Engineering Materials
Instructors
Rabya Aslam
Engr. Ali Nadeem
Institute of Chemical Engineering & Technology
University of the Punjab, Lahore
rabya.icet@pu.edu.pk
July, 2016
Learning objectives
To learn about the materials used for various
engineering purposes, and study of their suitability for a
specific end use.
Books
Smith, William Fortune (1990), Principles of
Materials Science and Engineering 2nd Ed. New
York: McGraw-Hill.
William D. Callister. Jr., (2002), Materials Science
and Engineering, 6th Edition, Wiley & Sons.
Srivastava C.M., Srinivasan C. (2000) Science of
Engineering Materials 2nd Ed. New Age
International Limited, Publishers.
Engineering materials
Materials are the substances of which anything is
composed of.
Engineering materials are the substances used to
produce society beneficial products or technical
products.
There is no distinguishable line between both
Materials and Engineering Materials, and they can be
used interchangeably.
Examples
?
7
Engineering Materials
What is Materials Science?
Why should we know about it?
Materials drive our society
Stone Age
Bronze Age
Iron Age
Now?
Silicon Age?
Polymer Age?
Metals
Ceramics
Electronic
Composites
Polymeric
Metals
Composites
Ceramics
Electronic
Polymeric
(Semiconductors)
Biomaterials
Advance
Materials
10
Engineering materials
Metals
Ceramics
Polymers
Composites
Electronic
Engineering materials
Biomaterials
Advance
materials
12
13
atomic number =
# of protons in nucleus of atom
= # of electrons
atomic mass unit = amu = 1/12 mass of 12C
Atomic wt = wt of 6.022 x 1023 molecules or atoms
1 amu/atom = 1 g/mol
14
15
Electronic Structure-Revision
Electrons have wavelike and particulate properties.
Two of the wavelike characteristics are
electrons are in orbitals defined by a probability.
each orbital at discrete energy level is determined by
quantum numbers.
Quantum #
Designation
, -
16
N-shell n = 4
3d
4s
Energy
3p
3s
M-shell n = 3
2p
2s
L-shell n = 2
1s
K-shell n = 1
17
valence electrons
18
Periodic table-Revision
accept 2eaccept 1einert gases
He
Li Be
F Ne
Na Mg
Cl Ar
K Ca Sc
Rb Sr
Cs Ba
Se Br Kr
Te
Xe
Po At Rn
Fr Ra
Electropositive elements:
Readily give up electrons
to become + ions.
Adapted from Fig. 2.8, Callister & Rethwisch 9e.
Electronegative elements:
Readily acquire electrons
to become - ions.
19
Electronegativity-Revision
Ranges from 0.9 to 4.1,
Large values: tendency to acquire electrons.
Smaller electronegativity
Larger electronegativity
20
Primary bonding-Revision
Primary or chemical bonding
1. Ionic bonding
2. Covalent bonding
3. Metallic bonding
21
Ionic bonding-Revision
Ionic bond metal
donates
electrons
nonmetal
accepts
electrons
Dissimilar electronegativities
ex: MgO
22
Ionic bonding-Revision
Na (metal)
unstable
Cl (nonmetal)
unstable
electron
Na (cation)
stable
Cl (anion)
stable
23
Ionic bonding-Revision
Predominant bonding in Ceramics
NaCl
MgO
CaF 2
CsCl
Give up electrons
Acquire electrons
24
Covalent bonding-Revision
Atoms with similar electronegativity share electrons
Example: H2
H2
shared 1s electron
from 1st hydrogen
atom
shared 1s electron
from 2nd hydrogen
atom
Covalent
bonding-Revision
Covalent
Bonding:
Carbon sp3
Example: CH4
C: has 4 valence e-,
needs 4 more
H: has 1 valence e-,
needs 1 more
Electronegativities of C and H
are comparable so electrons
are shared in covalent bonds.
26
MetallicBonding:
bonding-Revision
Covalent
Carbon sp3
Metallic bonding, the final primary bonding type, is found in
metals and their alloys and is mainly due to delocalized or
free valence electrons.
