1.

1 CLASSIFICATION OF MATERIALS

EM 025 MECHANICAL ENGINEERING

• Induction Set 1
LEARNING OUTCOMES

a) Differentiate the various types

of materials used in engineering:
i. metal;
ii. ceramics; and
iii.polymers.
d) Distinguish classification of
steel:
i. carbon steel; and
ii. alloy steel.
• Many engineers whether mechanical, civil or electrical will at one time be exposed to a design problem
involving materials.

• Materials problem is when selecting the right material from the many thousands that are available.

• There are several criteria on which the final decision is normally based such as :
i. The properties required of the material.
ii. Failure of material properties that may occur during service operation.
iii. Probably the overriding consideration is that of economics.
• Metals are solid substances, which are opaque(non-transparent) in
nature and have an excellent electric conductance.

• Metals have the property of ductility and malleability.

• Basic metal production encompasses(enclose) the activities of smelting
or refining ferrous and precious(costly) as well as other non-ferrous
metals from ore or scrap, using metallurgic techniques. It also comprises
the production of metal alloys and super-alloys by adding certain
chemical elements to pure metals.
• Induction Set 2
• Made of material produced by the high temperature firing of inorganic,
nonmetallic rocks and minerals.

• Ceramic materials are brittle(hard but liable to break easily) and hard by
nature.
• Some of the most common forming methods for ceramics
include extrusion, slip casting, pressing, tape casting and injection
molding. After the particles are formed, these "green" ceramics undergo
a heat-treatment (called firing or sintering) to produce a rigid, finished
product.
• Question through mentimeter: https://www.menti.com/9kedhmnfuk
• Response the questions related in blog:
https://tsazlanmecheng.blogspot.com/2022/01/material-in-
engineeringsteel.html
• Induction Set 3
• A long or larger molecule consisting of a chain or network of many
repeating units, formed by chemically bonding together many identical or
similar small molecules called monomers.

• High strength or modulus to weight ratios (light weight but comparatively

stiff and strong), toughness, resilience, resistance to corrosion, lack of
conductivity (heat and electrical).
• The polymer production process is quite interesting as it involves the
bonding or joining of small molecules called monomers. The chemical
reaction process that joins these monomers together is called
polymerization. ... A typical example of a natural polymer is rubber, while
plastics are man-made polymers.
 METAL
Metals are solid substances,
which are opaque(non-
transparent) in nature and have
an excellent electric conductance.
Metals have the property of
ductility and malleability
CERAMICS
Made of material produced by
the high temperature firing of
inorganic, nonmetallic rocks and
minerals.
Ceramic materials are brittle and
hard by nature.
POLYMERS
A long or larger molecule
consisting of a chain or network
of many repeating units, formed
by chemically bonding together
many identical or similar small
molecules called monomers.
High strength or modulus to
weight ratios (light weight but
comparatively stiff and strong),
toughness, resilience, resistance
to corrosion, lack of conductivity
(heat and electrical).
• Give your opinion about our lesson today..
• Relate the previous lesson with your current environment/situation.
• Response to the question given in google classroom.
https://classroom.google.com/u/2/h
• Ferrous metals are material with iron element as the base metal.

• The word is derived from the Latin word ferrum (iron).

• The properties of ferrous metals may be changed by adding various

alloying elements.

• Products of ferrous metals can be found as plates, bars and sheets.

