Introduction to Material Science and Engineering

Material Science

• Material science explores the relationship between a material's structure and its properties.

Materials Engineering

• Materials engineering designs the structure of a material to produce a set of properties.
• This design is based on structure-property correlations.

Materials Science and Engineering

• Materials science and engineering aims to understand the origins of material behavior.
• The goal is to optimize existing materials through structural changes and processing.
• Also seeks to design improved materials and investigate material failures.

Materials Development: Stone Age

• The Stone Age existed from the beginning of life until 3000 BC.
• Naturally occurring materials were used.
• Only changes in shape were made to these materials.

Materials Development: Bronze Age

• The Bronze Age existed from 3000 BC to 1200 BC.
• Copper and tin alloys were used.
• Materials could be modified through refining with heat, chemical changes (alloying), and cold working.

Materials Development: Iron Age

• The Iron Age began in 1200 BC and continues to the present.
• The mastery of steel enabled the Industrial Revolution in the 18th and 19th centuries.
• Materials can undergo heat treatment at high temperatures.
• Microstructure control occurs at different length scales
• It allows engineers to design specific microstructures for specific properties can be designed

Materials Development: Plastic Age

• The Plastic Age began in 1940 and continues to the present.
• Polymers were discovered and can be synthesized and processed.

Materials Development: Silicon Age

• The Silicon Age began in 1950 and continues to the present.
• Commercialization of silicon technology has led to the information age, boosting human productivity.
• Alloying can be controlled accurately.
• There is the ability to make thin films.

Materials Development: Future

• Nanotechnology involves the synthesis and characterization of nanomaterials and nanostructures.
• Biotechnology involves biomimetics and biomaterials.
• Energy/Environmental focuses on next-generation energy conversion.
• Information Technology focuses on materials informatics.

Types of Engineering Materials: Ferrous Metals

• Wrought iron is a soft, ductile, fibrous variety produced from a semifused mass of relatively pure iron globules surrounded by slag.
• Wrought iron is commonly used for fences, gates, railings, and other outdoor structures.
• Carbon steel is can have varying strength, hardness, and ductility based on the levels of carbon content.
• Carbon steel is divided into 3 types; low carbon, medium carbon and high carbon.
• Alloy steel is steel alloyed with elements such as molybdenum, manganese, nickel, chromium, vanadium, silicon, and boron.
• Alloy steel is frequently used for tools, vehicles, and building materials.
• Cast iron is a metal alloy made of iron, carbon, and silicon.
• Cast iron is commonly used for construction, cookware, and machinery.

Types of Engineering Materials: Non-Ferrous Metals

• Aluminum is a silvery-white, lightweight, soft, and malleable metal.
• Aluminum is commonly used for cans, foils, kitchen utensils, window frames, beer kegs and airplane parts.
• Copper is a pinkish-orange, soft, malleable, and ductile metal with very high thermal and electrical conductivity.
• Copper is commonly used for electrical generators, motors, wiring, and electronic goods.
• Lead is a silvery white or grayish metal that is very malleable, ductile, dense, and a poor conductor of electricity.
• Lead is commonly used for car batteries, pigments, ammunition, cable sheathing, weight belts for diving, lead crystal glass, and radiation protection.
• Silver is a soft, white, lustrous transition metal with the highest electrical conductivity, thermal conductivity, and reflectivity of any metal.
• Silver is commonly used for brazing, heavy-duty bearings, and electrical contacts.