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x (100%)
XMg = 1.3
XO = 3.5
28
Secondary
bonding-Revision
Covalent
Bonding:
Carbon sp3
van der Waals forces are week in comparison to primary
bonding and arises due to attraction between molecules.
29
Secondary bonding-Revision
Arises from interaction between dipoles
asymmetric electron
clouds
secondary
bonding
H Cl
secondary
bonding
H Cl
30
Secondary
bonding-Revision
Covalent
Bonding:
Carbon sp3
The strongest secondary bonding type, the hydrogen
bond, is a special case of polar molecule bonding. It
occurs between molecules in which hydrogen is
covalently
bonded to fluorine (as in HF), oxygen (as in H2O ),
and nitrogen (as in NH3 ).
31
Summary-Revision
Comments
Type
Bond Energy
Ionic
Large
Nondirectional (ceramics)
Covalent
Variable
large-Diamond
small-Bismuth
Directional
(semiconductors, ceramics
polymer chains)
Metallic
Variable
large-Tungsten
small-Mercury
Nondirectional (metals)
Secondary
smallest
Directional
inter-chain (polymer)
inter-molecular
32
Properties
inferred
fromTmbonding-Revision
Properties From
Bonding:
Bond length, r
Melting Temperature, Tm
Energy
r
Bond energy, Eo
ro
Energy
r
smaller Tm
unstretched length
ro
Eo=
bond energy
larger Tm
Tm is larger if Eo is larger.
33
Summary:
Primary Bondsdue to bonding
Summary-Properties
Ceramics
(Ionic & covalent bonding):
Metals
(Metallic bonding):
Polymers
(Covalent & Secondary):
34
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37
Important terminologies-Revision
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Electrical Properties
(resistivity, conductivity, capacitance)
Thermal Properties
(Melting point, latent heat, thermal shock resistance, thermal conductivity,
thermal expansion, specific heat)
Magnetic properties
(Reluctance, magnetic hysteresis, permeance)
Chemical properties
(chemical composition, atomic weight, molecular weight, reactive nature etc.)
Physical properties
(specific gravity, density, porosity, bed density)
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48
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50
Engineering Materials
51
Engineering Materials
Revision of phase
diagrams
Discuss applications of
Metals
Alloys
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Alloys
Alloys?
The term alloys is used to describe a mixture of elements
where primary component is a metal.
That primary metal is called base metal.
Why to form alloys?
To improve mechanical properties. (Iron is relatively soft
metal, carbon is brittle in nature but steel alloys of Fe and C
is tough and has high tensile strength.
To improve corrosion resistance.(Example, Cr is added in
steel to improve its corrosion resistant properties in oxidizing
environment).
To vary physical properties e.g. melting points.
55
Phase Diagrams
Phase B
Phase A
Nickel atom
Copper atom
Phase Diagrams
Sugar/Water Phase Diagram
100
Temperature (C)
Solubility
Limit
80
60
40
(liquid solution
i.e., syrup)
Water
20
40
(liquid)
+
S
(solid
sugar)
20
0
60
80
100
Sugar
(wt% sugar)
Class activity
What is the solubility limit for sugar in water at 20 C?
Sugar/Water Phase Diagram
Temperature (C)
10 0
Solubility
Limit
80
L
(liquid)
60
40
(liquid solution
i.e., syrup)
+
S
(solid
sugar)
20
0
Water
20
40
60
(wt% sugar)
80
100
Sugar
58
59
Liquid, L
Liquidus Line
Solidus
Line
Solid,
60
61
Liquid, L
Liquidus Line
Solidus
Line
Solid,
62
Amount of solid
phase
63
Class activity
65
Liquidu
s
Solid
us
solution rich in
copper, is
solid solution
rich in silver.
Solv
us
66
Solv
us
67
Class activity
68
Class activity
69
Class activity
Using NaCl-water
phase diagram,
explain how
spreading salt on ice
that is at 0 oC can
cause the ice to
melt.
