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8/12/2019 Module 1, Intro to Engg Materials
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1
Module 1
Introduction to Engineering Materials
Sanjib Jaypuria, SME, KIIT University
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2Sanjib Jaypuria, SME, KIIT University
1960s Engineering Materials Metals
Design Choice of Material
New Materials New Products
Number of Materials 40 80,000!
General Definition of Material
According to Websters dictionary, materials are defined as
substancesof which som eth ing is composed or made
Introduction
Stone Age: Naturally accessible materials, i.e. stone, wood, bone, fur
Gold was the 1s tmetal used by the mankind fo l lowed by copp er
Bronze Age: Copper and its alloy like bronze
Iron Age: Iron (sponge iron & later pig iron)
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Engineering Material: Part of inanimate matter, which is useful to
engineer in the practice of his profession (used to produce
products according to the needs and demand of society)
Material Science: Primarily concerned with the search for basic
knowledge about internal structure, properties and processing of
materials and their complex interactions/relationships
Material Engineering: Mainly concerned with the use of
fundamental and applied knowledge of materials, so that they may
be converted into products, as needed or desired by the society
(bridges materials knowledge from basic sciences to engineering
disciplines)
Note:Mater ial scienc e is the basic kn ow ledge end o f mater ials kn ow ledge
spectrum , wh ere as, mater ial engineer ing is appl ied know ledge end and
there is no d emarcat ion l ine between the two sub jects of interest
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Evolution of Engineering Materials
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Why Material Science & Engineering is important to technologists?
Examples:
Mechanical engineers search for high temp material so that gas
turbines, jet engines etc can operate more efficiently and wearresistance materials to manufacture bearing materials
Electrical engineers search for materials by which electrical
devices or machines can be operated at a faster rate with minimum
power losses
Aerospace & automobile engineers search for materials having
high strength-to-weight ratio
Electronic engineers search for material that are useful in the
fabrication & miniaturization of electronic devices
Chemical engineers search for highly corrosion-resistant materials
Note: All these demands may be fulfilled when the internal structure
and engineering properties are known to an engineer or technologist
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Classification
It is the systematic arrangement or division of materials into
groups on the basis of some common characteristic
1. Ac cord ing to General Propert ies
2. Ac cord ing to Nature of Mater ials
3. Ac cord ing to App l icat ions
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1. According to General Properties
(a). Metals (e.g.iron, aluminium, copper, zinc, lead, etc)
Iron as the base metal, and range from plain carbon (> 98 % Fe) to
( i). Ferrous : high alloy steel (< 50 % alloying elements), e.g. cast
iron, wrought iron, steel, alloys like high-speed steel, spring steel,
etc
( i i). Non-Ferrou s: Rest of the all other metals and their alloys, e.g.
copper, aluminium, zinc lead, alloys like brass, bronze, duralumin,
etc
(b). Non-Metals (e.g. leather, rubber, asbestos, plastics, etc)
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2. According to Nature of Materials
(a). Metals: e.g. Iron & Steel, Alloys & Superalloys, Intermetallic
Compounds, etc
(b). Ceramics: e.g. Structural Ceramics (high-temperature load
bearing), Refractories (corrosion-resistant, insulating), Whitewares
(porcelains), Glass, Electrical Ceramics (capacitors, insulators,
transducers), Chemically Bonded Ceramics (cement & concrete)
(c).Polymers: e.g. Plastics, Liquid Crystals, Adhesives
(d). Electronic Materials: e.g. Silicon, Germanium, Photonic
materials (solid-state lasers, LEDs)
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(e). Composites: e.g. Particulate composites (small particles
embedded in a different material), Laminate composites (golf club
shafts, tennis rackets), Fiber reinforced composites (fiberglass)
(f). Biomaterials: e.g. Man-made proteins (artificial bacterium),
Biosensors, etc
(g). Advanced / Smart Materials: e.g. materials in computers
(VCRs, CD Players, etc), fibreoptic systems, spacecrafts,
aircrafts, rockets, shape-memory alloys, piezoelectric ceramics,
magnetostrictive materials, optical fibres,microelectromechanical (MEMs) devices, electrorheological /
magnetorheological fluids, Nanomaterials, etc
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3. According to Applications
(a). Electr ical Materials :e.g. conductors, insulators, dielectrics,