 GENERAL PROPERTIES
LOW
USUALLY RESISTANCE
MAGNETIC TO
CORROSION
GREAT
TENSILE RECYCLABLE
STRENGTH
GOOD
These qualities make them usable in CONDUCTORS OF
DURABLE building constructions as well as in
making tools, vehicle engines, ELECTRICITY
pipelines, containers, automobiles,
cutlery etc.
 IRON
 Basic constituent of steel.
 Most rich metallic in the
earth’s crust after aluminum.
 Found in the form of ores as
oxides, carbonates, silicates
and sulfides.
 Produced in blast furnaces.
 Carbon exerts the most
significant effects on the
microstructure and
properties of iron products.
STEEL
Steel is defined as the
element of iron and
carbon.
Steel are supplied in
various forms such as
plates and wires to
suit its applications. Its
usage depends on the
percentage of carbon
in its composition.
 CARBON STEEL
• Carbon steel can be classified into three
types:
1. Low Carbon Steel
(0.15% - 0.30% Carbon)
Low hardness, ductile and easy to
shape.
2. Medium Carbon Steel
(0.30% - 0.80% Carbon)
Strong and tougher than low carbon
steel.
3. High Carbon Steel
(0.8% - 1.5% Carbon)
Hardness, toughness, durability and
brittle.
ALLOY STEEL
• Alloy steel is steel that is alloyed with a
variety of elements in total amounts
between 0.1% and 50% by weight to
improve its mechanical properties.
• Additional of alloying elements will altered
the mechanical properties of steel like
hardenability, brittleness, toughness,
stiffness, machinability and ductility.
• Low Alloy Steels is to increase strength and
hardenability. Product : Mild steel.
• High Alloy Steels is to improves corrosion
resistance and stability at high or low temps.
Product : Stainless steel.
CARBON STEEL ALLOY STEEL

USED IN
USED TO MAKE
LATHE TOOL BITS, PIPELINES,
RIVETS, AUTO PARTS,
ROD, TRANSFORMERS,
SPRING, POWER GENERATORS
CHISEL, ELECTRIC MOTORS.
WRENCH,
HAMMER
 CAST IRON
INTRODUCTION PROPERTIES

• Cast iron is a group of iron-carbon alloys • High compressive strength

with a carbon content greater than 2%. • Low tensile strength
• Its usefulness derives from its relatively low • Low melting point
melting temperature. • Tends to be brittle, except for malleable cast
irons.
• Cast iron is actually liquid metal casts into a
prepared mold. • Good castability
• Excellent machinability
• Manufactured by reheating pig iron and
blending it with other material such as • Resistance to deformation
carbon and other alloys. • Good wear resistance
 WROUGHT IRON
INTRODUCTION
• Wrought iron is an iron alloy with a very
low carbon content (less than 0.08%).
• Wrought iron is made by repeatedly
heating the iron and working it with tools
to deform it.
• Can be processed such as forging,
knocking, squeezing and rolling to get the
desired shapes.
PROPERTIES
• Strong in tension and weak in compression when
compared with cast iron
• Ductile and malleable
• Have a melting point of about 1500°C and at 900°C
it becomes so soft that two pieces can be joined by
hammering
• Can be forged and welded satisfactorily
• Tough and has great shock resistance
• Rusts more easily than cast iron
• Unaffected by salty water
• Temporary magnets but cannot be permanently
magnetized
• Tough and can withstand shocks and impacts
better than cast iron.
 Differences Between Wrought Iron And Cast Iron
WROUGHT IRON CAST IRON
 Manufactured by melting & refining iron to a  Manufactured by reheating pig iron and
high degree of purity. blending it with other materials of known
composition
 Its ductility is higher than steel and can be
shaped easily.  The amount and form of carbon (reduce 1.5%
- 4%) could affect the strength, hardness,
 Its tensile strength is lower dan steel. brittleness and stiffness

 It has good resistance to corrosion.  Adding such as nickel (0.5% - 3%) to iron
increases its hardness and strength but lowers
 It can be used to make pipes, corrugated the ductility
sheets, grills, bars, chains.
 has high compressive strength but
 It can be cold worked, forged and tensile strength is low.
welded like steel
23
 WROUGHT CAST IRON
IRON
USED IN
USED TO MAKE PIPES
PIPES MACHINES
CORRUGATED AUTOMOTIVE INDUSTRY
SHEETS PARTS SUCH AS
GRILLS -CYLINDER HEADS
BARS -CYLINDER BLOCKS
CHAINS -GEARBOX CASES
GATES
WROUGHT IRON CAST IRON
 NON-FERROUS METALS
DEFINITION
Non-ferrous metals are metals that do not contain iron.