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Temperature (oC)
MP
1538
o
C
1394
o
C
912
o
C
727
o
76
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MP = 327.5 oC
BP = 1749 oC
= 11.34 g/cm3
Titanium
Titanium is a hard and shiny metal. It is as
strong as steel but much less dense.
Its alloys with Al, Mo etc. are widely used in
aircraft, spacecraft and missiles because of
their low density and ability to withstand
extremes of temperature.
Titanium metal connects well with bone, so it
has found surgical applications such as in
joint replacements (especially hip joints) and
tooth implants.
It is resistant to chloride solutions, including
sea water and wet chlorine, therefore, widely
used as MOC for shell and tube heat
exchangers and plate exchangers.
MP = 1670 oC
BP = 3287 oC
= 4.51 g/cm3
79
Tantalum
Tantalum is shiny silver non-toxic transition metal that is
highly corrosive resistant. Corrosion resistant properties
are similar to glass therefore called as metallic glass. It
is quite expensive (about 5 times of stainless steel) and
only used for special applications.
Used as lining material where glass lining is not
suitable.
One of the main uses of tantalum is in the production
of electronic components. An oxide layer which forms
on the surface of tantalum can act as an insulating
(dielectric) layer.
MP = 3017 oC
BP = 5455 oC
= 16.4 g/cm3
Zirconium
Zirconium is a hard, silvery transition metal and is
very resistant to corrosion. Its resistance is
equivalent to Ta but Zr is less expensive, similar in
price to high nickel steel.
MP = 1855 oC
BP = 4406 oC
(RT) = 6.52 g/cm3
MP = 1538 oC
BP = 2862 oC
(RT) = 7.87 g/cm3
82
Iron alloys
Ferrous
Alloys
Steel
Low
carbon
steel
Medium
carbon
steel
Cast Iron
High
carbon
steel
ductile Iron
Grey Iron
white Iron mallea
ble
IronCompac
ted Iron
83
Low carbon
steel
Medium
carbon
steel
High carbon
steel
84
85
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Stainless Steel
The stainless steels are highly resistant to corrosion (rusting) in
a variety of environments, especially the ambient atmosphere.
Their predominant alloying element is chromium (up to 20%).
Corrosion resistance may also be enhanced by nickel and
molybdenum additions.
These are further divided into three categories
1-Ferritic SS (13-20 %Cr, 0.1 %C )
2- Austenitic SS (18-20 % Cr, 7% Ni, widely used category)
3- Martensitic SS (10-12 % Cr, 0.2-0.4 % C, up to 2% Ni)
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93
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Cast Iron
Cast Iron
Cast Iron
Generically, cast irons are a class of ferrous alloys with
carbon contents above 2.14 wt%.
In practice, most cast irons contain between 3.0 and 4.5
wt% C.
There MP is less than steels. They are easily melted
and amenable to casting. Moreover, some cast irons are
very brittle, and casting is the most convenient
fabrication technique.
For cast irons at, C exists as graphite in iron.
97
Cast Iron
98
99
101
102
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Non-Ferrous Alloys
Examples:
Copper and its alloys
Aluminum and its alloys
Nickel and its alloys
104
MP = 1085 oC
it could be hardened with a little tin to form the alloy bronze.
BP = 2563 oC
Traditionally it has been one of the metals used to make = 8.96 g/cm3
coins, along with silver and gold.
Due to excellent electrical and heat conductivity, most copper
is used in electrical equipment such as wiring and motors.
It is also used uses as MOC for heat exchangers.
Copper sulfate is used widely as an agricultural poison and as
an algicide in water purification.
Copper compounds, such as Fehlings solution, are used in
chemical tests for sugar detection.
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107
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Aluminium Alloys
The main structural alloys used are the Duralumin (Dural) range of
aluminium copper alloys (typical 4 % Cu with Mg and Mn)
Dural have a tensile strength equivalent to that of mild steel. It is used
where good machinability and good strength are required (wire, rod, and
bar for screw machine products). The pure Al metal can be used as a
cladding on Dural plates, to combine the corrosion resistance of the pure
metal with the strength of the alloy.
