BDE1013 Materials and Processes - Non-Metals (2024-2025) PDF

BDE1013 – MATERIALS AND PROCESSES – NON-METALS THEORY (I7 + I8) – WINTER SEMESTER 2024-25 FRIDAY @ 14:00 – 15:50 Hrs Dr. S. BABU ASSISTANT PROFESSOR - SENIOR GRADE SCHOOL OF MECHANICAL ENGINEERING VELLORE INSTITUTE OF TECHNOLOGY...

BDE1013 – MATERIALS AND PROCESSES – NON-METALS THEORY (I7 + I8) – WINTER SEMESTER 2024-25 FRIDAY @ 14:00 – 15:50 Hrs Dr. S. BABU ASSISTANT PROFESSOR - SENIOR GRADE SCHOOL OF MECHANICAL ENGINEERING VELLORE INSTITUTE OF TECHNOLOGY, VELLORE EMAIL: [email protected] MOBILE: 9894891929  My Profile Dr. S. BABU Areas of interest: Assistant Professor - Senior Grade Department of Manufacturing Engineering School of Mechanical Engineering (SMEC) Materials Joining Vellore Institute of Technology and VELLORE – 632 014, India Additive Manufacturing Mobile: +91-9894891929 Email: [email protected] Post-Doc (Mechanical Engineering) Indian Institute of Technology Madras Ph.D (Mechanical Engineering) Indian Institute of Technology Madras M.S (Metallurgical and Materials Engineering) Indian Institute of Technology Madras B.E (Mechanical and Production Engineering) Annamalai University, Chidambaram No. of Publications in SCI International Journals – 30; Citations – 1300 Scopus ID: https://www.scopus.com/authid/detail.uri?authorId=56350599800 Dr. S. BABU 2 Dr. S. BABU 3 Dr. S. BABU 4 Dr. S. BABU 5 Dr. S. BABU 6  MODE OF EVALUATION (ETH) Internal Assessment – 30 marks Digital Assignment 1 – 10 marks Digital Assignment 2 – 10 marks Quiz (Viva voce) – 10 marks Continuous Assessment Test - 1 – 15 marks Continuous Assessment Test - 2 – 15 marks Final Assessment Test – 40 marks Dr. S. BABU 7 Lecture 1.0 – Introduction to Engineering Materials and Significance of Structure-Property Dr. S. BABU 8 Dr. S. BABU 9 Dr. S. BABU 10 Dr. S. BABU 11 Evolution of Plastics Dr. S. BABU 12  Plastics are "pliable and easily shaped," long chains of molecules found in nature and created synthetically.  Synthetic polymers, derived from petroleum, have revolutionized manufacturing due to their strength, lightness, and flexibility.  First synthetic plastic, invented in 1869 by John Wesley Hyatt, substituted ivory, while Leo Baekeland's 1907 Bakelite marked the first fully synthetic plastic.  World War II further boosted plastic production for military needs, and post-war consumerism solidified its place in daily life.  However, environmental and health concerns arose over plastic waste and chemical additives.  Despite these issues, plastics remain vital in modern life, prompting efforts to develop safer, more sustainable alternatives like bioplastics and improved recycling methods. Dr. S. BABU 13 Dr. S. BABU 14  Evolution of Rubber  Rubber is an elastic substance made either from the juice of particular tropical trees or artificially  1839: Charles Goodyear discovered vulcanization, making rubber durable and elastic. The invention of automobile transforming towns like Manaus, Brazil, into prosperous centers, with rubber barons.  1876: Henry Wickham exported rubber seeds to England, leading to thriving plantations in Ceylon and Malaya by 1895, which outcompeted Brazilian production.  World War II (1939-1945): Synthetic rubber development accelerated, making up 75% of the market by 1964.  1973: The OPEC oil embargo and the rise of radial tyres, requiring natural rubber, which holds 39% of market by 1993. Today, natural rubber remains crucial for auto and aircraft tyres, mostly sourced from Southeast Asia. Dr. S. BABU 15 Dr. S. BABU 16  Evolution of Glass  Glass is a non-crystalline, often transparent, amorphous solid that is formed by the rapid cooling of a molten form of silica (sand) or other similar minerals.  3500 BC: The earliest production of glass occurred in Mesopotamia and Egypt, creating small beads and objects.  I Century BC: Invention of glassblowing in the Roman Empire revolutionized glass production, enabling more complex shapes and wider availability.  1674: George Ravenscroft discovered lead glass (crystal) in England, significantly improving glass clarity and brilliance.  1903: Michael Owens invented the automatic bottle-blowing machine, drastically reducing costs and speeding up glass bottle production.  1959: The float glass process, developed by Sir Alastair Pilkington, allowed for mass production of high-quality flat glass, transforming the architecture and automotive industries. Dr. S. BABU 17  Materials Science Materials science combines with many areas of science and how materials science draws from chemistry, physics, and engineering to make better, more useful, and more economical and efficient stuff Materials Science – Investigating relationships that exist between the structure and properties of materials Materials Engineering is, on the basis of the structure-property correlations, designing or engineering the structure of a material to produce a pre-determined set of properties Materials science is an interdisciplinary field involving the properties of matter and its