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ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met Eng. Colorado School of Mines, 1978-79 (Electro-Slag Welding of Heavy Section 2¼ Cr 1 Mo Steels) Ph.D., Ind. Eng. Penn State University, 1987 (Foundry Engineering – CG Alloy

ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

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Page 1: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

ME 2105 Introduction to Material Science (for Engineers)

Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met Eng. Colorado School of Mines, 1978-79 (Electro-Slag Welding of Heavy Section 2¼ Cr 1 Mo Steels) Ph.D., Ind. Eng. Penn State University, 1987 (Foundry Engineering – CG Alloy Development)

Page 2: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Syllabus and Website:

Review the Syllabus Attendance is your job – come to class! Final is Common Time at the Beginning of the Finals

Period Semi-Pop Quizzes and homework/Chapter Reviews (Ch

17 & 18) – (20% of your grade!) – note, additional homework (not to be collected) is suggested to prepare for quizzes and exams!

Don’t copy from others; don’t plagiarize – its just the right thing to do!!

Course Website: http://www.d.umn.edu/~rlindek1/ME2105/Cover_Page.htm

Page 3: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Our Text:

Materials Science for Engineering: an Introduction

 By Callister & Rethwisch

8th Edition, Wiley, 2010.

Page 4: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Materials Science and Engineering

It all about the (raw) materials and how they are processed

That is why we call it materials ENGINEERING

Minor differences in Raw materials or processing parameters can mean major changes in the performance of the final material or product

Page 5: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Why the class?

As ME/IE we are involved in design of products or processes

When making up a design, what materials we use are critical (and driven by the function of the design)

When investigating processes, minor changes can have a major impact on the results

Page 6: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Materials Science and Engineering

Materials Science The discipline of investigating the relationships that

exist between the structures and properties (or performance) of materials.

Materials Engineering The discipline of designing or engineering the

structure of a material to produce a predetermined set of properties based on established structure-property correlation.

Four Major Components of Material Science and Engineering:

Structure of Materials Properties of Materials Processing of Materials Performance of Materials

Page 7: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Properties are a link between the fundamental issues of materials science and the practical

challenges of materials engineering. (FromG. E. Dieter, in ASM Handbook,Vol. 20: Materials

Selection and Design, ASM International, Materials Park, OH, 1997, p. 245.)

Material Selection in Design

Page 8: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

And Remember: Materials “Drive” our Society!

Ages of “Man” and note, we survive based on the materials we control!

Stone Age – naturally occurring materials Special rocks, skins, wood

Bronze Age Casting and forging

Iron Age High Temperature furnaces and strong materials

Steel Age High Strength Alloys

Non-Ferrous and Polymer Age Aluminum, Titanium and Nickel (superalloys) – aerospace Silicon – Information Plastics and Composites – food preservation, housing, aerospace and

higher speeds Exotic Materials Age?

Nano-Material and bio-Materials – they are coming and then …

Page 9: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

A Timeline of Human Materials “Control”

Page 10: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

And Formula One – the future of automotive is …http://www.autofieldguide.com/articles/050701.html

Page 11: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Looking At CG Iron Alloy Development (Processing):

Page 12: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Looking At CG Iron Alloy Development (Processing):

Page 13: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

CG Structure – but with great care!

Good Structure 45KSI YS; 55KSI UTS

Poor “Too Little”

Poor “Too Much”

Page 14: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Looking At CG Iron Alloy Development (Structures)

Page 15: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Looking At CG Iron Alloy Development (Results)

Page 16: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Doing Materials! Engineered Materials are a function of:

Raw Materials Elemental Control Processing History

Our Role in Engineering Materials then is to understand the application and specify the appropriate material to do the job as a function of:

Strength: yield and ultimate Ductility, flexibility Weight/density Working Environment Cost: Lifecycle expenses, Environmental impact** Economic and Environmental Factors often are

the most important when making the final decision!

Page 17: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Introduction

List the Major Types of MATERIALS That You Know: METALS CERAMICS/Glasses POLYMERS COMPOSITES ADVANCED MATERIALS( Nano-

materials, electronic materials)

Page 18: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Introduction, cont. Metals

Steel, Cast Iron, Aluminum, Copper, Titanium, many others

Ceramics Glass, Concrete, Brick, Alumina,

Zirconia, SiN, SiC

Polymers Plastics, Wood, Cotton (rayon, nylon),

“glue” Composites

Glass Fiber-reinforced polymers, Carbon Fiber-reinforced polymers, Metal Matrix Composites, etc.

Page 19: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Thoughts about these “fundamental” Materials

Metals: Strong, ductile high thermal & electrical conductivity opaque, reflective.

Ceramics: ionic bonding (refractory) – compounds of metallic & non-metallic elements (oxides, carbides, nitrides, sulfides)

Brittle, glassy, inelastic non-conducting (insulators)

Polymers/plastics: Covalent bonding sharing of e’s

Soft, ductile, low strength, low density thermal & electrical insulators Optically translucent or transparent.

Page 20: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Structural Steel (a fundamental engineered metal) in Use: The Golden Gate Bridge

Page 21: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Periodic Table of Elements: The Metals

Page 22: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Structural Ceramics

Page 23: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Periodic table ceramic compounds are a combination of one or more metallic elements (in light color) with one or more nonmetallic elements (in dark color).