109
Nickel
Nickel is silvery metal that resists corrosion
even at high temperatures.
Nickel resists corrosion and is used to layer other
metals to protect them. It is mainly used in making
alloys such as stainless steel, Hastelloy, Inconel,
o
MP
=
1455
C
Monel etc.
o
BP = 2913 C
Nickel is used in batteries, including rechargeable = 8.90 g/cm3
Nickel alloys
Monel: Classical Ni-Cu Alloy( metal ratio 2:1) is most common
alloy for chemical plants after steel. It is more expensive than
SS but is not susceptible to stress cracking corrosion.
Inconel: 76% Ni, 7 % Fe, 15 % Cr is primarily used for acid
resistance at high temperature. It is also used for propeller
shafts, hot vessels for food and water, chemical processing
equipment, gas turbines, aircraft, and tank trucks.
Hastelloys: It is registered trade name of alloys of Ni, Cr, Mo,
and Fe that were developed for corrosion resistance to strong
mineral acids e.g. HCl. Primary metal is nickel. These have
good ductility and extensively used in welding applications.
Nichrome: It is an alloy of nickel and chromium with small
amounts of silicon, manganese and iron. It resists corrosion,
111
even when red hot, and is used in toasters and electric ovens.
Refractory metals
Metals that have extremely high melting
temperatures are classified as the refractory metals.
Niobium (Nb), molybdenum (Mo), tungsten (W), and
tantalum (Ta). MP ranges between 2400 to 3410 oC.
Tantalum and molybdenum are alloyed with stainless
steel to improve its corrosion resistance.
Molybdenum alloys are utilized for extrusion dies and
structural parts in space vehicles, x-ray tubes.
Welding electrodes employ tungsten alloys.
Niobium is used in welding and nuclear industries,
electronics, optics, numismatics, and jewelry.
112
Noble metals
The noble or precious metals are expensive and
characteristically soft, ductile, and oxidation resistant.
Examples include silver, gold, platinum, palladium,
rhodium, ruthenium, iridium, and osmium.
The Ag, Au, Pt are most common and are used
extensively in jewelry.
Alloys of both silver and gold are employed as dental
restoration materials
Platinum is used for chemical laboratory equipment, as a
catalyst and in thermocouples to measure elevated
temperatures.
Rh, Ru are used as catalyst and promoters.
Iridium is normally used in the production of platinum
alloys (with 5 to 10% of iridium)
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Engineering Materials
Ceramics
114
Ceramics
Derived from Greek word Keramos; meaning burnt clay.
Inorganic or non-metallic materials.
Non metallic materials which are processed and used at high
temperature.
Now a days, Study and manufacturing of ceramic materials is the
art and science of making and using inorganic and dominantly nonmetallic materials formed by the action of heat.
Examples are
Glass
Traditional ceramics
Refractories
Clay Products and cement
Advanced Ceramics
Modern ceramics
115
Glass
Glass are non-crystalline silicates containing other oxides (CaO,
Na2O, Al2O3 etc.)
SiO2 + Na2CO3
Na2SiO3 + CO2
Glass
117
*Callister, 7th edition
Liquid
(disordered)
Supercooled
Liquid
crystallization
Glass
Crystalline Solid
solid
Tg
Tm
119
Viscosity [Pa-s]
10 14
annealing point
10 10
10 6
Working range:
glass-forming carried out
10 2
1
200
Tmelt
600
1000
T(C)
1400
121
122
Pressin
g
Plunger
Raw glass/
gob
Mol
d
123
Pressing operation
Initial mold
Compressed air
Step
2
Suspended
parison
Finishing
mold
124
125
Fig. 17.26, Callister & Rethwisch 9e. (Courtesy of Pilkington Group Limited.)
orific
es
cooling
Fig. 17.25, Callister & Rethwisch 9e. (Courtesy of Pilkington Group Limited.)