applications to various areas of science and engineering. Dr. S. BABU 18  Materials Engineering & Technology - Tetrahedron Materials Science and Engineering is an interdisciplinary field concerned with inventing new materials and improving the previously known or existing materials by developing a deeper understanding Structure – Property - Composition – Synthesis – Processing relationships Tetrahedron Details Composition Chemical make up of the material performance-to- Property Synthesis cost ratio Refers to how materials are made from naturally occurring / man-made chemicals (i.e.) ores composition synthesis and processing microstructure Dr. S. BABU 19  Tetrahedron Details Structure – Structure refers to the arrangement of a material's components from an atomic to a macro scale. Understanding the structure of a substance is key to understanding the state or condition of a material, information which is then correlated with the processing of the material in tandem with its properties., Macrostructure, Microstructure, Nanostructure, Crystal structure, Atomic structure Processing - refers to the way in which a material is achieved. Solidification Processing - Most metals are formed by creating an alloy in the molten state, where it is relatively easy to mix the components. This process is also utilized for glasses and some polymers Powder Processing - Powder processing involves consolidation, or packing, of particulate to form a `green body'. Densification follows, usually by sintering. Deposition Processing - Deposition processing modifies a surface chemically, usually by depositing a chemical vapor or ions onto a surface. It is used in semiconductor processing and for decorative or protective coating Deformation Processing - One of the most common processes is the deformation of a solid to create a desired shape. Dr. S. BABU 20  Tetrahedron Details Properties - Does a material need to be strong and heat-resistant, yet lightweight? Is it possible to bring all the properties in one single material? Whether you're talking about a fork or the space shuttle, products have specific requirements which necessitate the use of materials with unique properties Mechanical Properties: Tensile strength, fracture toughness, fatigue strength, creep strength, hardness, shock resistance Electrical Properties: Conductivity or resistivity, ionic conductivity, semiconductor conductivity (mobility of holes and electrons) Magnetic Properties: Magnetic susceptibility, Curie Temperature, Neel Temperature, saturation magnetization Optical and Dielectric Properties: Polarization, capacitance, permittivity, refractive index, absorption Thermal Properties: Coefficient of thermal expansion, heat capacity, thermal conductivity Environmental Related Properties: Corrosion behavior, wear behavior Dr. S. BABU 21 Tetrahedron Details – Application (Electronics) What are the relationships between the structure of polymers and their electrical properties? How can devices be made using these plastics? Will these devices be compatible with existing silicon chip technology? How robust are these devices? How will the performance and cost of these devices compare with traditional devices? These are just a few of the factors that engineers and scientists must consider during the development, design, Dr. S. BABU and manufacture of semiconducting polymer devices 22  Classification of Non-Metals 1. Polymers (plastics); 2. Glasses and Rubbers; 3. Ceramics; 4. Composite materials; and 5. Semiconductors. Dr. S. BABU 23  Polymers Polymers are typically organic materials. They have lower strength; but high strength to weight ratio. Not suitable for high temperature applications Many polymers have good resistance to corrosion and good electrical conductivity Polymers have thousands of applications ranging from bullet proof vests, compact discs, ropes and LCDs. Polymers are of two types – Thermosetting & Thermoplastics Dr. S. BABU 24  Polymers Thermoplastic polymers are Thermosetting polymers are normally normally produced in one step and produced and formed in the same step. then made into products in a Upon heating, thermosetting polymers subsequent process. will become soft, but cannot be shaped They become soft and formable when or formed to any great extent, and will heated. When cooled significantly definitely not flow. below their softening point they again These forms have very strong bonds become rigid and usable as a formed between the different chains. article. This makes it almost impossible for the This type of polymer can be readily chains to slide past each other and recycled because each time it is result in plastics that are both hard and reheated it can again be reshaped or brittle. formed into a new article Dr. S. BABU 25  Polymerization The process in which relatively small molecules, called monomers, combine chemically to produce a very large chain-like or network molecule, called a polymer. Dr. S. BABU 26 Dr. S. BABU 27  Vulcanization  A chemical process involving the heating of natural or synthetic rubber with sulfur or other curatives to create cross-links between polymer chains  It enhances elasticity, strength, durability, and resistance to heat, cold, and solvents  It results a less sticky, flexible, and resilient material suitable for various industrial and commercial applications.  