MAE 301: Engineering Materials Science

Introduction to Engineering Materials Science

Introduction Engineering 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
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Introduction to Engineering Materials Science

Materials drive our society
Materials are probably more deeply rooted in our society than most realize (e.g. electronics, communication, aerospace/transportation, housing, etc) The development of many technologies have been intimately associated with accessibility to new materials.

Materials Make Technology Possible

Examples:
Automobile Industry Steel (including high-strength steels) Aluminum Plastics, rubber Glass Copper Iron Magnesium Composite materials
These materials are used to create everything from those small things we don't think about, such as dashboard needles and wiring, to the big stuff, such as the engine block or the transmission gears.

Materials Drive our Society

Transportation by Sea and Rail High-strength alloy steels are used for Submarine hulls Steel and Aluminum are used in building Passenger Ships Nickel, Aluminum, Bronze alloys are used for marine Propellers High strength steel alloys, Aluminum, Carbon fiber, and PVCrelated Plastics are used in High Speed Rail

Materials Make Technology Possible

Aerospace Industry: Aerospace materials must be lightweight and strong. Commercial Airplanes are mostly built using Aluminum Alloys. Newer planes are built with some Composite Materials. Jet engines often use Titanium. Some military aircraft use Titanium for structural and body pieces.

Special Ceramics are used for the heat shield of the space shuttle

Al-Li alloys are used in jetliner airframes. They are superior to aluminum alloys in strength and stiffness, so can be used to save weight. But they are ~ 3x as expensive.

Materials in Sports Equipment

Sports equipment uses almost advanced metal alloys, ceramics, polymers, and composites, as athletes and designers leverage state-of-the-art materials to maximize human efficiency, performance, comfort and safety.

Materials in Biomedical Engineering

Prosthetic devices often need to be lightweight. They are typically made from Polymeric materials (polyethylene, polypropylene, acrylics, and polyurethane ), Lightweight metals alloys of titanium and aluminum, and Composites (such as carbon fiber reinforced composites).

Example Hip Implant

With age or certain illnesses joints deteriorate, particularly joints with large loads (such as hip).

Adapted from Fig. 22.25, Callister 7e.

X-Rays of a normal hip joint (left) and a fractured hip joint (right). The arrows show the two ends of the fracture line through the femoral neck.

Materials for Hip Implant

Materials Requirements mechanical strength (many cycles) good lubricity Biocompatibility lightweight components Reasonable cost

Adapted from Fig. 22.24, Callister 7e.

Hip Implant

(a) Schematic diagram andAdapted (b) x-ray of an artificial total hip replacement. from Fig. 22.26, Callister 7e.

Hip Implant
Key problems to overcome
fixation agent to hold acetabular cup cup lubrication material femoral stem fixing agent must avoid any debris in cup Femoral Stem
Adapted from chapter-opening photograph, Chapter 22, Callister 7e.

Ball

Acetabular Cup and Liner

Hip Implant Materials

Femoral Stem: Materials used include:

Stainless steel, 316L (Cold worked)

Titanium-aluminum-vanadium Alloy, Ti-6Al-4V, (Hot Forged) Cobalt-chromium-molybdenum Alloy, Co-28Cr-6Mo, (Cast) Ball Component: Materials used include high-purity, polycrystalline aluminum oxide or zirconium oxide. These ceramic materials are harder and more wear resistant than metals, and generate lower frictional stresses at the joint.

Hip Implant Materials

Acetabular Cup: The inner-cup is often made from ultra-high molecular weight polyethylene, which is virtually inert in the body and has excellent wear resistance, and a low coefficient of friction with the ball material. The outer cup is fabricated from one of the metal alloys used for the femoral stem.
Fixation Agent: The most common is polymethyl methacrylate (acrylic) bone cement.

Hip Implant Example

Hip Implant Example illustrated the need for tailor-made materials for this human need. The solution required:
Knowledge of the responses of the various materials (e.g.Ti-6Al4V, Al2O3, ZrO2, polyethylene, etc.) when exposed to external stimuli (properties). Knowledge of the effect of alloying elements and fabrication processes (casting, forging, cold working,..) on the internal makeup of the material (material structures).

