ENGINEERING
MATERIALS
I
Grading Policy:
2 midterm exams
5-6 lab tests + quzzes + a project (optionalweighing as one mdterm)
1 final exam
Reference book: Properties of materials for
desing, by Prof.Dr Alp ESIN
Metal meslek bilgisi (MEB Yaynlar)
Malzeme bilgisi, by MEHMET YKSEL (MMO
Yaynlar)
Mekanik tasarmda elik ve zellikleri, by Cahit
TRE ((MMO Yaynlar)
CH-1 CLASSIFICATION OF
ENGINEERING MATERIALS
Materials used in engineering applications
cover a range from simple daily uses like
pencils and spoons to most complex and
extreme cases like space shuttles and bio
medical uses.
Engineering materials used in applications
from simple daily life to extreme ones are
divided into following sub-classes:
Engineering materials
A.1) Ferrous
metals
(iron based)
A.2) Non-ferrous
metals
(iron free)
B) Non-metals
B.1)Naturals
B.2) Artificials
Heavy metals
Copper
Chromium
Lead etc
Steel: (%C<2)
Plain Carbon steel
Alloy steel
Light metals
Titanium
Beryllium etc
Refractory (high temp)
metals
Tungusten
Molybdenum etc
Precious metals
Gold
Silver etc
B) Non-metals
B.1)Naturals
wood
granite etc
B.2) Artificials
Polymers
Rubber
Thermoplastics
Thermosets etc
Ceramics
Glass
Cermets
Composites
Metal matrix composites
Ceramic matrix composites
Polymer matrix composites
Ferrous metals (cast iron and steel) are still the most
widely used materials in many engineering applications.
Steel, in particular, has many versions (alloys) with
different advantages for different applications.
Steel can serve in applications varying from simple
machine construction to extreme load bearing (carrying)
applications and from simple springy (elastic) deflection
applications to very high temperature resistant or
corrosion resistant applications.
Steels as one of the most important engineering
materials are divided into following sub-classes:
Alloy Steels
Alloy Steels
with modest amount of alloying elements
Tool Steel
(used for tools and dies)
Stainless Steel
(%Cr > 10.5)
Blast furnace
STEELS
Steels are made by the removal of excess C and
other impurities of pig iron by oxidation followed by a
deoxidation process and addition of C and alloying
elements to the required level.
Oxidation is carried out by blowing air or oxygen
through molten pig iron in either
1)Bessemer-Thomas furnace
2)Siemens-Martin (open heart furnace)
3)Basic Oxygen Furnace
4)Electric Furnace
2-ALLOY STEELS
CAST IRON
Cast iron is a four element alloy containing
iron, carbon (2 to 4%),silicon and manganese.
Some cast iron types may contain additional
alloying elements.
Cast iron contains large amount of carbon in
the form of Fe3C (cementite) and this
composition is not stable and decomposes
under certain conditions:
Fe3C 3Fe + C
DESIGNATION OF STEELS
There are various standardization bodies for
steels
1) American AISI & ASTM
2) German DIN
3) Turkish TS, MKE
4) British BS
5) Euronorm
etc
process of manufacture
method of deoxidation
chemical composition and
mechanical properties
b- alloy steels:
in Turkey mainly DIN & AISI designations are
used.
In DIN designation,
multiplication factors are used for the content
of the alloying elements these factors are:
= 0.16% C
= 1.25% Mn
= 0 % Cr
= 0.5% S
nickel-chromium steels
nickel-cr steels with 1.25%Ni 0.6%Cr
nickel-cr steels with 1.75%Ni 1%Cr
nickel-cr steels with 3.5%N 1.5%Cr
4XXX
molydenum steels
5XXX
51XX
52XX
chromium steels
low cr
medium cr
6XXX
chromium-vanadium
7XXX
tungsten steels
8XXX
chromium-nickel-molybdenum
9XXX
C) Tool steels
These steels are divided into four broad
groups in German and Turkish designation as
follows:
In German standards tool steels are grouped
as:
Ex.
S10-4-3-10
S18-0-1
D) Stainless steels
These are the large and widely used family of
chromium alloys known for their corrosion resistance,
obtained by a large chromium content (min. 10.5%).
The DIN designation of the stainless steels is the
same as alloy steels.
X40 Cr 13, X12 CrNi 18 8, and X20 Cr 13 are the DIN
designations of the three types of stainless steel
produced by the MKE.
The MKE's own designation of these steels is based
on the basic SAE system (51440, 3915 and
51420, in the same order).
f- super alloys :
are designated by the AISI 600 series with the specifications of
high temperature & high strength.
