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Part1Introduction to Materials Science and Engineering:

Historical perspective and modern materials needs, taxonomy of materials, materials life cycle,

materials selection criteria and illustration, contribution of materials science and engineering indevelopment of technology.

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Why study materials sci. and eng.?

Range of materials associated with their characteristicsand application

Product development: materials selection and

manufacturing process design

Failure and degradation of components

Cost consideration in businesses and industry

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Why study materials sci. and eng.?

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Structural Typical

feature scale (m)

-------------------------------------------------------------------------Nuclear structure 10-15

Structure of atom 10-10

Crystal or glass structure 10-9

Structures of solutions and compounds 10-9

Structure of grain and phase boundaries 10-8

Shape of grains and phases 10-7to 10-3

Agregates of grains 10-5to 10-2Engineering structures 10-3to 103

Structure of Materials

Schematic picture of grain andphase structures in metallic alloys

The structure of a metal is defined by:

1. The constitution:

composition of the elements

number of phases, and composition of each phase

2. The geometric feature:

shape of each phase

sizes and spacing of the phases

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Synthesis /

processing

Properties

Structure /

composition

Empiricalknowledge

Scientificknowledge

Performance Societal needand experience

Basic scienceand understanding

Understanding Materials Science and Engineering

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Case in materials selection

Resistance to fracture toughnessDensity

Voyager aircraft made fromgraphite epoxy resin matrix

Broken ship madefrom brittle steels

Glass reinforced nylon(ZYTEL) air intake manifoldfor GM V-6 engines

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HISTORY OF MATERIALS

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Development of Engineering Materials(after Ashby 1992)

DATE (Year)10 000 BC 5000 BC 0 1000 1500 1800 1900 1940 1960 1980 1990 2000 2010 2020

METALS

POLYMERS,

ELASTOMERS

COMPOSITES

CERAMICS

Straw-brick paper

Gold Copper

Bronze

Iron

Cast Iron

Steels

Alloy Steels

Light Alloys

Super Alloys

Titanic

Zirconium

Etc

Alloys

Glassy Metal

Al - Lithium Alloys

Dual Phase Steels

Micro Alloyed Steels

New Super Alloys

Development Slow

Mostly Quality

Control and Processing

Wood

Skin

Fibers

Glues

Rubber

Bakelite

Nylon

P EPMA

PC PS

Arcrylics

PP

Exposies

Polyesters

High ModulusPolymers

High TemperaturePolymersStone

Flint

Pottery

Glass

Cement

RefractoriesPortland Cement

Fused

SilicaCerments Pyro-

Ceramics

Tough Engineering

ceramics (Al2O3,Si4,etc)

10 000 BC 5000 BC 0 1000 1500 1800 1900 1940 1960 1980 1990 2000 2010 2020

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Wood,stone Bronze Castiron Iron &steel Al alloy

Ti alloy

Composites

Aramid fibers,

carbon fibers

1800 1900 2000Year

Strength/density

(in

x

106)

Chronological advancesin strength-to-density ratio of materials

10

8

6

4

2

0

Example:

Development of Materials for Structural Application

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The Materials Cycle

RawMaterials

Bulk Materials EngineeringMaterials

Ground of Mineraland AgriculturalSciences andEngineering

Ground of MaterialsScience andEngineering

The Earth

Ore

OilWood

MineDrill

Harvest

Ore CoalSand Wood Oil

Rock Plants

ExtractRefine

Process

MetalsChemicals PaperCement Fibers

Process

*Crystals*Alloys * Ceramics*Plastics *Concrete

*Textiles

DesignManufactureAssembly

Performance

Service

UseWasteJunk

Recycle

DisposeStart

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Modern Materials Needs

Global Issues:1. Discovery of new aaditional reserves: depletion of non-renewable

resources (oil, metals)

2. New materials with less adverse environmental impact

3. New recycling technology

Materials for nuclear energy: fuels and containment for radioactive disposal.

Materials for transportation: new high strength, low density structural, high

temperature.

Materials for solar cells: economical resources. Materials for fuel cells: non-poluting, catalysts.