Materials Science and Engineering

The ability to fashion materials to fit a wide variety of needs is a capability unique to our modern society. Early Metallurgy
Used metals like Copper, Tin, Silver, Iron Understood that material properties could be altered by alloying and heat treatment

Modern Materials Science

Involves the relationships between the underlying structures of materials and the resultant properties This knowledge allows materials to be tailor-made for a variety of needs.

Materials Science and Engineering

Materials science
Involves investigating the relationship between the structures of materials and their properties

Materials Engineering
Engineering the structures of materials to produce a predetermined set of properties

Material Structures
This is the arrangement of the internal components of a material:
Subatomic structure: involve the electrons within the individual atoms and interactions with their nuclei Atomic level Structure: the organization of atoms or molecules with respect to one another Microscopic Structure: large groups of atoms that are agglomerated together Macroscopic Structure: Structural elements that can be viewed with the naked eys

Material Structures

Sub-Atomic Structure

Atomic Structure

Microstructure

Macrostructure

Common Material Properties

Mechanical (deformation resulting from an applied load)

Electrical (e.g. Electrical Conductivity)

Thermal (Thermal conductivity, heat capacity) Magnetic (Response to a magnetic field) Optical (Response to an electromagnetic field. e.g. reflection, transmission, refractive index) Deteriorative (Corrosion, Response to chemical activity)

Processing, Structure, Properties, & Performance

Processing Structure

Properties

Performance

Goal: To tailor-make/design materials with precise properties.

Structure-Property Relationships
Properties depend on structure
ex: hardness vs structure of steel
6 00
(d)
30 mm

Hardness (BHN)

5 00 4 00
(a) (b)

(c)
4 mm 30 mm
Data obtained from Figs. 11.31(a) and 11.33 with 4 wt% C composition, and from Fig. 14.8 and associated discussion, Callister & Rethwisch 3e. Micrographs adapted from (a) Fig. 11.19; (b) Fig. 10.34;(c) Fig. 11.34; and (d) Fig. 11.22, Callister & Rethwisch 3e.

3 00 2 00
30 mm

100 0.01 0.1

1 10 100 1000 Cooling Rate (C/s)

Processing can change structure

ex: structure vs cooling rate of steel

 Metals:

Types of Materials

Composed of one or more metallic elements Strong, ductile, High thermal & electrical conductivity Opaque, reflective.

Ceramics: compounds of metallic & nonmetallic elements (oxides,

carbides, nitrides, sulfides).

Stiff and strong (similar to metals). High temperature resistant. Very hard, extremely brittle, Non-conducting (insulators)

Polymers:
Very large molecular structures based on C, H, and nonmetals Soft, ductile, low strength, low density, translucent or transparent Thermal & electrical insulators, chemically inert Composites: Composed of two or more individual materials (metals, ceramics, or polymers), with a combination of properties not displayed by any single material.

Metals

Typical Metal Items

Examples of Ceramics
Silicon nitride (Si3N4) ceramics have good shock resistance compared to other ceramics. Si3N4 ball bearings are used in the main engines of the Space Shuttle. They are harder than metal have 80% less friction; last 3 to 10 times longer; operate at 80% higher speed; weigh 60% less; operate with lubrication starvation; have higher corrosion resistance higher operation temperature, compared to metal bearings.

Silicon Nitride Items

Typical Ceramic Items

Polymers
Two main types of polymers are thermosets and thermoplastics. Thermosets are cross-linked polymers that form 3-D networks, hence are strong and rigid. Thermoplastics are long-chain polymers that slide easily past one another when heated, hence, they tend to be easy to form, bend, and break.

Typical Polymeric Items

Materials Selection
Engineers will at one time or another have to make design decisions involving materials. Many time a materials problem is one of selecting the right material for the design from a many alternatives Rarely does a material possess the ideal combination of properties, and trade-off are necessary. A material may have the ideal combination of properties but may be expensiveand compromise is necessary.

The Materials Selection Process

1. Pick Application
Determine required Properties
Properties: mechanical, electrical, thermal, magnetic, optical, deteriorative.

