5501ICBTAE

Automotive Materials & Manufacturing Processes

Lecture 1-Introduction to
Automotive Materials I
What are Engineering Materials??
• Substances/Materials which are useful in the field
of Engineering

The primary function of an engineering material:

• Withstand applied loading without breaking and
without exhibiting excessive deflection
Four major components of the discipline of materials science
and Engineering
Classification of Engineering
Materials
• Metal
• Ceramic
• Polymer
• Composite /
Semiconductors
How it has evolved use of
materials in Automobiles?
Main Parts of an Automobile

Class Activity 1

What are the main parts of an

Automobile???
Why Engineering Materials?
Example:- Why did Tata Nano fail?
Classification of Automotive
Materials
Classification by Properties
What is a Property in Automotive Engineering
materials??
The magnitude of response to a specific imposed
stimulus. It independent of material shape and size.
Ex: A specimen subjected to a force will experience
deformation
Classification by Properties
• A huge range of materials, estimated to number up to 80
000, is available for today's engineers.
• As part of the procedures leading to the design of a new
product it is necessary to review the range of materials and
their properties before using the systems which have been
developed for material selection. One approach for the
selection is that the predominant quality must be
satisfactory but there must also be certain back-up
properties, for example:
• Basic requirement of corrosion resistance but is strength
adequate?
• Can material be welded but is the cost affordable?
• There are key properties of materials which are relevant for
engineering design involving mechanical, electrical,
chemical or other applications
Classification by Properties
Mechanical Properties
Mechanical Properties
Static Stresses and, Stress-Strain
Relationship
• 3 types of static stresses (load changes relatively slowly with
time and is applied uniformly over a cross section or surface of a
member)
1. Tensile: tends to stretch the material
2. Compressive : tends to contract the material
3. Shear: tends to cause adjacent portions of
material to slide
against each other

• Stress – strain relationship: Describes mechanical

properties for all three above static stresses
Engineering Stress & Strain

Engineering Stress & Strain

𝐹𝑡
Engineering stress=𝜎 =
𝐴𝑜
Where,
𝜎=Engineering stress
𝐹𝑡 =Force applied perpendicular to the specimen
cross section
𝐴𝑜 =Original cross sectional area before applying
load
Engineering Stress & Strain
𝑙𝑓 −𝑙𝑜
Engineering Strain =𝜀 =
𝑙𝑜
Where,
𝜀=Engineering strain
𝑙𝑓 =Instantaneous length (Length at any point of
elongation)
𝑙𝑜 =Original length
Elastic Deformation
Elastic Deformation Stress-Strain
Curve
Elastic Moduli
• The slope of the linear elastic part of the stress–
strain curve is known as Elastic moduli
✓Younger’s Moduli

Young’s modulus, E, describes response to tensile or

compressive loading .The constant of proportionality E (GPa or
psi) is the modulus of elasticity, or Young’s modulus
Example1 for Elastic computation
• A piece of copper originally 305 mm (12 in.) long is pulled in
tension with a stress of 276 MPa (40,000 psi). If the
deformation is entirely elastic, what will be the resultant
elongation? Delta l=0.72mm
Elastic Properties of Materials
• Poisson's Ratio (v)

If the applied stress is uniaxial (only in the z direction), and the

material is isotropic, then 𝜀𝑥 = 𝜀𝑦 . A parameter termed Poisson’s
ratio is defined as the ratio of the lateral and axial strains
Elastic Properties of Materials
Example 2 for elastic computation
• A tensile stress is to be applied along the long axis of a
cylindrical brass rod that has a diameter of 10 mm (0.4 in.).
Determine the magnitude of the load required to produce a
2.5 × 10−3 mm ( 10−4 in.) change in diameter if the
deformation is entirely elastic. E=97GPa
• Ans:--5.5x10^3N
Tensile Properties
➢Yielding and Yield Strength
Yielding: stress level at which plastic deformation begins
(gradual elastic–plastic transition). The point of yielding
cannot be measured easily. Therefore, a convention has been
established wherein a straight line is constructed parallel to
the elastic portion of the stress–strain curve at some specified
strain offset, usually 0.002.

Yield Strength (MPa or psi ): The stress corresponding to the

intersection of the construction line and the stress–strain
curve as it bends over in the plastic region is defined as the
yield strength 𝜎𝑦 .
Tensile Properties
➢Tensile Strength / Ultimate strength
The tensile strength (TS) (MPa or psi) is the stress at the
maximum on the engineering stress–strain curve.
Typical Engineering stress-strain curve up to fracture point
Ductility and Brittle Properties
• The measure of the degree of plastic deformation that has been
sustained at fracture is known Ductility. A metal that experiences very
little or no plastic deformation upon fracture is termed brittle. Ductility
may be expressed quantitatively as either percent elongation or percent
reduction in area.
Toughness
• Property that is indicative of a material’s resistance to
fracture when a crack (or other stress-concentrating defect)
is present or the ability of a material to absorb energy and
plastically deform before fracturing.
Hardness
• Resistance to permeant indentation (Plastic
Deformation)
• Good hardness generally means material is resistant to
scratching and wear
• Most tooling in manufacturing must be hard for scratch
and wear resistance
• Many hard materials tend to be brittle, limiting their
use-cases.
• Soft materials suffer indentations while hard ones resist
to any change in shape
Ex:- Tungsten
Electrical Properties
Electrical Properties
The importance of electrical behavior lies in the following:
✓ transference of current over long distances - needs high electrical
conductivity with low ohmic heating
✓ electrical insulation - dielectric properties to prevent breakdown and
arcing between conductors
✓ semi-conductors - numerous devices
 Thermal Properties
Heat capacity, thermal expansion, and thermal
conductivity are properties that are often critical in
the practical utilization of solids.

• Heat Capacity:
A property that is indicative of a
material’s ability to absorb heat
from the external surroundings; it
represents the amount of energy
required to produce a unit
temperature rise
Thermal Properties
• Thermal Expansion:
The change in length with
temperature for a solid material.
Most solid materials expand upon
heating and contract when cooled

• Thermal Conductivity:
the phenomenon by which heat is
transported from high- to low-
temperature regions of a
substance. The property that
characterizes the ability of a
material to transfer heat is the
thermal conductivity
 Chemical Properties
• Oxidation and corrosion behavior, degradation
Material loss by corrosion can greatly affect the behavior of a component and
hence in a study of materials selection we should consider degradation behavior.
The extent of attack on metals by wet corrosion is difficult to quantify. It is
dependent on several factors such as microstructure, stress condition,
temperature and whether there are other metals in contact, as well as on the
type of environment
ANY QUESTIONS??

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