Why Study Materials?

Materials have played

a significant role in
field of engineering
and education
Materials in
bulletproof vests worn
by Police
Warm, lightweight,
waterproof winter
coats
FYI
Interesting points about advanced
materials
Markets for advanced ceramics grew from less
than $2 billion in 1987 to over $20 billion in
2000
Materials consume up to 50% of manufactured
goods cost
According to U.S. Office of Technology, a key to
remaining competitive in the world is to train
more scientists and technologists with a broad
background in advanced materials
History of Materials
Science Babylonians first
makers of ceramic
building materials
Imprinted clay tablets
used to teach trades
from parents to
offspring in 2200 B.C.
Time periods named
after dominantly-used
material
http://www.livius.org/zo-zz/zopyrus/zopyrus.html
Time Periods
8000 B.C. - Hammered Copper
7000 B.C. - Clay Pottery
6000 B.C. - Silk Production
5000 B.C. - Glass Making
4000 B.C. - Smelted Copper (Bronze Age)
1000 B.C. - Iron Age
500 B.C. - Cast Iron
300 B.C. - Glass Blowing
105 A.D. - Paper
Time Periods
600 - 900 - Porcelain
1540 - First Foundries
1774 - Crude Steel
1789 - Discovery of Titanium
1800 - Battery
1824 - Portland Cement
1850 - Reinforced Concrete
1856 - Bessemer Steel-making Process
1870 - Celluloid Production
Time Periods
1871 - Periodic Table
1884 - Nitrocellulose
1886 - Electrolytic Reduction of Aluminum
1891 - Silicon Carbide
1907 - First Totally Synthetic Polymer
1923 - Tungsten Carbide
1930 - Fiberglass
1937 - Nylon
1947 - Germanium Transistor
Time Periods
1950s - Silicon Photovoltaic Cells &
Transistors
1958 - Ruby Laser
1959 - Integrated Circuit
1966 - Fiber Optics
1986 - High Temperature Super Conductors

Data Courtesy of Dept. of Energy and Energy Concepts, Inc.

New Materials
New materials are designed based on need

Engineers can design without worrying if a

material exists for their application
Characteristics of
Materials
Strength (Stiffness)
Ability to resist effects of tension, compression,
and torsion forces
Ductility
How well a material can be shaped without
fracturing
Brittleness
When a material will break while undergoing
small deformations
Characteristics of
Materials
Hardness
Ability to resist indentation and wear
Elasticity
Ability to return to original shape after
deformation
Electrical Conductivity
Ability to conduct electrons/electricity
Thermal Conductivity
Ability to conduct heat
Classifying Materials
Metals

Ceramics

Polymers

Composites
 Materials

Monolithic Hybrids Composites: have two (or more)

solid components; usually one is a
Metals (& Alloys) Composite matrix and other is a reinforcement

Ceramics & Glasses Sandwich structures: have a

Sandwich material on the surface (one or
more sides) of a core material
Polymers (& Elastomers)

Lattice Lattice* Structures: typically a

combination of material and space
(e.g. metallic or ceramic forms, aerogels
Segment etc.).

Segmented Structures: are Hybrids are designed

divided in 1D, 2D or 3D to improve certain
(may consist of one or properties of
monolithic materials
more materials).
Common materials: with various viewpoints

Graphite
Glass: amorphous
Ceramics

Crystal
Metals Polymers
Metals
Earliest used were native metals
Copper, Gold, Silver, and Iron
Can be classified as Ferrous or Non-Ferrous
Ferrous
Contain 50%+ of iron
Attract magnetic materials

Non-Ferrous
Contain less than 50% iron
Do not attract magnetic materials
Higher corrosion resistance
 METALS
Combinations of metallic elements
Non bound electrons thermal/electrical conductivity.

Steel gear produced using Powder Metallurgy

Close dimensional tolerance and high strength and wear resistance
Metals Mechanical
Properties
Strong
Tough
Malleable
Ductile
Most are
Opaque
Lustrous
Dense
Good Heat and Electric Conductors
High Melting Point
Metal Facts
Iron and Steel are 1st and 2nd most
commonly used metals

Aluminum is third
Lightweight
Can be stronger than steel
 CERAMICS
Compounds between metals and non-metals
Properties
Ceramics
Derived from Greek word - keramos
Burned material
Early applications were building materials and
containers
Glass, although considered a ceramic, is a
separate part
Lacks crystalline organization
No orderly atomic structure
Ceramics
Clay products
Refractories
Used in high
temperature
applications
Made of clay

Abrasives
Extremely hard, pure,
ceramic compounds or
mixtures
http://skovsantik.dk/keramik+stentj.htm
Glasses
 POLYMERS
Organic compounds
mainly based on Hydrogen, Carbon, and non-metallic element

Fighter plane fully covered with a paint replacement adhesive

$3 BILLION SAVED OVER LIFE TIME COSTS
Polymers
Formed by Greek
words:
Poly - Many
Mer - Parts
Natural Materials
Wood, leather, cotton,
wool, silk, rubber
Polymers processed
by plants and animals
Proteins, Enzymes,
starches, and cellulose
Plastics
Plastics
Polymers and Plastics ARE NOT the same
Plastics are a member of the polymer group
Are Synthetic Polymers
Thermoplastic
Can be reformed
Recyclables