GENERAL CHARACTERISTICS
 Corrosion resistance.
 High thermal and electrical conductivity.
 Ease of fabrication.
 Colors choices.
 Expensive than ferrous metals.
A Characteristics
 Silver in color.
L  It is a good heat and electrical conductor.
 Low melting point
U  Non-poisonous

M Mechanical Properties
 Ductile
I  Malleable (can be easily machined, cast, shape,

N
forged, rolled and extruded)
 Low density
I  High heat capacity

U Application
 Widely used in transportation vehicles, construction
M industry, aeronautics, cooking utensils and food
containers industry.
 APPLICATION OF ALUMINIUM

Vehicles

Cooking utensils

Food containers

Construction
 Characteristics
 Blue-white in color
 Hard, smooth material
 Reasonable conductor of electricity
 Does not corrode as easily as other metals, hence it is
Z an excellent material for electroplating onto surfaces
to protect them.
I Mechanical Properties
N  Brittle at ambient temperatures
 Malleable at 100 to 150°C
C
Application
 It is mainly used for die-casting alloys and as a coating for
sheet steel, chain, wire, screws and piping.
 Widely used in die-casting industries to produce
automotive parts, building hardware, padlock and toys.
 APPLICATION OF ZINC

Padlocks
Coating for chain
Coating for piping

Plated screws Building hardware Toys

 Characteristics
 Reddish-colored metal
C  It is a good heat and electrical conductor.
 Can be easily soldered, brazed and welded without
O corrosion problems.

P Mechanical Properties
 Malleable
P  Ductile
E  Tough

R Application
 Widely used in electrical and air-conditioning industries
 APPLICATION OF COPPER

Electronics product Copper plating

Copper finish parts Copper wires

 Characteristics
 Silvery-white in color.
 Low melting point
 Good transmission of heat or electricity
 Being so soft, tin is rarely used as a pure metal; instead, it is
combined with other metals in order to make alloys that possess

T tin's numerous beneficial properties.

 Can be forged and hammered to a very thin and fine sheet and

I wires.
Mechanical Properties
N  Malleable (easy to press and shape without breaking)
 Ductile (able to be stretched without tearing).

Application
 Use for electronic connections; soldering
 used to coat other metals to prevent corrosion
 used in food containers industry and pewter industry
 APPLICATION OF TIN

Soldering Pewter industry

• An alloy is an admixture of metals, or a metal combined with one or more other elements.

• In general, alloys have been found to be stronger and harder, less malleable, less ductile, and
more corrosion-resistant than the main metal making the alloy.

• An alloy mixture is stronger because it contains atoms from different elements that are
different in sizes.

• For example, combining the metallic elements gold and copper produces red gold, gold and
silver becomes white gold, and silver combined with copper produces sterling silver.

• Combining iron with non-metallic carbon or silicon produces alloys called steel or silicon
steel.
• Brass is an alloy made primarily of copper and zinc. The proportions of the copper and zinc
are varied to yield many different kinds of brass. Basic modern brass is 67% copper and 33%
zinc.1 However, the amount of copper may range from 55% to 95% by weight, with the
amount of zinc varying from 5% to 45%.2

• Brasses set the standard by which the machinability of other materials is judged and are also
available in a very wide variety of product forms and sizes to allow minimum machining to
finished dimensions. Brass does not become brittle at low temperatures like mild steel.

• Brass also has excellent thermal conductivity, making it a first choice for heat exchangers
(radiators). Its electrical conductivity ranges from 23 to 44% that of pure copper.
• Brass is the generic term for a range of copper-zinc alloys with differing combinations of properties, including
strength, machinability, ductility, wear-resistance, hardness, colour, electrical and thermal conductivity, hygiene
and corrosion resistance.

• Brass often has a bright gold appearance, however, it can also be reddish-gold or silvery-white. A higher
percentage of copper yields a rosy tone, while more zinc makes the alloy appear silver.

