CHAPTER
1
Introduction to Materials
Science and
Engineering
1-1
LEARNING OBJECTIVES
By the end of this chapter, students will be able to:
1. Describe the subject of materials science and
engineering as a scientific discipline
2. Cite the primary classification of solid materials.
3. Give distinctive features of each group of materials.
4. Cite one material from each group. Give some
applications of different types of materials.
5. Evaluate how much you know, how much you do not
know about materials.
6. Establish the importance of materials science and
engineering in selection of materials for various
application
What are Materials?
Materials may be defined as
substance of which something is
composed or made.
We obtain materials from earth crust
and atmosphere.
Examples : Silicon and Iron constitute 27.72 and 5.00
percentage of weight of earths crust respectively.
Nitrogen and Oxygen constitute 78.08 and 20.95
percentage of dry air by volume respectively.
1-2
Table 1.1
Materials are...
engineered structures...not blackboxes!
Structure...has many dimensions...
Structural feature
atomic bonding
missing/extra atoms
crystals (ordered atoms)
second phase particles
crystal texturing
Dimension (m)
< 10-10
10-10
10-8 -10-1
10-8 -10-4
> 10-6
Materials Science and Materials Engineering
Materials Science
and Engineering
Materials
Science
Basic
knowledge
of materials
Resultant
knowledge of the
structure,
properties,
processing,
performance of
engineering
materials
Material
Engineering
Applied
knowledge of
materials
Figure 1.4: This diagram illustrates how materials
science and engineering form a bridge of
knowledge from the basic sciences to the
engineering disciplines (Reprinted with
permission from National Academy of sciences,
courtesy of National Academic Press.)
Materials Science and
Engineering
Materials science deals with basic
knowledge about the internal
structure, properties and processing
of materials.
Materials engineering deals with the
application of knowledge gained by
materials science to convert materials
to products.
1-4
Structure, Processing, & Properties
Properties depend on structure
ex: hardness vs structure of steel
Hardness (BHN)
(d)
600
500
400
(a)
(b)
4m
300
200
30m
(c)
30m
100
0.01 0.1
30m
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.
1
10 100 1000
Cooling Rate (C/s)
Processing can change structure
ex: structure vs cooling rate of steel
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.
ELECTRICAL
Electrical Resistivity of Copper:
(1 0 -8 O h m -m )
R e s is tiv ity ,
6
5
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.)
4
3
2
1
0
-200
-100
T (C)
Adding impurity atoms to Cu increases resistivity.
Deforming Cu increases resistivity.
THERMAL
Space Shuttle Tiles:
Thermal Conductivity
--Silica fiber insulation
offers low heat conduction.
T h e rm a l C o n d u ctiv ity
(W /m -K )
Fig. 19.0,
Callister 6e.
(Courtesy of
Lockheed
Missiles and
Space
Company, Inc.)
of Copper:
--It decreases when
you add zinc!
Adapted from
Fig. 19.4W, Callister
6e. (Courtesy of
Lockheed Aerospace
Ceramics Systems,
Sunnyvale, CA)
(Note: "W" denotes
fig. is on CD-ROM.)
100m
400
300
200
100
0
0
10 20 30 40
Composition (wt%Zinc)
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.)
MAGNETIC
Magnetic Storage:
vs. Composition:
--Adding 3 atomic % Si
makes Fe a better recording
medium!
M agnetization
--Recording medium
is magnetized by
recording head.
Magnetic Permeability
Fig. 20.18, Callister 6e.
(Fig. 20.18 is from J.U. Lemke, MRS
Bulletin,
Vol. XV, No. 3, p. 31, 1990.)
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.
Transmittance:
OPTICAL
--Aluminum oxide may be transparent, translucent, or
opaque depending on the material structure.
single crystal
polycrystal:
low porosity
polycrystal:
high porosity
Adapted from Fig.
1.2,
Callister 6e.
(Specimen
preparation,
P.A. Lessing; photo
by J. Telford.)
DETERIORATIVE
--causes cracks!
Heat treatment: slows
crack speed in salt water!
c r a c k s p e e d ( m /s )
Stress & Saltwater...
10-8
10-10
Adapted from Fig. 17.0, Callister 6e.
