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FE Review Session Materials Science By Dr. Richard B. Griffin, P.E. Department of Mechanical Engineering Texas A&M University College Station, TX 77843 Phone No. 409/845/9779 FAX No. 409/862/2418 e-mail: rgriffin@mengr.tamu.edu Table of Contents Lopic | Page | Corrosion 6 | Atomic Bonding Lz | Crystallography oe (Planes and Directions | 12 bec 13 fee it hep iS (Density fie | Diffusion — 17 | Phase Diagrams ai | Eutectic al Eutectoid AA Thermal Processing a3 Mechanical Testing 30 ASTM Grain Size 86 Composite Materials 37 METALS HIERARCHY sid set Pi cre th en aon et Metals Zine alloys Aluminium alloys Magnesium alloys Titanium alloys ope ays vr aos ist a ‘Tungsten alloys Pru as 4 Light alloys Nonferrous alloys POLYMERS HIERARCHY 4 Potyatkenes Polyamides Pantally crystalline 4 Acetals Poty(phenytene sulphide) Poly(emeretherkerone) ‘Thermoplastics Polystyrenes } Pvc Amorphous Polycarbonates 4} poly(ether sulphone) 1 Epuries 4 Phenoplasts Polymers—t Highly crosslinked ———4 Aminoplasts Silicones Polyescers 4 Thermosets 4p Natural rubber Styrene-butadiene rubber Lightly crosslinked ————+ Nitrile rubber 4 Duty! rubber 4 Silicone rubber Cellulose-based 4 Natural polymers Pratein-hased CERAMICS HIERARCHY Ceramics 4} Domestic ceramics f Naira erie # Electronic materials ——f Pyroceramies 4 Porcelain $ Vitreous nina + Estthenwate $ Stoneware Cement $ Nitcides 4 Carbonaceous rocks 4 Siticaceous rocks 7 Ferrites $ Ferroelectrics 4} Semiconductors # Superconducting ceramics Corrosion A. Requirements 1. 2. B. Anodic Reaction C. Cathodic Reactions 1. Hydrogen reduction 2. QO, reduction acid solution 3. O2 reduction basic or neutral solution 3. D. EMF Table (p.61*") ‘Standard Oxidation Potentials for Corrosion Reactions* Potential, F,, Volts Corrosion Reaction vs. Normal Hydrogen Electrode + Au> Au* +3e ~ 1.498 2H,O + 0, + 4H* + de ~ 1.229 Pt Pitt +26 ~ 1.200 Pd-+ Pd* + 2e -0.987 Ag7 Ag* +e -0.799 2Hg-> Hes" + 20 ~0.788 Fe’? + Fe +e -0.771 4(OHY > 0; + 2H,0 + 4e -0.401 Cu> Cu?* + 2 -0.337 Sn?* + n‘* + 20 -0.150 H, 7 2H* + 26 0.000 Pb~ Pbi* + 2e +0.126 Sn + Sn** + 26 +0.136 Ni> Ni* + 2e +0.250 Co Co?* + 20 +0277 (Cd+ Cd?* + 20 +0403 Fe~ Fe?" +20 0.440 Cr Cr5* + 3e +0.744 Zn Zn** +20 +0.763 Als Al’ + 3e + 1.662 Mg—> Mg? + ze +2.363 Na+ Na +e +2714 K> Kite +2.925 * Measured at 25°C. Reactions are written as anode halfcells. Arrows are reversed for cathode half- cells. H+ tn some chemistry texts, the signa of the values (inthis table) are reversed; for example, the half-ell potential of zinc is given as -0.763 volt. The present convention is adopted so that when the poten- tial _E, is positive, the reaction proceeds spontaneously as written. Fina Rata A wl Pa Ts Engineing Nerina The opts, th Elon. Coppigh © 19000) Hoaghon Win Goapany Tito oak Pages numbers listed are from the Fundamentals of Engineering Discipline Specific Reference Handbook. 17 Atomic Bonding A. Primary Bonding 1.Metallic 2. Ionic 3.Covalent B. Secondary 1. van derWaals or hydrogen bonding AB FIGURE 2-6 The metallic bond forms when atoms give up their valence electrons, which then form an electron sea. The Positively charged atom cores are bonded by mutual attraction to the negatively charged electrons. covalent bonds contains si abel sructuce of slic (S1O,), whi = aterent x! electronegatmtes. When sodium donates ts valence electron to chionne, each ‘anon. atiacvon occurs, and the ionic bond i formed S @X oe) Ae The lorie Bond created between two unike stom with FIGURE 2-11 Van der Waals bonds +— Force 7», Nan