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DEMI

Industrial Technology Center

Introduction to Mechanical Technologies and Processes

T2 - Engineering Materials

Miguel A. Machado
Telmo G. Santos
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What?
-What are the engineering materials?

-How many?

-How do they rank?

-What is its chemical constitution?

-What about your properties?

- How is a carbon fiber component manufactured?

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Learning Outcomes

- Recognize the historical and current importance of the materials;

- Knowing examples of advanced materials / state of the art;

- Identify the 4 major groups of materials and their subgroups;

- Know their compositions and chemical structures;

- Relate the groups of materials with their properties;

- Recognize and separate Engineering materials into their groups.

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Engineering Materials

Materials:

- Knowledge of materials is absolutely fundamental at

Eng. Mechanics and Eng. Industrial.

- Materials are so important to humanity that they name the

divisions of history.

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Materials: What things are made of!

Stone Age c. 2.5 Bronze Age c. 3300 Iron Age c. 1300

MA – 6000 AC BC – 1300 BC BC – 500 BC
Silicon Age!
Engineering materials currently available:

How to choose the material?

Based on a systematic
Based on experience
methodology that allows a
gained?
“logical” decision?

YES YES
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Materials: What things are made of!

Airgel – 99.8% air (Able Vantablack

to protect down to -196°C) Vertically Aligned NanoTube
Ex. Silicon dioxide (SiO2 ) Arrays (Absorbs 99.96% of light)

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Materials: What things are made of!

Graphene: a 2D material
One of the allotropic forms of carbon
One atom thick hexagonal lattice
High conductivity (electrical and thermal)

High Young's modulus (1000 GPa)

Very high mechanical resistance

(Stress = 130 000 MPa)

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Materials: What things are made of!

The three-dimensional geometry of the part itself may vary over time.

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Materials: What things are made of!

The three-dimensional geometry of the part itself may vary over time.

4D printing

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Materials: What things are made of!

self-healing material

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Materials: What things are made of!

Biomimetic materials:
nature as a source of
Inspiration

Lotus flower leaf and its lotus effect

Innovation inspired by Nature…

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Materials: What things are made of!

Functionally Graded Material (FGM)…

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Materials: What things are made of!

Functionally Graded Material (FGM)…

3D printing of metals
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Materials: What things are made of!

Functionally Graded Material (FGM)…

Material Material
#1 #2

3D printing of metals
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Materials: What things are made of!

Classification of Materials
< Practical activity >

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Engineering Materials: the 4 Groups

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Engineering Materials: the 4 Groups

Mechanical resistance
Ductility
conductors
Materials dense
composites
Metals Corrosion

polymers ceramics
little dense
insulators
corrosion resistant insulators
little resistant Corrosion and UV resistant
UV sensitive fragile
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Engineering Materials: the 4 Groups

Composite materials: the best

Headquarters
of both worlds

Reinforcement

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Engineering Materials: the 4 Groups

Composite
materials: the
best of both

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Carbon steel (AISI 1020)
HSLA steel - High-strength low-alloy steel
copper plated steel
ferrous
316L stainless steel
Cast iron

Aluminum (6xxx)
Aluminum (5xxx)
Metallic / Aluminum (2xxx)
metallic Copper Alumina (Al2O3)
Lead SiC
Tin macor
non-ferrous
Titanium (Grade 2) Technical Graphite
Magnesium (AZ31)
single-line fiberglass
Brass (Cu+Zn) ceramics /
single-filament carbon fiber
Nickel Alloy ceramics
Nordic Gold (89%Cu, 5%Al, 5%Zn, 1% Sn)
Clay
PE - Polyethylene Silica
traditional
PET - Polyethylene Terephthalate Porcelain

PP - Polypropylene
PC - Polycarbonate GLARE
PS - Polystyrene metallic matrix
PLA - Polylactic acid
Thermoplastics
ABS - Acrylonitrile Butadiene Styrene
Carbon fiber (3 mm lamellar)
PTFE - Polytetrafluoroethylene (Teflon)
Fiberglass (lamellar 3 mm)
Polyamide (Nylon) composites
Polymeric Matrix PU coated carbon fiber
PVC - Polyvinyl chloride
polymeric Wood (natural composite)
PMMA - Polymethylmethacrylate (Acrylic)

Plaster with Fibers

Epoxy Resin
PU - Polyurethane Ceramic Matrix Concrete

thermosets Bakelite
Aramid Fiber

Elastic
Rubber
elastomers
Silicone
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Engineering Materials

Engineering Materials

Metals plastics ceramics and composites

Others

non-
ferrous amorphous Thermoplastics thermosets elastomers
ferrous

reinforced
steels Oxides
plastics
Aluminum acrylics epoxies
steels nitrides metallic matrix
stainless steel Copper ABS Phenolics Polyurethanes
carbides Headquarters

steels from Titanium Polystyrene polyesters erasers ceramics

glasses
Tools Others
Tungsten PVC Silicones Laminates
graffiti
irons Others Polyamides
castings Diamond

