introduction to materials science & engineering

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Chapter 1 - 1 MSE XXX: Introduction to Materials Science & Engineering Course Objective... Introduce fundamental concepts in Materials Science You will learn about: material structure how structure dictates properties how processing can change structure This course will help you to: use materials properly realize new design opportunities with materials

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Page 1: Introduction to Materials Science & Engineering

Chapter 1 - 1

MSE XXX: Introduction to Materials Science & Engineering

Course Objective...Introduce fundamental concepts in Materials Science

You will learn about:• material structure• how structure dictates properties• how processing can change structure

This course will help you to:• use materials properly• realize new design opportunities

with materials

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LECTURESLecturer:Time: Location: Activities:

• Present new material• Announce reading and homework• Take quizzes and midterms*

*Make-ups given only for emergencies.*Discuss potential conflicts beforehand.

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RECITATIONS

Purpose:• Discuss homework, quizzes, exams• Hand back graded quizzes, exams• Discuss concepts from lecture

Instructor:Times and Places:

___.___.___.___.___.

X:XXamX:XXpmX:XXpmX:XXamX:XXpm

_____ XXX_____ XXX_____ XXX_____ XXX_____ XXX

Recitations start next week. Try to attend your registered recitation.If necessary, attend an alternate recitation.

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Purpose: To learn more about materials by relating lecture material with observations. Also to learn to properly formulate and write engineering reports and proposals.

Instructor:

Location:

LABORATORY SECTIONS

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TEACHING ASSISTANTS

Teaching Assistants will• participate in recitation sessions,

• have office hours to help you with course material and problem sets.

Name_________________________

Office_____ XXX_____ XXX_____ XXX_____ XXX_____ XXX

Tel.X-XXXXX-XXXXX-XXXXX-XXXXX-XXXX

E-mail_________________________

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OFFICE HOURS

Activities:• Discuss homework, quizzes, exams• Discuss lectures, book• Pick up missed handouts

X:XX-X:XX each weekday**____.____.____.____.____.

_____ XXX_____ XXX_____ XXX_____ XXX_____ XXX

_________________________

**Contact professors for special arrangements

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Required text:• Materials Science and Engineering: An Introduction,

W.D. Callister, Jr. and D.G. Rethwisch, 8th edition, John Wiley and Sons, Inc. (2010).

COURSE MATERIALS (with text)

• _____________.

Optional Material:• _____

________.• _____

________.

Page 8: Introduction to Materials Science & Engineering

Chapter 1 - 8

Required text:• WileyPLUS for Materials Science and Engineering: An Introduction,

W.D. Callister, Jr. and D.G. Rethwisch, 8th edition, John Wiley and Sons, Inc. (2010).

COURSE MATERIALS (with WileyPLUS)

Website: http://www.wileyplus.com/xxxxxxxxxxx• Can be bought online at wileyplus.com for 40% of textbook price

• Includes complete online version of textbook• Or comes bundled with textbook at bookstore

• $5 more than textbook alone • Homework assignments with instant feedback and hints• Computer graded self-help problems• Hotlinks in homework to supporting text section• Quizzes

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Text Website: http://www.wiley.com/college/callister• VMSE for 3D visualization and manipulation of atomic structures• Mechanical Engineering and Biomaterials online support modules• Case studies of materials usage• Extended learning objectives• Self-assessment exercises

Course Website: http://www.xxx.edu/xxxxx• Syllabus• Lecture notes• Answer keys• Grades

WEBSITES

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Website: http://www.wileyplus.com/college/callisterStudent Companion Site

• Users can manipulate molecules and crystals to better visualize atomic structures

• Unit cells such as BCC, FCC, HCP• Crystallographic planes, directions, and defects• Polymer repeat units and molecules

• Diffusion computations

Virtual Materials Science & Engineering (VMSE)

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GRADINGWeekly in-lecture quizzes XX%

Held on _____ at the beginning of classBased on core homework problemsYour lowest quiz grade will be dropped

Midterm #1 XX%Tentatively scheduled for:Material covered:

Midterm #2 XX%Tentatively scheduled for:Material covered:

Final XX%Tentatively scheduled for:Material covered:

Page 12: Introduction to Materials Science & Engineering

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READING SCHEDULEWeek

123456

789

10

TopicGeneral Intro; Atomic Bonding

Crystalline Structures; ImperfectionsDiffusion; Mechanical Properties

Strengthening Mechanisms; FailurePhase Diagrams

Phase TransformationsApplications & Processing of Metal AlloysStruc., Prop., Proc., Applic. of CeramicsStruc., Prop. of Polymers; Composites

Corrosion; Elec. & Thermal Prop.Magnetic & Optical Prop.

Econ. & Envir. Issues

Chapter1,23,45,67,891011

12,1314,15,1617,18,19

20,2122

Lectures: will highlight important portions of each chapter.

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Chapter 1 - Introduction

• 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?

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Example – Hip Implant• With age or certain illnesses joints deteriorate.

Particularly those with large loads (such as hip).

Adapted from Fig. 22.25, Callister 7e.

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Example – Hip Implant

• Requirements– mechanical

strength (many cycles)

– good lubricity– biocompatibility

Adapted from Fig. 22.24, Callister 7e.

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Example – Hip Implant

Adapted from Fig. 22.26, Callister 7e.

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Hip Implant• Key problems to overcome

– fixation agent to hold acetabular cup

– cup lubrication material– femoral stem – fixing agent

(“glue”)– must avoid any debris in cup

Femoral Stem

Ball

AcetabularCup and Liner

Adapted from chapter-opening photograph, Chapter 22, Callister 7e.

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Example – Develop New Types of Polymers

• Commodity plastics – large volume ca. $0.50 / lbEx. Polyethylene

PolypropylenePolystyreneetc.