2. Properties 3. Material

Identify candidate Material(s)

Material: structure, composition.

Identify required Processing

Processing: changes structure and overall shape ex: casting, sintering, vapor deposition, doping forming, joining, annealing.

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 Electrical Resistivity of Copper:

6 5

ELECTRICAL
Adapted from Fig. 12.8, Callister & Rethwisch 3e. (Fig. 12.8 adapted from: J.O. Linde, Ann Physik 5, 219 (1932); and C.A. Wert and R.M. Thomson, Physics of Solids, 2nd edition, McGraw-Hill Company, New York, 1970.)

Resistivity, r

(10-8 Ohm-m)

4 3 2 1

-200

-100

T (C)

Adding impurity atoms to Cu increases resistivity. Deforming Cu increases resistivity.

 Space Shuttle Tiles:

THERMAL

-- Silica fiber insulation offers low heat conduction.

Adapted from chapteropening photograph, Chapter 17, Callister & Rethwisch 3e. (Courtesy of Lockheed Missiles and Space Company, Inc.)

Thermal Conductivity of Copper:

-- It decreases when you add zinc!
Thermal Conductivity (W/m-K) 400 300 200 100 0 0 10 20 30 40 Composition (wt% Zinc)

100 mm

Adapted from Fig. 19.4W, Callister 6e. (Courtesy of Lockheed Aerospace Ceramics Systems, Sunnyvale, CA) (Note: "W" denotes fig. is on CD-ROM.)

Adapted from Fig. 17.4, Callister & Rethwisch 3e. (Fig. 17.4 is adapted from Metals Handbook: Properties and Selection: Nonferrous alloys and Pure Metals, Vol. 2, 9th ed., H. Baker, (Managing Editor), American Society for Metals, 1979, p. 315.) 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!
Magnetization Fe+3%Si Fe

Magnetic Field
Fig. 18.23, Callister & Rethwisch 3e. (Fig. 18.23 is from J.U. Lemke, MRS Bulletin, Vol. XV, No. 3, p. 31, 1990.) Adapted from C.R. Barrett, W.D. Nix, and A.S. Tetelman, The Principles of Engineering Materials, Fig. 1-7(a), p. 9, 1973. Electronically reproduced by permission of Pearson Education, Inc., Upper Saddle River, New Jersey.

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 Transmittance:

Example: Optical Properties of Aluminum Oxide

-- Aluminum oxide may be transparent, translucent, or opaque depending on the material structure.
single crystal polycrystal: low porosity polycrystal: high porosity

Adapted from Fig. 1.2, Callister & Rethwisch 3e. (Specimen preparation, P.A. Lessing; photo by S. Tanner.)

DETERIORATIVE
Stress & Saltwater...
-- causes cracks!

Heat treatment: slows

crack speed in salt water!
crack speed (m/s)
10-8 as-is held at 160C for 1 hr before testing
Alloy 7178 tested in saturated aqueous NaCl solution at 23C

10-10

increasing load

Adapted from chapter-opening photograph, Chapter 16, Callister & Rethwisch 3e. (from Marine Corrosion, Causes, and Prevention, John Wiley and Sons, Inc., 1975.)

Adapted from Fig. 11.20(b), R.W. Hertzberg, "Deformation and Fracture Mechanics of Engineering Materials" (4th ed.), p. 505, John Wiley and Sons, 1996. (Original source: Markus O. Speidel, Brown Boveri Co.)

-- material:
7150-T651 Al "alloy" (Zn,Cu,Mg,Zr)

4 mm

Adapted from chapter-opening photograph, Chapter 11, Callister & Rethwisch 3e. (Provided courtesy of G.H. Narayanan and A.G. Miller, Boeing Commercial Airplane Company.)

SUMMARY
Course Goals:
Use the right material for the job. Understand the relation between properties, structure, and processing. Recognize new design opportunities offered by materials selection.

Review Assignment
Chapter 1 Question 1.1

Reading Assignment
Chapter 2.1 2.8 Atomic Structures Interatomic Bonding Forces and Energies Primary and Secondary Bonds