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Behavior and Influential Properties of the
manufacture

Behavior and Manufacturing Properties

properties Physical and chemical Modification of

Structure of materials
Mechanics properties properties

Atomic bonds: Resistance Density

metallic, covalent and Heat treatment:
Ductility Fusion point
ionic
Aging
Toughness thermal conductivity
Crystalline structure
Quench and temper
amorphous Fatigue Dilation coefficient
Aging
Fluency electrical conductivity
partially
Superficial treatment
crystalline tenacity and Oxidation
Fracture leagues
polymeric chains Corrosion
Reinforcements

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Metallic Materials

They are inorganic substances that contain one or more metallic elements
that may also contain some non-metallic elements, such as, for example,
carbon, nitrogen or oxygen.
Carbon steels (C < 2%)
Alloyed steels
ferrous Stainless steel (12%<Cr)
Cast iron (2% < C < 4%)
Metallic Materials
Aluminum Alloys
Magnesium Alloys
non-ferrous Copper Alloys
Titanium Alloys…

Crystal structure: atoms arranged in an orderly manner in arrangements of the type:

CCC CFC HC
Body Centered Cubic Face Centered Cubic Compact Hexagonal

Chromium
Aluminum Copper Zinc
Iron (CFC at 910ºC) Lead Gold Magnesium
Silver Titanium (CCC at 883ºC)

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Polymeric Materials

Polymeric materials are currently the most important group of non-metallic materials
used in industrial applications. Polymeric materials are made up of long chains or
networks of organic molecules that form non-crystalline structures.

Polyethylene (PE)

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Polymeric Materials

Acrylonitrile
butadiene
Styrene

Polyethylene terephthalate (PET)

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Ceramic Materials

Ceramic materials are inorganic substances made up of metallic (or semi-metallic) and
non-metallic elements chemically bonded together by ionic and/or covalent bonds. The
physical structure of these materials can be crystalline, non-crystalline or mixed.

They can be grouped into: 1)

Traditional ceramics.
Traditional ceramic materials are obtained from the following raw
materials: Al2Si2O5(OH)4 clay, SiO2 silica and KAlSi3O8 feldspar.
Example: Porcelain (density 2.5 g/cm3)

2) Technical ceramics:
They are obtained artificially from pure, or almost pure, compounds of oxides, carbides and nitrides
For example aluminum oxide Al2O3, silicon carbide SiC, silicon nitride Si3N4 and zirconia ZrO2.

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Composite materials

Composite materials are mixtures or combinations of two or more

materials that can be grouped into three distinct groups: 1) Polymer-
ceramic; 2) Metal-polymer; 3) Metal-ceramic.

The characteristic structure of a composite is formed by a binder material (which

serves as a matrix) and a reinforcing material (or filler). The reinforcing material can
be included in the structure in the form of particles, continuous fibers or staple fibers.

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Composite Production

Production Demonstration of
Carbon Fiber Composite

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Materials: Comparison and Development

What to do with the materials given to us?

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Materials: Comparison and Development

What is the mechanical strength of pure iron?

Ø = 1mm Ø = 1mm Ø = 1mm

Steel DP 1400
Iron 316L steel

80 kg
224 kg
(2.8x) 512 kg
(6.4x)

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Materials: Comparison and Development

What is the atomic structure of Iron?

Strength

Strength

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Materials: Comparison and Development

How does iron break down?

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Materials: Comparison and Development

How can mechanical strength be increased?

Faith

Ø = 280 pm
(280/1000,000,000 mm)

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Materials: Comparison and Development

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Materials: Comparison and Development

Faith w An intelligence that

applies is the
Ø = 280 pm Ø = 140 pm beginning of all good
(280/1000,000,000 mm)

Iron -> Steel

Strength

Strength

Technology: applying intelligence to what we've been given to make it even better
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Materials: Comparison and Development

Inventing steel is a huge pride, but…

Darwini of Caerostris

Breaking
Breaking Stress = two

Strength Resistant Section Area

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Materials: Comparison and Development

Nature continues to surprise…

ÿRot = 250 MPa 1600 MPa 1652 MPa

Ø = 1mm Ø = 1mm Ø = 1mm

DP 1400 web of
Iron steel
ÿ = 7800 Spider ÿ =
kg/m3 1200 kg/
m3

80 kg

512 kg 529 kg
(6.4x) (6.6x)
The strength per unit weight of a spider's web is 43 times greater!
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Materials: Comparison and Development

Other metal alloys…

4Fe + 3O2 ÿ 2Fe2O3 Stainless Steel: Iron+Carbon+Chromium

Chromium oxide - Cr2O3

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