Types of Glasses
Soda Lime glass
Lead glass
Borosilicate glass
High Silica glass
Special glasses
Colored glass
High strength glass
Laminated glass
128
Types of Glasses
1: Soda Lime glasses
SiO2 and Na2O are main ingredients,
composition of Al2O3, K2O, CaO etc
varies with application.
It is used in window glasses, electric
bulbs, bottles, cheap table ware etc.
2: Lead Glasses/ flint glasses/ lead
crystal glasses
Contains 18-40 % PbO.
It is used as optical glasses, shield to
protect X-rays, neon sign tubing etc.
129
Types of Glasses
3: Borosilicate glasses/ Pyrex
It contains silica, B2O3, Al2O3 and small
amount of alkaline oxides. Highly
chemical resistant.
It is used for laboratory glass wares and
cook wares such as baking dishes etc.
4: High Silica glass
Contains higher amount of Silica ( 90%).
Highly durable and heat resistant. Used
to manufacture lab wares such as
crucible and glass wool etc.
130
Special Glasses
a) Colored glasses: manufactured by adding coloring
ions.
Iron (II) oxide may be added to glass resulting in bluish-green glass which is
frequently used in beer bottles.
Iron oxide with Cr it gives a richer green color, used for wine bottles.
Materials
Color added to glass
Potassium dichromate greenish yellow
Mgo
purple or pink
Cobalt oxide
blue (royal blue/ intense blue)
Cuprous salt
red
Cupric salt
blue
Gold chloride
ruby
Carbon
amber
131
Special Glasses
b) High strength glass
Contains 65% SiO2, 25 % Al2O3 and up to 10 % MgO.
It is used in military and aerospace applications.
c) Laminated glass
It is manufactured by placing a non-brittle plastic sheer between
two glass layers.
Used in cars, buses, and for safety purposes.
Bullet proof glasses also falls in this category.
132
Ceramics: Refractories
Materials which can withstand high temperature and thermal
shocks are termed as refractory materials.
The salient properties of these materials include
the capacity to withstand high temperatures without melting or
decomposing
the capacity to remain unreactive and inert when exposed to
severe environments
the ability to provide thermal insulation is often an important
consideration.
Mainly used in Furnaces, Nuclear reactors, Missiles, etc.
133
strength
at
operating
134
Types of Refractories
Acidic Refractories (Silica bricks, Fireclay bricks,
Alumina bricks: used in arched roof of steel and glass
making furnaces)
Basic refractories (rich in periclase or MgO: used in
steel making open hearth furnaces, furnaces used in
refining Au, Ag and Pt)
Neutral refractories (graphite, chromite; in making
stainless steel)
Super refractories (ThO2,BeO, ZrO2,3Al2O3-2SiO2: high
temp applications up to 3200 oC and in chemical
reactors)
135
136
Table 13.2 , Callister & Rethwisch 6e.
Modern Ceramics:Nano-tubes
Fullerenes spherical cluster of 60 carbon atoms, C60 like a
soccer ball
Carbon nanotubes sheet of graphite rolled into a tube with
ends capped with fullerene hemispheres
137
Callister & Rethwisch 9e.
Modern Ceramics
Graphene single-atomic-layer of graphite composed of
138
Callister & Rethwisch 9e.
Applications of Ceramics
Die blanks and die surfaces: due to
wear resistant properties.
For example 4m polycrystalline
diamond particles that are sintered
onto a cemented tungsten carbide
substrate. This polycrystalline
diamond gives uniform hardness in all
directions to reduce wear.
Tools:
-- for grinding glass, tungsten,
carbide, ceramics
-- for cutting Si wafers
-- for oil drilling
139
Applications of Ceramics
Sensors: due to Piezoelectric properties.
Commonly used piezoelectric ceramics include barium titanate (BaTiO 3), lead
titanate (PbTiO3), and potassium niobate (KNbO3). Common applications are
transducers, strain gauges, ultrasonic detectors.
Refractory materials:
For high temperature applications
141
Polymeric materials
Polymers are high molecular weight compounds whose structure
are made up of large number of simple repeating units.
