mme 323 materials science week 1 - intro to materials science & engineering

MME 323: MATERIALS SCIENCE WEEK 1 :

INTRODUCTION TO MATERIALS SCIENCE&

ENGINEERING*

Adhi Primartomo, PhDEmail: [email protected]: Room 191 – JIC Academic Building* Source: Materials Science and Engineering; 9th Edition; W.D.Callister;

Wiley; 2011

https://sites.google.com/site/primartomo/file-cabinet

2

ME Department - Course Management Rules

3

Course Assessment

Theory 70%

Activities Marks

- Quiz 1 7.5

- Mid-Term 20

- Quiz 2 7.5

- Assignment 5

- Final Exam 30

Practical 30%

Course Description

This course covers the crystalline and non-crystallinestructure of materials, mechanical behavior of materials,phase diagrams, FE-C diagram and IT diagram, heattreatment of steels, iron and steel production process andcorrosion and degradation of metals. The classification,properties of: steels, cast irons, non-ferrous metals,polymers, ceramics and composite materials are alsocovered.

4

Course Learning Outcomes (CLOs)

Upon completion of this course, the student should be able to:

1. Classify engineering materials and apply its knowledge to select suitable materials for specific applications;

2. Acquire a sound understanding of crystalline and non-crystalline structures through theoretical and practical sessions;

3. Define the mechanical properties and the effect of alloying elements on the properties of materials, and conduct the mechanical testing of materials and analyze the results;

4. Discuss the properties and the applications of steels and cast irons, and explain the iron and steel production process;

5. Understand the phase diagram and employ the iron carbon diagram and isothermal transformation diagram to construct the heat treatment experiment and analyze the results;

6. Discuss the properties and the applications of non-ferrous metals and non-metallic materials; and

7. Explain the mechanism and types of corrosion in metals and select appropriate corrosion protection methods.

5

~ LECTURE OUTLINE ~

Chapter 1: Introduction to Materials Science & Engineering (page 2 - 15)*

• Materials Science and Materials Engineering,

• Why Study Materials Science and Engineering,

• Classification of Engineering Materials,

• Advanced Materials,

• Materials Selection and Design.

6

~ Week 1 Learning Objective ~

After studying this chapter, you should be able to:

• Explain the different between materials science & materials engineering,

• Explain 4 components that are involved in the design, production and utilization of materials; and briefly describe the relationship between them,

• List 6 different property classification of materials that determine their applicability,

• List 3 primary classifications of solid materials and mention their distinctive properties,

• Explain 4 types of advanced materials,

• Explain 3 criteria which are important in the materials selection and design.

7

MATERIALS SCIENCE & ENGINEERING(page 2 – 4)

What is Material ?

• Basic substance that have mass and occupy space

• It can be natural or human made

• There are now about 300,000 different known materials

8

What is Materials Science?

• Materials science involve investigating the relationships that exist between the structure and properties of materials

What is Materials Engineering?

• Materials engineering involve, on the basis of these structure property correlation, design/engineer the structure of a material to produce a predetermined set of properties


9

Who is Materials Scientist?

• To develop/synthesize new materials

Who is Materials Engineer?

• To create new product/systems using existing materials

• To develop new techniques for processing materials


10

Four components that involve in the design, production and utilization of materials?

1. Structure

?2. Property

?

Classification: mechanical, electrical, thermal, magnetic, optical and deteriorative/chemical.

3. Processing ?

4. Performance ?

The relationship between the four components:

WHY STUDY MATERIALS SCIENCE AND ENGINEERING?

(page 4 – 5)

11

New materials have been among the greatestachievements of every age and they have been centralto the growth, prosperity, security, and quality of life ofhumans since the beginning of history. It is always newmaterials that open the door to new technologies,whether they are in civil, chemical, construction,nuclear, aeronautical, agricultural, mechanical,biomedical or electrical engineering.

CLASSIFICATION of ENGINEERING MATERIALS(page 6 – 11)

12

1. Metals

2. Ceramics

3. Polymer

4. Composites

Fig.1. Venn diagram showing three basic material types plus composites

13

1. Metals• Most Utilized Engineering Materials

• Properties that Satisfy a Wide Range of Engineering Design Requirements

• General Properties:

• Strength & Stiffness

• Toughness & Formability

• Electrical & Thermal Conductivity

• Usually used in Alloys (mixed of 2 or more metals

• Examples: Steel, Aluminium, magnesium, zinc, cast iron, titanium, copper, nickel, etc.


14

1. Metals

Fig.2. Metals (a. Steel; b. Aluminium; c. Copper; d. Titanium)

(a) (b)

(c)(d)


15

2. Ceramics

• A Compound containing metallic & non-metallic elements formed by the action of heat

• General Properties:

• Hard & Brittle

• Compressive Strength tensile strength

• Resistance to chemical action and weathering

• Thermal Insulator (Thermal Conductivity )

• Examples: sand, brick, glass, graphite, tile, pottery, etc.


