1. ME 2105 Introduction to Material Science (for Engineers)
Dr. Richard R. Lindeke, Ph.D.
B Met. Eng. University of Minnesota, 1970
Master’s Studies, Met Eng. Colorado School of Mines, (Electro-Slag Welding of Heavy Section 2¼ Cr 1 Mo Steels)
Ph.D., Ind. Eng. Penn State University, (Foundry Engineering – CG Alloy Development)

2. Syllabus and Website: Review the Syllabus
Attendance is your job – come to class!
Final is Common Time at the Beginning of the Finals Period
Semi-Pop Quizzes and homework/Chapter Reviews (Ch 17 & 18) – (20% of your grade!) – note, additional homework (not to be collected) is suggested to prepare for quizzes and exams!
Don’t copy from others; don’t plagiarize – its just the right thing to do!!
Course Website:

3. Materials Science for Engineering: an Introduction
Our Text:
Materials Science for Engineering: an Introduction
 By Callister & Rethwisch
8th Edition, Wiley, 2010.

4. Materials Science and Engineering
It all about the (raw) materials and how they are processed
That is why we call it materials ENGINEERING
Minor differences in Raw materials or processing parameters can mean major changes in the performance of the final material or product

5. Why the class?
As ME/IE we are involved in design of products or processes
When making up a design, what materials we use are critical (and driven by the function of the design)
When investigating processes, minor changes can have a major impact on the results

6. Materials Science and Engineering
The discipline of investigating the relationships that exist between the structures and properties (or performance) of materials.
Materials Engineering
The discipline of designing or engineering the structure of a material to produce a predetermined set of properties based on established structure-property correlation.
Four Major Components of Material Science and Engineering:
Structure of Materials
Properties of Materials
Processing of Materials
Performance of Materials

7. Material Selection in Design
Properties are a link between the fundamental issues of materials science and the practical challenges of materials engineering. (FromG. E. Dieter, in ASM Handbook,Vol. 20: Materials Selection and Design, ASM International, Materials Park, OH, 1997, p. 245.)

8. And Remember: Materials “Drive” our Society!
Ages of “Man” and note, we survive based on the materials we control!
Stone Age – naturally occurring materials
Special rocks, skins, wood
Bronze Age
Casting and forging
Iron Age
High Temperature furnaces and strong materials
Steel Age
High Strength Alloys
Non-Ferrous and Polymer Age
Aluminum, Titanium and Nickel (superalloys) – aerospace
Silicon – Information
Plastics and Composites – food preservation, housing, aerospace and higher speeds
Exotic Materials Age?
Nano-Material and bio-Materials – they are coming and then …

9. A Timeline of Human Materials “Control”

10. And Formula One – the future of automotive is …

11. Looking At CG Iron Alloy Development (Processing):

12. Looking At CG Iron Alloy Development (Processing):

13. CG Structure – but with great care!
Poor “Too Little”
Good Structure 45KSI YS; 55KSI UTS
Poor “Too Much”

14. Looking At CG Iron Alloy Development (Structures)

15. Looking At CG Iron Alloy Development (Results)

16. Doing Materials! Engineered Materials are a function of:
Raw Materials Elemental Control
Processing History
Our Role in Engineering Materials then is to understand the application and specify the appropriate material to do the job as a function of:
Strength: yield and ultimate
Ductility, flexibility
Weight/density
Working Environment
Cost: Lifecycle expenses, Environmental impact*
* Economic and Environmental Factors often are the most important when making the final decision!

17. Introduction List the Major Types of MATERIALS That You Know: METALS
CERAMICS/Glasses
POLYMERS
COMPOSITES
ADVANCED MATERIALS( Nano-materials, electronic materials)

18. Introduction, cont. Metals Ceramics Polymers Composites
Steel, Cast Iron, Aluminum, Copper, Titanium, many others
Ceramics
Glass, Concrete, Brick, Alumina, Zirconia, SiN, SiC
Polymers
Plastics, Wood, Cotton (rayon, nylon), “glue”
Composites
Glass Fiber-reinforced polymers, Carbon Fiber-reinforced polymers, Metal Matrix Composites, etc.

19. Thoughts about these “fundamental” Materials
Metals:
Strong, ductile
high thermal & electrical conductivity
opaque, reflective.
Ceramics: ionic bonding (refractory) – compounds of metallic & non-metallic elements (oxides, carbides, nitrides, sulfides)
Brittle, glassy, inelastic
non-conducting (insulators)
Polymers/plastics: Covalent bonding  sharing of e’s
Soft, ductile, low strength, low density
thermal & electrical insulators
Optically translucent or transparent.
Metals have high thermal & electrical conductivity because valence electrons are free to roam

20. Structural Steel (a fundamental engineered metal) in Use: The Golden Gate Bridge

21. Periodic Table of Elements: The Metals

22. Structural Ceramics

23. Periodic table ceramic compounds are a combination of one or more metallic elements (in light color) with one or more nonmetallic elements (in dark color).

24. Glasses: atomic-scale structure of (a) a ceramic (crystalline) and (b) a glass (noncrystalline)

25. Optical Properties of Ceramic are controlled by “Grain Structure”
Grain Structure is a function of “Solidification” processing!