Types of Engineering Materials: Polymers

• Phenol formaldehyde is a polymer with mechanical strength, thermal stability, and chemical resistance.
• It's commonly used in wood adhesives for plywood and particleboard.
• Polyvinyl chloride (PVC) is a synthetic polymer from the vinyl chloride monomer and is known for its durability, chemical resistance, and affordability.
• It is commonly used for piping, siding, wire and cable insulation, and windshield system components.
• Polyester resin is formed from the reaction of dibasic organic acids and polyhydric alcohols.
• It is commonly used for flat roofs, pipes, and storage tanks.
• Epoxy resin is made from monomers containing at least two epoxide groups.
• It provides strong adhesion and chemical resistance
• It is commonly used for metal coatings, composites, electronics, woodworks and structural adhesives
• Polythyne is one of the most commonly used plastics in the world and usually has a linear structure
• Which is known to be an addition polymer.
• It is commonly used for plastic bags, bottles, plastic films, containers, and geomembranes
• Acrylic resin is a type of resin synthesized from acrylic and methacrylic ester monomers with good UV and oxidative stability.
• It is commonly used for paints, coatings, plastic molding, lenses, medical implants, automotive finishes, and architectural coatings.

Types of Engineering Materials: Ceramics

• Refractories are heat-resistant engineered materials designed to withstand extreme temperatures in manufacturing and industrial processes.
• Refractories are commonly used for fired heaters, hydrogen reformers, ammonia primary and secondary reformers, cracking furnaces, utility boilers, catalytic cracking units, and air heaters.
• Abrasives are used to grind or cut away other softer materials.
• Hardness and wear resistance are important when designing abrasive materials.
• They're commonly used for grinding, polishing, buffing, honing, cutting, drilling, sharpening, lapping, and sanding.
• Glass is an inorganic solid material that is transparent or translucent, as well as hard, brittle, and not affected by natural elements.
• It's commonly used for window panels, tableware, and optics.
• Cement is a binder, a chemical substance for construction that sets, hardens, and adheres to other materials.
• It is commonly used for building materials, functional dinnerware, and decorative sculpture.

Composite Materials

• Composite materials combine two materials with different physical and chemical properties.
• This creates a material specialized for a certain purpose (e.g., to be stronger, lighter, or resistant to electricity).
• Composites can also improve strength and stiffness.
• Laminar composites are composed of two-dimensional sheets or panels (plies or laminae) bonded together and oriented to build strength, flexibility, or stiffness.
• Plywood and carbon fiber composites are examples.
• Fiber-reinforced composites (FRC) are hybrid materials of polymeric, metallic, or ceramic matrices in which high strength fibers are embedded or bonded.
• Carbon-fiber-reinforced polymers and metal matrix composites are examples.
• Particulate composites (PC) are characterized by particles suspended in a matrix, which can have any shape, size, or configuration.
• Concrete, particle board, and carbon-black-filled rubber are examples.

Biomaterial

• Biomaterials are natural or synthetic materials used in the body to treat, augment, or replace tissues, organs, or bodily functions.
• Examples include: heart valves, hip joint replacements, dental implants, or contact lenses.

Nanoengineered Material

• Nanoengineered materials are intentionally made to have dimensions of 1–100 nanometers.
• They are created by manipulating materials at the molecular level.
• Examples include carbon buckeyballs or fullerenes, carbon nanotubes, and metal oxide nanoparticles.

Engineering Materials Composition

• The composition of a material directly influences its properties.
• Engineers can predict and understand material behavior by knowing the arrangement of atoms.

Metals Definition

• Metals have a unique atomic structure with distinctive properties like malleability, ductility, electrical conductivity, and luster.

Metals: Crystal Lattice

• Metals have a crystalline structure where atoms are arranged in an orderly and repeating pattern.

Metals: Metallic Bonding

• Electrons are shared among all atoms, creating a cohesive and conductive structure.

Metals: Metallic Luster

• The arrangement of atoms in metals allows them to reflect light uniformly.

Metals: Ductility and Malleability

• Metals can be stretched into wires (ductility) and be shaped without breaking (malleability).

Metals: Electrical and Thermal Conductivity

• Electrons can move freely through the lattice and carry an electric current.
• This facilitates efficient thermal conductivity

Metals: Solid State

• Metals are typically found in a solid state at room temperature due to strong metallic bonding and exhibit a high melting point.

Polymers Definition

• Polymers are large molecules made up of long chains or networks of monomer units covalently bonded together.