(Fig. 17.0 is from Marine Corrosion,
Causes, and Prevention, John Wiley and
Sons, Inc., 1975.)
as-is
held at
160C for 1hr
before testing
Alloy 7178 tested in
saturated aqueous NaCl
solution at 23C
increasing load
Adapted from Fig. 11.20(b), R.W. Hertzberg,
"Deformation and Fracture Mechanics of Engineering
Materials" (4th ed.), p. 505, John Wiley and Sons, 1996.
(Original source: Markus O. Speidel, Brown Boveri Co.)
--material:
7150-T651 Al "alloy"
(Zn,Cu,Mg,Zr)
Adapted from Fig. 11.24,
Callister 6e. (Fig. 11.24 provided courtesy of
G.H.
Narayanan and A.G. Miller, Boeing Commercial
Airplane Company.)
4m
Classification of Materials
* Metals
* Polymer
* Semiconductor
* Advanced Materials
* Smart Materials
* Nanotechnology
* Composite
* Ceramics
* Biomaterials
Materials
Metal
Properties
Examples
Good conductivity of heat and electricity
Not transparent to visible light
Polished surface has lustrous appearance
Strong
Deformable (machinable)
Extensive use in structure
Ferrous Iron and
Steels
Non ferrous
Aluminum,
aluminum
alloy, Titanium
alloy etc
Polymer
Large molecular structure
Low densities
Flexible (compare to other material)
Low electrical and thermal conductivity
Plastic
Rubber
Adhesive
Ceramics
/ glasses
Strong and hard
Low thermal conductivity and electrical conductivity
(extensive use as refractory material)
Brittle
Resistant to harsh environment
Resistant to high temperature
Clay
Cement
Glasses
Material
Properties
Composite
Combination of more than one material type
and displays combination of the best
characteristics
Light weight
Hard, strong, very stiff
high temperature resistance materials
Semiconductor Electrical properties are intermediate
/ electronic
between insulator and conductor
Able to convert electrical signal
Biomaterials
Components implanted into the human body
for replacement of disease or damaged body
parts
Non-toxic
Biocompatible with body tissues
Example
Fiberglass
Concrete
Plywood
Germanium;
Silicon;
Gallium
arsenide
Metal
Ceramics
Polymer
Composite
Semiconductor
Ch
apt
er
120
Types of Materials
Metallic Materials
Composed of one or more metallic elements.
Example:- Iron, Copper, Aluminum.
Metallic element may combine with nonmetallic
elements.
Example:- Silicon Carbide, Iron Oxide.
Inorganic and have crystalline structure.
Good thermal and electric conductors.
Metals and Alloys
Ferrous
Eg: Steel,
Cast Iron
Nonferrous
Eg:Copper
Aluminum
Metallic Materials
The aircraft turbine engine shown is made principally of metal alloys. The latest hightemperature, heat resistant, high-strength nickel-base alloys are used in this engine. This
engine has many advanced, service-proven technologies to enhance operational performance
and durability. These include second-generation single-crystal turbine blade materials, powder
metal disks, and an improved full authority digital electronic control
Polymeric (Plastic) Materials
Organic giant molecules and mostly noncrystalline.
Some are mixtures of crystalline and noncrystalline
regions.
Poor conductors of electricity and hence used as
insulators.
Strength and ductility vary greatly.
Low densities and decomposition temperatures.
Examples :- Poly vinyl
Chloride (PVC), Polyester.
Applications :- Appliances,
DVDs, Fabrics etc.
Ceramic Materials
Metallic and nonmetallic elements are chemically
bonded together.
Inorganic but can be either crystalline, noncrystalline
or mixture of both.
High hardness, strength and wear resistance.
Very good insulator. Hence used for furnace lining for
heat treating and melting metals.
Also used in space shuttle to insulate it during exit and
reentry into atmosphere.
Other applications : Abrasives, construction materials,
utensils etc.
Example:- Porcelain, Glass,
Silicon nitride.
(a) Examples of a newly developed
generation of engineered ceramic
materials for advanced engine
applications. The black items
include engine valves, valve seat
inserts, and piston pins made of
silicon nitride. The white item is a
port-manifold liner made of an
alumina ceramic material
(b) Potential ceramic component
applications in a turbocharged
diesel engine
High-performance ceramic ball bearings and races are
made from titanium and carbon nitride feedstocks through
power metal technology
Composite Materials
Mixture of two or more materials.
