Material Science

Len Bin Annuar Rigos

Mechanical Engineering Dept
 Material Science
SYNOPSIS
MATERIAL SCIENCE provides students
with an understanding of material science
and engineering which emphasizes on
atomic and crystal structure, material
properties and behavior including material
classification and its application in the
engineering field.

The topic also covers the processes of

metal work used to produce engineering
components and apply basic principles of
material testing and processing through
practical.
Summary
(30 LECTURE : 30 PRACTICAL)
TOPIC 1 INTRODUCTION TO MATERIAL SCIENCE

TOPIC 2 MATERIAL STRUCTURE AND BONDING

TOPIC 3 MATERIAL PROPERTIES AND BEHAVIOUR

TOPIC 4 SOLID SOLUTION AND EQUILIBRIUM PHASE DIAGRAM

Summary
(30 LECTURE : 30 PRACTICAL)
TOPIC 5 METAL ALLOYS

TOPIC 6 MATERIAL PROCESSING

TOPIC 7 HEAT TREATMENT

TOPIC 8 MATERIAL TESTING

 UNIT 5 METAL ALLOYS
This topic describes the characteristics and application of ferrous
alloys and non ferrous alloys. It also explains the electrochemical
corrosion phenomenon includes the differences between the type of
corrosion and their remedial action to metal alloys.

On successful completion of the unit the student will be able to:

• Differentiate between ferrous and nonferrous alloys
• List the ferrous alloys metals
• Describe the characteristics and application of nonferrous alloy
materials
• Identify the basic principle of corrosion
METAL ALLOYS
Metals
All metals can be classified as either Ferrous or Non-
ferrous.

Ferrous
• These are metals which contain iron.
• They may have small amounts of other metals or other
elements added, to give the required properties.
• All ferrous metals are magnetic and give little
resistance to corrosion.
Non-Ferrous Metals

These are metals which do not contain any iron. They

are not magnetic and are usually more resistant to
corrosion than ferrous metals.

Examples are: aluminium, copper, lead, zinc and tin.

Aluminium
Composition: Pure Metal
Properties : Greyish-White, soft, malleable, conductive
to heat and electricity, It is corrosion resistant.
Applications: Aircraft, boats, window frames,
packaging and insulation, pistons and cranks.
 Aluminium alloys (Duralumin)

• Duralumin, strong, hard, lightweight alloy of aluminium, widely used

in aircraft construction, discovered in 1906 and patented in 1909 by
Alfred Wilm, a German metallurgist.

• Aluminium alloys (Duralumin)is composed of Aluminium, Copper

and Manganese.

• Its also Ductile, Malleable, Work Hardens.

• It is used in the manufacturing of aircrafts and vehicle parts.

Aluminium foil.

Aluminium and its

alloys used in
aircraft.
Aluminium metal
cover.

Aluminium can
products.
Copper
Composition: Pure metal
Properties : Red, tough, ductile, High electrical
conductor, corrosion resistant, Can work hard or
cold.
Applications: Electrical wire, cables and
conductors, water and central heating pipes and
cylinders.
Copper Tube for
Heating
Application &
Solar Panels.

Copper Tube for

Electrical
Engineering.
Copper Tube for
Gas.

Copper Tube for

Medical Gas.
 Brass

• Another important non ferrous metal is Brass which is not a pure

metal but combination of Copper and Zinc.

• It contains 65% copper and 35% Zinc.

• It is harder than copper and its good electrical conductor.

Main properties of titanium:

 High strength to weight ratio.

 High melting temperature(1670c)
 Low density.
 High creep and corrosion resistance.
 Biocompatible (non-toxic and it is not rejected by the body).
 silvery grey-white metallic.

This metal is a very applicable material for many uses.

Titanium applications generally are
classified into several main groups :

 Aerospace Applications: such as

engines and airframes.

 Chemical Processing: Many

chemical processing operations specify
titanium to increase equipment lifetime.

 Petroleum: In petroleum exploration

and production, flexible titanium pipe's
light weight, makes it an excellent
material for deep sea production risers.

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 Automotive applications:
Particularly in motorcycling racing,
This area is extremely challenging
because of its cost sensitivity.

 Consumer products: such as

spectacle frames; cameras;
watches; jewelries and various
kinds of sporting goods.

 Biomedical field: Such as surgical

implements and implants.

 Architectural applications: Such

as exterior walls and roofing
materials.
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Aluminium and Titanium resist corrosion as they have a very thin
layer of their oxides on the surface, which stops air and water getting
to the metal.
 Aluminum Calcium Antimony
Zinc Manganese Osmium
Copper Molybdenum Rhodium
Lanthum Indium
Lead Barium Palladium
Chromium Bismuth Silver
Lithium Cobalt Gold
Vandium Niobium Cadmium
Ruthenium Nickel Thallium
Zirconium Hafnium
Beryllium Gallium Titanium
Titanium Yttrium Tin
Sodium Rubidium Platinum
Magnesium Strontium Tungsten
Scandium Cesium Iridium
Technetium Rhenium
Potassium
 Definition

• Corrosion can be defined as the destructive attack of a

metal through interaction with its environment.