•  Engineering Resins – small volume > $1.00 / lbEx. Polycarbonate

NylonPolysulfoneetc.

 Can polypropylene be “upgraded” to properties (and price) near those of engineering resins?

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ex: hardness vs structure of steel • Properties depend on structure

Data obtained from Figs. 10.30(a)and 10.32 with 4 wt% C composition,and from Fig. 11.14 and associateddiscussion, Callister & Rethwisch 8e.Micrographs adapted from (a) Fig.10.19; (b) Fig. 9.30;(c) Fig. 10.33;and (d) Fig. 10.21, Callister & Rethwisch 8e.

ex: structure vs cooling rate of steel • Processing can change structure

Structure, Processing, & Properties

Har

dnes

s (B

HN

)

Cooling Rate (ºC/s)

100

200

300

400

500

600

0.01 0.1 1 10 100 1000

(d)

30 m(c)

4 m

(b)

30 m

(a)

30 m

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Types of Materials• Metals:

– Strong, ductile– High thermal & electrical conductivity– Opaque, reflective.

• Polymers/plastics: Covalent bonding sharing of e’s– Soft, ductile, low strength, low density– Thermal & electrical insulators– Optically translucent or transparent.

• Ceramics: ionic bonding (refractory) – compounds of metallic & non-metallic elements (oxides, carbides, nitrides, sulfides)– Brittle, glassy, elastic– Non-conducting (insulators)

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1. Pick Application Determine required Properties

Processing: changes structure and overall shapeex: casting, sintering, vapor deposition, doping forming, joining, annealing.

Properties: mechanical, electrical, thermal,magnetic, optical, deteriorative.

Material: structure, composition.2. Properties Identify candidate Material(s)

3. Material Identify required Processing

The Materials Selection Process

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ELECTRICAL• Electrical Resistivity of Copper:

• Adding “impurity” atoms to Cu increases resistivity.• Deforming Cu increases resistivity.

Adapted from Fig. 18.8, Callister & Rethwisch 8e. (Fig. 18.8 adapted from: J.O. Linde, Ann Physik 5, 219 (1932); and C.A. Wert and R.M. Thomson, Physics of Solids, 2nd edition, McGraw-Hill Company, New York, 1970.)

T (ºC)-200 -100 0

Cu + 3.32 at%Ni

Cu + 2.16 at%Ni

deformed Cu + 1.12 at%Ni

1

2

3

4

5

6R

esis

tivity

,

(10-8

Ohm

-m)

0

Cu + 1.12 at%Ni

“Pure” Cu

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THERMAL• Space Shuttle Tiles: -- Silica fiber insulation offers low heat conduction.

• Thermal Conductivity of Copper: -- It decreases when you add zinc!

Adapted fromFig. 19.4W, Callister 6e. (Courtesy of Lockheed Aerospace Ceramics Systems, Sunnyvale, CA)(Note: "W" denotes fig. is on CD-ROM.)

Adapted from Fig. 19.4, Callister & Rethwisch 8e. (Fig. 19.4 is adapted from Metals Handbook: Properties and Selection: Nonferrous alloys and Pure Metals, Vol. 2, 9th ed., H. Baker, (Managing Editor), American Society for Metals, 1979, p. 315.)

Composition (wt% Zinc)Th

erm

al C

ondu

ctiv

ity

(W/m

-K)

400

300

200

100

00 10 20 30 40

100 m

Adapted from chapter-opening photograph, Chapter 17, Callister & Rethwisch 3e. (Courtesy of LockheedMissiles and SpaceCompany, Inc.)

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MAGNETIC• Magnetic Permeability vs. Composition: -- Adding 3 atomic % Si makes Fe a better recording medium!

Adapted from C.R. Barrett, W.D. Nix, andA.S. Tetelman, The Principles ofEngineering Materials, Fig. 1-7(a), p. 9,1973. Electronically reproducedby permission of Pearson Education, Inc.,Upper Saddle River, New Jersey.

Fig. 20.23, Callister & Rethwisch 8e.

• Magnetic Storage: -- Recording medium is magnetized by recording head.

Magnetic FieldM

agne

tizat

ion Fe+3%Si

Fe

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• Transmittance: -- Aluminum oxide may be transparent, translucent, or opaque depending on the material structure.

Adapted from Fig. 1.2,Callister & Rethwisch 8e.(Specimen preparation,P.A. Lessing; photo by S. Tanner.)

single crystalpolycrystal:low porosity

polycrystal:high porosity

OPTICAL

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DETERIORATIVE• Stress & Saltwater... -- causes cracks!

Adapted from chapter-opening photograph, Chapter 16, Callister & Rethwisch 3e.(from Marine Corrosion, Causes, and Prevention, John Wiley and Sons, Inc., 1975.) 4 m-- material:

7150-T651 Al "alloy" (Zn,Cu,Mg,Zr)

Adapted from Fig. 11.26, Callister & Rethwisch 8e. (Provided courtesy of G.H. Narayanan and A.G. Miller, Boeing Commercial Airplane Company.)

• Heat treatment: slows crack speed in salt water!

Adapted from Fig. 11.20(b), R.W. Hertzberg, "Deformation and Fracture Mechanics of Engineering Materials" (4th ed.), p. 505, John Wiley and Sons, 1996. (Original source: Markus O. Speidel, Brown Boveri Co.)

“held at 160ºC for 1 hr before testing”

increasing loadcrac

k sp

eed

(m/s

)

“as-is”

10-10

10-8

Alloy 7178 tested in saturated aqueous NaCl solution at 23ºC

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• Use the right material for the job.

• Understand the relation between properties, structure, and processing.

• Recognize new design opportunities offered by materials selection.

Course Goals:SUMMARY