St xx-y
is the DIN designation where xx is the
tensile strength in kg/mm2 and y is the quality grade
number denoting maximum P &S content
designation
DDL-XX kg/mm2
GL-XX kg/mm2
class -XX lb/in2x1000
grade-XX MPa
XX is the tensile
strength in kg/mm2
White iron
There are no specifications for white iron unlike
the gray iron
the symbols DDB and GGW are used to
designate the white iron in short form by the
TS&DIN respectively
Malleable cast iron
is designated as
DDTS-xx (and DDTB-xx) in TS 1111 and
GTS-xx (and GTW-xx) DIN 1692
NON-FERRIOUS METALS
By the definition all metalic materials that do not
have iron (Fe) as their major ingredent are
called non-ferrous metals.
The arbitrary classifications or grouping of the
non-ferrous metals are:
1)Light metals (Al,Mg,Ti,Be)
2)Heavy metals (Cu,Zn,Pb,Sn .)
3)Precious metals (Au,silver,platinum)
4)Reftractory metals (tungsten,Ni,Mo,Cr)
LIGHT METALS
2) HEAVY METALS
Copper is probably the first engineering metal
to be used;
because, unlike other metals, it can occur in
nature in the metallic form as well as an ore.
It has very good heat and electric conductivity
and resist to corrosion when alloyed with other
metals.
Copper alloys can be grouped into two major
catagories as
(1) cast alloys and
(2) wrought alloys.
REFTRACTORY METALS
Refractory metals have melting points above
1900C.
These metals are characterized by hightemperature strength and corrosion resistance.
Although nickel has a lower melting point
(1455C), because of its use in applications
usually requiring specific corrosion resistance or
strength at high temperatures, it is also
categorized in this group.
it must, however, be pointed out that the
prominent, actual refractory metals are tungsten,
molybdenum, tantalum and columbium.
In addition to these, chromium and nio-bium are
receiving major consideration as hightemperature materials.
PRECIOUS METALS
The family of metals called precious metals can be divided
into three subgroups:
(1) gold and gold alloys;
(2) silver and silver alloys; and
(3) "platinum group" metals.
Non-metals
B.1)Naturals
wood
granite etc
B.2) Artificials
Polymers
Rubber
Thermoplastics
Thermosets etc
Ceramics
Glass
Cermets
Composites
Metal matrix composites
Ceramic matrix composites
Polymer matrix composites
Polymers
Plastics: A plastic is a synthetic material of
high molecular weight, composed of repeating
organic chemical units.
Plastics can be moulded or formed into useful
shapes by various proceses usually involving
heat and/or pressure.
Plastics are not found in nature.They are
made synthetically from basic chemical raw
materials called monomers.
alkyd,
aminos(melamine),
epoxy ,
polyester,
polyurethan,
Silicone
etc
ADDITIVES
Few plastics are used on their own.
Nearly all contain a number of additives to
improve the properties, to facilitate processing
or to reduce costs.
the following are the important additives
employed by the plastics industry.
colourants, filler, catalysts, plasticizers,
stabilizers, fibre reterdants, labricants.
STRUCTURAL FOAM
While several different methods are used to
produce structural-foam parts, all systems
disperse a gas into the polymer melt during
processing.
This is done either by adding a chemical
blowing agent to the compound or by inducing
a gas directly into the melt.
The gas creates the cellular core structure in
the part during the moulding process making
the material more efficient in terms of strength
to weight ratio compared to conventional
mouldings
ELASTOMERS
These are commonly refered to as "rubbers
The ASTM defines an elastomer as "a
polymeric material which at room temperature
can be stretched to at least twice its original
length and upon immediate release of the
stress will return quickly to approximately its
original length".
CERAMICS
Generally, ceramics are hard and brittle and cannot
endure high tensile loads or sudden impact.
On the other hand, ceramics have high compressive
strengths and resistance to high temperature.
Ceramics are made of metal oxides, metal carbides,
and silicates, though some borides, hydrides, sulfides,
and nitrides are also in use in industry.
Ceramics can be made into bricks, trbine blades,
grinding wheels, carbide bits to machine materials.
These are only few examples of the ceramic products.
Ceramics are becoming increasingly important as
materials used in manufacturing.
They have had extensive use in the electrical industry
due to high electrical resistance.
high temperature,
compressive loads,
severe abrasion,
corrosion,
extreme rigidity,
creep resistance,
high-temperature corrosion resistance, and
special physical properties.
CARBON
Carbon, a nonmetallic element, exists in three
generic forms:
diamond,
graphite and
black, or amorphous carbon.
Graphite is
readily machinable,
resist heat and thermal shock,
a good heat conductor, and
is chemically inert to almost all corrosives except
strong oxidizing agents.
COMPOSITE MATERIALS
Composite is a combination of two or more
materials that has the properties that the
components do not have by themselves
composites bring the superior properties of
components together to serve better in
applications like:
high strength
high temperature ,
good lubricity
good chemical resistance ,
low density,
ease of processing
etc.
Laminated
Honeycomb
Sandwch
Corrugated
Waffle