26. Polymers are typically inexpensive and are characterized by ease of formation and adequate structural properties

27. Periodic table with the elements associated with commercial polymers in color

28. Composite Materials – oh so many combinations
Fiber Glass Composite:

29. The Materials Selection Process – as a part of design1.
Engineered Application will Determine required Properties
Properties: mechanical, electrical, thermal,
magnetic, optical, deteriorative. 2.
Properties
Identify candidate Material(s)
Material: structure, composition. 3.
Material
Identify required Processing
Processing: changes structure and overall shape
ex: casting, sintering, vapor deposition, doping
forming, joining, annealing.

30. These so-called Ashby Charts are developed for comparing candidate materials considering many design factors
Materials property chart with a view of relative materials performance. Here plots of elastic modulus and density data (on logarithmic scales) for various materials indicate that members of the different categories of structural materials tend to group together. (After M. F. Ashby, Materials Selection in Engineering Design, Pergamon Press, Inc., Elmsford, NY, 1992.)

31. Processing can change structure! (see above structure vs Cooling Rate)
But:
Properties depend on Structure (strength or hardness)
(d)
30 mm 6 00 5 00
(c)
4 mm 4 00
(b)
30 mm
(a)
30 mm
Hardness (BHN) 3 00 2 00
100
0.01
0.1 1 10
100
1000
Cooling Rate (ºC/s)
And:
Processing can change structure! (see above structure vs Cooling Rate)

32. Another Example: Rolling of Steel
At h1, L1
low UTS
low YS
high ductility
round grains
At h2, L2
high UTS
high YS
low ductility
elongated grains
Structure determines Properties but Processing determines Structure!

33. Electrical Properties (of Copper):
T (°C)
-200
-100
Cu at%Ni
Cu at%Ni
deformed Cu at%Ni 1 2 3 4 5 6
Resistivity, r
(10-8 Ohm-m)
Cu at%Ni
“Pure” Cu
Electrical Resistivity of Copper is affected by:
Contaminate level
Degree of deformation
Operating temperature
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.)

34. THERMAL Properties • Space Shuttle Tiles: • Thermal Conductivity
--Silica fiber insulation
offers low heat conduction.
• Thermal Conductivity
of Copper: --It decreases when
you add zinc!
Composition (wt% Zinc)
Thermal Conductivity
(W/m-K)
400
300
200
100 10 20 30 40
100 mm
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.)
Courtesy of Lockheed Aerospace Ceramics Systems, Sunnyvale, CA)

35. MAGNETIC Properties • Magnetic Permeability vs. Composition:
--Adding 3 atomic % Si makes Fe a better recording medium!
• Magnetic Storage:
--Recording medium
is magnetized by
recording head.
Magnetic Field
Magnetization
Fe+3%Si Fe
Adapted from C.R. Barrett, W.D. Nix, and
A.S. Tetelman, The Principles of
Engineering Materials, Fig. 1-7(a), p. 9,
Electronically reproduced
by permission of Pearson Education, Inc.,
Upper Saddle River, New Jersey.
J.U. Lemke, MRS Bulletin, Vol. XV, No. 3, p. 31, 1990

36. DETERIORATIVE Properties
• Heat treatment: slows
crack speed in salt water!
• Stress & Saltwater...
--causes cracks!
“held at
160ºC for 1 hr
before testing”
increasing load
crack speed (m/s)
“as-is” 10
-10 -8
Alloy 7178 tested in
saturated aqueous NaCl
solution at 23ºC
Adapted from Fig (b), R.W. Hertzberg, "Deformation and Fracture Mechanics of Engineering Materials" (4th ed.), p. 505, John Wiley and Sons, (Original source: Markus O. Speidel, Brown Boveri Co.)
4 mm
--material:
7150-T651 Al "alloy"
(Zn,Cu,Mg,Zr)
G.H. Narayanan and A.G. Miller, Boeing Commercial Airplane Company.
Marine Corrosion, Causes, and Prevention, John Wiley and Sons, Inc., 1975.

37. Example of Materials Engineering Work – Hip Implant
With age or certain illnesses joints deteriorate. Particularly those with large loads (such as hip).

38. Example – Hip Implant Requirements mechanical strength (many cycles)
good lubricity
biocompatibility

39. Example – Hip Implant

40. Solution – Hip Implant Key Problems to overcome: Acetabular
Cup and Liner
Key Problems to overcome:
fixation agent to hold acetabular cup
cup lubrication material
femoral stem – fixing agent (“glue”)
must avoid any debris in cup
Must hold up in body chemistry
Must be strong yet flexible
Ball
Femoral
Stem

41. Often, material selection comes down to a tradeoff of cost vs
Often, material selection comes down to a tradeoff of cost vs. design property

42. Course Goal is to make you aware of the importance of Material Selection by:
Choosing the right material for the job
-- one that is the most economical and “Greenest” when life cycle usage is considered. As designers we must consider “Sustainability” in our designs and material choices
Understanding the relation between properties, structure, and processing.
Recognizing new design opportunities offered by materials selection.