MT201B

Materials Science
Dr. B.S.S. Daniel
MMED, IITR

s4danfmt@iitr.ernet.in

1
MT201B Materials Science

Course Objective...
Introduce fundamental concepts in Materials Science
You will learn about:
• material structure
• how structure dictates properties
• how processing can change structure
This course will help you to:
• use materials properly
• realize new design opportunities with materials

2
 Course Outline: Available in course website
z Introduction to Materials (0.5 Week) z Strengthening mechanism (1.0 Week; Tut Sheet 6)
z Crystallography (1.5 Weeks; Tut Sheet 1 & 2) z Solid solution
z Crystal structure z strain hardening
z Bravais lattice z precipitation hardening
z FCC, BCC, HCP
z Hall-Petch
z Miller Indices
z Indexing of planes and direction z Failure (1.0 Week; Tut Sheet 7)
z Bragg’s law – determination of crystal z Fracture
structure z Fatigue
z Imperfection in crystals (1.0 Week; Tut Sheet 3)
z Creep
z Point defects – solid solutions
z Line defects z Heat Treatment (1.0 Week; Tut Sheet 8)
z Volume defects z Isothermal transformation
z Mechanical properties of materials (1.0 Week; Tut z CCT
Sheet 4)
z TTT
z Elastic deformation
z Plastic deformation z Annealing
z Phase Diagram (1.5 Week; Tut Sheet 5) z Normalizing
z Gibbs Phase rule z Important Engineering Alloys (2.0 Weeks; Tut Sheet
z Binary phase diagram 9 & 10)
z Isomorphous, Eutectic, Eutectoid, z Ferrous
z Peritectic, Peritectoid
z Non-ferrous
z Lever Rule
z Phase Diagram z Ceramics
z Fe-Fe3C diagram – different alloys z Polymers
z Composites
z Materials Selection and Design (1.5 Weeks) 3
z Case studies of interest to discipline
Resource Material
Text book:
• Materials Science and Engineering: An Introduction
W.D. Callister, Jr., 7th edition, John Wiley and Sons,
Inc. (2007). http://www.wiley.com/college/callister
Additional Books:
• Materials Science and Engineers: A first course, V.
Raghavan, 5th edition, PHI (2003) – Rs. 225
•The Science and Engineering of Materials, Donald R.
Askeland, Thomson Books/Cole, (2003).
• Introduction to Materials Science for Engineers, James F.
Shackelford, Macmillan Publishing Company, (2004)
• Engineering Materials, part 1 & 2, M.F. Ashby, D.R.H.
Jones, Butterworth-Heinemann (2005)
•Structure and Properties of Engineering Materials, V.S.R. 4

Murthy et al, Tata McGraw-Hill (2003) – Rs. 235

 Tutorial Schedule, Spring 2009
# Topic Upload Discussion Submission Solution

Tut 1 Crystallography 1 6-Jan Jan 12-16 19-Jan 20-Jan

Tut 2 Crystallography 2 13-Jan Jan 19-23 27-Jan 28-Jan
Crystal
Tut 3 Imperfections 20-Jan Jan 27-31 2-Feb 3-Feb
Mechanical
Tut 4 Properties 27-Jan Feb 2-6 9-Feb 10-Feb
Tut 5 Phase Diagram 3-Feb Feb 16-20 24-Feb 25-Feb
Strengthening
Tut 6 Mechanisms 17-Feb Feb 24-28 2-Mar 3-Mar
Tut 7 Failure 24-Feb Mar 2-6 16-Mar 17-Mar
Tut 8 Heat Treatment 3-Mar Mar 16-19 23-Mar 24-Mar
Polymers &
Tut 9 Ceramics 17-Mar Mar 23-27 30-Mar 31-Mar
5
Tut 10 Composites 24-Mar Mar 30-Apr 3 9-Apr 10-Apr
Some Instructions …
z Tutorial class compensation due to holiday
z Two surprise quizzes
z Cheating / plagiarism in exam / tutorial
prohibited
z Minimum 75% attendance
z Marks distribution
z Quizzes – 15 Marks
z Tutorial Submission – 10 Marks
z Mid Term Exams – 25 Marks
z Final Exam (3 hr) – 50 Marks
6
 Materials – Historical perspective

