ENGINEERING MATERIALS MAK 214E PART 1

Yrd. Do. Dr. Ali Gkenli Teaching Assistant: Esin akr

TODAY
Introduction Classification of materials

Materials Science and Engineering

Materials Science:
Basic knowledge of materials

Materials Engineering:
Applied knowledge of materials which can be converted into products.

Materials Science and Engineering:

Considers both basic and applied knowledge of materials and ties them.

Engineering Material

Material Science

Composition means the chemical make-up of a material. Structure means a description of the arrangements of atoms or ions in a material. Synthesis is the process by which materials are made from naturally occurring or other chemicals. Processing means different ways for shaping materials into useful components or changing their properties.

2003 Brooks/Cole Publishing / Thomson Learning

2003 Brooks/Cole Publishing / Thomson Learning

Application of the tetrahedron of materials science and engineering to semiconducting polymers for microelectronics

2003 Brooks/Cole Publishing / Thomson Learning 2003 Brooks/Cole Publishing / Thomson Learning

Classification of Materials
Metals and Alloys Ceramics, Glasses,and Glass-ceramics Polymers (plastics), Thermoplastics and Thermosets Semiconductors Composite Materials

Polymeric Materials
Most of them consist organic long molecules Carbon (C) is essential in all molecules Structure is noncrystalline but some of them contains mixtures of crystalline and noncrystalline regions Strength and ductility varies due to structure of molecular chains Poor conduction of heat and electricity (good insulation) Low densities Low softening or decomposition temperatures.

Polymeric Materials
Thermoplastics
ABS Nylon PVC

Thermoset
Epoxy Polyester

Elastomers
Rubber

Ceramic Materials
Inorganic materials Consist of metallic and non metallic elements Ionic and/or covalent bonding Crystalline / Glassy / both structures High hardness High elevated temperature strength Low ductility and toughness

Ceramic Materials
Chemical Stablity against the effects of environment Poor conduction of heat and electricity Good wear and heat resistance

Ceramic Materials
Main Classes:
Traditional: Silica, porcelain Refractories:Silica brick Glasses Abrasives: Alumina, Silicon Carbide Advanced engineering ceramics: Partially Stabilized Zirconia

Composite Materials
Mixture of 2 or more different types of materials. Contains matrix and reinforcing components Matrix generally soft and ductile, reinforcing component hard and brittle

Composite Materials
Reinforcement types:
Fiber Particle Lamellar

Matrix types:
Polymeric Metallic

Important composites:
Glass fiber reinforced plastics Carbon fiber reinforced aluminium Thoria dispersed Nickel

Representative examples, applications, and properties for each category of materials

Example of Applications Metals and Alloys Gray cast iron Ceramics and Glasses SiO2-Na2O-CaO Polymers Polyethylene

Properties

Automobile engine blocks

Castable, machinable, vibration damping

Window glass

Optically transparent, thermally insulating Easily formed into thin, flexible, airtight film

Food packaging

Representative examples, applications, and properties for each category of materials

Example of Applications Semiconductors Silicon Properties

Transistors and integrated circuits

Unique electrical behavior

Composites Carbide cutting tools for Tungsten carbide machining -cobalt (WC-Co)

High hardness, yet good shock resistance

Representative strengths of various categories of materials

2003 Brooks/Cole Publishing / Thomson Learning

Functional Classification of Materials

Aerospace Biomedical Electronic Materials Energy Technology and Environmental Technology Magnetic Materials Photonic or Optical Materials Smart Materials Structural Materials

Future Trends in Materials Usage

Metallic materials:
Powder Metallurgy Titanium alloys Ni based superalloys Single crystals

Polymeris materials: Ceramic materials:

Ductile enginnering ceramics

Composite materials:
Advanced composites Cermets Graphite-epoxy, Aramid-epoxy

2003 Brooks/Cole Publishing / Thomson Learning

IRON AND STEEL MAKING

STEEL

PIG IRON

Blast Furnace
Nearly 40 meters high. The steel shell around the furnace is lined with heat resisting bricks (refractors).

Blast Furnace

The Slag The Slag which sits on top of the Molten Metal, because it is less dense, is the waste material from the process of creating Steel. It consists of the impurities, that is most materials other than Iron and Carbon which were put into the Furnace at the start when the Furnace was being Charged. The Slag is removed from the Furnace when the time is ready through the Slagging Hole.

Basic Oxygen Furnace

Molten pig iron (sometimes referred to as "hot metal") from a blast furnace is poured into a large refractory-lined container called a ladle; The vessel is then set upright and a water-cooled lance is lowered down into it. The lance blows 99% pure oxygen onto the steel and iron, igniting the carbon dissolved in the steel and burning it to form carbon monoxide and carbon dioxide, causing the temperature to rise to about 1700C. This melts the scrap, lowers the carbon content of the molten iron and helps remove unwanted chemical elements. High purity oxygen is blown into the furnace or BOS vessel through a vertically oriented water-cooled lance with velocities faster than Mach 1. Fluxes (burnt lime or dolomite) are fed into the vessel to form slag, which absorbs impurities of the steelmaking process. A typical chemistry of the blown metal is 0.3-0.6% C, 0.05-0.1% Mn, 0.01-0.03% Si, 0.01-0.03% S and P. The steel is further refined in the ladle furnace, by adding alloying materials to give the steel special properties required by the customer. The steel now contains 0.1-1% carbon.

Electric Arc Furnace

Scrap und/or pig iron is used. Arc forms between Carbon electrodes and metal charge. Capacity: 50 tons. Clean steel is achieved. The furnace uses massive amount of energy. It allows to produce high quality steels and recycling of steel in cheapest and quickest way.

Electric Arc Furnace

Clean Steel
Fatigue and Fracture performance of steels are directly propotional to the size and volume fraction of INCLUSIONS. The inclusions are non-metalic in character and may be classified as OXIDES, SILICATES, SULFIDES. The inclusions should be eliminated. CLEAN STEEL are defined as a class of steels containing minimum amount of inclusions. REFINIG METHODS should be used.

REFINING METHODS
After tapping from a BOP or EAF, molten steel for high quality or specialty applications is subjected to further refining in a number of alternative processes collectively known as ladle metallurgy, ladle refining, or secondary steelmaking. The objectives of these processes are: Deoxidization - Removal of Oxygen Degassing - Removal of Hydrogen Desulfurization - To sulfur concentrations as low as 0.002% Microcleanliness - Removal of undesirable nonmetallic elements Inclusion morphology - Changing the composition of remaining impurities to improve the microstructure of the steel Mechanical properties - Increases toughness, ductility, and transverse properties

INGOT TEEMING

Pipe formation

CONTINUOUS CASTING

Steel Making Movies