DJJ3213- MATERIAL SCIENCE

Chapter 1 - Introduction

MOHD HAFIZ BIN ALI

JABATAN KEJURUTERAAN MEKANIKAL
POLITEKNIK KOTA KINABALU

1.1

FUNDAMENTAL OF MATERIAL SCIENCE

What is materials science?

Structure-properties
Applications

All fields make use of materials

Why should we know about it?

Materials drive our society
Stone Age
Bronze Age
Iron Age
Now?

Silicon Age?
Polymer Age?
Nano age

Example Hip Implant

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

3
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.

4

Example Hip Implant

5
Adapted from Fig. 22.26, Callister 7e.

Hip Implant
Ball

Key problems to overcome

fixation agent to hold

acetabular cup
cup lubrication material
femoral stem fixing agent
must avoid any debris in cup

Acetabular
Cup and Liner

Femoral
Stem
Adapted from chapter-opening
photograph, Chapter 22, Callister 7e.
6

Example Develop New Types of Polymers

Commodity plastics large volume

Ex. Polyethylene
Polypropylene
Polystyrene
etc.

Engineering Resins small volume

Ex. Polycarbonate
Nylon
Polysulfone
etc.

Can polypropylene be upgraded to properties (and

price) near those of engineering resins?

Structure, Processing, & Properties

Properties depend on structure

ex: hardness vs structure of steel

(d)

Hardness (BHN)

600
500
400

(c)
(a)

(b)
4 m

300
200

30 m

30 m

100
0.01 0.1

30 m

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 4e.
Micrographs adapted from (a) Fig.
11.19; (b) Fig. 10.34;(c) Fig. 11.34;
and (d) Fig. 11.22, Callister &
Rethwisch 4e.

1
10 100 1000
Cooling Rate (C/s)

Processing can change structure

ex: structure vs cooling rate of steel

The Materials Selection Process

1. Pick Application

Determine required Properties

Properties: mechanical, electrical, thermal,

magnetic, optical, deteriorative.

2. Properties

Identify candidate Material(s)

Material: structure, composition.

3. Material

Identify required Processing

Processing: changes structure and overall shape

ex: casting, sintering, vapor deposition, doping
forming, joining, annealing.
9

ELECTRICAL
Electrical Resistivity of Copper:
6

(10-8 Ohm-m)

Resistivity,

5
4
3
2
1
0

Cu

2
3.3

i
t %N

Ni
%
t
Ni
16 a
.
%
t
2
a
+
2
1
.
Cu
+1
u
C
d
e
i
rm
N
o
f
%
e
t
d
a
2
1
.
+1
u
C
Cu

e
r
Pu

-200

-100

Adapted from Fig. 12.8, Callister &

Rethwisch 4e. (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.)

T (C)

Adding impurity atoms to Cu increases resistivity.

Deforming Cu increases resistivity.

18

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.)

100 m

Thermal Conductivity
of Copper:
-- It decreases when
you add zinc!
Thermal Conductivity
(W/m-K)

Space Shuttle Tiles:

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

400
300
200
100
0

0
10 20 30 40
Composition (wt% Zinc)

Adapted from Fig. 17.4, Callister & Rethwisch

4e. (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.)
19

OPTICAL

Transmittance:
-- Aluminum oxide may be transparent, translucent, or
opaque depending on the materials structure (i.e.,
single crystal vs. polycrystal, and degree of porosity).
single crystal

polycrystal:
no porosity

polycrystal:
some porosity

Adapted from Fig. 1.2,

Callister & Rethwisch 4e.
(Specimen preparation,
P.A. Lessing; photo by S.
Tanner.)
20

DETERIORATIVE

Stress & Saltwater...

crack speed in salt water!

crack speed (m/s)

-- causes cracks!

Heat treatment: slows

Adapted from Fig. 16.21, Callister & Rethwisch

4e. (from Marine Corrosion, Causes, and
Prevention, John Wiley and Sons, Inc., 1975.)

10 -8

as-is
held at
160C for 1 hr
before testing

10 -10

Alloy 7178 tested in

saturated aqueous NaCl
solution at 23C

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.)

22

1.2 Types of Materials

1.2.1 Metals:

Strong, ductile
High thermal & electrical conductivity
Opaque, reflective.