• Brass has higher malleability than either bronze or zinc.

• Brass has desirable acoustic properties appropriate for use in musical instruments.

• The metal exhibits low friction.

• Brass is a soft metal that may be used in cases when a low chance of sparking is necessary.

• The alloy has a relatively low melting point.

• It's a good conductor of heat.

• Antibacterial Property.
• Brass is still commonly used in applications where corrosion resistance
and low friction are required, such as locks, hinges, gears, bearings,
ammunition casings, zippers, plumbing, hose couplings, valves, and
electrical plugs and sockets.

• Also use in Musical instruments, plumbing, decoration, tools and fittings

used around explosives.
• Bronze is an alloy consisting primarily of copper, commonly with about
12–12.5% tin and often with the addition of other metals and sometimes
non-metals or metalloids such as arsenic, phosphorus or silicon.
• Bronzes are typically ductile alloys, considerably less brittle than cast iron. Typically bronze oxidizes only superficially; once a
copper oxide (eventually becoming copper carbonate) layer is formed, the underlying metal is protected from further corrosion.

• Copper-based alloys have lower melting points than steel or iron and are more readily produced from their constituent metals.

• They are generally about 10 percent denser than steel, although alloys using aluminium or silicon may be slightly less dense.

• Bronze is a better conductor of heat and electricity than most steels. The cost of copper-base alloys is generally higher than that
of steels but lower than that of nickel-base alloys.

• Reddish-brown color.

• Hardness and brittleness (although typically it is less brittle than cast iron)

• Melting point of 950 degrees Celsius.

• High resistance to corrosion from saltwater.

• Exhibits low metal-to-metal friction.

• Bronze, or bronze-like alloys and mixtures, were used for coins over a longer period.

• Bronze was especially suitable for use in boat and ship fittings prior to the wide employment of stainless steel
owing to its combination of toughness and resistance to salt water corrosion.

• Bronze is still commonly used in ship propellers and submerged bearings.Brass is a soft metal that may be used in
cases when a low chance of sparking is necessary.

• Bronze parts are tough and typically used for bearings, clips, electrical connectors and springs.

• It is still widely used today for springs, bearings, bushings, automobile transmission pilot bearings, and similar
fittings, and is particularly common in the bearings of small electric motors.

• Phosphor bronze is particularly suited to precision-grade bearings and springs. It is also used in guitar and piano
strings.
• Pewter is a malleable metal alloy consisting of tin, antimony, copper,
bismuth, and sometimes silver. Copper and antimony act as hardeners
but lead may be used in lower grades of pewter, imparting a bluish tint.
Pewter has a low melting point, around 170–230 °C, depending on the
exact mixture of metals.
• The surface of modern pewter is bluish white with either a crisp,
bright finish or a soft, satin sheen. It resists tarnish, retaining its
colour and finish indefinitely.
• Since pewter is soft at room temperature, a pewter bell does not
ring clearly.

• Cooling it in liquid nitrogen hardens it and enables it to ring, while

also making it more brittle.
• Pewter was widely used for dishes, church vessels, and decorative items. Being a
common alloy, pewter has been primarily utilitarian and only secondarily ornamental,
being used where the precious metals were too expensive.

• Pewter is used in decorative objects, mainly collectible statuettes and figurines, game
figures, aircraft and other models, (replica) coins, pendants, etc.
• Steel is an alloy of iron and carbon. Stainless steels are steels containing at least 10.5% chromium, less
than 1.2% carbon and other alloying elements.

• Stainless steel is a group of ferrous alloys that contain a minimum of approximately 11% chromium, a
composition that prevents the iron from rusting and also provides heat-resistant properties.

• Different types of stainless steel include the elements carbon (from 0.03% to greater than 1.00%),
nitrogen, aluminium, silicon, sulfur, titanium, nickel, copper, selenium, niobium, and molybdenum.

