Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 1 IE 251 Manufacturing materials l Instructor: Dr. Mohamed Ali Eissa Saleh s Room: ………….... 2A 128/1 s Phone: ………… l Grading s Midterm #1: ………..……….....…… 15% s Midterm #2: ………. ……………….. 15% s Lecture assignments ……………… 10 s Lab #3: ………. ………………….……20% s Final Exam:. ……...………………… 40%

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 2 Visual Materials... Texts ● Fundamentals of Materials Science and Engineering, by William D. Callister, Jr.; John Wiley & Sons, Inc. References l Engineering Materials 1: An introduction to their properties and applications - M. Ashby & D.Jones l Engineering Materials 2: An introduction to microstructures, processing & design - M. R. Ashby & D. R. H. Jones

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 3 l Introduction to the structure, processing, properties and performance of Manufacturing materials s metals, polymers, glasses, ceramics and composites l Case studies covering... s selection of materials s component design s analysis of component failures IE 251 Manufacturing Materials

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 4 The course objectives for the student l To develop an understanding of the impact of modern materials on the performance of products that are encountered daily, such as bicycles, beverage containers, and sports equipment. l To develop an understanding of the classes of engineering materials (metal alloys, polymers, ceramics and composites), with an emphasis on their properties and their uses. l To understand how the materials selection process fits into the product design, development and manufacturing process used by industry today. To come to appreciate that product cost and quality play a key role in the materials selection process. l To recognize that environmental regulations (emissions), and societal pressures (energy, safety) can strongly influence the adoption of new technologies and alternate materials. l To discuss the competition of alternate materials for the same application

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 5 syllabus l *Chapter 1. Introduction* l *Chapter 2. Atomic Structure and Bonding* l *Chapter 3. The Structure of Crystalline Solids* l *Chapter 4. Imperfections in Solids* l *Chapter 5. Diffusion* l *Chapter 6. Mechanical Properties of Metals* l *Chapter 7. Dislocations and Strengthening Mechanisms* l *Chapter 8. Failure** l Chapter 9. Phase Diagrams* l *Chapter 10. Phase Transformations in Metals* l *Chapter 11. Thermal Processing of Metal Alloys* l *Chapter 13. Structure and Properties of Ceramics* l *Chapter 14. Applications and Processing of Ceramics* l *Chapter 15. Polymer Structures* l *Chapter 16. Characteristics, Applications, and Processing of Polymers* l *Chapter 19. Electrical Properties*

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 6 1. Engineering materials and their properties Key points l Enormous range of engineering materials s Types of material properties s Range of properties within and among materials classes s Development of new materials and their impact on design l Failure to select suitable materials can lead to failure of engineering structures and systems s Some failures can be quite spectacular m Liberty ships m Comet (1st commercial jetliner) m Space Shuttle Challenger

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 7

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 8 There are more than 50,000 commercially available materials with which an engineer may choose to design Table 1.2 l Metals and alloys s Steel, aluminum, etc. l Polymers s Polyethylene, polystyrene, nylon, epoxies, etc. l Ceramics and glasses s Alumina, silica, silicon carbide, etc. l Composite materials s Fiberglass, carbon fiber reinforced polymers, etc. l Natural materials s Wood, leather, silk, bone How to Choose?

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 9 The Possible Combinations of Composite Materials are Virtually Unlimited (Fig. 1.1) Composites Polymers Ceramics, Glasses Metals, Alloys Steel cord tires cermets Filled polymers

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 10 The Three P’s Successful Commercial Products Price PerformanceProducibility

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 11 We Make Decisions Regarding Material Selection Based on Material Properties l Economic l Mechanical l Physical and Chemical l Electrical, magnetic, optical l Manufacturing l Aesthetics l Price, availablity, recyclability, etc. l Modulus, yield strength, tensile strength, etc. l Density, reactivity (oxidation & corrosion), thermal expansion, melting temp., etc. l Resistivity, dielectric constant, optical absorption, etc. l Forming, joining, finishing, etc. l Color, touch, texture, etc.

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 12 Screwdriver Aesthetics Economic Mechanical Physical and Chemical Electrical Magnetic optical Manufacturing

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 13 Jet Engine Fan Blades (complex Ni base alloys) Conventional Directionally Cast Single Crystal High Temperature Strength (creep) Oxidation Resistance

Manufacturing materials – IE251 Chapter 1 Chapter 1, Slide 14 Microelectronic Devices are Complex Composite Structures