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Materials Science & Selection
Integrated Science & Technology
431
Fall 2003
Fall 2003 2Dr. Ken LewisISAT-431 Module 1 Overview
Introduction
• This is a course in the science of materials.– That is….
• How we use the raw materials of our word to suit our needs and wants.
• Why we can see each other.
• Why we don’t fall through the floor.
Fall 2003 3Dr. Ken LewisISAT-431 Module 1 Overview
Introduction2
• We will look at the various types of materials, both naturally occurring and man made– HOW materials are different (easy)– WHY materials are different (not so easy)
Fall 2003 4Dr. Ken LewisISAT-431 Module 1 Overview
Manufacturing
• Manufacturing.– Manus (Hand).– Factus (make).
• No longer true.– Most items of value are mass made by
automated systems.
Fall 2003 5Dr. Ken LewisISAT-431 Module 1 Overview
Manufacturing2
• Technologically– Application of chemical and physical processes
to materials to alter;• Geometry
• Properties
• Appearance
Fall 2003 6Dr. Ken LewisISAT-431 Module 1 Overview
Manufacturing3
• Economically– Transformation of materials into items of
greater value• By processing
• By assembly
Fall 2003 7Dr. Ken LewisISAT-431 Module 1 Overview
Manufacturing4
– Production control
– Support services
– Marketing
– Sales
– Shipping
– Customer service
A complex process involving…
– Product design
– Machinery and tooling
– Process planning
– Purchasing
– Manufacturing
Fall 2003 8Dr. Ken LewisISAT-431 Module 1 Overview
Manufacturing5
Product Number of parts
Rotary lawn mower 300
Grand piano 12,000
Automobile 15,000
C-5B transport plane >4,000,000
Boeing 747-400 >6,000,000
Fall 2003 9Dr. Ken LewisISAT-431 Module 1 Overview
Manaufacturing5
• Manufacturing is a process which uses material.
• Three primary types of manufacturing, and all use different material.
Fall 2003 10Dr. Ken LewisISAT-431 Module 1 Overview
Primary Secondary TertiaryAgriculture Aerospace Banking
Forestry Apparel Communications
Fishing Automotive Education
Livestock Basic metals Entertainment
Quarries Beverages Financial Services
Mining Building materials Government
Petroleum Chemicals Health and Medical
Computers Hotel
Construction Information
Consumer appliances Insurance
Electronics Legal
Fabricated metals Real estate
Food Processing Repair and maintenance
Glass, ceramics Restaurant
Heavy machinery Retail trade
Paper Tourism
Petroleum refining Transportation
Pharmaceuticals Wholesale trade
Plastics
Power utilities
Publishing
Textiles
Tire and Rubber
Wood and furniture
Fall 2003 11Dr. Ken LewisISAT-431 Module 1 Overview
Materials
• Why do we study materials?
Because theyare interesting.
Understandthe
differences
Understand thematerial limits
Establish parametersfor design calculations
Predict the mechanicalbehavior of
the manufactured
product
Select theRight material
For thejob
Fall 2003 12Dr. Ken LewisISAT-431 Module 1 Overview
Materials
• Can be anything of substance in the known universe.