• Specific types of stainless steel are often designated by their AISI three-digit number, e.g., 304
stainless. The ISO 15510 standard lists the chemical compositions of stainless steels of the
specifications in existing ISO, ASTM, EN, JIS, and GB (Chinese) standards in a useful interchange table.
• Stainless steel has different corrosion properties which include being non-corrosive, rust-resistant steel, which is
simply designated as stainless steel. In comparison with aluminium, stainless steel is approximately 3 times heavier.

• Stainless steel, like steel itself, is an alloy. An alloy always consists of different materials. Among the most frequent
alloying elements in non-corrosive stainless steel is chrome, where nickel, molybdenum and further elements are
used for special requirements.

• The magnetisability, as well as the corrosion resistance, are two of these requirements which are controlled by the
different alloys.
1. Automotive and transportation

Stainless steel was introduced in automotive in the 1930s by Ford to manufacture their concept cars. Since then, it is used to produce a variety
of automotive parts such as exhaust systems, grills, and trims. With advancing technology, stainless steel is being favoured by manufacturers to
make structural components.

2. Medical technology

Stainless steel is preferred in clean and sterile environments as it is simple to clean and does not easily corrode. Stainless is used in the
production of a wide range of medical equipment, including surgical and dental instruments. It is also used in building operation tables,
kidney dishes, MRI scanners, cannulas, and steam sterilizers.
3. Building trade
Due to its strength, resistance, and flexibility, stainless steel application has become a vital element of the building trade. It is
commonly featured in the interior on countertops, backsplashes, and handrails, and is also used externally in cladding for high
impact buildings.
4. Aircraft construction
The aviation industry also has a preference for stainless steel. It is used in various applications including the frames of aeroplanes
because of its strength and ability to withstand extreme temperatures. It can also be applied in jet engines as it can help prevent
against its rusting. Why not also read aircraft grade aluminum.
• Duralumin is actually a metal, which is an alloy of aluminum, copper,
magnesium, and manganese.
• Duralumin is a strong, light-weighted, and hard alloy of aluminum.

• It is also reflective and impermeable.

• It is a malleable metal and can be easily shaped.

• It is a very good conductor of heat and electricity.

• It is odorless, and reacts with the oxygen that is around, and forms aluminum oxide. It is resistant to corrosion.

• It has a thin surface, which is made up of a layer of pure aluminum, which is corrosion-resistant and covers the core of the strong
duralumin.

• Generally, Duralumin alloys are soft, ductile, and workable when they are in a normal state.

• They can be easily rolled, folded, or forged. They can also be drawn into a variety of shapes and forges.

• It has a high strength, which can be easily lost during wielding.

• It is used for making wire, bar, and rods for screw machine products. It is used in places where good
strength and good machinability are required.

• It is used in heavy-duty forgings, wheels, plates, extrusions, aircraft fittings, space booster tankage and
truck frame, and other suspension components. It finds applications in places where high strength is
required, and services at elevated temperatures.

• It is used for making Aircraft structures, truck wheels, screw machine products, rivets, and other
structural application products.

• It is used as a sheet for the auto body panels.

• It is also used in forgings, in aircraft engine pistons, impellers of the jet engines, and compressor rings.

• It is also used for making die and hand forgings.

• Materials that are specifically engineered to exhibit novel or enhanced
properties that confer superior performance relative to conventional
materials.

• Also known as materials with engineered properties created through

the development of specialized processing and synthesis technology,
including ceramics, high value-added metals, electronic materials,
composites, polymers, and biomaterials.
• Meaning: relating to or involving electric polarization resulting from the application of mechanical stress.

• Characteristics: Piezoelectric materials exhibit both a direct and a reverse piezoelectric effect. The direct
effect produces an electrical charge when a mechanical vibration or shock is applied to the material, while the
reverse effect creates a mechanical vibration or shock when electricity is applied.

• Properties: Piezoelectric property is due to atomic scale polarization. In theory, piezoelectricity refers to a
reverse process in which a contraction or elongation is created in the crystal once it is positioned in an electric
field. Crystals can only be piezoelectric if they are non-centrally symmetric.

