Materials Science & Selection Integrated Science & Technology 431 Fall 2003

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 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.

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Introduction 2 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)

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Manufacturing Manufacturing. –Manus (Hand). –Factus (make). No longer true. –Most items of value are mass made by automated systems.

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Manufacturing 2 Technologically –Application of chemical and physical processes to materials to alter; Geometry Properties Appearance

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Manufacturing 3 Economically –Transformation of materials into items of greater value By processing By assembly

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Manufacturing 4 –Production control –Support services –Marketing –Sales –Shipping –Customer service A complex process involving… –Product design –Machinery and tooling –Process planning –Purchasing –Manufacturing

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Manufacturing 5 ProductNumber of parts Rotary lawn mower300 Grand piano12,000 Automobile15,000 C-5B transport plane>4,000,000 Boeing >6,000,000

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Manaufacturing 5 Manufacturing is a process which uses material. Three primary types of manufacturing, and all use different material.

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall PrimarySecondaryTertiary AgricultureAerospaceBanking ForestryApparelCommunications FishingAutomotiveEducation LivestockBasic metalsEntertainment QuarriesBeveragesFinancial Services MiningBuilding materialsGovernment PetroleumChemicalsHealth and Medical ComputersHotel ConstructionInformation Consumer appliancesInsurance ElectronicsLegal Fabricated metalsReal estate Food ProcessingRepair and maintenance Glass, ceramicsRestaurant Heavy machineryRetail trade PaperTourism Petroleum refiningTransportation PharmaceuticalsWholesale trade Plastics Power utilities Publishing Textiles Tire and Rubber Wood and furniture

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Materials Why do we study materials? Because they are interesting. Understand the differences Understand the material limits Establish parameters for design calculations Predict the mechanical behavior of the manufactured product Select the Right material For the job

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Materials Can be anything of substance in the known universe. For our purposes we will restrict the discussion essentially to solids

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Engineering Materials Metals Non-metals (Ceramics) Polymers Natural stuff

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Engineering Materials 2 Metals Non-metals (Ceramics) Polymers Natural stuff Blends produce unique materials called: Composites

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Engineering Materials -- Examples Metals 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,

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Property Metals PolymersCeramicsComposite Crystal Structure XtalAmorphousXtalVaries DensityHighLow Varies Thermal Conductivity HighLow Directional Electrical Conductivity HighLow Directional Tensile StrengthHigh LowDirectional Compressive Strength Low HighDirectional Hardness Varie s LowHighvaries

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Evolution of Engineering Materials

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Material and Civilization Timeline

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Evolution of material normalized strength

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 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

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Metallic Materials Substances composed of one or more metallic elements –For example: Iron (Fe) Copper (Cu) Aluminum (Al) Nickel (Ni) ….

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Metallic Materials 2 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

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Metallic Materials 3 Two Classes –Ferrous metals and alloys Contain a large percentage of iron –Non-ferrous Usually softer and used at lower temperatures.

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 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

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Ceramics 2 Properties –Light weight –Electrical and thermal insulators (usually but not always) –Retain properties to very high temperatures Examples –Furnace linings –Space shuttle tiles

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Polymerics Two major constituents –Carbon –Silicon Polymers generally are giant molecules consisting of long chains –Structures may be one, two, or three dimensional.

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Polymerics 2 Properties can be tailored –Strength varies greatly –Flexibility varies –Usually thermal and electrical insulators –Usually will not withstand real high temperatures. –Light weight

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 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

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Composites 2 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

Dr. Ken Lewis ISAT-431 Module 1 Overview Fall Competition amongst six major materials