Material Science and Engineering

Material science – study materials + create new materials

Materials engineering – use materials + create new processes

The success of many manufactured products depends on the selection of materials

whose properties meet the requirements of the application.

How are Carbon Fiber Bikes Made

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 Part 1: Properties – Type of Materials

Metals Metals
• metals and its alloys
• luster, high thermal conductivity, and high electrical Ceramics Advanced Ceramics
conductivity, ductile

Polymers Engineered plastics

Non metals Composites Hybrid Composites

• wood, brick, concrete, glass, rubber and
plastics
• weaker, less ductile, less dense, poor
electrical and thermal properties

Cost of material
Cost of fabricating
Product lifetime
Environmental
impact
Energy
requirements
Recyclability
 Part 1: Properties (cont’)

• Properties adequate for the anticipated operating conditions

- mechanical characteristics (strength, rigidity, resistance to fracture, the ability to withstand vibrations or impacts)
- physical characteristics (weight, electrical properties, appearance)
- features relating to the service environment (ability to operate under extremes of temperature or resist
corrosion) of possibilities

• Taking advantage of the properties

To help evaluate the properties of engineering materials, a variety of standard tests have been developed .

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 Part 1: Properties (cont’)
Physical Mechanical
Density Stress and strain
Melting point
- strength
Optical characteristics (transparency, -stiffness/modulus
opaqueness, color) = stress over strain
Thermal properties (specific heat,
thermal expansion, thermal
conductivity, electrical conductivity,
magnetic properties)

Stress/strain?
When a force or load is applied to
a material, it deforms or distorts
(becomes strained), and internal
reactive forces (stresses) are
transmitted through the solid

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 Part 1: Properties - Testing
• mechanical loading of a material specimen or product up to a pre-determined deformation level or up to the
point where the sample fails
• further used to characterize the materials and product

Tensile

Compression

Flexural

Impact

Toughness

• value displayed on their instrument is a constant

• conducted at the component level in incremental steps to determine structural

integrity

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 Basic Manufacturing Processes

Casting, Foundry, Moulding Heat treating

Rapid
Forming/metalworking
prototyping

Surface treatment
Machining (material removal)
(finishing)

Joining and assembly

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Process Details Advantage Disadvantage Types

Casting/molding/ Use molten metal to fill cavity materials can be Need follow-up 1. permanent mold
foundry converted from a process like (a mold can be used
Metal retains the desired shape of the mold cavity crude form into a machining repeatedly)
(plastics/composites) after solidification desired shape in a 2. nonpermanent mold
single step

excess or scrap
material can easily
be recycled

Forming/metal Basic purpose: modify the shape and size and/or

working/shearing physical properties of the material
(metal/plastics that’s Reference to the temperature of the material at
has been previously the time it is being processed with respect to the
casted or moulded) temperature at which this material can
recrystallize (i.e., grow new grain structure)

Metal Removal of certain selected areas from a part in machine tools are called
cutting/machining/ma order to obtain a desired shape or finish, shapers (and planers),
terial removal producing chips drill presses, lathes, boring
Cutting tools are mounted on in machine tools machines, milling machines,
which provide the required movements of the tool saws, broaches, and grinders
with respect to the work (or vice versa) to
accomplish the process desired

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Joining and The biggest; which includes:
assembly 1. Mechanical fastening 4. Press, shrink,
or snap fittings
2. Soldering and brazing 5. Adhesive
bonding
3. Welding 6. Assembly
processes

Surface cleaning, removing residue left by machining, or include chemical and

treatment/finishing providing protective and/or decorative surfaces on mechanical cleaning,
workpieces deburring, painting, plating,
buffing, galvanizing, and
anodizing
Rapid prototyping/ fabrication of a physical part, model or assembly ability to produce
additive using 3D computer aided design components with
manufacturing Prototype components is produced first directly great precision
from the software using specialized machines and accuracy
(nonmetallic, driven by computer-aided design packages. The
metallic, prototypes can be field tested and modifications to
composites) the design quickly implemented

Heat treatment heating and cooling of a metal for the specific

purpose of altering its metallurgical and mechanical
properties
Have to know how a selected metal can be altered
by heat treatment, how a selected metal will react
to any heating or cooling that may be incidental to
the manufacturing processes

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METAL FORMING PROCESSES-
HOT FORMING
 Metal Forming
• Metal forming includes a large group of manufacturing processes in which plastic deformation
is used to change the shape of metal workpieces

• Deformation results from the use of a tool, usually called a die in metal forming, which
applies stresses that exceed the yield strength of the metal

• The metal therefore deforms to take shape determined by the geometry of the die

No need to handle molten material or

Forces required are often high
deal with the complexities of
solidification
Machinery and
tooling can be quite expensive
Material is simply moved (or
rearranged) to produce the shape,
Large production quantities may be
amount of waste can be substantially
necessary to
reduced since there are no cutting away
justify the approach
of unwanted region

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 Metal Forming
Bulk Deformation Sheet-metal working/deformation

•severe deformation and massive shape changes •forming and cutting operations

•mostly done in hot working condition •performed on thin sheets (<6mm), thin strips or coils