Glass Blowing Gas blowing is a manufacturing process where a gas, usually nitrogen or carbon dioxide, is introduced into molten or semi-molten material to create a foamed structure. This results in lightweight, porous materials like foam rubber, plastics, and metals, with improved insulating, cushioning, or structural properties. Dr. S. BABU 29  Ceramics inorganic crystalline materials; naturally occurring materials Outstanding properties : Hard, brittle, high temperature resistance Ceramics are used in the substrates that houses computer chips, capacitors and spark plugs Some ceramics such as silicon based ceramic barrier coatings show great potential for use in advanced, higher efficiency engines Traditional ceramics are used to make bricks, refractories / abrasives Advanced ceramics offer higher strength, better wear & corrosion resistance, enhanced thermal shock Ceramics are used to make the cutting tools – Boron Carbide, Boron Nitride; Grinding Wheels – SiC, Alumina Structural clay products (bricks, sewer pipe, roofing and wall tile, flue linings, etc.) White-wares (dinnerware, floor and wall tile, electrical porcelain, etc.) Refractories (brick and monolithic products used in metal, glass, cements, ceramics, energy conversion, petroleum, and chemicals industries Dr. S. BABU 30  Ceramics and Advanced Ceramics Glasses (flat glass (windows), container glass (bottles), pressed and blown glass (dinnerware), glass fibers (home insulation), and advanced/specialty glass (optical fibers)) Abrasives (natural garnet, diamond, etc.) and synthetic abrasives (silicon carbide, diamond, fused alumina, etc.) are used for grinding, cutting, polishing, lapping, or pressure blasting of materials) Cements (for roads, bridges, buildings, dams, and etc.) Advanced ceramics Structural (wear resistant parts, cutting tools, and engine components) Electrical (capacitors, insulators, substrates, integrated circuit packages, piezo-electrics, magnets and superconductors) Coatings (engine components, cutting tools, and industrial wear parts) Dr. S. BABU 31  Composites Blending different properties of the material so as to get a single material with unique properties Composite material may be defined as 2 or more materials (phases/constituents) integrated to form a newer one The individual materials that make up composites are called constituents. Most composites have two constituent materials: a binder or matrix, and a reinforcement. The reinforcement is usually much stronger and stiffer than the matrix, and gives the composite its good properties. A common example of a composite is concrete. It consists of a binder (cement) and a reinforcement (gravel). Adding another reinforcement (rebar) transforms concrete into a three-phase composite. The matrix holds the reinforcements in an orderly pattern. Because the reinforcements are usually discontinuous, the matrix also helps to transfer load among the reinforcements; Reinforcements basically come in three forms: particulate, discontinuous fiber, and continuous fiber. Dr. S. BABU 32  Composites Reinforcement Matrix and Reinforcements: Matrix materials: Polymers, Metals, Ceramics and Matrix Reinforcement: Fibers, Glass, Carbon, Organic Boron, Ceramic, Metallic Dr. S. BABU 33  Composites Glass reinforced composites are the most desired materials as a result of advanced technology that has gone beyond the design and application Graphite is a widely available economical reinforcement material with high stiffness, high modulus, high strength and high theoretical efficiency The first structural composite aircraft components, which were introduced during 1950-60, were made from glass fibre reinforced plastics. These components included the fin and the rudder of Grumman E-2A, helicopter canopies, frames, radomes, fairings, rotor blades, etc. Due to high strength and stiffness combined with low density, composites like Boron Fibre Reinforced Plastics (BFRP) and Carbon Fibre Reinforced Plastics (CFRP) were preferred instead of aluminium for high performance aircraft structures. For lightly loaded structures, Aramid Fibre Reinforced Plastics (AFRP) which possess low density, have been used in versatile applications Dr. S. BABU 34  Semiconductors relatively small group of elements and compounds has an important electrical property, semi-conduction, in which they are neither good electrical conductors nor good electrical insulators. Instead, their ability to conduct electricity is intermediate. These materials are called semiconductors, and in general, they do not fit into any of the four structural materials categories based on atomic bonding. Si, Ge, GaAs are the best examples for Semiconductors Dr. S. BABU 35