivity.
• Deforming Cu increases resistivity.
Chapter 1 - 25
 THERMAL
• Space Shuttle Tiles: • Thermal Conductivity
--Silica fiber insulation of Copper:
offers low heat conduction. --It decreases when
Adapted from chapter- you add zinc!
opening photograph,
Chapter 19, Callister 7e.
(Courtesy of Lockheed 400

Thermal Conductivity
Missiles and Space
Company, Inc.)
300

(W/m-K)
200

100
0
0 10 20 30 40
Composition (wt% Zinc)
Adapted from Adapted from Fig. 19.4, Callister 7e.
Fig. 19.4W, Callister (Fig. 19.4 is adapted from Metals Handbook:
6e. (Courtesy of Properties and Selection: Nonferrous alloys and
Lockheed Aerospace Pure Metals, Vol. 2, 9th ed., H. Baker,
Ceramics Systems, (Managing Editor), American Society for Metals,
Sunnyvale, CA) 1979, p. 315.)
(Note: "W" denotes fig.
100 mm is on CD-ROM.) Chapter 1 - 26
 MAGNETIC
• Magnetic Storage: • Magnetic Permeability
--Recording medium vs. Composition:
is magnetized by --Adding 3 atomic % Si
recording head. makes Fe a better
recording medium!

Magnetization
Fe+3%Si

Fe

Fig. 20.23, Callister 7e.
(Fig. 20.23 is from J.U. Lemke, MRS Bulletin,
Vol. XV, No. 3, p. 31, 1990.)
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.

Chapter 1 - 27
 OPTICAL
• Transmittance:
--Aluminum oxide may be transparent, translucent, or
opaque depending on the material structure.

polycrystal: polycrystal:
single crystal low porosity high porosity

Adapted from Fig. 1.2,

Callister 7e.
(Specimen preparation,
P.A. Lessing; photo by S.
Tanner.)

Chapter 1 - 28
 DETERIORATIVE
• Stress & Saltwater... • Heat treatment: slows
--causes cracks! crack speed in salt water!

crack speed (m/s)

10-8 “as-is”
“held at
160ºC for 1 hr
before testing”
10-10 Alloy 7178 tested in
saturated aqueous NaCl
solution at 23ºC

increasing load
Adapted from Fig. 11.20(b), R.W. Hertzberg, "Deformation and
Fracture Mechanics of Engineering Materials" (4th ed.), p. 505, John
Adapted from chapter-opening photograph, Wiley and Sons, 1996. (Original source: Markus O. Speidel, Brown
Chapter 17, Callister 7e. Boveri Co.)
(from Marine Corrosion, Causes, and
4 mm
Prevention, John Wiley and Sons, Inc., 1975.)
--material:
7150-T651 Al "alloy"
(Zn,Cu,Mg,Zr)

Adapted from Fig. 11.26,

Callister 7e. (Fig. 11.26 provided courtesy of G.H.
Narayanan and A.G. Miller, Boeing Commercial
Airplane Company.) Chapter 1 - 29