ME 2105 Introduction to Material Science (for Engineers)

B Met. Eng. University of Minnesota, 1970 Masters Studies, Met Eng. Colorado School of Mines, 1978-79 (Electro-Slag Welding of Heavy Section 2 Cr 1 Mo Steels) Ph.D., Ind. Eng. Penn State University, 1987 (Foundry Engineering CG Alloy Development)

Dr. Richard R. Lindeke, Ph.D.

Syllabus and Website:

Review the Syllabus

Attendance is your job come to class! Final is Common Time Thursday, Friday or Sat (Dec 17, 18 or 19) Semi-Pop Quizzes and homework/Chapter Reviews (Ch 14) (20% of your grade!) note, homework is suggested to prepare for quizzes and exams! Dont copy from others; dont plagiarize its just the right thing to do!!

Course Website: http://www.d.umn.edu/~rlindek1/ME2105/Cover_Page.h tm

Materials Science and Engineering

It all about the raw materials and how they are processed That is why we call it materials processing parameters can mean

ENGINEERING Minor differences in Raw materials or major changes in the performance

of the final material or product

Materials Science and Engineering

Materials Science

Materials Engineering

The discipline of investigating the relationships that exist between the structures and properties of materials.
The discipline of designing or engineering the structure of a material to produce a predetermined set of properties based on established structure-property correlation.

Four Major Components of Material Science and Engineering:

Structure of Materials Properties of Materials Processing of Materials Performance of Materials

And Remember: Materials Drive our Society!

Ages of Man we survive based on the materials we control

Stone Age naturally occurring materials

Bronze Age

Special rocks, skins, wood Casting and forging

Iron Age

Steel Age

High Temperature furnaces High Strength Alloys

Non-Ferrous and Polymer Age

Exotic Materials Age?

Aluminum, Titanium and Nickel (superalloys) aerospace Silicon Information Plastics and Composites food preservation, housing, aerospace and higher speeds Nano-Material and bio-Materials they are coming and then

A Timeline of Human Materials Control

And Formula One the future of automotive is

http://www.autofieldguide.com/articles/050701.html

Looking At CG Iron Alloy Development (Processing):

Looking At CG Iron Alloy Development (Processing):

CG Structure but with great care!

Good Structure 45KSI YS; 55KSI UTS Poor Too Little

Poor Too Much

Looking At CG Iron Alloy Development (Structures)

Looking At CG Iron Alloy Development (Results)

Our Text:
Introduction to Materials Science for Engineers By James F. Shackelford
Seventh Edition, Pearson/Prentice Hall, 2009.

Doing Materials!

Engineered Materials are a function of:

Raw Materials Elemental Control Processing History

Our Role in Engineering Materials then is to understand the application and specify the appropriate material to do the job as a function of:

Strength: yield and ultimate Ductility, flexibility Weight/density Working Environment Cost: Lifecycle expenses, Environmental impact*
* Economic and Environmental Factors often are the most important when making the final decision!

Introduction

List the Major Types of MATERIALS That You Know:

METALS CERAMICS/Glasses POLYMERS COMPOSITES ADVANCED MATERIALS( Nanomaterials, electronic materials)

Introduction, cont.

Metals

Polymers

Steel, Cast Iron, Aluminum, Copper, Titanium, many others Glass, Concrete, Brick, Alumina, Zirconia, SiN, SiC

Plastics, Wood, Cotton (rayon, nylon), glue Glass Fiberreinforced polymers, Carbon Fiberreinforced polymers, Metal Matrix Composites, etc.

Ceramics

Composites

Structural Steel in Use: The Golden Gate Bridge

Periodic Table of Elements: The Metals

Structural Ceramics

Periodic table ceramic compounds are a combination of one or more metallic elements (in light color) with one or more nonmetallic elements (in dark color).

Glasses: atomic-scale structure of (a) a ceramic (crystalline) and (b) a glass (noncrystalline)

Optical Properties of Ceramic are controlled by Grain Structure MAE 224: ENGINEERING MATERIALS

SINGLE CRYSTAL

POLYCRYSTAL POLYCRYSTAL + PORES

Figure 1.2 Alumina (Al2O3) single crystal and polycrystal

Grain Structure is a function of Solidification processing! 1.Introduction

19

Polymers are typically inexpensive and are characterized by ease of formation and adequate structural properties

Periodic table with the elements associated with commercial polymers in color

Composite Materials oh so many combinations

Fiber Glass Composite:

Thoughts about these fundamental Materials

Metals:

Strong, ductile high thermal & electrical conductivity opaque, reflective.

Ceramics: ionic bonding (refractory) compounds of metallic & non-metallic elements (oxides, carbides, nitrides, sulfides)

Brittle, glassy, elastic non-conducting (insulators)

Polymers/plastics: Covalent bonding sharing of es

Soft, ductile, low strength, low density thermal & electrical insulators Optically translucent or transparent.

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.

But:
6 00

Properties depend on Structure (strength or hardness)

(d)

Hardness (BHN)

5 00 4 00
(a) (b)

30 mm

(c)
4 mm 30 mm

3 00 2 00
30 mm

100 0.01 0.1

1 10 100 1000 Cooling Rate (C/s)

And:

Processing can change structure! (see above structure vs Cooling Rate)

Another Example: Rolling of Steel

At h1, L1

low UTS low YS high ductility round grains

At h2, L2

high UTS high YS low ductility elongated grains

Structure determines Properties but Processing determines Structure!

Electrical Properties (of Copper):

6
5
Resistivity, r
(10-8 Ohm-m)

4 3 2

Electrical Resistivity of Copper is affected by:

Contaminate level Degree of deformation Operating temperature

1
0 -200 -100 0
Adapted from Fig. 18.8, Callister 7e. (Fig. 18.8 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.)

T (C)

THERMAL Properties
Space Shuttle Tiles:
--Silica fiber insulation offers low heat conduction.

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. 19.4, Callister 7e. (Fig. 19.4 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.)

MAGNETIC Properties
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. 20.23, Callister 7e. (Fig. 20.23 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.

DETERIORATIVE Properties
Stress & Saltwater...
--causes cracks!
crack speed (m/s)

Heat treatment: slows

crack speed in salt water!
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 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:
Adapted from chapter-opening photograph, Chapter 17, Callister 7e. (from Marine Corrosion, Causes, and Prevention, John Wiley and Sons, Inc., 1975.)

4 mm

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

Adapted from Fig. 11.26, Callister 7e. (Fig. 11.26 provided courtesy of G.H. Narayanan and A.G. Miller, Boeing Commercial Airplane Company.)

Example of Materials Engineering Work Hip Implant

With age or certain illnesses joints deteriorate. Particularly those with large loads (such as hip).
Adapted from Fig. 22.25, Callister 7e.

Example Hip Implant

Requirements

mechanical strength (many cycles) good lubricity biocompatibility

Adapted from Fig. 22.24, Callister 7e.

Example Hip Implant

Adapted from Fig. 22.24, Callister 7e.

Solution Hip Implant

Key Problems to overcome:

Acetabular Cup and Liner Ball

fixation agent to hold acetabular cup cup lubrication material femoral stem fixing agent (glue) must avoid any debris in cup Must hold up in body chemistry Must be strong yet flexible

Femoral Stem

Course Goal is to make you aware of the importance of Material Selection by:
Using the right material for the job.

one that is most economical and Greenest when life cycle usage is considered properties, structure, and processing. by materials selection.

Understanding the relation between

Recognizing new design opportunities offered