etc
(b). Electronic Materials: e.g. conductors, semi-conductors, etc
(c ). Magnetic Materials : e.g. ferromagnetic, paramagnetic &diamagnetic materials, etc
(d). Opt ical Materials : e.g. glass, quartz, etc
(e). Bio Materials: e.g. man-made proteins, artificial bacterium
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Engineering Materials
Ceramics
Alumina
Diamond
Magnesia
Silicon
Carbide
Zirconia
Composites
Carbon F iber
Ceramic
Matrix
Glass F iber
Metal M atrix
Electronic
Materials
Silicon
Germanium
Photonic
Materials
Solid-State
Lasers
LEDs
Bio-
Materials
Man-Made
Proteins
Artif icial
Bacterium
Biosensors
Advanced /
Smart
Materials
Shape-Memory Al loys
Piezoelectric Cerami cs
Magnetostri ctive Materi als
Optical Fi bres
Electrorheological Fl uids
Nanomaterials
Metals
Ferrous
Non-
Ferrous
Cast Ir on
Carbon Steels
Al loy Steels
Stain less Steels
Aluminium
Brass
Bronze
Copper
Lead
Magnesium
Nickel
TinZinc
Titanium
Polymers
Thermoplastic
Thermosetting
Elastomers
ABS
Acrylic
Nylon
Polyethylene
Polystyrene
Vinyl
Epoxy
Phenolic
Polyester
Butyl
Fluorocarbon
Neoprene
Rubber
Silicone
Classification of Engineering Materials
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Property Metals Non-MetalsStructure Crystalline AmorphicState Generally solids at room
temp. Gaseous & solid at ordinary temp.Luster Metallic luster No metallic luster (except iodine &
graphite)Conductivity Good conductors of heat &
electricityBad conductors
Malleability Malleable Not malleableDuctility Ductile Not ductileHardness Generally hard Hardness variesElectrolysis Form anions Form anioinsExcitation ofvalence electron
by e.m.f.Easy Difficult
Density High Low
Difference between Metals & Non-Metals
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Procedure for Selection of Materials (Engineering Applications)
Analysis of material application problem
Translation of material application requirements to material
property values
Selection of candidate materials
Evaluation of candidate materials
Decision making
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Factors Affecting Material Selection
1. Material Performance (depend upon material properties):
Adequate properties for anticipated operating conditions /
performance
2. Cons traints : Design, Availability, Cost etc
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1. Material Performance
Physical : e.g. appearance, shape, weight, boiling point, melting
point, freezing point, density, glass transition temperature,
permeability
Mechanical: e.g. strength (tensile, compressive, shear, torsion,
bending), elasticity, plasticity, ductility, malleability, rigidity,
toughness, hardness, brittleness, impact, fatigue, creep, strain
hardening, Bauschinger effect, strain rate effect, vibration
resistance, wear
Thermal: e.g. thermal conductivity, expansion coefficient,
resistivity, thermal shock resistance, thermal diffusivity
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Types of Force / Stress System
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Electr ical: e.g. conductivity, resistivity, dielectric strength,
thermoelectricity, superconductivity, electric hysteresis
Magnetic: e.g. ferromagnetism, paramagnetism, diamagnetism,
magnetic permeability, coercive force, curie temperature,
magnetic hysteresis
Chemical: e.g. reactivity, corrosion resistance, polymerization,
composition, acidity, alkalinity
Optical : e.g. reflectivity, refractivity, absorptivity, transparency,
opaqueness, color, luster
Metallurgical: e.g. grain size, heat treatment done / required,
anisotropy, hardenability
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2. Constraints
Design Requirements
Existing Facilities
Availability
Compatibility
Marketability
Manufacturability (Fabricability / Castability / Formability /
Machinability / Weldability)
Cost (Material + Fabrication / Manufacturing)
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Others Factors Affecting Material Performance
Structure-property -Processing Relationships
Hot Work, Cold Work,
Solid Solution Strengthening
Precipitation Hardening
Inclusions
Imperfections (Number of Dislocations)
Crystal structures: Crystalline vs Amorphous
Toughening
Heat treatment (Annealing, Normalizing, Quenching)
Residual Stresses
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Investigating relationship between Structure & Properties
Materials Engineering
Designing the structure
to achieve the specific
properties of the
materials
Materials Science
Investigating the
relationship between
structure and
properties of thematerials
Processing
Structure
Properties
Performance
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Competition among Materials
Factors causing material replacement: Cost (breakthrough in
processing cost) & development of new materials with specific
properties for some specific applications
Usage of material in US automobiles