1. King Fahd University of Petroleum & Minerals Mechanical Engineering Department ME 205 – 01&02 : MATERIALS SCIENCE Fall Semester 2006-2007 (061) Instructor: Mr. Muhammad Younas Office: 22-206Phone: 3049 Office Hours: SMW ( 9:00-9:50 AM ) & UT ( 11:00-11:50 AM ) E-mail: myounasa@kfupm.edu.sa

2. Textbook Callister, W.D., Materials Science and Engineering 6th Ed., 2003

3. Lecture Schedule Lecture #Lecture TopicSection# 1Classification of Materials, Materials of Future1.4, 1.6 2The Periodic Table, Bonding Forces and Energies.2.4,2.5 3Primary and Secondary Bonds.2.6, 2.7 4Crystal Structures, Unit Cells.3.2,3.3 5Metallic Crystal Structures, Density Computation.3.4,3.5 6Polymorphism, Crystal systems, Point coordinates3.6,3.7, 3.8 7Crystallographic Directions, Crystallographic Planes.3.9, 3.10 8Linear and Planar Atomic Densities.3.11 9Closed Packed Crystal Structures, Single Crystals, Polycrystalline Materials, Anisotropy.3.12, 3.13, 3.14,3.15 10Imperfection in Solids, Point Defects, Vacancies and Self-interstitials, Impurities in Solids. Specification of composition 4.2, 4.3, 4.4 11Dislocations-Linear Defects, Interfacial Defects (external surface & grain boundaries only).4.5, 4.6 EXAM 1: Sunday October 29, 2006 @ 7:00 – 9:00 PM 12Diffusion, Introduction, Diffusion Mechanisms.5.1,5.2 13Steady-State Diffusion.5.3 14Non-Steady State Diffusion. Factors that influence Diffusion.5.4, 5.5 15Mechanical Properties of Metals, Elastic Deformation, Concepts of Stress and Strain.6.2 16Stress-Strain Behavior, Elastic Properties of Materials.6.3, 6.5 17Plastic Deformation, Tensile Properties.6.6 18Tensile Properties6.6 19True Stress-True Strain, Elastic Recovery During Plastic Deformation.6.7, 6.8 20Dislocations and Strengthening Mechanisms, Basic concepts, Characteristics of Dislocations.7.2, 7.3 21Slip Systems.7.4 22Slip in Single Crystals, Plastic Deformation of Polycrystalline Materials.7.5, 7.6

4. Lecture #Lecture TopicSection# 23Strengthening by Grain Size Reduction, Solid Solution Strengthening, Strain Hardening. 7.8, 7.9, 7.10 24Recovery, Recrystallization and Grain growth.7.11, 7.12, 7.13 EXAM 2 November 29, 2006 @ 5:30 – 7:30 PM 25Phase Diagram, Solubility Limit, Phases, Microstructure, Phase Equilibria.9.1, 9.2, 9.3, 9.4, 9.5 26Binary Iso-morphous System9.6,9.7 27Interpretation of Phase diagram9.7, 9.8 28Binary Eutectic Phase Diagrams, Development of Microstructure in Eutectic Alloys 9.10, 9.11 29 Iron-Iron Carbide Phase Diagram, Development of Microstructure in in Iron- Carbon Alloys, The influence of other alloying elements 9.17, 9.18, 9.18 30Review class Final Exam

5. Grading Policy 1) Home works: 05% 2) Quizzes: 10% 3) Lab. Work: 15% 4) Exam # 1: 15% 5) Exam # 2: 20% 6) Final Exam: 35%

7. Attendance in the class will be strictly observed starting first day of classes. IN CASE OF AN UNEXCUSED ABSENCE, 0.5 POINT WILL BE DEDUCTED FROM FINAL GRADE. A DN grade will be immediately reported for SIX (6) unexcused absences. A DN grade will be immediately reported if both unexcused and excused absences reach TEN (10) absences. CLASS ATTENDANCE

8. Materials Science and Engineering  Material Science Involves investigating the relationships that exist between the structures and properties of materials.  Materials Engineering On the basis of structure-property correlations, involves designing or engineering the structure of a material to produce a predetermined set of properties.

9. Materials Science and Engineering (Contd.) Materials Science and Engineering (Contd.) The structure of a material usually relates to the arrangement of its internal components. Subatomic structure involves electrons within the individual atoms and interactions with their nuclei. On an atomic level, structure encompasses the organization of atoms or molecules relative to one another. Microscopic structure contains large groups of atoms that are normally agglomerated together and subject to direct observation using some type of microscope. Macroscopic structure meaning structural elements that may be viewed with naked eye.

10. Materials Science and Engineering (Contd.)  Property is a material trait in terms of the kind and magnitude of response to a specified imposed stimulus. It is independent of shape and size.  Six categories of material properties: 1. Mechanical properties relate deformation to an applied load or force; examples include elastic modulus and strength. 2. For electrical properties, such as electrical conductivity and dielectric constant, the stimulus is an electric field. 3. The thermal behavior can be represented in terms of heat capacity and thermal conductivity. 4. Magnetic properties demonstrate the response of a material to the application of a magnetic field. 5. For optical properties, the stimulus is electromagnetic or light radiation; index of refraction and reflectivity are representative optical properties. 6. Deteriorative characteristics indicate the chemical reactivity of materials.