Page 24: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Glasses: atomic-scale structure of (a) a ceramic (crystalline) and (b) a glass (noncrystalline)

Page 25: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Optical Properties of Ceramic are controlled by “Grain Structure”

MAE 224: ENGINEERING MATERIALS

1.Introduction 19

Figure 1.2 – Alumina (Al2O3) – single crystal and polycrystal

SINGLE CRYSTAL POLYCRYSTAL

POLYCRYSTAL+ PORES

Grain Structure is a function of “Solidification” processing!

Page 26: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Polymers are typically inexpensive and are characterized by ease of formation and adequate structural properties

Page 27: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Periodic table with the elements associated with commercial polymers in color

Page 28: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Composite Materials – oh so many combinations

Fiber Glass Composite:

Page 29: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

The Materials Selection Process – as a part of design

1. Engineered Application will 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 shapeex: casting, sintering, vapor deposition, doping forming, joining, annealing.

Page 30: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Materials property chart with a view of relative materials performance. Here plots of elastic modulus and density data (on logarithmic scales) for various materials indicate that members of the different categories of structural materials tend to group together. (After M. F. Ashby, Materials Selection in Engineering Design, Pergamon Press, Inc., Elmsford, NY, 1992.)

These so-called Ashby Charts are developed for comparing candidate materials considering many design

factors

Page 31: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

But: Properties depend on Structure (strength or hardness)

Har

dnes

s (B

HN

)

Cooling Rate (ºC/s)

100

200

300

400

500

600

0.01 0.1 1 10 100 1000

(d)

30 mm(c)

4 mm

(b)

30 mm

(a)

30 mm

And:

Processing can change structure! (see above structure vs Cooling

Rate)

Page 32: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Another Example: Rolling of Steel

At h1, L1

low UTS low YS high ductility round grains

At h2, L2

high UTS high YS low ductility elongated grains

Structure determines Properties but Processing determines Structure!

Page 33: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Electrical Properties (of Copper):

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.)

T (°C)

-200 -100 0

Cu + 3.32 at%Ni

Cu + 2.16 at%Ni

deformed Cu + 1.12 at%Ni

1

2

3

4

5

6

Re

sist

ivity

, r

(10-8

Ohm

-m

)

0

Cu + 1.12 at%Ni

“Pure” Cu

Electrical Resistivity of Copper is affected by:• Contaminate level• Degree of deformation• Operating temperature

Page 34: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

THERMAL Properties• Space Shuttle Tiles: --Silica fiber insulation offers low heat conduction.

• Thermal Conductivity of Copper: --It decreases when you add zinc!

Courtesy of Lockheed Aerospace Ceramics Systems, Sunnyvale, CA)

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.)

Composition (wt% Zinc)

The

rmal

Con

duct

ivity

(W

/m-K

)

400

300

200

100

00 10 20 30 40

100 mm

Page 35: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

MAGNETIC Properties

• Magnetic Permeability vs. Composition: --Adding 3 atomic % Si makes Fe a

better recording medium!

Adapted from C.R. Barrett, W.D. Nix, andA.S. Tetelman, The Principles ofEngineering Materials, Fig. 1-7(a), p. 9,1973. Electronically reproducedby permission of Pearson Education, Inc.,Upper Saddle River, New Jersey.

J.U. Lemke, MRS Bulletin, Vol. XV, No. 3, p. 31, 1990

• Magnetic Storage: --Recording medium is magnetized by recording head.

Magnetic FieldM

ag

net

iza

tion Fe+3%Si

Fe

Page 36: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

DETERIORATIVE Properties

• Stress & Saltwater... --causes cracks!

Marine Corrosion, Causes, and Prevention, John Wiley and Sons, Inc., 1975.

4 mm--material: 7150-T651 Al "alloy" (Zn,Cu,Mg,Zr)

G.H. Narayanan and A.G. Miller, Boeing Commercial Airplane Company.

• Heat treatment: slows crack speed in salt water!

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.)

“held at 160ºC for 1 hr before testing”

increasing loadcra

ck s

pe

ed

(m

/s)

“as-is”

10-10

10-8

Alloy 7178 tested in saturated aqueous NaCl solution at 23ºC

Page 37: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Example of Materials Engineering Work – Hip Implant

With age or certain illnesses joints deteriorate. Particularly those with large loads (such as hip).

Page 38: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Example – Hip Implant Requirements

mechanical strength (many cycles)

good lubricity biocompatibility

Page 39: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Example – Hip Implant

Page 40: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Solution – Hip Implant Key Problems to

overcome: fixation agent to hold

acetabular cup cup lubrication

material femoral stem – fixing

agent (“glue”) must avoid any debris

in cup Must hold up in body

chemistry Must be strong yet

flexible

AcetabularCup and

Liner

Ball

Femoral Stem

Page 41: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Often, material selection comes down to a tradeoff of cost vs. design property

Page 42: ME 2105 Introduction to Material Science (for Engineers) Dr. Richard R. Lindeke, Ph.D. B Met. Eng. University of Minnesota, 1970 Master’s Studies, Met

Choosing the right material for the job -- one that is the most economical and “Greenest” when life cycle usage is considered. As designers we must consider “Sustainability” in our designs and material choices Understanding the relation between

properties, structure, and processing. Recognizing new design

opportunities offered by materials selection.

Course Goal is to make you aware of the importance of Material Selection by: