materials science & selection integrated science & technology 431 fall 2003

Materials Science & Selection

Integrated Science & Technology

431

Fall 2003

Fall 2003 2Dr. Ken LewisISAT-431 Module 1 Overview

Introduction

• This is a course in the science of materials.– That is….

• How we use the raw materials of our word to suit our needs and wants.

• Why we can see each other.

• Why we don’t fall through the floor.


Introduction2

• We will look at the various types of materials, both naturally occurring and man made– HOW materials are different (easy)– WHY materials are different (not so easy)


Manufacturing

• Manufacturing.– Manus (Hand).– Factus (make).

• No longer true.– Most items of value are mass made by

automated systems.


Manufacturing2

• Technologically– Application of chemical and physical processes

to materials to alter;• Geometry

• Properties

• Appearance


Manufacturing3

• Economically– Transformation of materials into items of

greater value• By processing

• By assembly


Manufacturing4

– Production control

– Support services

– Marketing

– Sales

– Shipping

– Customer service

A complex process involving…

– Product design

– Machinery and tooling

– Process planning

– Purchasing

– Manufacturing


Manufacturing5

Product Number of parts

Rotary lawn mower 300

Grand piano 12,000

Automobile 15,000

C-5B transport plane >4,000,000

Boeing 747-400 >6,000,000


Manaufacturing5

• Manufacturing is a process which uses material.

• Three primary types of manufacturing, and all use different material.


Primary Secondary TertiaryAgriculture Aerospace Banking

Forestry Apparel Communications

Fishing Automotive Education

Livestock Basic metals Entertainment

Quarries Beverages Financial Services

Mining Building materials Government

Petroleum Chemicals Health and Medical

Computers Hotel

Construction Information

Consumer appliances Insurance

Electronics Legal

Fabricated metals Real estate

Food Processing Repair and maintenance

Glass, ceramics Restaurant

Heavy machinery Retail trade

Paper Tourism

Petroleum refining Transportation

Pharmaceuticals Wholesale trade

Plastics

Power utilities

Publishing

Textiles

Tire and Rubber

Wood and furniture


Materials

• Why do we study materials?

Because theyare interesting.

Understandthe

differences

Understand thematerial limits

Establish parametersfor design calculations

Predict the mechanicalbehavior of

the manufactured

product

Select theRight material

For thejob


Materials

• Can be anything of substance in the known universe.

• For our purposes we will restrict the discussion essentially to solids


Engineering Materials

Metals

Non-metals(Ceramics)

Polymers

Natural stuff


Engineering Materials2

MetalsNon-metals(Ceramics)PolymersNatural stuff

Blends produce unique materials called:

Composites


Engineering Materials -- ExamplesMetals

• Ferrous - Cast Iron - Steel•Non-ferrous - Al, Mg, Cu, Ti, Ni, Zn, etc. & their alloys• Precious metals - Au, Pt, • Superalloys

Polymers• Thermoplastics - nylons, - polystyrene, - polypropylene

• Thermosets - epoxies - polyesters

• Elastomers - Spandex - vulcanized rubber

Ceramics• Traditional - Clay - Silica - Feldspar

• Advanced - Oxides, - Nitrides, - Carbides, - Ferrites, - Titanates

• Glasses

Miscellaneous• Composites - Dispersion - Particle - Fiber

• Electronic

• Magnetic

• Fibers

•Construction - Concrete, - Wood,


Property

Metals Polymers Ceramics Composite

Crystal Structure Xtal Amorphous Xtal Varies

Density High Low Low Varies

Thermal Conductivity

High Low Low Directional

Electrical Conductivity

High Low Low Directional

Tensile Strength High High Low Directional

Compressive Strength

Low Low High Directional

Hardness Varies

Low High varies


Evolution of Engineering Materials


Material and Civilization Timeline


Stre

ngt

h/den

sity

(in

x 1

06)

Year

1800 1900 2000

Wood & Stone Bronze

Castiron steel

Composites

KevlarCarbonFibers

Evolution of material normalized strength


Are These Things…Metal Polymer Ceramic Composite

Semiconductor?• Clay

• Steel• Aluminum beer cans• Fiberglass surfboards• Si chip• Nylons• cement

• Polyester slacks• CD jewel case• Aluminum foil• Kleenex• Fiber reinforced tennis

racquet• Polyethylene milk

bottle


Metallic Materials

• Substances composed of one or more metallic elements– For example:

• Iron (Fe)

• Copper (Cu)

• Aluminum (Al)

• Nickel (Ni)

• ….


Metallic Materials2

• May contain impurities such as:– Oxygen (O)– Carbon (C) – Nitrogen (N)

((As long as they are not chemically bonded))• Have a crystalline structure• Good thermal and electrical conductors• Usually relatively strong• Usually ductile


Metallic Materials3

• Two Classes– Ferrous metals and alloys

• Contain a large percentage of iron

– Non-ferrous• Usually softer and used at lower temperatures.


Ceramics

• Inorganic material– Made of a metal and non metal bonded together

• Can be crystalline or non-crystalline

• Usually very hard and have strength at high temperatures– High compressive strength– brittle


Ceramics2

• Properties– Light weight– Electrical and thermal insulators (usually but

not always)– Retain properties to very high temperatures

• Examples– Furnace linings

– Space shuttle tiles


Polymerics

• Two major constituents– Carbon– Silicon

• Polymers generally are giant molecules consisting of long chains– Structures may be one, two, or three

dimensional.


Polymerics2

• Properties can be tailored– Strength varies greatly– Flexibility varies– Usually thermal and electrical insulators– Usually will not withstand real high

temperatures.– Light weight


Composites

• Mixtures of two or more dissimilar materials.– Usually one is a reinforcing agent and the other

is the filler• Fiberglass

• Carbon epoxy

– Many times the reinforcing agent is fibrous


Composites2

• Properties– Usually asymmetric if one agent is a long fiber– Will borrow properties according to the volume

percent of each material present.

• There are many different combinations


Competition amongst six major materials

materials science & selection integrated science & technology 431 fall 2003

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