11. Materials Science and Engineering (Contd.)  Four components involved in the science and engineering of materials, and their interrelationship: Processing ===> Structure ===> Properties ===> Performance

12. Why Study Materials Science and Engineering?  Many an applied scientist or engineer, whether mechanical, civil, electrical, or electrical, will at one time or another be exposed to a design problem involving materials.  Examples: gear, building, oil refinery component, or an integrated circuit chip.  Selection considerations 1. The in-service conditions must be characterized, for this will dictate the properties required of the material. 2. Any deterioration of material properties that may occur during service operation. For example, significant reductions in mechanical strength may result from exposure to elevated temperatures or corrosive environment. 3. Economics: A material may be found that has the ideal set of properties but is prohibitively expensive.

13. CLASSIFICATION OF MATERIALS

14. Major Classes Of Materials 1. METALS1. METALS 2. CERAMICS2. CERAMICS 3. POLYMERS3. POLYMERS 4. COMPOSITES4. COMPOSITES 5. ELECTRONIC MATERIALS5. ELECTRONIC MATERIALS 6. BIO MATERIALS6. BIO MATERIALS

15. BASIS OF MATERIAL CLASSIFICATIONS  Chemical Makeup  Atomic Bonding  Atomic Arrangement  Characteristic Physical Properties  Characteristic Mechanical Properties

16. METALS DDDDistinguishing Features o Atoms arranged in a regular repeating manner. o Relatively High Strength. o High Density. o Ductile. o Excellent conductors of Electricity and Heat. o Opaque to visible light. o Shiny appearance.

17. APPLICATIONS OF METALS EEEElectrical wiring BBBBuildings, Structures, Bridges etc. AAAAutomobiles: body, chassis, engine block, springs, etc. AAAAir planes: engines, fuselage (airplane body), landing gears, etc. TTTTrains: rails, engines, body, wheels MMMMachines MMMMachine tools: drills, hammers, saw blades, nuts, bolts, etc. IIIIndustrial Plant components, structures MMMMagnets

18. METALLIC MATERIAL EXAMPLES  Pure Metals  Cu, Fe, Zn, Al, Ag, Au, Cr, Ni, Sn, etc Alloys Steel, Brass, Stainless Steels, etc. Steel, Brass, Stainless Steels, etc.

19. CERAMICS  D D D Distinguishing Features Most have a regular arrangement of atoms (except glasses) Compounds of Metallic and Non- Metallic elements Density lower than Metals Stronger than Metals Low resistance to Fracture Brittle (low ductility) High Melting Points Poor Conductors of Electricity and Heat

20. APPLICATIONS OF CERAMICS  Electrical Insulators  Thermal Insulations and Coatings  Abrasives  Glasses (windows, TV screens, Optical fibers  Cement, Concrete  Ceramic tiles for space shuttles  Furnace Lining bricks

21. CERAMIC MATERIAL EXAMPLES  Diamond, Graphite  Glasses  Building Materials  Oxides (SiO 2, Al 2 O 3 )  Carbide Tools (WC, TiC)

22. POLYMERS  Distinguishing Feature  Composed Primarily of C and H (hydrocarbons)  Low Melting Points  Some partly crystalline, Most are not  Most are poor conductors of Electricity and Heat  Many have high plasticity  Some are transparent, most are opaque

23. APPLICATIONS OF POLYMERS  Adhesives and Glues  Plastic products (plastic pipes, bottles, house hold utensils, etc.)  Coatings and Paints  Solid Lubricants (Teflon)  Rubber Products (gaskets, seals, and o- rings)  Clothing and furniture coverings (leather, nylon)

24. EXAMPLES OF POLYMER MATERIALS  PVC (Poly Vinyl Chlorides)  PE (Poly ethylene)  PC (Poly Carbonates)  Teflon  Nylon

25. COMPOSITES  Distinguishing Features  Composed of Two or More Different Materials  Strong, Light weight, Good resistance to fracture  High stiffness and good deformability  Collection of good Properties of each material used

26. APPLICATIONS OF COMPOSITE MATERIALS  Aerospace, Marine, Automotive  Sporting Goods  Storage Tanks (water, fuel, chemicals)  Transport Piping (oil, seawater, sewage)

27. EXAMPLES OF COMPOSITE MATERIALS  PMCs (polymer matrix composites) Fiber Glass, Concrete)  MMCs (Metal Matrix Composites)  CMCs (Ceramic Matrix Composites)

28. The bridge in the picture is built entirely from composite material. Weighs one-tenth of the conventional concrete bridge. It took only 18 hours to assemble the bridge.

29. MATERIALS OF FUTURE  SMART MATERIALS Shape Memory Alloys Shape Memory Alloys Piezoelectric ceramics Piezoelectric ceramics MEMS (Micro-Electrical Mechanical Systems) MEMS (Micro-Electrical Mechanical Systems)NANOTECHNOLOGY Materials by design Carbon Nanotubes (500 atom diameters)