~ CLASSIFICATION of ENGINEERING MATERIALS ~

16

2. Ceramics

Fig.2. Ceramics (a. tile; b. pottery; c. sand; d. glass)

(a) (b)

(c)(d)

17

3. Polymers• Organic Compounds, formed by repeating structural unit (Mers),

where the atoms share electron to form very large molecules

• General Properties:• Light Weight• Low Thermal & Electrical Conductivity• Moderate Resistance on Inorganic Acids, Bases & Salts

• Examples: PVC, polyethylene, polypropylene, rubber, nylon, Teflon,

Fig.3.


18

3. Polymers

Fig.4. Polymers (a. polyethylene; b. PVC; c. rubber; d. melamine)

(a) (b)

(c)(d)


19

4. Composites

• Combination of Two or More Different Materials• Combination of the Best Characteristics of Each

Components Materials• Better properties than any individuals component• Examples: fiberglass, textiles, vehicle tires, wood

papers, etc


20

4. Composites

Fig.4. Polymers (a. carbon fibres; b. fiberglass; c. wood; d. textile)

(b)

(c)(d)

(a)


21

Table 1. Examples of representative, applications & properties of each type of materials


22

ADVANCED MATERIALS(page 12 – 13)

Materials utilized in high-tech applications

1. Semiconductor

?

2. Biomaterials

?

3. Smart MaterialsComponents of a smart material/system:a. Sensorb. Actuators

23

ADVANCED MATERIALS(page 12 – 13)

3. Smart MaterialsType of materials used for actuators:• Shape memory alloys• Piezoelectric ceramics• Magnetostrictive materials• Electrorheological/magnetorheological fluids

4. Nanomaterials

? (top-down science, bottom-up approach,

nanotechnology)

~ MATERIALS SELECTION & DESIGN ~

24

Selecting suitable material for a given application

Factors to be considered in selecting a materials for a given application:

• Must have desired physical & mechanical properties

• Can be processed/manufactured into desired shape

• Provide economic solution to design problem (relatively cheap)

• Environmental friendly

Design specification: Provides in depth detail information about the requirement for a

product This including assumptions, constraints, performance, dimensions,

weight & reliability


25

Choosing the right material:

• Relating the design specifications with material properties

Example of relating design specifications with material properties:

Design Specifications Materials Properties

Must support load without breaking Strength

Can not be too expensive Cost per weight (Cost/kg)

Must Conduct Heat Thermal Conductivity


26

Case 1: Design/materials selection for a coffee cup

Design specifications for coffee cup: Avoid burning the user’s hands Might be re-used Less danger to environment

Materials properties for coffee cup: Excellent thermal insulation

(thermal conductivity )

Reusable Recyclable

Candidate Materials: Ceramics & Polymers Both appropriate due to their low thermal conductivity

However: Polymers cup (polyethylene) should not be re-used (become poisonous) Disposing polymers cause environmental damage unrecyclable

Ceramics can be reused and less danger to environment.

Proposed Material: Ceramics


27

Case 2: Design/materials selection for a soda drink container

Design specification for a soda drink container: provide a leak free environment

for storing liquid protect the liquid from health

hazards withstand internal pressurization

and prevent escape of bubbles be easy to store and transport be cheap to produce for volumes

of 10,000+

Materials Properties for a soda drink container: Relatively High Strength

High Corrosion resistance

Solid & Relatively High Strength

Light (Low Weight-Density) Low Cost per Weight

Candidate Materials: Light Metals & Polymers Both own all the required materials properties Materials must be: Relatively high strength, low weight & high

corrosion resistance, low cost in materials & manufacturing


28


“Strength to Weight Ratio”: The ratio between Material’s Strength and its Weight (Density) Materials that are light and also very strong, have a High Strength

to Weight Ratio Higher Strength to Weight ratio are usually linear with Higher cost

of Materials


29

List of Strength to Weight Ratio of Some Engineering Materials:

Materials Strength (MPa) Density (g/cm³)Strength to Weight Ratio

(kN·m/kg)

Concrete 10 2.3 4.35

Rubber 15 0.92 16.3

PET (Polyethylene) 70 1.4 50

Brass 580 8.55 67.8

Polypropylene 80 0.9 88.88

Nylon 78 1.13 69

Magnesium 275 1.74 158

Aluminium alloy 600 2.7 222

Steel alloy 2,000 7.86 254

Titanium alloy 1,300 4.51 288

Carbon-epoxy composite 1240 1.58 785

Silicon carbide 3,440 3.16 1,088

Glass fiber 3,400 2.6 1,307

1 μm iron whiskers 14,000 7.87 1800

Vectran 2,900 1.4 2,071

Carbon fiber (AS4) 4,300 1.75 2,457

Kevlar 3,620 1.44 2,514

Spectra fiber 3,510 0.97 3,619

Colossal carbon tube 6,900 0.116 59,483

Carbon nanotube 62,000 .037-1.34 46,268-N/A


30


Proposed Materials: Aluminium Alloy & PET, Polypropylene

Aluminium Alloy:• Considerably high enough strength• Low weight• Highest corrosion resistance among metals• Low cost material & easy to manufacture

PET (Polyethylene Terephthalate) & Polypropylene:• High enough strength & low weight• Low cost material & easy to manufacture• Under certain conditions will not leach harmful elements into liquid.

mme 323 materials science week 1 - intro to materials science & engineering

Education

properties of materials

engineering materials

new materials

utilization of materials

suitable materials

composite materials

materials scientist

materials selection