Materials Science and Engineering PDF

ARAB ACADEMY FOR SCIENCE, TECHNOLOGY AND MARITIME TRANSPORT [Sheraton Branch - Cairo] Material Science (EME2701=60 , (ME274=50)...

ARAB ACADEMY FOR SCIENCE, TECHNOLOGY AND MARITIME TRANSPORT [Sheraton Branch - Cairo] Material Science (EME2701=60 , (ME274=50) By Ass. Prof. Dr. / Waled Mohamed B. Sc. : Mech. Eng. 1994-EGYPT M. Sc.: Mechanical behaviour and corrosion of stainless steel alloys, 2000, EGYPT PhD : Advanced Joining Technology , 2010-Calgary, CANADA E-mail: [email protected] , Phone no: 01112078637 Provided by : Mechanical Engineering Department Course for : Mechatronics Engineering – Power Engineering 1  Course Evaluation Item Mark Semester Work 10 7th Week evaluation 30 12th Week evaluation 20 Total Course work 60 Final Written Exam 40 Total 100 2  Textbooks 1. William D. Callister, “Materials Science and Engineering: An Introduction”, 9th Ed, Book, John Wiley & Sons, Inc, USA, 2014 2. Donald R. Askeland, “The Science and Engineering of Materials”, 6th Ed, Book, Global Engineering: Christopher M. Shortt, USA, 2010. 3  Course Content 1. Materials Classifications, properties and applications. 2. Atomic structures and interatomic bonding. 3. The structure of crystalline solids. Crystallography and densities. 4. Imperfections in solids. 5. Strain hardening and annealing. 6. Metallic Systems and Binary diagram with unlimited solid solubility. 7. Eutectic phase diagrams. 8. Iron carbon phase diagram. 9. Phase Transformations: (TTT) and (CCT) Transformation 10.Destructive material testing: Tension 11.Destructive material testing: Hardness, Impact, Fatigue 12.Metallurgy and processing of Composite materials 4  L1 Materials Classifications, properties and applications I. Introduction II. Classification of materials I- Introduction  What is Materials science and engineering? Field of science that studies and influences the composition and structure of materials across in order to control materials properties through synthesis and processing. Performance: Behaviour, endurance, coast,. Synthesis: how materials are made from Processing: how materials are shaped Structure: description of the arrangement of atoms Composition : the chemical make-up of a material 6  Historical Development of materials  The number of materials available to engineers >160,000.  Man`s historical ages are named for the materials he used: o Stone o Bronze o Iron  Weapons always drive materials technology What will you select?  Titanium watch  Carbon-fiber–reinforced tennis racquet  Metal-matrix composite mountain bike  Shape-memory alloy eyeglass frame with lenses coated with diamond-like carbon  Polyether-ethyl-ketone crash helmet  Carbon nanotube reinforced iPod 7  The main properties of solid materials Mechanical Electrical Thermal Magnetic Optical Deteriorative 8 Mechanical Properties  Strength is the material’s ability to withstand an applied load without failure. 9  Stiffness is the resistance of an elastic body to deflection or deformation by an applied force.  Young’s Modulus is a measure of the stiffness and quantified as the slope of the elastic line 10  Toughness is the amount of energy required (both plastic and elastic deformation energies) to fracture the material. 11 Electrical Properties Electrical conductivity a property of materials that determines how well a given material will conduct electricity Dielectric Constant a quantity measuring the ability of a substance to store electrical energy in an electric field. 12 Deteriorative Properties  Deteriorative properties measure the chemical reactivity of the material (Corrosion behavior)  Density is the relationship between the mass of the substance and how much space it takes up (volume). 13 Optical Properties Single Crystal ALUMINIUM OXIDE 14  Material Science and Material Engineering Material Science Material Engineering Objectives : Objectives: – Investigating the relationship – Designing or engineering the that exists between the structure of a material to produce structures and properties of a predetermined set of properties. the material. Aims: Aims : – To create new products or systems – To develop or synthesize using existing materials and/or new materials. develop techniques for processing of materials. 15 II- Classifications of materials Nature point of view Metals Polymers Ceramics Semiconductors Composite Natural Iron and steels Alumina (AI2O3) CFRP Wood Aluminium / alloys Magnesia (MgO) GFRP Leather Copper / alloys Silica (SiO2) Cotton Nickel / alloys Silicon carbide (SiC) Wool Titanium / alloys Silicon nitride (Si3N4) Silk Cement and concrete0 Bone  Polyethylene (PE)  Nylon  Silicon  Polyvinylchloride (PVC)  Germanium  Elastomers (natural rubber NR)  Gallium arsenide 16 A. Metals and alloys ─ Pure Metals: Include Iron, Aluminum, Magnesium, Zinc, Titanium, Copper, Nickel, ….etc 17  Alloy is a combination of one or more metals (or non-metals) in order to improve a particular property or permit better combinations of properties (ex. Steels, Cast iron, Brass, Bronze, Aluminum alloys, Super alloys, ………….. etc.)  Characteristics of Metals  Good electrical conductivity.  High thermal conductivity.  High strength  High stiffness  Sufficient ductility or formability  Shock resistance.  Polished metal surface has a shiny appearance 18  Applications of metals  Commercial and Industrial applications (Casting – forging – welding)  Space and satellite applications  Military applications 19 B. Ceramics  They are inorganic materials consisting of metallic and non-metallic elements that are chemically bonded together to form complex compounds. 