1.2.2 Polymers/plastics:
Covalent bonding sharing of es
Soft, ductile, low strength, low density
Thermal & electrical insulators
Optically translucent or transparent.
1.2.3 Ceramics: ionic bonding (refractory) compounds of
metallic & non-metallic elements (oxides, carbides, nitrides,
sulfides)
Brittle, glassy, elastic
Non-conducting (insulators)
27

1.2.4 COMPOSITES

A Composite material is a material system

composed of two or more macro constituents
that differ in shape and chemical composition
and which are insoluble in each other. The
history of composite materials dates back to
early 20th century. In 1940, fiber glass was first
used to reinforce epoxy.
Applications:

Aerospace industry
Sporting Goods Industry
Automotive Industry
Home Appliance Industry

1. Why Composites are

Important

Composites

can be very strong and stiff, yet

very light in weight, so ratios
of
strengthtoweight and stiffnesstoweight are
several times greater than steel or aluminum
Fatigue properties are generally better than for
common engineering metals
Toughness is often greater too
Composites can be designed that do not
corrode like steel
Possible to achieve combinations of properties
not attainable with metals, ceramics, or
polymers alone

1. Disadvantages and Limitations

of Composite Materials

Properties of many important composites are

anisotropic the properties differ depending on

the direction in which they are measured this
may be an advantage or a disadvantage
Many of the polymerbased composites are
subject to attack by chemicals or solvents, just
as the polymers themselves are susceptible to
attack
Composite materials are generally expensive
Manufacturing methods for shaping composite
materials are often slow and costly

1. One Possible Classification of

Composite Materials

Traditional

composites composite materials

that occur in nature or have been produced by
civilizations for many years

Examples: wood, concrete, asphalt

Synthetic

composites - modern material

systems
normally
associated
with
the
manufacturing
industries,
in
which
the
components are first produced separately and
then combined in a controlled way to achieve
the desired structure, properties, and part
geometry

Advanced Aerospace
Application:
Lear Fan 2100 all-composite aircraft

Advanced Aerospace
Boeing
767 (and in 777, 787 airplanes w/ the latest, full wing box is composite):
Application:

Composite Benefits

CMCs: Increased toughness

Force

103

particle-reinf

un-reinf

10 -4
ss (s-1)
10 -6
10 -8
10 -10

metal/
metal alloys

.1 G=3E/8 polymers
.01 K=E
.1 .3 1 3 10 30
Density, [mg/m3]

Bend displacement

Increased
creep
resistance

ceramics

E(GPa)
PMCs
102
10

fiber-reinf

MMCs:

PMCs: Increased E/

6061 Al

6061 Al
w/SiC
whiskers

20 30 50

Adapted from T.G. Nieh, "Creep rupture of

a silicon-carbide reinforced aluminum
composite", Metall. Trans. A Vol. 15(1), pp.
139-146, 1984. Used with permission.

(MPa)
100 200

Composite Survey: Particle-I

Particle-reinforced
Examples:
- Spheroidite matrix:
ferrite ()
steel

Fiber-reinforced

(ductile)

60 m

- WC/Co
cemented
carbide

matrix:
cobalt
(ductile)
Vm :
5-12 vol%!

Structural
particles:
cementite
(Fe3 C)
(brittle)

Adapted from Fig.

10.19, Callister 7e.
(Fig. 10.19 is
copyright United
States Steel
Corporation, 1971.)

particles:
WC
(brittle,
hard)

Adapted from Fig.

16.4, Callister 7e.
(Fig. 16.4 is courtesy
Carboloy Systems,
Department, General
Electric Company.)

600 m

- Automobile matrix:
rubber
tires

particles:
C
(stiffer)

(compliant)
0.75 m

Adapted from Fig.

16.5, Callister 7e.
(Fig. 16.5 is courtesy
Goodyear Tire and
Rubber Company.)

1.2.5 ADVANCE MATERIALS

a. Biomaterials
A biomaterial is a nonviable material used in a

medical device, intended to interact with

biological systems.
Defined by their application NOT chemical makeup.

Characteristics of
Biomaterials

Chemical Requirements
Must not react with any tissue in the body.
Must be non-toxic to the body.
Long-term replacement must not be biodegradable.