•compressive deformation force •mostly done in cold working condition

•starting work shapes include billets and rectangular •tools include punch and die on machine tools called
bars stamping presses

•small surface area-to-volume •high surface area-to-volume

•cross section does not change, only shape changes

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 Metal Forming – Hot or cold

TA is ambient temperature, Tm is the work metal melting temperature

  is the temperature that a metal begins to

transform from a solid phase into a liquid phase
 at the melting temperature, the solid phase and
liquid phase of a metal exist in equilibrium
 once this temperature is achieved, heat can be
continuously added to the metal, however this
will not raise the overall temperature.
 once the metal is completely in the liquid phase,
additional heat will again continue to raise the
temperature of the metal

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 Hot Working Processes
• Involves deformation of preheated material at temperatures above the recrystallization
temperature
• At elevated temperatures, metals weaken and become more ductile
• With continual recrystallization, massive deformation takes place without exhausting
materials plasticity
• Hot working processes includes rolling, forging, extrusion, drawing

 recrystallization - a process by which deformed grains are

replaced by a new set of nondeformed grains that nucleate
and grow until the original grains have been entirely
consumed

 recrystallisation temperature for steels is typically between

400 and 700 °C. The recrystallisation conditions, such as
heating rate and soaking time depend on the degree of cold
work and the steel composition

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Part 1: Rolling

Flow chart for the production of various finished and semifinished steel shapes.
Note the rolling operations. 14
Rolling – Basic Rolling Process
• metal is passed between two rolls that rotate in opposite directions
• because the rolls rotate with a surface velocity that
exceeds the speed of the incoming metal, friction along the contact
interface acts to propel the metal forward
• metal is then squeezed and elongates to compensate for the decrease in
thickness or cross-sectional area
• amount of deformation that can be achieved in a single pass between a
given pair of rolls depends on the friction conditions along the interface
• If too much is demanded, the rolls cannot advance the material and
simply skid over its surface
• too little deformation is taken, the operation will be successful, but the
additional passes required to produce a given part will increase the cost
of production

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 Hot Rolling Cold Rolling
Hot rolled metal
cleaned

• Temperature is keep at above recrystallization
temperature. For plain-carbon and low-alloy steels, the
soaking temperature is usually about 2200 F (1200 C)
• During the rolling there will be change in its grain
structure, the temperature at recrystallization
temperature will prevent from work hardening
• Metal is fed into rolls at below recrystallization
temperature
• To provide smooth and bright finish
• To bring it to accurate size
• To obtain clean surface

• Due to squeezing action, the grains are elongated in

direction of rolling and velocity of material at exit is
higher than at entry 17
Hot Rolling
 Hot Rolling
1. Metal is fed into rolls after being heated
above recrystallization temperature
2. Coefficient of friction between rolls and
metal is higher
3. Heavy reduction in cross sectional area is
possible
4. Close dimensional tolerance cannot be
obtained
5. Poor surface finish
6. Does not show work hardening effect
Cold Rolling
1. Metal is fed into rolls after being heated
above recrystallization temperature
2. Coefficient of friction between rolls and
metal is higher
3. Heavy reduction in cross sectional area is
possible
4. Section dimension can be obtain at close
tolerance
5. Smooth and oxide-free surface
6. Shows hardening effect
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 Advantage of hot rolling
1. greatly reduce energy consumption and costs
- metal plastic deformation is high during hot rolling, and the deformation resistance is
low, which reduces the energy consumption of metal deformation

2. improve the processing performance of metals and alloys

- coarse grains during foundry are broken, the cracks are healed, the casting defects
are reduced or eliminated, and the as-cast microstructure is transformed into a
deformed structure to improve the processing properties of the alloy

3. Hot rolling usually uses large ingots and large reduction rolling, which not only
improves production efficiency, but also creates conditions for increasing rolling
speed and achieving continuous and automated rolling process

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 Limitation of hot rolling
1. Delamination
- due to non-metallic inclusions (mainly sulfides and oxides, as well as silicates) inside the steel are
pressed into thin sheets
delamination greatly deteriorates the tensile properties of the steel in the thickness direction

2. Residual stress caused by uneven cooling

- residual stress is the internal self-phase equilibrium stress that occurs due to uneven cooling which
can easily happen

3. Uncontrollable mechanical properties

- difficult to control properties required for the product accurately, and the microstructure and
properties of the hot-rolled product are not uniform. The strength index is lower than that of the cold
work hardened product

4. The thickness of the hot rolled product is difficult to control and the control precision is relatively poor

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 Rolling (cont…)

Shape rolling
The work is deformed by a gradual reduction into a contoured cross section (I-beams, L-
beams, U-channels, rails, round, square bars and rods, etc.).

Ring rolling
Thick-walled ring of small diameter is rolled into a thin-walled ring of larger diameter.

Thread rolling
Threads are formed on cylindrical parts by rolling them between two thread dies.

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 Rolling (cont…)
Defects in Rolled Plates and Sheets
1. Wavy edges on sheets – due to roll bending. The strip is
thinner along its edges than its center.
2. Cracks – poor material ductility at the rolling temperature
3. Alligatoring – due to non-uniform deformation during rolling or
defects in the original cast billet.

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