Design for Engineering Unit 8 Material Science and Engineering Annette Beattie August 15, 2006

Materials Science
ETP 2006 Annette Beattie This material is based upon work supported by the National Science Foundation under Grant No. 0402616. Any opinions, findings and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the view of the National Science Foundation (NSF).

What are Materials?

It derives from the Latin word Materia which means

wood. Material is anything made of matter. Our clothes are made of materials, our homes are made of materials - mostly manufactured. Most things are made from many different kinds of materials.

Materials Science
Defined as the study of the properties of solid

materials and how those properties are determined by a materials composition and structure.
Example - the dramatic role of iron throughout the ages is

not really the result of it being "strong". In reality, iron has been important because we can change its properties by heating and cooling it. The ability to change the properties and/or behavior of a material is what makes most materials useful and this is at the heart of materials science!

Materials Science and Engineering

An interdisciplinary study that combines metallurgy,

physics, chemistry, and engineering to solve real-world problems with real-world materials in an acceptable societal and economical manner. The following elements and their interaction define Materials Science and Engineering:
Performance Properties Structure and composition Synthesis and processing

Kinds of Materials
Metals
Ceramics Polymers Composites Semiconductors Biomaterials etc.

Metals
Materials that are normally combinations of "metallic elements". Example : Fe, Al, Cu etc.

 Properties High Density Good electrical and thermal conductivity

(Due to presence of free electrons) Magnetic in nature Resistant to fracture Highly stiff

Ceramics
Compounds between metallic and nonmetallic

elements. Generally oxides, nitrides and carbides come in this category. Example : SiC, Silicon nitride, Alumina etc. Less dense in comparison to metals Brittle in nature Easily fractural (Griffith crakes) because the surfaces of ceramics nearly always contain minute cracks ("Griffith cracks"), which magnify the applied stress.

How do we make ceramics

Ceremics are produced by compacting powders into a

body which is then sintered at high temperatures. During sintering the body shrinks, the grains bond together and a solid material is produced. Dry Pressing, Isostatic Pressing, Roll Compaction, Continuous Tape Casting, Slip Casting, Extrusion, Injection Molding, Pre-Sinter Machining, HotPressing, Hot Isostatic Pressing, Grinding, Lapping and Polishing.

Conductivity
In contrast to Metals, Ceramics have very low electrical

conductivity due to Ionic-Covalent Bonding which does not form free electrons. Most of ceramic materials are dielectric (materials, having very low electric conductivity, but supporting electrostatic field).

 Electrical conductivity of ceramics varies with the

frequency of field applied and also with temperature. This is due to the fact that charge transport mechanisms are frequency dependent. Further, the activation energy needed for charge migration is achieved through thermal energy and immobile charge career becomes mobile. The activcation energy can be calculated very easily using the Arrheneous relation.

Polymers
They are generally organic compounds based upon carbon and hydrogen. They are very large molecular structures. Ex : PE, PVC, PS etc. Low density Low stiffness Non magnetic Non electrical conductivity

Semiconductors
They have electrical properties intermediate between

metallic conductors and ceramic insulators. Intrinsic semiconductor (Pure Si, Ge) Extrinsic semiconductor P-Type (B,Al doping) N-Type (P,As doping)

Composites:
They consist of more than one material type.

Fiberglass, a combination of glass and a polymer, is an example. CFRP- Carbon Fiber Reinforced Polymer Composite material is a material composed of two or more distinct phases (matrix phase and dispersed phase) and having bulk properties significantly different form those of any of the constituents.

Matrix Phase
The primary phase, having a continuous character, is

called matrix. Matrix is usually more ductile and less hard phase. It holds the dispersed phase and shares a load with it.

Dispersed (Reinforcing) Phase

The second phase (or phases) is embedded in the

matrix in a discontinuous form. This secondary phase is called dispersed phase. Dispersed phase is usually stronger than the matrix, therefore it is sometimes called reinforcing phase.

Types
Metal Matrix Composites (MMC) Metal Matrix Composites are composed of a metallic matrix

(aluminum, magnesium, iron, cobalt, copper) and a dispersed ceramic (oxides,carbides) or metallic (lead, tungsten, molybdenum) phase. Ceramic Matrix Composites (CMC) Ceramic Matrix Composites are composed of a ceramic matrix and embedded fibers of other ceramic material (dispersed phase). Polymer Matrix Composites (PMC) Polymer Matrix Composites are composed of a matrix from thermoset (Unsaturated Polyester (UP), Epoxiy (EP)) or thermoplastic(Polycarbonate (PC), Polyvinylchloride, Nylon, Polysterene) and embedded glass, carbon, steel or Kevlar fibers (dispersed phase).

Density calculation
Rule of Mixtures- is a method of approach to

approximate estimation of composite material properties, based on an assumption that a composite property is the volume weighed average of the phases (matrix and dispersed phase) properties. According to Rule of Mixtures properties of composite materials are estimated as follows:

 Density
dc = dm*Vm + df *Vf Where dc,dm,df densities of the composite, matrix and

dispersed phase respectively; Vm,Vf volume fraction of the matrix and dispersed phase respectively.

Can we do welding on composites?

Hot Plate welding-

In hot plate welding, the parts to be welded are held in fixtures, which press them against either side of a heated platen. Once the parts are sufficiently molten, the platen is removed. The components are then pressed together and held until they are cooled.

