Module 1
The Importance of Engineering Materials
Engineering Materials: properties and selection, 9th ed.
Kenneth G. Budinski, Michael K. Budinski
Goals
This module is intended to stimulate interest on the part of students in engineering
materials.
It also contains most of the information that material users will need to know about
inspecting materials for incipient failures (cracks) or manufacturing defects (NDE*).
Our reason for putting NDE information in the introduction is that it applies to all
materials.
It is important and yet most curricula cannot afford a complete lecture on just this
topic.
Upon completion of this Module, the student should:
Have a feel for materials used to make things
Understand the importance of using the “right” material for an application
Have knowledge of the reasons why products fail
Understand of NDE and how to apply it
*NDE = Non-Destructive Evaluation
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 2
What is Materials Engineering?
Multidisciplinary Field:
Materials Engineering is a multidisciplinary branch that combines principles
from physics, chemistry, and engineering to study and manipulate the
properties of materials.
Design and Development:
It involves the design, development, and optimization of materials to meet
specific performance criteria for diverse applications in industries such as
aerospace, automotive, and healthcare.
Material Types:
Mechanical/materials engineers work with a variety of materials, including
metals, polymers, ceramics, and composites, tailoring their properties to
achieve desired characteristics.
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 3
What is Materials Engineering?
Applications Across Industries:
The field finds applications in a wide range of industries, from creating
lightweight and durable materials for aircraft to developing biocompatible
materials for medical implants.
Understanding Material Properties:
Mechanical/Materials engineers focus on understanding the fundamental
properties of materials, such as strength, elasticity, conductivity, and
corrosion resistance, to control and enhance their performance.
Innovation and Sustainability:
The field drives innovation by developing new materials and technologies,
while also addressing sustainability concerns by exploring eco-friendly and
renewable material alternatives.
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 4
Timeline of materials development
from the Stone Age to the present day
Stone Age (2.5 million years ago - 3000 BCE):
Materials: Flint, obsidian, and other natural stones.
Development: Humans use stones for tools, weapons, and basic implements.
Bronze Age (3300 BCE - 1200 BCE):
Materials: Bronze (copper and tin alloy).
Development: Introduction of metalworking, leading to the creation of stronger and more durable
tools and weapons.
Iron Age (1200 BCE - 1 CE):
Materials: Iron and steel.
Development: Iron smelting becomes widespread, enabling the production of stronger and more
versatile materials.
Middle Ages (500 CE - 1500 CE):
Materials: Wrought iron, glass, and early ceramics.
Development: Advancements in metallurgy, glassmaking, and ceramics contribute to improved
construction, weaponry, and artistry.
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 5
Timeline of materials development
from the Stone Age to the present day…….
Renaissance (14th - 17th centuries):
Materials: Improved steel, glass, and early polymers.
Development: Renaissance-era innovations in metallurgy and glassmaking contribute to the production of finer
tools and artistic materials.
Industrial Revolution (18th - 19th centuries):
Materials: Cast iron, steel, and early synthetic materials (e.g., vulcanized rubber).
Development: Mass production and advancements in metallurgy lead to the widespread use of iron and steel in
industry. The first synthetic materials emerge.
20th Century:
1900s - 1930s: Plastics (e.g., Bakelite) and stainless steel.
1940s - 1950s: Nylon, polyester, and Teflon.
1960s - 1970s: High-performance polymers, carbon fiber, and advanced ceramics.
1980s - 1990s: Smart materials, composites, and biocompatible materials.
21st Century (2000s - Present):
Materials: Graphene, nanomaterials, and advanced alloys.
Development: Continued innovation in nanotechnology, materials science, and sustainable materials. Emphasis on
environmentally friendly and energy-efficient materials.
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 6
1.2 The Language of Materials
Figure 1-1 Relationship between the basic sciences and applied fields of study
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 7
Materials Science Tetrahedron
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 8
1.3 The Role of Materials in Product Success
Materials selection is a critical factor in determining the success of a product.
Influence on Design:
Material properties directly impact design elements such as strength, weight, and aesthetics.
The right materials enhance product functionality, durability, and user experience.
Performance and Durability:
Proper material selection contributes to overall product performance and longevity.
Materials influence how well a product withstands environmental factors and everyday use.
Innovation and Competitive Edge:
Innovative materials drive product differentiation and provide a competitive edge in the market.
Continuous material innovation is essential for staying ahead in a rapidly evolving business landscape.
Environmental Considerations:
Materials play a crucial role in the sustainability of a product.
Choosing eco-friendly and recyclable materials aligns with modern consumer expectations.
The success of a product is intricately tied to the thoughtful selection and application of materials.
Strategic materials choices contribute to functionality, aesthetics, and the overall value proposition of a
product.
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 9
1.3 The Role of Materials in Product Success
Failure of the products attributed to just two factors:
(i) Insufficient design and/or (ii) Insufficient properties
Figure 1-2 Example of a design flaw in a beverage container
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 10
Example of a design flaw
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 11
1.3 The Role of Materials in Product Success
Figure 1-3 Examples of chemical, physical, and mechanical properties of materials
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 12
1.4 Inspection to Prevent Failures
Figure 1-4 Example of a forging burst flaw in the center of a
stainless steel bar
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 13
Importance of Inspection in Preventing Failures
Quality Assurance: Ensures products meet standards, preventing substandard releases.
Safety Compliance: Identifies hazards early, ensuring adherence to safety regulations.
Risk Mitigation: Proactively addresses vulnerabilities, minimizing potential consequences.
Early Defect Detection: Identifies and corrects defects in early stages, reducing system-wide
issues.
Cost Savings: Prevents costly consequences, making proactive measures cost-effective.
Increased Reliability: Regular inspections enhance confidence in system and machinery
reliability.
Enhanced Productivity: Minimizes unplanned downtime, ensuring a smoother workflow.
Regulatory Compliance: Meets legal requirements and builds trust with customers and
stakeholders.
Extended Equipment Life: Maximizes ROI through preventive maintenance and extended
equipment life.
Customer Satisfaction: Ensures quality, enhancing customer satisfaction and loyalty.
In summary, inspection is a proactive strategy for quality, safety, and reliability,
preventing failures and contributing to long-term success.
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 14
1.4 Inspection to Prevent Failures
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 15
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 16
1.4 Radiography
Radiography - nondestructive testing techniques
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 17
1.4 Dye Penetrant Testing
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 18
Ultrasonic Testing
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
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Magnetic Particle Testing
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
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1.5 Evolution of Engineering Materials
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 21
1.6 A Materials Repertoire
There are 50,000 plastics, 50,000 metals, hundreds of ceramics, and an infinite number of
composites.
Nobody can know them all, this course will provide a usable repertoire in each material
category.
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 22
Reading Assignment
Chapter 1
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 23
