1. 1 Ice Breaking -About me Lecturer: C. W. Zanariah C. W. N. (PhD Analytical Chemistry) Lecturer: C. W. Zanariah C. W. N. (PhD Analytical Chemistry) Time: 10:00 – 12:00 pm Monday; BKS2.3FKP 8:00 -9:00 am Wed BTS2.3FKP My office: Level 1 Pejabat Pengarah Pusat Inovasi Pembelajaran dan Pengajaran (InnoLearning Centre) Pusat Komersil Contact me through GOALs Forum @ cwzanariah@gmail.com/cwzanariah@gmail.com/ facebook Hp 019-9476342, write your name and course if you send your msg.

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3. INDUSTRIAL VISIT SABAH GAS INDUSTRY 1991

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6.  Find a partner…  Say ASSALA’MUALAIKUM… in 2 minutes introduces each other,  Compulsory questions to ask your friend; What does she or he knows/ do not know about metals and alloys?  Next.. Introduces your friend to the class members– beside your friend particular details, tell everyone what she/ he knows or rather what she/he do not know about metals and alloys 6

7.  The course gives an introduction to the structure of metals and alloys in the solid state (lattice systems, crystal and their defects, solid solution, phase diagrams). Description of the fundamentals of metals and alloys processing (solidification, deformation, diffusion), the main families of commercial metallic alloys (ferrous and non- ferrous) will be reviewed. 7

8. 8 Course Objective... Introduce fundamental concepts in Metals and Alloys You will learn about: metal and alloy structures how structure dictates properties how processing can change structure This course will help you to: use metals and alloys properly realize new design opportunities with metals and alloys

9. Upon successful completion of this course students should have the ability to: 1. Explain in depth the structure of metals in solid state and the concept of metallic alloys to differentiate between the basics of metals and alloys processing. (LO3), CT 2. Point out the importance of metals and alloys in product design and manufacture, as demonstrated by class work and exams (LO1), C4 3. Collaborate with team members in team-related assessment tasks. (LO5-TS3) A3  ILO’s Topic 2 ILO’s Topic 2 9

10. 10 COURSE MATERIALS (with text) Required text: Materials Science and Engineering: An Introduction, W.D. Callister, Jr. and D.G. Rethwisch, 8th edition, John Wiley and Sons, Inc. (2010). Optional Material: Kassner, M. 2009. Fundamentals of Creep in Metals and Alloys (2 nd Edition). Elsevier Science. Porter, D.A., Easterling, K.E. and Sherif, M. 2009. Phase Transformations in Metals and Alloys (3 rd Edition). CRC Press. American Society for Testing and MaterialsAmerican Society for Testing and Materials (ASTM). 2008. Metals & Alloys in the Unified Numbering System (11 th Edition). ASTM International. 4.Zlateva, G. and Martinova, Z. 2008. Microstructure of Metals and Alloys: An Atlas of Transmission Electron Microscopy Images. CRC Press. 5.Christian, J.W. 2002. The Theory of Transformations in Metals and Alloys (3 rd Edition). Mon. 6.Professor Harry Bhadeshia, University of Cambridge

11. 11 Week 1 2 3 4 5 6 7 8 9 10 Topics General Intro; Atomic Bonding Atomic structure and bonding in solid Atomic diffusion The structure of metals Phase Diagrams Phase Transformations Applications & Processing of Metal Alloys Corrosion and degradation of materials Magnetic properties electrical characteristics of commercial alloys Case study Economic, environmental and societal issues H. K. D. H. Bhadeshia Lectures: will highlight important portions of each chapter.

12.   An important reason to have an understanding of interatomic bonding in solid is that, in some instances, the type of bond allows us to explain a material’s properties. For example, consider carbon, which may exist as both graphite and diamond, whereas graphite is relatively soft and has a “greasy” feel to it, diamond is the hardest known material. This dramatic disparity in properties is directly attributable to a type of interatomic bonding found in graphite that does not exist in diamond 12

13.  What is metals and alloys?  Why should we know about it?  Materials drive our society-) ◦ Stone Age Stone Age ◦ Bronze Age Bronze Age ◦ Iron Age Iron Age ◦ Now?  Silicon Age?  Polymer Age? 13

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17.  final technological and cultural stage in the Stone–Bronze–Iron-Age sequence.  The date of the full Iron Age, in which this metal for the most part replaced bronze in implements and weapons,weapons  varied geographically, beginning in the Middle East and southeastern Europe about 1200 bce but in China not until about 600 bce. Although in the Middle East iron had limited use as a scarce and precious metal as early as 3000 bce, Middle Eastprecious metal 17

18.  This group ◦ One or more metallic element (EXAMPLES: ) 18 Iron, aliminum, titanium, gold nickel Carbon, N, O in small amounts Metal alloy –refers to metallic substance that is composed of two or more elements Also non metallic elements eg Atoms in metals and their alloys are arrange in a very orderly manner

19. 19 Adapted from Fig. 22.26, Callister 7e.