 Vibration welding- It is also known as linear friction

welding. in this heat is generated by the mechanical movement of the components to be joined. The two parts to be joined are brought into contact under an applied load. One part is constrained whilst the other undergoes a rapid linear reciprocating motion in the plane of the joint. The heat generated by the friction at the two surfaces creates local melting. Subsequently, the vibration stops, the parts are aligned and the joint is cooled under pressure to consolidate the weld.

Newer Branches of Materials Science

Nanotechnology: a relatively new area grown out of techniques used to manufacture semiconductor circuits. Machines can be produced on a microscopic level. Example - miniature robots to do surgery inside the body or miniature chemical laboratories and instruments that will continuously analyze blood and dispense medications inside the body.

Biomaterials
Biomaterials are employed in components implanted

into the human body to replace diseased or damaged body parts. These materials must not produce toxic substances and must be compatible with body tissues (i.e., must not cause adverse biological reactions). All of the preceding materialsmetals, ceramics, polymers, composites, and semiconductorsmay be used as biomaterials. Example, some of the biomaterials that are utilized in artificial hip replacements.

 In the United States, 45% of the 250,000 valve

replacement procedures performed annually involve a mechanical valve implant. The most widely used valve is a bileaflet disc heart valve, or St. Jude valve.

Materials Testing
Materials testing is a much narrower field than

materials science or engineering. It is determining the strength of certain materials. It is mostly used to determine safety. Ex. concrete samples are tested. It is not used to design new materials to be used in new applications. (VCSU, 2006)

Metal
Density Electrical & Thermal conductivity Strength stiffness High High

Ceramics
less low

Polymers
low low

Composites
low low

high high

High (less than metal) high

low low

high high

Resistance to fracture

high

low

low

high

Crystal structure
Because there are many different possible crystal

structures, it is sometimes convenient to divide them into groups according to unit cell configurations and On this basis there are seven different possible combinations of a, b, and c, and , , and each of which represents a distinct crystal system.


1. 2. 3. 4. 5. 6. 7.

Seven types of crystal systems are thereCubic Hexagonal Tetragonal Rhombohedral (Trigonal) Orthorhombic Monoclinic Triclinic

Point coordinates
Point position specified in terms of its coordinates as

fractional multiples of the unit cell edge lengths.

CRYSTALLOGRAPHIC DIRECTIONS
A crystallographic direction is defined as a line between

two points 1. A crystallographic direction is defined as a line between two points,

2. These three numbers are multiplied or divided by a common factor to reduce them to the smallest integer values. 3. These three numbers are multiplied or divided by a common factor to reduce them to the smallest integer values.

CRYSTALLOGRAPHIC PLANES
If the plane passes through the selected origin, either another parallel plane must be constructed within the unit cell by an appropriate translation, or a new origin must be established at the corner of another unit cell. 2. If the plane passes through the selected origin, either another parallel plane must be constructed within the unit cell by an appropriate translation, or a new origin must be established at the corner of another unit cell.
1.

 The reciprocals of these numbers are taken. A plane

that parallels an axis may be considered to have an infinite intercept, and, therefore, a zero index. If necessary, these three numbers are changed to the set of smallest integers by multiplication or division by a common factor. Finally, the integer indices, not separated by commas, are enclosed within parentheses, thus: (hkl).

Application
Deformation under loading (slip) occurs on certain

crystalline planes and in certain crystallographic directions. Before we can predict how materials fail, we need to know what modes of failure are more likely to occur. Other properties of materials (electrical conductivity, thermal conductivity, elastic modulus) can vary in a crystal with orientation.

Diffusion
the phenomenon of material transport by atomic motion Ficks 1st law-

J =D (dC/dx) One practical example of steady-state diffusion is found in the purification of hydrogen gas. One side of a thin sheet of palladium metal is exposed to the impure gas composed of hydrogen and other gaseous species such as nitrogen, oxygen, and water vapor. The hydrogen selectively diffuses through the sheet to the opposite side, which is maintained at a constant and lower hydrogen pressure.

 Ficks 2nd law

C/t =D (2C/ 2x)

Applications
A steel gear that has

been case hardened. Its outer surface layer was selectively hardened by a high-temperature heat treatment during which carbon from the surrounding atmosphere diffused into the surface

 Case-hardened

steel gears are used in automobile transmissions.

 Increase in the carbon content raises the surface

hardness which in turn leads to an improvement of wear resistance of the gear. In addition, residual compressive stresses are introduced within the case region; these give rise to an enhancement of the gears resistance to failure by fatigue.

Bibliography
www.crc4mse.org
www.vcsu.edu www.britannica.com

www.subtech.com
www. global.kyocera.com

Standards
Standard #2: Students will develop an understanding of the core concepts of technology.

2.CC New technologies create new processes.

Standard #3: Students will develop an understanding of the relationships among technologies and the connections between technology and other fields of study.
3.H Technological innovation often results when ideas, knowledge, or skills are shared within a technology, among technologies, or across other fields. 3.J Technological progress promotes the advancement of science and mathematics.

Standard #7: Students will develop an understanding of the influence of technology on history.
7.H The evolution of civilization has been directly affected by, and has in turn affected, the development and use of tools and materials. 7.K The Iron Age was defined by the use of iron and steel as the primary materials for tools.