Derived from Greek word poly-, "many" + -mer, "part"
Monomers: repeating unit; mono-, single/one" + -mer, "part"
Examples:
Polyethylene, Polyethylene terephthalate, Nylon etc.
142
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145
146
147
148
Examples: Polyethylene,
polymethylmethacrylate, polypropylene
Thermosetting polymers
Polymers which cannot be remelted or reformed upon heating.
These are normally network polymer containing cross-linked
molecules that does not soften when heated.
150
151
152
Bulk Polymerization
Simplest of the techniques requiring only monomer and
monomer-soluble initiator.
Process is extensively used for condensation
polymerization.
Difficulty of removing unreacted monomer and heat control
are negative features.
Examples of polymers produced by bulk polymerization
include poly(methyl methacrylate), polystyrene, and lowdensity polyethylene.
153
Solution Polymerization
Monomer and initiator must be soluble in the
liquid and the solvent must have the desired
chain-transfer characteristics, boiling point
(above the temperature necessary to carry out
the polymerization).
The presence of the solvent assists in heat
removal and control.
Polymer yield per reaction volume is lower than
for bulk reactions. Also, solvent recovery and
removal (from the polymer) is necessary.
Examples: water-soluble polymers prepared in
aqueous solution polyacrylamide, and
poly(Nvinylpyrrolidinone).Polystyrene, poly(vinyl
chloride), and polybutadiene are prepared from
154
Suspension Polymerization
The monomer is mixed with catalyst and then dispersed as
suspension in water.
Droplets of monomer containing initiator and chain-transfer
agent are formed. A protective colloidal agent, often
poly(vinyl alcohol), is added to prevent coalescence of the
droplets.
Because the liquid is water-based, solvent recovery and
treatment problems are minimal.
Examples: polystyrene resins, and copolymers such as
poly(styrene-coacrylonitrile)
155
Emulsion Polymerization
Similar to suspension polymerization, however, an emulsifier
is added to disperse the monomers in to very small particles.
It is customary to use a water-soluble initiator such as
potassium persulfate and surfactant sodium sterate.
Many water-soluble vinyl monomers may be polymerized by
the emulsion polymerization technique.
156
Crystallinity:
Polymers are amorphous materials, however, sometimes portion of
chain attains such an arrangement that they become crystalline.
Crystallinity results in
Increase in MP.
Prevents solvent attack
Increase ultimate strength and reduce % elongation
158
plastic
elastomer
159
160
Melting temperature, TM
This is the point at which the crystalline polymer molecules have gained
enough vibrational freedom to break free from the solid binding forces and
form a liquid.
161
Elastomers
Elastomers are elastic materials that stretch to high extensions and
rapidly recover their original dimensions once the applied stress is
released. They are formed by a loose network. Styrene-butadiene rubber
(SBR) and ethylene-propylene-diene monomer (EPDM) are examples of
important elastomers.
162
163
PET/PETE is a
clear, strong, and lightweight plastic that is widely used for
packaging foods and beverages, especially conveniencesized soft drinks, juices and water. It is one of the major
consumable plastic in the world. Most commonly used
method for production of PET on industrial scale is based on
copolymerization of ethylene glycol and terephthalic acid. It
is an amorphous and rigid polymer.
Applications
Soft drink bottles
Carpets
Rope
Fabrics and Cassette manufacturing etc.
164
PE is produce by addition
polymerization of ethylene. Three types are available in
market; High density polyethylene (HDPE), ultrahigh
molecular weight polyethylene and low density polyethylene
(LDPE).
Applications
Food containers
Detergent bottles
Garden furniture
Shopping bags
Coating cables etc.
165
It is produced by polymerization of
styrene. it is an amorphous, non flexible polymer which has
very good insulation properties.
Applications
Radio & TV parts
Toys
Electronic Components
Window frames
Disposable cups
Foam Containers
166
Applications
Nylon 6,6 is used when high mechanical strength,
rigidity and good stability under heat and/or chemical
resistance are required.
It is used in fibers for textiles and carpets.
Used in manufacturing of airbags.
167
168
FCC structure
169
BCC structure
170
Polymerization Processes
171