1. Materials

2. “Materials can effectively generate and capture students’ interest in science, mathematics, engineering, and technology.”
-Dr. Thomas Strobe
University of Washington

3. Why Study Materials? Materials in bulletproof vests worn by Police
Warm, lightweight, waterproof winter coats
Materials have played a significant role in field of engineering and education

4. 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

5. 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

6. 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

7. Time Periods 600 - 900 - Porcelain 1540 - First Foundries
Crude Steel
Discovery of Titanium
Battery
Portland Cement
Reinforced Concrete
Bessemer Steel-making Process
Celluloid Production

8. Time Periods 1871 - Periodic Table 1884 - Nitrocellulose
Electrolytic Reduction of Aluminum
Silicon Carbide
First Totally Synthetic Polymer
Tungsten Carbide
Fiberglass
Nylon
Germanium Transistor

9. Time Periods 1950s - Silicon Photovoltaic Cells & Transistors
Ruby Laser
Integrated Circuit
Fiber Optics
High Temperature Super Conductors
Data Courtesy of Dept. of Energy and Energy Concepts, Inc.

10. New Materials New materials are designed based on need
Engineers can design without worrying if a material exists for their application

11. 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

12. 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

13. Classifying Materials
Metals
Ceramics
Polymers
Composites

14. Metals Earliest used were “native” metals
Copper, Gold, Silver, and Meteoric 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

15. Metals Mechanical Properties
Strong
Tough
Malleable
Ductile
Most are
Opaque
Lustrous
Dense
Good Heat and Electric Conductors
High Melting Point

16. Metal Facts Iron and Steel are 1st and 2nd most commonly used metals
Aluminum is third
Lightweight
Can be stronger than steel

17. 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

18. Ceramics Clay products Refractories Abrasives Glasses
Used in high temperature applications
Made of clay
Abrasives
Extremely hard, pure, ceramic compounds or mixtures
Glasses

19. Polymers Formed by Greek words: Natural Materials
Poly - Many
Mer - Parts
Natural Materials
Wood, leather, cotton, wool, silk, rubber
Polymers processed by plants and animals
Proteins, Enzymes, starches, and cellulose
Plastics

20. Plastics Polymers and Plastics ARE NOT the same Are Synthetic Polymers
Plastics are a member of the polymer group
Are Synthetic Polymers
Thermoplastic
Can be reformed
Recyclables
Thermoset
Once set, cannot be softened by heat

21. More About Polymers Are not strong Good electrical insulators
Low melting temperatures

22. 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

23. 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 bins, traffic barrier cones, golf bag liners, and toys

24. Polyvinyl Chloride or Vinyl
PVC or V
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
Plastic Separating System

25. Low-density Polyethylene
LDPE
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, lawn mower wheels, and automobile battery parts

26. Polypropylene PP Recycle Code - 5 Recycled Uses
License plate holders, desktop accessories, hanging files, food service trays, flower pots, and trash cans

27. 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

28. 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

29. 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 from Mt. Vesuvius

30. 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

31. 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

32. Laid Up By Hand vs. Factory
Form materials on a mold and paint the them on the matrix of resin (epoxy)
My Be Difficult to Use, but inexpensive
Combined by two different parts
Resin
Hardner
Factory has materials with epoxy matrix pre-impregnated into
More expensive
Less mess/easy-use

33. 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

34. 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

35. 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

36. Industry Support ASM International (ASMI)
Society for materials engineers and scientists
Dedicated to advancing industry, technology, and applications of metals and materials

37. Industry Support American Ceramic Society (ACerS)
Dedicated to dissemination of scientific, commercial, and educational information about ceramic materials and industry