det Waals N, bonds easily break na © mi Force ———> (b) FIGURE 2-14 (a) In polwiny! chloride, the chiorine atoms attached to the polymer chain have a negative charge and the hydrogen atoms are positively charged. The chains are weakly bonded by Van Ger Waals bonds. (b] When a force is applied to the polymer, the Van der Waals bonds are broken and the chains slide past one another. Crystallography A. Crystal planes . Miller Indices J B. Directions | | 7 fd Crystallography A. bee r= f(a) 1. atoms/unit cell 2. coordination number (CN) 3. packing factor Crystallography B. fee r= f(a) 3. atoms/unit cell 4. coordination number (CN) 3. packing factor Crystallography <> i <> 5. atoms/unit cell C. hep 6. coordination number (CN) 3. packing factor Crystallography A. Density B. Close packed plane and close packed directions Oy Diffusion (Thermally Activated Process) oeal\ 1. vacancy C) a “ C) OO _ © OOOO 122 ‘Chapter §__ATOM MOVEMENT IN MATERIALS Substitutional FIGURE 5-4 As atoms squeeze past one another during diflusion, a high energy is required. This energy is the activation energy Q. Generally more energy is required for a substitutional atom than for an interstitial atom Woo. OOOO OOOO OOOO 10 Temperature (°C) 2000 1500 1200 1000900 800 700 ET T y lo" 600 r t Hin i BCC a ion 3 Diffusion coef S 1o-" 10-8 10-P FO a 1o-# 10-15 3 S 0. 04 0.5 06 07 08 09 10 Vi 1000 TK) FIGURE 5-7 The diffusion coefficient D as a function of Aa procal temperature for several metals and ceramics. In this Arthenius plot, D represents the rate of the diffusion process 12 13 40 Phase Diagrams A. Eutectic diagrams Eutectic reaction Temperature, °C | | A Xq x 0% B Composition, wt % 100% A B. Gibb’s Phase Rule P+F=C+2 For solids, pressure generally can be ignored and the Gibb’s phase rule may be written as: F=C-P+1 mal Temperature, °F Phase Diagrams A. Eutectoid diagrams Iron-Iron Carbide Phase Diagram Atomic percent carbon ° 5 10 i i : s 7 B es liquid t -Jrsco ‘ Liquid ! e004? s 1 2600 i ™ 2400 Tliquid y ' 1200 | 2200 ° ra" SK? i ¢ 7 ou 4 1 {2000 * fl i Z 2 060] 4 : - 51800 z RY Yhearbide é i +1600 00S et 737° (1340°F) +1200 oa ony doz {1200 600 etearbide req] ~}1000 | {00 1005 a Eutectoid reaction Peritectic reaction Peritectoid reaction Weight percent carbon WAX Thermal Processing A. Cold working (strain or work hardening) T<1/3Tvp. B. Annealing 1. Recovery 2. Recrystallization 3. Grain growth wa Flinn/Trojan: Cngincering Materials and Thetr Applications, Fuh Edition Figure 3.18 The effects of different amounts of cold work on mechanical properties (Lawrence Van Vlack, Elements of Materials Science, fig. 6.26, © 1964, Addison-Wesley Publishing Co., Inc., Reading Massachuseus. Reprinted with permission of the publisher} : 8 7 g is é 4 4 28 e <8 S si a 3 é o 4d s 6 2 g t — as f. f=] Rs =448 a 4 3 ; es t 12 te 8 3 & 8 $ isdggo1 ‘yiBuans apsuay, (ww g'¢) “ul z ur voneSuoTy % g og +B 8 z 7 4¢ 5 88 Jit og zg a aH ‘ssouprey, at Cold work, percent (ci Flinn/Trojan: Engineering Materials and Their Applications, Fourth Edition Figure 3.9 Effect of heating on hardness of cold-worked 65% Cu, 35% Za brass, 1 hr. (Lawrence Van Vlack, Elements of Materials Science, fig. 628, © 1964, Addison-Wesley Publishing Co., Inc., Reading, Massachusetts. Reprinted with permission of tne publisher] Sr g s SF g f I | | | | 2 Lt \ 2 a ‘ g ¥ ¥ ¥ 3 8 5 S B B z z 3 S 8 8 8 =f es & 8 2 Ss 2 oO ea {8 g \ \ \ i oF g s Ss & & $ a & = S dH ‘ssoupreyy © 1990 Houehton Mifflin Company Temperature, °F C. Heat treatment 1. Quenched and Tempered Austenitize Quench Temper 2. Hardenability