Petroleum Engineering Design

PTE 320

Department of Petroleum Engineering

Assistant Professor

Zisis Vryzas

1- Introduction
 General

• Instructor: Zisis Vryzas

(zisis.vryzas@lau.edu.lb)
• Office: 201 (Eng. Building)
• Class Schedule and Location:
MWF 13.00 – 13.50, Room 406
 Method of evaluation
• Quiz 20%

• Midterm Exam 40%

• Final Exam 40%

• Total 100%
 Classroom policies
• No cell phones allowed in class and particularly during
quizzes and exams.

• No side talks during class.

• Leaving the class during lecture is only allowed for

serious reason and only after getting permission.

• You are strongly encouraged to ask questions in class.

Engineering Materials

Introduction
 Engineering Materials

Materials play an important role for our existence, for our day to
day needs ,and even for our survival. In the stone age the naturally
accessible materials were stone, wood, bone, etc.

Gold was the 1st metal used by the mankind followed by copper. In
the bronze age Copper and its alloy like bronze was used and in the
iron age they discovered Iron (sponge iron & later pig iron).
 Engineering Materials
- Number of Materials: >80,000 kinds and grades
- According to Webster’s dictionary, materials are defined
as ‘substances of which something is composed or made’
- 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)
 Why Material Science & Engineering is
important?
- Mechanical engineers search for high temp material
so that gas turbines, jet engines etc can operate
more efficiently
- 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
- Petroleum/Chemical engineers search for highly
corrosion-resistant materials
 Classification of Materials

We can categorize the materials into

groups on the basis of some common
characteristics according to:

- General properties
- Nature of materials
- Applications
 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
(ii). Non-Ferrous: 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)
 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 (lasers,
LEDs)
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
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, magnetorheological fluids, nanomaterials etc.

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 Applications

A) Electrical 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) Optical Materials: e.g. glass, quartz, etc
E) Bio Materials: e.g. man-made proteins,
artificial bacterium
 The three basic materials

Metals

Polymers

Ceramics
Composites: A composite is a combination
of two or more materials which gives a
certain benefit to at least one property
Common materials
 Metal

Cast Iron
Steel
 Mild steel, medium carbon steel, high carbon steel
Specialty steel
 Stainless (tin plated or galvanized)
Alloys (two or more pure metals)
 Steel= iron & carbon
 Brass= copper & zinc
 Bronze= copper & tin
 Polymers

Natural
 Animal cellulose

Synthetic-
 Thermoplastics
 Thermosets
 Natural composites

Hardwood

Softwood
 Ceramics

Clay based
 Structural clay-tile, brick
 Porcelain
Refractories
 Heat resistant (fire bricks)
Glasses
Inorganic cements
Classification of Materials
Difference between metals and non-metals
 Material Properties (1)

- 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
 Material Properties (2)

- Electrical: 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
 The Materials Tetrahedron
- An engineer has to consider four ‘intertwined’ concepts,
which are schematically shown as the ‘Materials
Tetrahedron’.
- When a certain performance is expected from a component
(and hence the material constituting the same), the
‘expectation’ is put forth as a set of properties.
- The material is synthesized and further made into a
component by a set of processing methods (casting, forming,
welding, powder metallurgy etc.).
- The structure (at various lengthscales) is determined by
this processing.
- The structure in turn determines the properties, which will
dictate the performance of the component.
- Hence each of these aspects is dependent on the others.
The Materials Tetrahedron

The broad goal for an Engineer is

to understand and ‘engineer’ this
tetrahedron
What determines the properties of materials?

- The following factors put together determines the

properties of a material:
Composition
Phases present and their distribution
Defect Structure (in the phases and between the
phases)
Residual stress (can have multiple origins and one
may have to travel across lengthscales)
- These factors do NOT act independent of one
another (there is an interdependency)
 Effect of Bonding on properties: a broad
flavour
- Two important contributing factors to the properties
of materials is the nature of bonding and the atomic
structure.
- Both of these are a result of electron interactions
and resulting distribution in the material.
 Material Usage Strategies
- There are basically three strategies available for the
use of materials for specific purposes.
Design a material with better properties (e.g.
materials with better creep resistance at high
temperatures).
Protect the material with surface coatings,
cooling etc.
(e.g. paint the material to avoid corrosion).
Use ‘sacrificial materials’ to protect the key
component
(e.g. use of sacrificial anodes to prevent corrosion).
- The obvious has not been stated above- i.e. use more
“quantity” of material.
- Also, we could do a better design of the
component/mechanism/machine/… itself (so that the
“load” on the material is not as much).
 Smart Materials
- Self reporting: lets us know of changes occurring in the
material e.g. damage accumulation can lead to magnetization.
- Responsive: responds to the environment and alters its
properties (e.g. photochromatic lenses which darken on
exposure to sun light).
- Responsive and self healing: responds to the environment or
changes within the material and can heal any deleterious
changes (e.g. cements in oil and gas!!!!)
- Self cleaning
- Self lubricating: an old concept, wherein the material puts
up a surface layer which acts like a lubricant (e.g. Al-
graphite composites, wherein the graphite acts like a
lubricant).
- Multi-functional: the material performs multiple roles in a
single structure or component. e.g.: the cover of a mobile can
be its power cell too
 Summary

- The goal of an engineer is to design materials

with a certain set of properties, which gives a
certain desired performance. Using suitable
processing techniques the material can be
synthesized and processed. The processing also
determines the microstructure of the material.
- Common types of materials available to an
engineer are: Metals, Ceramics and Polymers. A
hybrid made out of these materials may serve
certain engineering goals better.
Questions?