Consists of a filler material and a binding material.
Materials only bond, will not dissolve in each other.
Mainly two types :o Fibrous: Fibers in a matrix
o Particulate: Particles in a matrix
o Matrix can be metals, ceramic or polymer
Examples : Fiber Glass ( Reinforcing material in a polyester or epoxy
matrix)
Concrete ( Gravels or
steel rods reinforced in
cement and sand)
Applications:- Aircraft wings
and engine, construction.
Composite materials
Composite materials
Electronic Materials
Not Major by volume but very important.
Silicon is a common electronic material.
Its electrical characteristics are changed by adding
impurities.
Examples:- Silicon chips,
transistors
Applications :- Computers, Integrated Circuits,
Satellites etc.
3
2
Competition Among
Materials
Materials compete with
each other to exist in new
market
Example:-
Over a period of time
usage of different
materials changes
depending on cost and
performance.
New, cheaper or better
materials replace the old
materials when there is a
breakthrough in
technology
Figure 1.14
Predictions and use of
materials in US automobiles.
Competition Among
Materials
Breakdown of weight percentage of major materials used in the average 1985 U.S.
automobile
Recent Advances and
Future Trends
Nanomaterials
Smaller than 100 nm particle size.
Materials have special properties.
Very hard and strong characteristics.
Research in progress.
Example: Carbon nanofiber reinforced plastic: very
light but stronger than metals.
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Recent Advances and
Future Trends
Smart Materials
React to environment Stimuli.
Change their properties by sensing
external stimulus.
Examples: Shape memory alloys used in the
artery stents.
Microelectromechanical systems (MEMS)
devices.
Future Trends
Polymeric (Plastic Materials)
Fastest growing basic material (9%
per year).
After 1995 growth rate decreased due
to saturation.
Different polymeric materials can be
blend together to produce new plastic
alloys.
Search for new plastic continues.
1-12
Future Trends
Ceramic Materials
New family of engineering ceramics are
produced last decade
New materials and applications are constantly
found.
Now used in Auto and Biomedical
applications.
Processing of ceramics is expensive.
Easily damaged as they are highly brittle.
Better processing techniques and high-impact
ceramics are to be found.
1-13
Future Trends
Composite Materials
Fiber reinforced plastics are primary
products.
On an average 3% annual growth from
1981 to 1987.
Annual growth rate of 5% is predicted
for new composites such as FiberglassEpoxy and Graphite-Epoxy combinations.
Commercial aircrafts are expected to
use more and more composite materials.
1-14
Future Trends
Smart Materials : Change their
properties by sensing external stimulus.
Shape memory alloys: Strained material
reverts back to its original shape above a
critical temperature.
Used in heart valves and to expand arteries.
Piezoelectric materials: Produce electric
field when exposed to force and vice
versa.
Used in actuators and vibration reducers.
Future Trends
Electronic Materials
Use of electronic materials such as silicon
increased rapidly from 1970.
Electronic materials are expected to play
vital role in Factories of Future.
Use of computers and robots will increase
resulting in extensive growth in use of
electronic materials.
Aluminum for interconnections in integrated
circuits might be replaced by copper
resulting in better conductivity.
1-15
Recent Advances and
Future Trends
Nanomaterials
Smaller than 100 nm particle size.
Materials have special properties.
Very hard and strong characteristics.
Research in progress.
Example: Carbon nanofiber reinforced plastic: very
light but stronger than metals.
Case Study Material
Problem:Selection
Select suitable material
for bicycle frame and fork.
Steel and
alloys
Low cost but
Heavy. Less
Corrosion
resistance
Wood
Carbon fiber
Reinforced
plastic
Aluminum
alloys
Light and
strong. But
Cannot be
shaped
Very light and
strong. No
corrosion.
Very expensive
Light, moderately
Strong. Corrosion
Resistance.
expensive
Cost important? Select steel
Properties important? Select CFRP
Ti and Mg
alloys
Slightly better
Than Al
alloys. But much
expensive
The End
Thank You
