Unit 5 A - Mec108t

18MEC108T
Materials Technology –
Unit – 5A (S1-S3)
3/26/2020 Deborah Serenade Stephen 1
Topics
• Introduction to smart materials, types
• Shape Memory Alloys
• Superalloys – Ni based and others.
• Polymers: Classes; Properties and applications of PE, PP, PS, PVC, Teflon
Shape Memory Alloy
These two lamps are animated lamps. The one on the left is designed by Romolo Stanco and the one on
the right was designed by a Japanese design group, Nendo. It uses shape-memory alloys to change the
shape of the lamp when the lamp is on. The change is initiated with heat from the light bulb.
Courtesy: https://makingtoys.net/2011/04/14/smas-research-applications/
Shape Memory Alloy (SMA)
• A shape memory alloy (SMA, smart metal, memory metal, memory alloy,
muscle wire, smart alloy) is an alloy that "remembers" its original, cold‐forged
shape: returning the pre‐ deformed shape by heating.
• This material is a lightweight, solid‐state alternative to conventional actuators
such as hydraulic, pneumatic, and motor‐based systems.
• Shape memory alloys have applications in industries including medical and
aerospace
The three main types of shape memory alloys are the copper‐zinc aluminium‐
nickel, copper‐aluminium‐nickel, and nickel‐titanium (NiTi) alloys but SMA's can
also be created by alloying zinc, copper, gold, and iron.
NiTi alloys are generally more expensive and change from austenite to martensite
upon cooling;
Mf is the temperature at which the transition to Martensite is finished during
cooling. Accordingly, during heating As and Af are the temperatures at which the
transformation from Martensite to Austenite starts and finishes.
Repeated use of the shape memory effect may lead to a shift of the characteristic
transformation temperatures (this effect is known as functional fatigue, as it is
closely related with a change of microstructural and functional properties of the
material)
(SMA)
Available via license: CC BY-NC-ND 4.0
(SMA)
The difference between the heating transition and the cooling transition gives rise
to the hysteresis effect where some of the mechanical energy is lost in the process.
The shape of the curve depends on the material properties of the shape memory
alloy, such as the alloying and work hardening.
SMA – 1 Way and 2 Way
The procedures are very
similar:
•Starting from martensite
(a),
•Adding a reversible
deformation for the one-
way effect or severe
deformation with an
irreversible amount for the
two-way (b),
•Heating the sample (c)
and
•Cooling it again (d).
https://en.wikipedia.org/wiki/Shape‐memory_alloy
SMA -Pseudo‐Elasticity�
One of the commercial uses of shape memory alloy involves using the pseudo‐elastic properties
of the metal during the high temperature (austenitic) phase.
The frames of reading glasses have been made of shape memory alloy as they can undergo large
deformations in their high temperature state and then instantly revert back to their original
shape when the stress is removed. This is the result of pseudoelasticity;
The martensitic phase is generated by stressing the metal in the austenitic state and this
martensite phase is capable of large strains. With the removal of the load, the martensite
transforms back into the austenite phase and resumes its original shape. This allows the
metal to be bent, twisted and pulled, before reforming its shape when released.
This means the frames of shape memory alloy glasses are claimed to be "nearly indestructible"
because it appears no amount of bending results in permanent plastic deformation.
SMA -Manufacture
• Shape memory alloys are typically made by casting, using vacuum arc melting or
induction melting. These are specialist techniques used to keep impurities in the
alloy to a minimum and ensure the metals are well mixed. The ingot is then hot
rolled into longer sections and then drawn to turn it into wire.
• The way in which the alloys are "trained" depends on the properties wanted. The
"training" dictates the shape that the alloy will remember when it is heated. This
occurs by heating the alloy so that the dislocations re‐order into stable positions.
• They are then shaped while hot and are cooled rapidly by quenching in water or by
cooling with air.
SMA –Some examples
• Ag‐Cd 44/49 at.% Cd
• Au‐Cd 46.5/50 at.% Cd
• Cu‐Al‐Ni 14/14.5 wt.% Al
and 3/4.5 wt.% Ni
• Cu‐Sn approx. 15 at.% Sn
• Cu‐Zn 38.5/41.5 wt.% Zn Smart Tabs
• Cu‐Zn‐X (X = Si, Al, Sn)
actuated tabs that allow tuning
• Fe‐Pt approx. 25 at.% Pt of rotor blade aerodynamics in-
flight for tracking, survivability,
• Mn‐Cu 5/35 at.% Cu performance enhancement and
noise reduction .
SMA Applications
• Aircraft: Boeing, General Electric Aircraft Engines, Goodrich Corporation, NASA, and All
Nippon Airways developed the Variable Geometry Chevron using shape memory alloy
that reduces aircraft's engine noise.
• Robotics: There have also been limited studies on using these materials in robotics
(such as "Roboterfrau Lara"), as they make it possible to create very light robots. Weak
points of the technology are energy inefficiency, slow response times, and large
hysteresis.
• Medicine: Shape memory alloys are applied in medicine, for example, as fixation
devices for osteotomies in orthopaedic surgery, in dental braces to exert constant
tooth‐moving forces on the teeth and in stent grafts where it gives the ability to adapt
to the shape of certain blood vessels when exposed to body temperature.
SMA Applications ‐ Nitinol
Nitinol is a nickel‐titanium alloy distinguished from other materials by its shape
memory and superelastic characteristics.
Nitinol is a trade name taken from the elements it's composed of—nickel (Ni) and
titanium (Ti)—and the scientific group that discovered it—the Naval Ordnance Laboratory
(NOL).
Austenite Strain Temperature, AS = 54℃
Austenite Peak Temperature, AP = 69 to 70 ℃
Austenite Final Temperature, AF = 73 to 74℃
Martensite Strain Temperature, MS = 41℃
Martensite Peak Temperature, MP = 35 to 36℃
Martensite Final Temperature, MF = 27 to 28℃
https://www.teachersource.com/product/memory-wire-samples-pk-of-10/energy-wire
Introduction
What is Superalloy?
A superalloy is a metallic alloy which can be used at high temperatures, often in excess
of 0.7 Tm
Alloying additions for solution strengthening is by addition of lower amount of W, Mo,
Ta, Nb and for Precipitation hardening by addition of Υ (gamma) and Υ’ (gamma prime)
formers like Ti, Al, & Nb.
Types:
 Ni – Based
 Co – Based
 Fe‐Ni – Based
There is yet another phase called
Topologically Close-Packed phase.
These are generally undesirable, brittle
phasesthat can form during heat
treatment or service.
TCPs (Sigma, Mu, Laves, etc.)
usually form as plates (which appear as
needles on a single-plane
microstructure).
TCPs are potentially damaging for
two reasons: they tie up Υ and Υ' ,
strengthening elements in a non-useful
form, thus reducing creep strength, and
they can act as crack initiators because
of their brittle nature.
The Shearing of γ' Precipitates
A dislocation cutting a particle
Effect of
Alloying
Elements
APPLICATIONS
Nickel-based super alloys are widely used in load- bearing structures to the
highest homologous temperature 0.9 Tm, or 90% of their melting point.
 Aerospace
 Turbine blades and jet/rocket engines
 Marine industry
 Submarines
 Nuclear reactors
 Heat exchanger tubing
 Industrial gas turbines
Industrial requirement
 Cost effective
 100 000 hrs. creep lifetime under 100 MPa at 750 C
 Stable at service temperature
 Forgeable & Weldable
 Corrosion resistance
 Toughness
Type of Hot Inter Thermal
Oxidation
engines corrosion diffusion fatigue
Aircraft
severe moderate severe severe
engines
Land-based
power moderate severe moderate light
generation
Marine
moderate severe light moderate
engines
Jet Engine
Alstom Gas Turbine
Nuclear Reactor
Polymeric Materials
• The ‘Polymer’ can be broken down to ‘poly’ as in ‘many units’ and ‘monomer’ which
stands for a ‘single unit’
• Thus Polymers are composed of large number of small molecules
Characteristics of polymeric materials :‐
• Low density
• Good corrosion resistance
• Low coefficient of friction
• Good mouldability
• Excellent surface finish
• Highly economical
• Can be produced with close dimensional tolerance
Courtesy: Material Science and
Strength of polymers Engineering‐ An Introduction; 9E;
William D Callister Jr, David G.
Rethwisch
Strength of polymers
Engineering‐ An Introduction; 9E;
William D Callister Jr, David G.
Rethwisch
Different groups in monomers
• Carbon is the most important element in polymer (4 valence electrons)
• To form a single molecule carbon makes bonding with oxygen, nitrogen, hydrogen, sulphur,
silicon, chloride.
• Type of Bonding that occur between carbon atoms and other elements are covalent bonding.
• Different type of bonding in a monomer
single bond – share one pair of electrons
double bond – share two pair of electrons
Triple bond – share three pair of electrons
Single bond molecules are found to be saturated
‐‐Where as double bond and triple bond moleules are unsaturated
S
5. Foams
Engineering‐ An Introduction; 9E; William
3/26/2020 D Callister Jr, David G. Rethwisch Deborah Serenade Stephen 43
Formation of polymeric structure
• “Polymerization” maybe defined as the process of linking small
molecules to form large molecules that are strongly joined by
covalent bonding.
• Polymerization links together monomers.
• Most polymers are organic, meaning that they are carbon‐based;
however, polymers can be inorganic (e.g., silicones based on a Si‐
O network).
• There are 3 mechanisms of polymerization
• Addition Polymerization
• Copolymerization
• Condensation polymerization
Addition Polymerization
Addition polymerization (sometimes called chain reaction polymerization) is a
process by which monomer units are attached one at a time in chainlike fashion to form a
linear macromolecule.
The composition of the resultant product molecule is an exact multiple of that of the
original reactant monomer.
Three distinct stages —initiation, propagation, and termination—are involved in
addition polymerization.
During the initiation step, an active center capable of propagation is formed by a
reaction between an initiator (or catalyst) species and the monomer unit.
Addition Polymerization
Polyethylene
R. represents the active initiator, and . is an unpaired electron.
Propagation involves the linear growth of the polymer chain by
the sequential addition of monomer units to this active growing chain
molecule. This may be represented, again for polyethylene, as follows:
Courtesy: Material Science
and Engineering‐ An
Introduction; 9E; William D
Callister Jr, David G.
Rethwisch
Addition
Polymerization
Rethwisch
Condensation Polymerization
Polymer chains can also form by condensation reactions, or step‐growth
polymerization, producing structures and properties that resemble those of addition
polymers.
In condensation polymerization, a relatively small molecule (such as water, ethanol,
methanol, etc.) is formed as a result of the polymerization reaction. This mechanism
may often involve different monomers as starting or precursor molecules.
• The polymerization of dimethyl terephthalate and ethylene glycol (also used as
radiator coolant) to produce polyester is an important example. During
polymerization, a hydrogen atom on the end of the ethylene glycol monomer
combines with an OCH3 (methoxy) group from the dimethyl terephthalate.
• A byproduct, methyl alcohol (CH3OH), is “condensed” off, and the two
monomers combine to produce a larger molecule.
• Each of the monomers in this example is bifunctional, meaning that both ends
of the monomer may react, and the condensation polymerization can continue by
the same reaction.
Eventually, a long polymer chain—a polyester—is produced. The length of the
polymer chain depends on the ease with which the monomers can diffuse to the ends
and undergo the condensation reaction. Chain growth ceases when no more monomers
reach the end of the chain to continue the reaction. Eg. Esters.
Rethwisch
Various Polymers
Polythene :
• Polyethylene (abbreviated PE) or polythene (IUPAC name polyethene or
poly(methylene)) is the most common plastic. Many kinds of polyethylene are known,
but they almost always have the chemical formula (C2H4)nH2.
Properties :
• Polyethylene is a thermoplastic polymer
consisting of long hydrocarbon chains.
• Have excellent chemical resistance. Courtesy: Google images
Repeating unit in PE
• It is also resistant to gentle oxidants and reducing agents.
• The melting point for average, commercial, low‐density polyethylene is typically 105 to
115 °C (221 to 239 °F).
Applications :
• In its foam form, polyethylene is used in packaging, vibration damping and insulation,
as a barrier or buoyancy component, or as material for cushioning.
• Many types of polyethylene foam are approved for use in the food industry. Found in
all types of packaging, polyethylene foam is used to wrap furniture, computer
components, electronics, sporting goods, plants, frozen foods, clothing, bowling balls,
signs, metal products, and more.
Courtesy: Google images
Poly Vinyl Chloride (PVC)
‐ the third‐most widely produced plastic, after polyethylene
and polypropylene.
Properties :
• PVC is a thermoplastic polymer.
• PVC is a useful material because of its inertness and this Polymerization reaction for PVC from vinyl
inertness is the basis of its low toxicity chloride
• PVC is a material resistant to ignition due to its chlorine
content.
• PVC products can last up to 100 years and even more.
Applications :
• It is used for sewerage pipes
• PVC is commonly used as the insulation on electrical
cables
• PVC has become widely used in clothing, to either create
a leather‐like material or at times simply for the effect of
PVC.
3/26/2020 Deborah Serenade Stephen Courtesy: Google images 56
Polystyrene :
• Polystyrene (PS) also known as Thermocole, abbreviated following ISO Standard PS, is an
aromatic polymer made from the monomer styrene.
Properties :
• Polystyrene is hard and brittle
• Polystyrene is chemically nonreactive
• Polystyrene is flexible and can be made into moldable solid or thick viscous solids
• It is highly flammable and burns with an orange yellow flame, giving off soot
Applications :
• Used to make containers for other chemicals, solvents and even food items Courtesy: Google images
• Is used in casting and molding
Nylon 6,6 :
• Nylon 6,6 is made of hexamethylenediamine and adipic acid, which give nylon 6,6 a total of 12
carbon atoms in each repeating unit, and its name.
Properties :
• Nylon 6,6 has a melting point of 265°C, high for a synthetic fiber, though not a match for
polyesters or aramids such as Kevlar. This fact makes it resistant to heat and friction.
• Its long molecular chain results in more sites for hydrogen bonds, creating chemical “springs”,
making it very resilient.
Applications :
• Carpet fiber
• Airbags
• Tires Courtesy: Google images
• Ropes
Teflon :
• Polytetrafluoroethylene (PTFE) is a synthetic fluoropolymer of tetrafluoroethylene that finds
numerous applications.
Properties :
• PTFE is a thermoplastic polymer
• It has a low coefficient of friction
• PTFE has excellent dielectric properties
• It has a high melting point .
Applications :
• Used in those components where sliding or action occurs such as plain bearings, gears, slide
plates
• They are used in solid rocket fuel propellants
• PTFE membrane filters are among the most efficient used in industrial air filtration applications
Polypropylene
• Polypropylene is a tough, rigid and
crystalline thermoplastic produced from
propene (or propylene) monomer.
• It is a linear hydrocarbon resin.
• The chemical formula of polypropylene is
(C3H6)n.
• PP is among the cheapest plastics
available today.
Applications: Polypropylene has applications
both as a plastic and a fiber in:
Automotive Industry
• Industrial Applications
• Consumer Goods, and
• Furniture Market
https://www.thongguan.com/blog/39/plastic-food-packaging-symbols-and-what-they-mean
References
1. Material Science and Engineering‐ An Introduction; 9E; William D Callister Jr,
David G. Rethwisch; Wiley Binder Version ISBN: 978‐1‐118‐47770‐0
2. https://pediaa.com/
3. https://omnexus.specialchem.com/
4. https://www.thongguan.com/
5. https://www.slideshare.net/N.Prakasan/superalloys‐22683088

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