AE 845: Advanced Materials in

Engineering
Course Objectives...
Elaborate on details of concepts in Materials
Science and Engineering

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

Chapter 1 - 1

LECTURES
Instructor: Dr. Mehr Nigar
Time: TBD!
Location: IAA Building, Room 104
Grading Policy:
Assignments
Mid-Term Exam*
End-Semester Exam

15-20%
25-30%
50-55%

*No Make-ups!
*Discuss potential conflicts beforehand.

Chapter 1 - 2

COURSE MATERIALS
Required text:
Materials Science and Engineering: An Introduction
W.D. Callister, Jr., 7th edition, John Wiley and Sons,
Inc. (2007).

Reference Material:

Engineering Materials I, Ashby and Jones,

Butterworth-Heinemann.
Engineering Materials II, Ashby and Jones
Butterworth-Heinemann.

Chapter 1 - 3

COURSE WEBSITES
Text Website: http://www.wiley.com/college/callister
Additional Chapters (Chapters 19-23)
Complete solutions to selected problems
Links to other web resources
Extended learning objectives
Self-assessment exercises

Chapter 1 - 4

LECTURE SCHEDULE
Week
1,2
3-4
4-5
6-7
8
9-10

Topic
General Intro; Atomic Bonding
Crystalline Structure; Imperfections
Diffusion; Mechanical Properties
Strengthening Mechanisms; Failure
Phase Diagrams
Kinetics & Phase Transformations
Processing & Applications of Metals
11 Struc., Prop., Proc., Applic. of Ceramics
12-13 Struc., Prop. of Polymers; Composites
14-15
Corrosion; Elec. & Thermal Prop.
16 Materials Selection; Econ. & Envir. Issues

Chapter
1,2
3,4
5,6
7,8
9
10
11
12,13
15,16
17,18,19*
22*,23*

Lectures: will highlight important portions of each chapter.

*These chapters available at website www.wiley.com/college/callister.
Chapter 1 - 5

Chapter 1 - Introduction
What is materials science?
Why should we know about it?
Materials drive our society
Stone Age
Bronze Age
Iron Age
Now?
Silicon Age?
Polymer Age?

Chapter 1 - 6

Example Hip Implant

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

Adapted from Fig. 22.25, Callister 7e.

Chapter 1 - 7

Example Hip Implant

Requirements
mechanical
strength (many
cycles)
good lubricity
biocompatibility

Adapted from Fig. 22.24, Callister 7e.

Chapter 1 - 8

Example Hip Implant

Adapted from Fig. 22.26, Callister 7e.

Chapter 1 - 9

Hip Implant
Key problems to overcome
fixation agent to hold
acetabular cup
cup lubrication material
femoral stem fixing agent
(glue)
must avoid any debris in cup

Ball

Acetabular
Cup and Liner

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

Chapter 1 - 10

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. 10.30(a)

and 10.32 with 4 wt% C composition,
and from Fig. 11.14 and associated
discussion, Callister 7e.
Micrographs adapted from (a) Fig.
10.19; (b) Fig. 9.30;(c) Fig. 10.33;
and (d) Fig. 10.21, Callister 7e.

1
10 100 1000
Cooling Rate (C/s)

Processing can change structure

ex: structure vs cooling rate of steel

Chapter 1 - 11

Types of Materials
Metals: Metallic bonding free electrons not attracted to any
one particular nucleus
Strong, ductile
high thermal & electrical conductivity
opaque, reflective.

Polymers/plastics: Covalent bonding sharing of es

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

Ceramics: ionic bonding (refractory) compounds of metallic

& non-metallic elements (oxides, carbides, nitrides, sulfides)
Brittle, glassy, elastic
non-conducting (insulators)

Chapter 1 - 12

Types of Materials

Chapter 1 - 13

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.

Chapter 1 - 14

The Materials Selection Process

Chapter 1 - 15

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
o
N
f
e
%
t
d
a
2
1
.
+1
u
C
Cu

e
r
Pu

-200

-100

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)

Adding impurity atoms to Cu increases resistivity.

Deforming Cu increases resistivity.
Chapter 1 - 16

THERMAL
Space Shuttle Tiles:

Thermal Conductivity
of Copper:

--Silica fiber insulation

offers low heat conduction.

Thermal Conductivity
(W/m-K)

Adapted from chapteropening photograph,

Chapter 19, Callister 7e.
(Courtesy of Lockheed
Missiles and Space
Company, Inc.)

--It decreases when

you add zinc!

100 m

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. 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.)
Chapter 1 - 17

OPTICAL
Transmittance:
--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 7e.
(Specimen preparation,
P.A. Lessing; photo by S.
Tanner.)

Chapter 1 - 18

DETERIORATIVE
Stress & Saltwater...

crack speed in salt water!

crack speed (m/s)

--causes cracks!

Heat treatment: slows

10-8

10-10

Adapted from chapter-opening photograph,

Chapter 17, Callister 7e.
(from Marine Corrosion, Causes, and
Prevention, John Wiley and Sons, Inc., 1975.)

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

--material:

4 m

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
Chapter 1 - 19
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.

Chapter 1 - 20