20  Ceramics are found in the form of oxides (SiO2), nitrides (Si3N4, TiN, AlN) and carbides (SiC, WC, TiC)  Characteristics of ceramics o High hardness, strength, stiffness, and wear resistance o Low ductility o Good Chemical stability and high corrosion resistance o High electrical resistance o Thermal and electrical insulation o High melting temperatures (furnace linings) o It can be transparent, translucent, or opaque 21  Applications of ceramics o Computer chip o Sensors and actuators o Capacitors o Wireless communications o Spark plugs o Inductors o Electrical insulators. 22  C. Polymers ─ Polymers are materials composed of repeating molecules of high molecular weight. Examples: polyethylene (PE), nylon, polyvinyl chloride) (PVC), polycarbonate (PC), polystyrene (PS), and silicone rubber. polyethylene polycarbonate silicone rubber polyvinyl chloride polystyrene 23 ─ Polymerization: It is the process by which small molecules (monomers) are chemically joined together (covalent bond) to create giant molecules ─ Polymers are classified as:  Thermoset (non recyclable)  Thermoplastic (recyclable)  Elastomers (rubber) 24  Characteristics of polymers:  Good electrical and thermal insulators, however with some additives polymers can act as semi or even electrical conductive material.  Low mechanical properties (strength, hardness,…….)  Very good strength-to-weight ratio  Not suitable for use at high temperatures  Good resistance to corrosive chemicals.  Applications of polymers  Bulletproof vests  Compact disks (CDs)  Ropes  Liquid crystal displays (LCDs)  Clothes and coffee cups. 25  D. Semiconductors  Definition: Semiconducting material is between that of ceramic (insulators) and metallic (conductors).  Examples: Silicon – germanium - gallium arsenide-based  Applications: computers and electronics devices such as transistors, diodes that are used to build integrated circuits. Transistors 26 Diodes E. Composite materials ─ The main idea in developing composites is to blend the properties of different materials. ─ These are formed from two or more materials, producing properties that are not found in each Glass fiber Carbon fiber single material. Examples: - CFRP (carbon fiber reinforced polymer) - GFRP (glass fiber reinforced polymer) 27  Classification of composite materials A- Based on The Geometry of Reinforcement 28  B- Based on The Type of Matrix Material Polymeric Matrix Metallic Matrix Ceramic Matrix Carbon / Carbon Composites (PMC) Composites (MMC) Composites (CMC) Composite (CC) Aluminum Magnesium Titanium Oxides Non oxides  Al2O3  TiO  ZrO Carbides Nitrides Borides WC AlN TiB2 SiC Thermoset Thermoplastic Elastomers Fe3C Epoxy Polystyrene Rubber Polyester Nylons Silicon 29  Applications of composites  Aerospace industry  Automotive industry  Electronic components  Sporting goods industry  Miscellaneous applications 30 31 2- Functional Classification of Materials  Light materials  Biocompatibility  Industry & Building  Semiconductors  Sensors & actuators  Neutronic mat. & Energy storage  Laser, communication & Data transferee  Ferromagnetism 32 Aerospace: (Light materials) Ex: wood and an aluminum alloy  NASA’s space shuttle makes use of - Aluminum powder for booster rockets. - Aluminum alloys, plastics, silica for space shuttle tiles. Biomedical: (Biocompatibility)  Bones and teeth are made from a naturally formed ceramic known as hydroxyapatite.  A number of artificial organs, bone Bone replacement replacement parts, cardiovascular stents, Braces stents braces, and other components are made using different plastics, titanium alloys, and nonmagnetic stainless steels. 33 33 Electronic Materials: (Semiconductors)  Semiconductors (Si) are used to make integrated circuits for computer chips.  Barium titanate (BaTiO3), tantalum oxide (Ta2O5), are used to make ceramic capacitors and other devices.  Superconductors are used in making powerful magnets.  Copper, aluminum, and other metals are used as conductors in power transmission and in microelectronics. 34 Energy Technology and Environmental  The nuclear industry uses materials such as uranium dioxide and plutonium as fuel.  Handling nuclear materials and managing radioactive waste (glasses and stainless steels)  Batteries and fuel cells in electric cars make use of many ceramic materials such as zirconia (ZrO2) and polymers.  Catalyst substrates in oil and petroleum industry (zeolites, alumina, Pt, Pt/Rh)  Many membrane technologies for purification of liquids and gases make use of ceramics and plastics.  Solar power is generated using materials such as amorphous silicon. 35 Magnetic Materials:  Computer hard disks make use of ceramic, polymeric and metallic alloys based on cobalt- platinum-tantalum-chromium (Co-Pt-Ta-Cr).  Many magnetic ferrites are used to make inductors and components for wireless communications.  Steels based on iron and silicon are used to make transformer cores. Optical or Photonic Materials  Optical fiber are made of Silica  Optical materials for making semiconductor detectors and lasers used in fiber optic communications systems.  Alumina (Al2O3) and yttrium aluminum garnets (YAG) are used for making lasers.  Amorphous silicon is used to make solar cells and photovoltaic modules.  Polymers for liquid crystal displays (LCDs). 36 Smart Materials  Sensor, a smart material can sense and respond to an external stimulus such as a change in temperature, the application of a stress, or a change in humidity or chemical environment.  An example of a passively smart material is lead zirconium titanate (PZT) and shape- memory alloys Structural Materials  Steels, concrete, and composites are used to make buildings and bridges as they are designed for carrying different type of stress. 37 Material Property charts 38 Material Property charts 39 Required Readings Book Title Materials Science and Engineering An Introduction Jhon Wiley , William D. Callister Chapter Chapter 1 : Introduction Required 1.2 materials science and engineering subsections 1.4 classification of materials 1.5 advanced materials 40