Materials
drive our
society:
Stone Age
Bronze Age
Iron Age

What Now?
Silicon
Age?
Polymer
Age? 7
Some definitions …
z What is Materials Science?
Æ Understanding the relationship between stucture and
properies
z What is Materials Engineering?
Æ Designing the structure to produce a predetermined set
of properties
Main problem:
Selecting the right material from the many
thousands that are available

Two other important components: processing and

performance
8
Materials Selection process

1. Pick Application Determine required Properties

2. Properties Identify candidate Material(s)

Material: structure, composition.

3. Material Identify required Processing

Processing: changes structure and overall shape

ex: casting, sintering, vapor deposition, doping
forming, joining, annealing.

9
Carbonated beverage containers
Constraints:
• provide a barrier to the passage of carbon
dioxide, which is under pressure in the container
ceramic (glass) • be nontoxic, unreactive with the beverage, and,
preferably be recyclabe
• be relatively strong, and capable of surviving a
drop from a height of several meters when
containing the beverage
polymer (plastic) • be inexpensive and the cost to fabricate the final
shape should be relatively low
• if optically transparent, retain its optical clarity
• capable of being produced in different colors
and/or able to be adorned with decorative labels
metal (aluminum)
10
The Inter-relationships …
Engineers make things. They make them out of materials. The
materials have to support loads, to insulate or conduct heat and
electricity, etc.

Processing
method

Micro- Property
structure
11
Materials Classification
z Metals
z Ceramics
z Polymers
z Glasses
z Elastomers
z Advanced Materials
z composites
z semiconductors
z biomaterials
z smart (inteligent) materials
z nanomaterials

12
 13
Functional Classification

© 2003 Brooks/Cole Publishing / Thomson Learning™

Structural Classification
z Crystalline material is a material comprised of one or
many crystals. In each crystal, atoms or ions show a
long-range periodic arrangement.
z Single crystal is a crystalline material that is made
of only one crystal (there are no grain boundaries).
z Grains are the crystals in a polycrystalline material.
z Polycrystalline material is a material comprised of
many crystals (as opposed to a single-crystal
material that has only one crystal).
z Grain boundaries are regions between grains of a
polycrystalline material.

14
Structure in different scales

How will the following

processes affect the
materials structure at
different length scale?
• Mechanical working
• Thermal treatment

15
Classes of Processes

16
Classes of Processes

17
Taxonomy of the process
kingdom

18
Taxonomy of the process
kingdom

19
Properties
Property – all materials exposed to external stimuli evoke response
Force deformation, failure
Light reflection, absorbtion

Important: Properties are independent of shape and size

Response of the materials as a whole

SIX CATEGORIES:

z mechanical z magnetic
z electrical z optical
z thermal z deteriorative
20
Metals
z Relatively dense
z Stiff
z Strong
z Ductile
z Resistant to fracture
z Good conductors of heat and electricity
z Not transparent to visible light
z Some of them magnetic (Fe, Co, Ni)
21
Ceramics
Compounds between metallic and nonmetallic
elements
z Relatively stiff
z Strong
z Very hard
z Extremely brittle
z Susceptible to fracture
z Insulative to heat and electricity
z Resistant to high temperature
z May be transparent,translucent or opaque 22
Polymers
z Low density
z Not as stiff and strong as metals
z May be ductile
z May be pliable (easily formed into complex
shapes)
z Unreactive in most environments
z Low conductivityofheat and electricity
z Tendency to soften and decomposed with
temperature
23
Examples of Polymers
z Polyethylen (PE)
z Nylon
z Polyvinyl chloride (PCV)
z Polycarbonate (PC)
z Polystyrene (PS|)
z Silicon rubber