Physical Requirements

Hard Materials.
Flexible Material.

Drug
Delivery
Devices

Polymers

Skin/cartila
ge
Ocular
implants
Bone
replacement
s

Orthopedic
screws/fixati
on

Metals

Dental
Implants

Implantable
Microelectr
odes

Synthetic
BIOMATERIALS

Semiconductor
Materials

Ceramics

Dental
Implants
Biosensors

Heart
valves

Biomaterial Science

b. Semiconductor
Low resistivity => conductor
High resistivity => insulator
Intermediate resistivity => semiconductor
conductivity lies between that of conductors and

insulators
generally crystalline in structure for IC devices

In recent years, however, non-crystalline semiconductors

have become commercially very important

polycrystalline amorphous crystalline

c. Nanoengineered materials
Nanoscale materials can have
properties that are unrealizable in
bulk materials

Making a material nanoscale

Melting temperature
Magnetization
Ability to hold charge

can change its

Structure
Chemical reactivity
among other

Chewy Chocolate

Chewing gum gets its

elasticity from polymers

Cocoa butter causes
those polymers to fall
apart
Choco'la Chewing Gum
uses nanoscale crystals
to incorporate the
creamier texture and
chocolate flavor into
chewing gum.
Sugar free
Five calories per piece

Cosmetics
Size
active ingredient
biodegradable shell

Pores
30,000 nm 50,000 nm

likes water
(hydrophillic)

10-100 nm

skin cells

Added bonus: At this size, suspensions are translucent!

$12.95

Buckyballs in Skin Cream

Zelens Fullerene C-60 Face Cream

Buckyballs have remarkable antioxidant

properties
$250/jar

Hitting a Home Run

Slugger-Easton Sports

Stealth CNT (carbon

nanotube) technology
The spaces between
fibers in ordinary carbon
fiber bats are filled with
resin
This bat has CNTs in the
resin for optimized flex,
responsiveness and more
"kick" through the hitting
zone
$175 and up

Stain Proof Fabric

Nano-Tex nano-enhanced clothing has

fibers with tiny whiskers aligned by
proprietary spines to

repel liquids
reduce static
resist stains
without affecting texture.
In May 2005, a group of
people stripped naked at
an Eddie Bauer store in
Chicago to protest the
sale of stain-resistant
nanopants

Improving Smelly Socks

19-nanometer antimicrobial silver
particles within their fibers.
A comfortable synthetic fiber sock
with permanent resistance to odor
and fungus.

Other Possible Advances

Wear-resistant tires made by combining
nanometer-scale particles of inorganic
clays with polymers
Environmentally friendly dyes and
pigments Nanometer-scale traps to remove
pollutants from the environment and
deactivate chemical warfare agents.
Computers with the capabilities of current
workstations will be the size of a grain of
sand and able to operate for decades with
the equivalent of a single wristwatch
battery.
Robotic spacecraft that weigh only a few
pounds will be sent out to explore the solar
system, and perhaps even the nearest

d. Smart materials
Smart materials are materials that have one
or more properties that can be significantly
altered in a controlled fashion by external
stimuli, such as stress, temperature, moisture,
pH, electric or magnetic fields.

What are the examples?

Piezoelectric materials
Shape memory alloys
Magnetic shape memory alloys
PH sensitive polymers
Halochromic materials
Chromogenic systems

Electrochromic

Flip a switch and an

electrochromic window can
change from clear to fully
darkened or any level of tint
in-between.
The action of an electric field
signals the change in the
window's optical and thermal
properties. Once the field is
reversed, the process is also
reversed. The windows
operate on a very low voltage
-- one to three volts -- and
only use energy to change
their condition, not to
maintain any particular state.

Thermochromic
Kettles that change colour
and signs that glow-in-thedark are two recent
examples of products
becoming smarter as a
result of new materials.
Colour-changing
thermochromic pigments are
now routinely made as inks
for paper and fabrics and
incorporated into injection
moulded plastics. A new
type of phosphorescent
pigment, capable of emitting
light for up to 10 hours, has
opened up entirely new
design opportunities for
instrumentation, low-level
lighting systems etc.

Warm

Cool

Photochromic

Photochromism is the reversible transformation of colour

upon exposure to light. This phenomenon is illustrated in
sun glasses.

THE END