Jominy Hardenability Curve Flinn/Troyan: Engineering Materials and Their Applications, Fourth Edition Figure 5.1 Sclictatic diagtant of « ermal weatment for a 0.9% casboon steel ¥ HB 500 Fine carbide in « (BCC) matrix room temperature) ‘Temperature supersat Quend Room HB 200 1600°F (879°C) © 1990 Houghton Miffin Company * 0 -as0 Cooling rate at 700°C, *C/see [ [ss 25 125 8 55 45 3 25 70 - 5 6o| _| y 9 nt * i - 2 00 = an \ —_ Tt 1060 (#2){_ | a T1000 0. |~~y1020 1040. q : uhhh 9 i0 20 30 40 50 mm booed z raf EAR Din Distance from quenched end, Dye (#2) and (#8) indicate grain size Hardenability Curves For Six Steels Cooling rate at TONG, *G/see Cuuting rate at THOE, *C/Ae€ x0 a Gn: 150 Gv0: 150 os us ye 4 3s ie nee a ways 4 8 sg ER/ ACR y ae 7 Wey | ] € 3 | T7 3 i / i sf ay Js Perry Z Le 5 : - & Pe 30 5 5 s yy MK = a Y 5 20) 4! 3 I acid 10 7 . telassslaae Llu % 3 10 +20, 2", uw "o o 25 min eee renee eee ieee eee nena i Rea Distance feum quenched! ent, Daye Distanve from quenehed eu, Dye ® o Cooling Rates For Round Bars Quenched in (a) Agitated Water and (b) Agitated Oil. aN 3. Precipitation Hardening Solution treatment Quenching Aging wat Mechanical Testing A. Tensile Test Stress Psi (MPa) Strain (in/in) E, Modulus of Elasticity Yield strength 0.2% YS Tensile Strength (Ultimate Tensile Strength) Ductility %Elongation %Reduction in Area Figure 2.8 (a) Stess-stain curves for various alloys. (b) Details of an engineering stress-strain curve for mild sel (0.3% carbon) (Part (a) from J, Marin, Mechanical Behavior of Engineering Materials, © 1962, pp. 24, Reprinted by permission of Prentice-Hall, Ine, Englewood Cliff, NJ] 270 SAE 1340 stecl, water-quenched and] 1800 tempered at 700°F (370°C) 1600 Nickel-alloy steel 1400 Stainless-steel sheet 17-7PH 2 ess steel (18-8 "200 2 Stainless steel (18-8) é el ~ 1000 = 2 Annealed titanium-alloy sheet (6A1-4V) g a Annealed N-155 alloy shee B ; ne Salloy sheet] 4) 3 Nickel-alloy steel ~ ° 600 Bare aluminum-alloy sheet (2024-T81) ‘Alcoa 27ST. ri 4200 0 0 0.02 0.04 0.08 0.12 016020 024 Swaine, infin, or vin @ Yield strength at 0.2 percent offset ~]300 40,000 250 30,000 z 200 5 150, 2 20,000 2 100 10,000 50 0 0.001 0.002 0.003 0.004 infin. or m/m ol 02 03 04 percent Strain () 3l © 1950 Houghton Mifflin Company B. Impact Test Energy Ft-lbs DBTT | Temperature te ceajates ing iicer ang nae Unik Heer MppHeMHUHa, HUbHE KE Figure 3.6 (a) Operation of a Charpy impact test. (6) Etfect of temperature on the impact strength of various materials (Schematic) (Part (a) from H.W. Hayden, W.G. Moffatt, and John Wulff, The Structure and Properties of Materials, Vol. 3: Mechanical Behavior, John Wiley & Sons, New York, 1965) Hammer —. BCC metals ceramics, polymers Brittle +— /, —* Tough Impac: energy | High-strength materials t~+Transition temperature ‘Temperature (b) ‘© 1990 Houghton Mifflin Company C. Fatigue Test (Endurance Test) S-N approach Stress (psi) Flinn/Teojan: Engineering Materials and Their Applications, Fourth Edition Figure 2.29 Typical SN curves for ferrous and noaferrous alloys (Courtesy of H. Mindlin, Batlle] eq ‘ssans : 2 2 2 2 Ss Se Ss 3 Ss Ss Ss 5 6 a = oa a 2 > eee 2 Es 3 SE = 3s E a 3 a E 3 & 2 5 5 a : é ge a hd Tr a o L fs L L ° S Ss 2 ° Ss ~ S + isd Qn ‘sses © 1990 Houghton Mifflin Company 100 (T4 heat treatment) 10° 107 108 Number of cycles 105 tot ASTM Grain Size A. Surface area: S, = 2P, B. Grain size: Noss mm’) = 2"! 1=1/n(M) REE Composite Materials A. Rule of Mixtures p= Zip; c= Lfi¢j E= xfE parallel perpendicular

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