24
Mechanical
Displayed when a force
is applied to a material

z Strength
z Stiffness
z Hardness
z Ductility
z Toughness
z Wear resistance
z Fatigue resistance
z Creep resistance
25
 26

© 2003 Brooks/Cole Publishing / Thomson Learning™

Strength of various categories of
materials
Electrical
• Electrical Resistivity of Copper:
6
i The electrical resistivity
at%N versus temperature for
5 3. 32
u + copper and three copper–
Resistivity, ρ

C
t% Ni
(10-8 Ohm-m)

nickel alloys, one of which

4 2 . 16 a a t% Ni
+ 2 has been deformed.
Cu +1 .1
3 C u Thermal, impurity, and
ed
rm Ni deformation contributions
defo t%
2 1 . 12 a to the resistivity are
+
Cu indicated at -100C.
1 r e ” Cu
“Pu
0
-200 -100 0 T (°C)
• Adding “impurity” atoms to Cu increases resistivity.
• Deforming Cu increases resistivity.
27
Electrical Conductivity
Conductors
insulators
semiconductors

28
Thermal
Thermal Conductivity of Copper:
- It decreases when you add zinc!

400

Thermal Conductivity
300

(W/m-K)
200

100
0
0 10 20 30 40
Composition (wt% Zinc)

Thermal diffusivity differs from the

conductivity because materials
differ in their heat capasity.
29
 Thermal
Space Shuttle Tiles:
- Silica fiber insulation
offers low heat conduction.

This photograph shows a white-hot

cube of a silica fiber insulation
material, which, only seconds after
having been removed from a hot
furnace, can be held by its edges
with the bare hands. Initially, the
heat transfer from the surface is
relatively rapid; however, the
thermal conductivity of this
material is so small that heat
conduction from the interior
[maximum temperature
approximately 1250°C] is
extremely slow.

30
Magnetic
Magnetic Storage:
- Recording medium
is magnetized by
recording head.

Magnetic Permeability vs. Composition:

Adding 3 atomic % Si makes Fe a better
recording medium!

Fe+3%Si

Magnetization
Fe

Schematic representation showing

how information is stored and
retrieved using a magnetic storage Magnetic Field
medium. 31
Optical
Transmittance:
Aluminum oxide may
be transparent,
translucent, or
opaque depending on
the material structure.

polycrystal: polycrystal:
single crystal low porosity high porosity

32
 Deteriorative
• Stress & Saltwater... • Heat treatment: slows
--causes cracks! crack speed in salt water!
10 -8 “as-is”
“held at

crack speed (m/s)

160ºC for 1 hr
before testing”
10 -10 Alloy 7178 tested in
saturated aqueous NaCl
solution at 23ºC

increasing load

Photograph showing a bar of steel that 4 μm

7150-T651 Al alloy
has been bent into a ‘‘horseshoe’’
shape using a nut-and-bolt assembly. (Zn,Cu,Mg,Zr)
While immersed in seawater, stress
corrosion cracks formed along the
bend at those regions where the
tensile stresses are the greatest.
33
Material Property Charts

A bar chart of modulus. It reveals the difference in

stiffness between the families 34
Material Property Charts
• The charts give an
overview of the
physical, mechanical
and functional
properties of materials,
presenting the
information about them
in a compact way
• They reveal aspects of
the physical origins of
properties, helpful
inunderstanding the
underlying science.
• They become a tool for
optimized selection of
materials in existing
A bubble chart of modulus and density.
products
Families occupy discrete areas of the chart. 35
Material Property Chart

36
• Properties depend on structure
ex: hardness vs structure of steel (d)
600
Hardness (BHN)

30 μm
500 (c)
400 (b)
(a)
4 μm
300
30 μm
200 30 μm

100
0.01 0.1 1 10 100 1000
Cooling Rate (ºC/s)
• Processing can change structure
ex: structure vs cooling rate of steel 37