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Family of Materials*)

Group Subgroup Examples Group Sub Group ExamplesMetallic(metals and alloys) Ferrous Iron, Steel Metallic based Boron aluminium

Cast iron Primex

Nonferrous Al, Zn, Sn, Reinforced concrete

Cu, Ni Ceramic based CFCC

Powdered metal Sintered steel Cermet Tugsten carbide

Sintered brass Chrom. aluminia

Polymers Human-made Plastic Other Reinforced glass

ElastomersAdhesives Others Electronic mat. Semiconductors

Paper (advanced) Superconductors

Natural Wood, rubber Lubricant Graphite

Animal Bone, skin Fuels Coal, oil

Ceramics Crystalline Porcelain Protective- Anodised aluminiumcompound Structural clay coatings

Abrasives Biomaterials Carbon implantsGlass Glassware Smart materils Shape memory alloysAnnealed glass Shape memory polymer

Composites Polymer based PlywoodLaminated timberImpregnated woodFiberglassGraphite epoxy

Plastic laminates

*)J.A. Jaconbs, TF Kilduff,Eng. Mat. Tech. 2001

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Materials Characteristics:

Density

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Materials Characteristics:

Stiffnes

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Materials Characteristics:

Strength

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Materials Characteristics:

Resistance to Fracture

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Materials Characteristics METALS

Combinations of metallic elements Having large number of nonlocalized electrons Metal properties are attributable to electrons Good conductors of electricity and heat, not transparent to visible light

CERAMICS Compounds between metallic and nometallic elements: oxides, nitrides and carbides Ceramics: clay minerals, cement and glass Insulative to the passage of electricity and heat More resistant to high temperatures and harsh environments than metals and polymers Hard but brittle

POLYMERS Familiar plastic and rubber materials. Mainly organic compounds based on carbon, hydrogen, other nonmetallic elements Very large molecular structures, low density and may be extremely flexible.

COMPOSITES Compose of more than one materials types Fiberglass is a familiar example. Designed to display a combination of best characteristics of each the component materials: acquires strength from

glass and flexibility from the polymer SEMICONDUCTORS

Having electrical properties intermediate between the electrical conductors and insulators. Sensitive to the presence of impurities

BIOMATERIALS Components implanted into the human body for replacement of diseased of damaged body parts.

Not produce toxic substances Compatible with body tissues Can be metals, ceramics, polymers, composites, and semiconductors.

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The Golden Gate Bridge north of San Francisco, California, is one ofthe most famous and most beautiful examples of a steel bridge.

(Courtesy of Dr. Michael Meier.)

Materials in development of technology

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Copyright 2005 by Pearson Education, Inc.

Upper Saddle River, New Jersey 07458

All rights reserved.

James A. Jacobs and Thomas F. Kilduff

Engineering Materials Technology: Structures, Processing, Properties, and

Selection, 5e

The 1903 Flyer used conventional materials in

innovative ways. (Library of Congress DigitalImages)

Concept design of future spacecraft involving applicationof nanotechnology. (NASA Ames Research Center)

Materials in development of technology

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Kevlar reinforcement is a popular application in

modern high-performance tires. In this case, the

durability of sidewall reinforcement is tested along

concrete ridges at a proving ground track. (Courtesy of

the Goodyear Tire and Rubber Company.)

Materials in development of technology

Example of a fiberglass composite

composed of microscopic-scale

reinforcing glass fibers in a polymer

matrix. (Courtesy of Owens-Corning

Fiberglas Corporation.)

http://localhost/var/www/apps/conversion/tmp/scratch_1//upload.wikimedia.org/wikipedia/commons/0/09/Aramid_fiber2.jpg

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The modern integrated circuit fabrication

laboratory represents the state of the art

in materials processing. (Courtesy of the

College of Engineering, University of

California, Davis.)

Materials in development of technology

(a) Typical microcircuit containing a complex array ofsemiconducting regions. (Photograph courtesy of Intel

Corporation) (b) A microscopic cross section of a

single circuit element in (a). The dark rectangular

shape in the middle of the micrograph is a metal

component less than 50 nm wide. (Micrograph

courtesy of Intel Corporation)

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Motivation for materials selection and its criteria

Motivation

1. The introduction of a new product which consequently followed by

the requirement of suitable materials

2. A desire of the improvement of an existing product

3. A problem situation(such as: service or manufacturing failure, customer rejection)

Selection criteria

1. Define the application: what the material has to do when it is in service

2. Properties required: what the material should present its propertieswhen it is in service

3. Availability: whether the materials already commercially produced, or not.

4. Manufacturing method: the possibility to be industrially produced, and

5. Cost consideration

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EXERCISE:

Find out the requirements of materials to be used for

drink container and comes up with a choice of suitable

materials for this purpose