Thermoset
Once set, cannot be softened by heat
More About Polymers
Are not strong

Good electrical insulators

Low melting temperatures

Polyethylene
Terephthalate PETE
Recycle Code - 1
Most comes from
beverage containers
99% pure, granulated
recycled PETE sells half
cost of new PETE
Recycled Uses
Fiberfill of jackets,
strapping, liquid soap
bottles, surfboards, paint
brushes, tennis ball fuzz,
and more beverage
bottles
http://www.designinsite.dk/htmsider/mb0011.htm
High-density
Polyethylene
HDPE
Recycle Code - 2
Well-developed process
for recycling
Recycled Uses
Drain pipes, flower pots,
plastic lumber, trash cans,
automotive mud flaps,
kitchen drain boards,
beverage bottle crates,
stadium seats, recycling http://www.inglass.com/hdpe_bottles.htm
bins, traffic barrier cones,
golf bag liners, and toys
Polyvinyl Chloride or
Vinyl PVC or V
Plastic Separating System
Recycle Code - 3
Not burned due to
release of hazardous
fumes
Dioxins and Furans
Recycled Uses
Drainage pipes, pipe
fittings, floor tiles,
bottles, doormats,
hoses, mud flaps
http://www.labs.nec.co.jp/rel/english/topics/t12.html
Low-density
PolyethyleneLDPE
Recycle Code - 4
Burned in incinerator-
powered generators to
produce electricity
Recycled Uses in where
color is not important
Garbage can liners,
grocery bags, paint
buckets, fast food trays,
http://www.pop-international.com/POP/products_plastic.htm
lawn mower wheels, and
automobile battery parts
Polypropylene
PP
Recycle Code - 5
Recycled Uses
License plate
holders, desktop
accessories,
hanging files, food
http://www.cawalker.co.uk/index.asp?id=43 service trays,
flower pots, and
trash cans
Polystyrene
PS
Recycle Code - 6
Most challenging to
recycle
Styrofoam cups and
packing material made
Some methods for
recycling in place
Chemists still looking for
more effective ways to
recycle huge amounts
http://www.lafourmi.be/contenu/produits/decorer/
decorer_polystyrene.html
Composites
Combination of two or more constituent
materials bonded together in an effort to
provide better properties than those of the
individual materials

Ubiquitous in recreational equipment

Used extensively in International Space

Station and make over 10,000 pounds of
each space shuttle
Composite History
Ancient Israelites and Egyptians added straw
to bricks to hold them together
Incas used plant fibers to strengthen pottery
The Colosseum (Coliseum) and other ancient
Roman structures were held together with
cement containing slackened lime and
pozzolana (hydraulic cement)
Slackened Lime
Heating lime and crumbling by adding water

Pozzolana
Volcanic ash
What consists in a
composite?
Reinforcement
Part that provides strength to composite
Shape of a fiber, whisker, or particulate

Matrix
Glue that holds everything together

Boundary in between
Lay Ups
Unidirectional and bidirectional carbon fiber,
Kevlar, and plain-weave fiberglass used in lay
ups

Composed of consecutive layers of fabric,

resin, and sometimes a core material
Laid Up By Hand vs.
Factory
Form materials on a Factory has
mold and paint the materials with epoxy
them on the matrix matrix pre-
of resin (epoxy) impregnated into
My Be Difficult to
More expensive
Use, but inexpensive
Less mess/easy-use
Combined by two
different parts
Resin
Hardner
Epoxy Matrix
When mixed, has a specific time to spend
in container to be used
pot life
Also has prescribed work time based on
amount of hardener used
Time available to work with materials by
placing and forming into mold/application
Start of hardening process is called going off
When matrix goes off, little work time remains
Effective Lay Up
Procedure
1. Fabric is cut to appropriate size
2. Bag, peel ply, perforated plastic, and bleeder
cut to appropriate sizes
3. Mold is prepared with gel coat, mold release
and/or wax
4. Correct amount of resin and hardener used
5. Pot life is not compromised
6. Material laid up within appropriate work time
Effective Lay Up
Procedure
7. No sections of the lay up are starved
(without correct amount of matrix or the
resin or epoxy)
8. No sections are over filled with matrix
9. Good seal on the vacuum bag (12-15psi)
10. Peel ply is able to be removed with no
folds/creases
11. Mold is released from fabric
12. Clean up of work area completed promptly
 COMPOSITES

* Metal matrix composites (MMCs)

* Ceramic matrix composites (CMCs)

SiC Alumina

10 m
Fibers

* Polymer composites - fiberglass

ULTRALIGHT MATERIALS METALLIC FOAMS
 ADVANCED MATERIALS
High performance applications

Nickel based super alloys Turbine blade mechanically fixed to the

rotor of a high performance gas turbine engine
Thanks