• Corrosion is the deterioration of materials by chemical

interaction with their environment.
 INTRODUCTION

• The term corrosion is sometimes also applied to the degradation

of plastics, concrete and wood, but generally refers to metals.

• Most metals corrode on contact with water (and moisture in the

air), acids, salts and gaseous materials.

*Degradation: reduction in performance of component during lifetime.

 loss of cross-
sectional
reduced value area
of goods
produce
rusting

CORROSION
EFFECT

lost surface reduced

properties strength
downtime of
equipment
1 2
• Dry corrosion generally takes place in high temperatures.

• Wet corrosion generally occurs when there is water present,

especially when the metal is exposed to a water solution.
 DRY CORROSION
(OXIDATION REDUCTION REACTION )

• Single metal react with environment (Direct combination of a

metal with oxygen).

• Dry corrosion occurs when oxygen in the air reacts with metal
without the presence of a liquid.
• When a piece of iron reacts with air it forms Iron oxide.

Particularly if it is heated.
• This process is called Oxidation
• When an atom or ion loses electrons it is said to have been
oxidized  corrode
• Iron has been oxidised to iron oxide.
 The equation :
2Fe + O2 -----2 FeO

• The reaction between metal and oxygen (atmosphere) at elevated

temperatures in perfectly dry conditions.

• The metal loses electrons to form an ion and some free electrons.
The ionic metal can then react with oxygen to form a metal oxide.
 2Fe + O2 -----2 FeO

• All metallic materials react with oxygen at high temperatures.

• As the temperature increases, the OXIDATION resistance of

materials decreases.
 WET CORROSION
(ELECTROCHEMICAL REACTIONS)

Also called galvanic corrosion;

• Occurs when two metals with different electrode potential is

connected in a corrosive electrolytic environment.

• It will occur if an “electrochemical cell” is produced.

• An electrochemical cell consists of an Anode, a Cathode, a

Connection, and an Electrolyte.
• The anode is the metal that
corrodes. It undergoes
oxidation and therefore loses
electrons.

• The cathode can be a metal or

any other conducting material.
It undergoes reduction and
therefore gains electrons.

• Wet corrosion therefore

involves an oxidation
reaction at the anode and a
reduction reaction at the
cathode.
GALVANIC CORROSION: ELECTRODE
POTENTIAL
• Anode metal is more corrosive to the cathode metal in electrolyte
environment.

• If you have two metals in contact, with an electrolyte present, how do you
determine which metal will corrode?.....
 Types of corrosion
Uniform Corrosion Pitting Corrosion Crevice Corrosion
• The metal loss is • The metal loss is • Occurs at places with
uniform from the randomly located on gaskets, bolts and lap
surface. the metal surface. joints where crevice
• Corrosion over the • A form of extremely exists.
entire exposed localized attack • Crevice corrosion
surface at a uniform causing holes in the creates pits similar to
rate. metal pitting corrosion.
 Types of corrosion
Stress Corrosion Intergranular Corrosion
Concentration
Cracking • Intergranular corrosion is
Corrosion an attack on or adjacent to
• Caused by the
• Occurs when two or the grain boundaries of a
simultaneous effects metal or alloy.
more areas of a metal
of tensile stress and a
surface are in contact
specific corrosive
with different
environment.
concentrations of the
same solution. • due to applied loads,
residual stresses.
 Protective
Cathode and Coatings
Anode • Metallic
Protection • Non metallic

CORROSION
REMEDIAL
ACTION

Material
Design
selection
 DESIGN DO’S & DONT’S
• Avoid excessive mechanical stresses and stress concentrations in
components exposed to corrosive mediums.

• Avoid galvanic contact / electrical contact between dissimilar metals

to prevent galvanic corrosion.

• Avoid sharp bends in piping systems when high velocities and/or

solid in suspension are involved – erosion corrosion.
 DESIGN DO’S & DONT’S

• Avoid crevices – e.g weld rather than rivet tanks and other
containers, proper trimming of gasket, etc.

• Avoid sharp corners – paint tends to be thinner at sharp corners

and often starts to fail.

• Provide for easy drainage – avoid remaining liquids collect at

bottom.
Avoid angles and pockets in which
water can collect.

Instead, use a shape that

promotes draining.
 PROTECTIVE COATINGS
• Surface modification – to structure or composition by use of directed
energy or particle beams.

• Inorganic coating : cement coatings, glass coatings, ceramic

coatings, chemical conversion coatings.

• Chemical conversion – anodizing, oxide coating, chromate.

• Organic coating : paints, lacquers, varnishes. Coating liquid

generally consists of solvent, resin and pigment. The resin provides
chemical and corrosion resistance, and pigments may also have
corrosion inhibition functions.
CATHODIC PROTECTION
TERMS YOU SHOULD REMEMBER:

• nonferrous alloys
• Corrosion
• Dry Corrosion
• Wet Corrosion
LEN BIN ANNUAR RIGOS
MECHANICAL ENGINEERING DEPARTMENT