• For our purposes we will restrict the discussion essentially to solids
Fall 2003 13Dr. Ken LewisISAT-431 Module 1 Overview
Engineering Materials
Metals
Non-metals(Ceramics)
Polymers
Natural stuff
Fall 2003 14Dr. Ken LewisISAT-431 Module 1 Overview
Engineering Materials2
MetalsNon-metals(Ceramics)PolymersNatural stuff
Blends produce unique materials called:
Composites
Fall 2003 15Dr. Ken LewisISAT-431 Module 1 Overview
Engineering Materials -- ExamplesMetals
• Ferrous - Cast Iron - Steel•Non-ferrous - Al, Mg, Cu, Ti, Ni, Zn, etc. & their alloys• Precious metals - Au, Pt, • Superalloys
Polymers• Thermoplastics - nylons, - polystyrene, - polypropylene
• Thermosets - epoxies - polyesters
• Elastomers - Spandex - vulcanized rubber
Ceramics• Traditional - Clay - Silica - Feldspar
• Advanced - Oxides, - Nitrides, - Carbides, - Ferrites, - Titanates
• Glasses
Miscellaneous• Composites - Dispersion - Particle - Fiber
• Electronic
• Magnetic
• Fibers
•Construction - Concrete, - Wood,
Fall 2003 16Dr. Ken LewisISAT-431 Module 1 Overview
Property
Metals Polymers Ceramics Composite
Crystal Structure Xtal Amorphous Xtal Varies
Density High Low Low Varies
Thermal Conductivity
High Low Low Directional
Electrical Conductivity
High Low Low Directional
Tensile Strength High High Low Directional
Compressive Strength
Low Low High Directional
Hardness Varies
Low High varies
Fall 2003 17Dr. Ken LewisISAT-431 Module 1 Overview
Evolution of Engineering Materials
Fall 2003 18Dr. Ken LewisISAT-431 Module 1 Overview
Material and Civilization Timeline
Fall 2003 19Dr. Ken LewisISAT-431 Module 1 Overview
Stre
ngt
h/den
sity
(in
x 1
06)
Year
1800 1900 2000
Wood & Stone Bronze
Castiron steel
Composites
KevlarCarbonFibers
Evolution of material normalized strength
Fall 2003 20Dr. Ken LewisISAT-431 Module 1 Overview
Are These Things…Metal Polymer Ceramic Composite
Semiconductor?• Clay
• Steel• Aluminum beer cans• Fiberglass surfboards• Si chip• Nylons• cement
• Polyester slacks• CD jewel case• Aluminum foil• Kleenex• Fiber reinforced tennis
racquet• Polyethylene milk
bottle
Fall 2003 21Dr. Ken LewisISAT-431 Module 1 Overview
Metallic Materials
• Substances composed of one or more metallic elements– For example:
• Iron (Fe)
• Copper (Cu)
• Aluminum (Al)
• Nickel (Ni)
• ….
Fall 2003 22Dr. Ken LewisISAT-431 Module 1 Overview
Metallic Materials2
• May contain impurities such as:– Oxygen (O)– Carbon (C) – Nitrogen (N)
((As long as they are not chemically bonded))• Have a crystalline structure• Good thermal and electrical conductors• Usually relatively strong• Usually ductile
Fall 2003 23Dr. Ken LewisISAT-431 Module 1 Overview
Metallic Materials3
• Two Classes– Ferrous metals and alloys
• Contain a large percentage of iron
– Non-ferrous• Usually softer and used at lower temperatures.
Fall 2003 24Dr. Ken LewisISAT-431 Module 1 Overview
Ceramics
• Inorganic material– Made of a metal and non metal bonded together
• Can be crystalline or non-crystalline
• Usually very hard and have strength at high temperatures– High compressive strength– brittle
Fall 2003 25Dr. Ken LewisISAT-431 Module 1 Overview
Ceramics2
• Properties– Light weight– Electrical and thermal insulators (usually but
not always)– Retain properties to very high temperatures
• Examples– Furnace linings
– Space shuttle tiles
Fall 2003 26Dr. Ken LewisISAT-431 Module 1 Overview
Polymerics
• Two major constituents– Carbon– Silicon
• Polymers generally are giant molecules consisting of long chains– Structures may be one, two, or three
dimensional.
Fall 2003 27Dr. Ken LewisISAT-431 Module 1 Overview
Polymerics2
• Properties can be tailored– Strength varies greatly– Flexibility varies– Usually thermal and electrical insulators– Usually will not withstand real high
temperatures.– Light weight
Fall 2003 28Dr. Ken LewisISAT-431 Module 1 Overview
Composites
• Mixtures of two or more dissimilar materials.– Usually one is a reinforcing agent and the other
is the filler• Fiberglass
• Carbon epoxy
– Many times the reinforcing agent is fibrous
Fall 2003 29Dr. Ken LewisISAT-431 Module 1 Overview
Composites2
• Properties– Usually asymmetric if one agent is a long fiber– Will borrow properties according to the volume
percent of each material present.
• There are many different combinations
Fall 2003 30Dr. Ken LewisISAT-431 Module 1 Overview
Competition amongst six major materials
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