• Applications: The piezoelectric effect has been exploited in many useful applications, including the production
and detection of sound, piezoelectric inkjet printing, generation of high voltage electricity, as a clock generator
in electronic devices, in microbalances, to drive an ultrasonic nozzle, and in ultrafine focusing of optical
assemblies. It forms the basis for scanning probe microscopes that resolve images at the scale of atoms. It is
used in the pickups of some electronically amplified guitars and as triggers in most modern electronic drums.
The piezoelectric effect also finds everyday uses, such as generating sparks to ignite gas cooking and heating
devices, torches, and cigarette lighters.
• Meaning: A smart fluid is a fluid whose properties (for example the viscosity) can be changed by applying an
electric field or a magnetic field.

• Characteristics: Smart fluids belong to the class of field responsive composites and they have the capacity
to undergo significant, reversible and controllable transformations with respect to their material
characteristics.

• Properties: These materials have the ability to change from a liquid to a solid almost instantly when

subjected to electric or magnetic field. Smart fluid comprises a suspension of micro-meter-sized particles in a

dielectric carrier liquid

• Applications: Smart fluids, which change some of their material properties when subjected to an electric or
magnetic field, are used for damping, vibration reduction and shock absorption in a variety of applications.
• Meaning: Colorless, endogenous or exogenous pigment precursors that may be transformed by
biological mechanisms into colored compounds; used in biochemical assays and in diagnosis as
indicators, especially in the form of enzyme substrates. Synonym: chromogens (not to be confused with
pigment-synthesizing bacteria also called chromogens).

• Characteristics: These technologies consist of electrically-driven media including electrochromism,

suspended particle electrophoresis, polymer dispersed liquid crystals, electrically heated thermotropics,
and gaschromics.

• Properties: It is dynamic and interactive in nature. So that, it commonly used when referring to the study
and use of materials that show a reversible change in their optical properties when they are subjected to
certain ambient conditions and different external stimuli, such as light, electric field.
• Applications: In chromogenic photography, film or paper contains one or many layers of silver halide
(AgX) emulsion, along with dye couplers that, in combination with processing chemistry, form visible
dyes. Also can be used for large area glazing in buildings, automobiles, planes, and for certain types of
electronic display.
• Meaning: Ferrofluid is a liquid that is attracted to the poles of a magnet. It is a colloidal liquid made of nanoscale
ferromagnetic, or ferrimagnetic, particles suspended in a carrier fluid (usually an organic solvent or water). Each magnetic
particle is thoroughly coated with a surfactant to inhibit clumping.

• Characteristics: Each magnetic particle is thoroughly coated with a surfactant to inhibit clumping. Large ferromagnetic
particles can be ripped out of the homogeneous colloidal mixture, forming a separate clump of magnetic dust when exposed
to strong magnetic fields. The magnetic attraction of tiny nanoparticles is weak enough that the surfactant's Van der Waals
force is sufficient to prevent magnetic clumping or agglomeration. Ferrofluids usually do not retain magnetization in the
absence of an externally applied field and thus are often classified as "superparamagnets" rather than ferromagnets.

• Properties: A ferrofluid is composed of three components: magnetic nano particles, dispersion medium (also called carrier
liquid) and a dispersant or surface active agent. The fluid responds to an applied magnetic field as one homogeneous system.

• Applications: Ferrofluids are used to form liquid seals around the spinning drive shafts in hard disks. The rotating shaft is
surrounded by magnets. A small amount of ferrofluid, placed in the gap between the magnet and the shaft, will be held in
place by its attraction to the magnet. The fluid of magnetic particles forms a barrier which prevents debris from entering the
interior of the hard drive. According to engineers at Ferrotec, ferrofluid seals on rotating shafts typically withstand 3 to 4
psi;[citation needed] additional seals can be stacked to form assemblies capable of withstanding higher pressures.