Polymers: Monomer Units

• Polymers are formed by the repetition of smaller units called monomers.

Polymers: Stereochemistry

• The spatial arrangement of atoms in the polymer chain, known as stereochemistry, can affect the polymer's physical and chemical properties.

Polymers: Covalent Bonds

• Covalent bonds are bonds involve the sharing of electrons between adjacent atoms, providing stability to the polymer structure.

Polymers: Lack of Conductivity

• Polymers tend to lack electrical conductivity because of their unique molecular and structural characteristics

Polymers: Cross-Linking

• Polymers may exhibit cross-linking, where additional bonds form between polymer chains.

Polymers: Polymerization

• Polymerization involves the chemical reaction that links monomers together to form the polymer chain.

Ceramics Definition

• Ceramics are compounds composed of metallic and non-metallic elements.
• They often exhibit high melting points, hardness, and resistance to wear and corrosion.

Ceramics: High Coordination Number

• Atoms in ceramic crystals often have high coordination numbers, meaning each atom is surrounded by many neighboring atoms.

Ceramics: Cations and Anions

• In ionic ceramics, there are positively charged cations (metal ions) and negatively charged anions (non-metal ions).
• The arrangement of cations and anions in the crystal lattice contributes to the overall stability of the ceramic.

Ceramics: Ionic or Covalent Bonds

• Ionic bonds transfer electrons between a metal and a non-metal.
• Covalent bonds share electrons between non-metallic elements.

Ceramics: Thermal Stability

• Ceramics often exhibit high thermal stability and can withstand high temperatures without significant deformation.

Ceramics: Hardness and Brittleness

• Ceramics are known for their hardness and brittleness.
• This is due to the strong bonds and ordered structure.
• The lack of slip planes in the crystal lattice makes ceramics prone to fracture under stress.

Ceramics: Electrical Insulators

• Many ceramics are excellent electrical insulators because of the absence of free electrons for electrical conduction.

Chemical Bonding Types

• Ionic bonding
• Covalent bonding
• Metallic bonding

Chemical Bonding: Ionic Bonding

• Ionic bonds typically form between metals and nonmetals because of their electronegativity differences.
• Metals have low electronegativity and lose electrons.
• Nonmetals have higher electronegativity and readily accept electrons.

Chemical Bonding: Ionic Bonding Example

• Sodium has an electron configuration of 2, 8, 1 and wants to lose one electron to have a stable configuration of 2, 8.
• Chlorine has an electron configuration of 2, 8, 7 and wants to gain one electron to achieve a stable configuration of 2, 8, 8.
• The Na⁺ and Cl⁻ ions are oppositely charged, so they attract each other and form the ionic compound NaCl.

Chemical Bonding: Covalent Bonding

• Covalent bonding occurs when two atoms share electrons to achieve a stable electron configuration.
• They are typically between nonmetals.
• Covalent bonds involve the sharing of electrons to fill the outer electron shells of atoms, unlike ionic bonds where electrons are transferred.

Chemical Bonding: Covalent Bonding Example

• Methane (CH4) is molecule made up of one carbon (C) atom and four hydrogen (H) atoms.
• Carbon has 4 electrons in its outer shell and wants to gain 4 more to fill its outer shell to have 8 electrons, like the noble gases.
• Hydrogen has 1 electron in its outer shell and wants to gain 1 more electron to achieve 2 electrons, which is stable for hydrogen (similar to helium).

Chemical Bonding: Metallic Bonding

• Metallic bonding occurs between metal atoms.
• It involves the delocalization of electrons: these electrons are free to move throughout the entire metal structure, often called an "electron sea."
• Metallic bonding gives metals unique properties: conductivity, malleability, ductility, and strength.

Chemical Bonding: Metallic Bonding Example

• Aluminum (Al) exhibits metallic bonding and is silvery-white and lightweight
• It is often employed in products such as cans and aircraft components
• Like other metals, aluminum atoms are arranged in lattice structure where electrons form an electron ‘sea’ around metal ions