20.  Key problems to overcome ◦ fixation agent to hold acetabular cup ◦ cup lubrication material ◦ femoral stem – fixing agent (“glue”) ◦ must avoid any debris in cup 20 Femoral Stem Ball Acetabular Cup and Liner Adapted from chapter-opening photograph, Chapter 22, Callister 7e.

21. 21 Structure, Processing, & Properties ex: hardness vs structure of steel Properties depend on structure Data obtained from Figs. 10.30(a) and 10.32 with 4 wt% C composition, and from Fig. 11.14 and associated discussion, Callister & Rethwisch 8e. Micrographs adapted from (a) Fig. 10.19; (b) Fig. 9.30;(c) Fig. 10.33; and (d) Fig. 10.21, Callister & Rethwisch 8e. ex: structure vs cooling rate of steel Processing can change structure Hardness (BHN) Cooling Rate (ºC/s) 100 200 3 4 5 6 0.010.11101001000 (d) 30  m (c) 4 m4 m (b) 30  m (a) 30  m

22. 22 Metals : –Strong, ductile –High thermal & electrical conductivity –Opaque, reflective. Polymers/plastics : Covalent bonding  sharing of e’s –Soft, ductile, low strength, low density –Thermal & electrical insulators –Optically translucent or transparent. Ceramics : ionic bonding (refractory) – compounds of metallic & non-metallic elements (oxides, carbides, nitrides, sulfides) –Brittle, glassy, elastic –Non-conducting (insulators)

23. 23 The Materials Selection Process 1. Pick ApplicationDetermine required Properties Processing: changes structure and overall shape ex: casting, sintering, vapor deposition, doping forming, joining, annealing. Properties: mechanical, electrical, thermal, magnetic, optical, deteriorative. Material: structure, composition. 2. Properties Identify candidate Material(s) 3. Material Identify required Processing

24. 24 Electrical Resistivity of Copper: Adding “impurity” atoms to Cu increases resistivity. Deforming Cu increases resistivity. Adapted from Fig. 18.8, Callister & Rethwisch 8e. (Fig. 18.8 adapted 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.) T (ºC) -200-1000 Cu + 3.32 at%Ni Cu + 2.16 at%Ni deformed Cu + 1.12 at%Ni 1 2 3 4 5 6 Resistivity,  (10 -8 Ohm-m) 0 Cu + 1.12 at%Ni “Pure” Cu

25. 25 Space Shuttle Tiles: -- Silica fiber insulation offers low heat conduction. Thermal Conductivity of Copper: -- It decreases when you add zinc! Adapted from Fig. 19.4W, Callister 6e. (Courtesy of Lockheed Aerospace Ceramics Systems, Sunnyvale, CA) (Note: "W" denotes fig. is on CD-ROM.) Adapted from Fig. 19.4, Callister & Rethwisch 8e. (Fig. 19.4 is adapted 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.) Composition (wt% Zinc) Thermal Conductivity (W/m-K) 400 300 200 100 0 010203040 100  m Adapted from chapter- opening photograph, Chapter 17, Callister & Rethwisch 3e. (Courtesy of Lockheed Missiles and Space Company, Inc.)

26. 26 Magnetic Permeability vs. Composition: -- Adding 3 atomic % Si makes Fe a better recording medium! Adapted from C.R. Barrett, W.D. Nix, and A.S. Tetelman, The Principles of Engineering Materials, Fig. 1-7(a), p. 9, 1973.Electronically reproduced by permission of Pearson Education, Inc., Upper Saddle River, New Jersey. Fig. 20.23, Callister & Rethwisch 8e. Magnetic Storage: -- Recording medium is magnetized by recording head. Magnetic Field Magnetization Fe+3%Si Fe

27. 27 OPTICAL Transmittance: -- Aluminum oxide may be transparent, translucent, or opaque depending on the material structure. Adapted from Fig. 1.2, Callister & Rethwisch 8e. (Specimen preparation, P.A. Lessing; photo by S. Tanner.) single crystal polycrystal: low porosity polycrystal: high porosity

28. 28 Stress & Saltwater... -- causes cracks! Adapted from chapter-opening photograph, Chapter 16, Callister & Rethwisch 3e. (from Marine Corrosion, Causes, and Prevention, John Wiley and Sons, Inc., 1975.) 4 m4 m -- material: 7150-T651 Al "alloy" (Zn,Cu,Mg,Zr) Adapted from Fig. 11.26, Callister & Rethwisch 8e. (Provided courtesy of G.H. Narayanan and A.G. Miller, Boeing Commercial Airplane Company.) Heat treatment: slows crack speed in salt water! Adapted from Fig. 11.20(b), R.W. Hertzberg, "Deformation and Fracture Mechanics of Engineering Materials" (4th ed.), p. 505, John Wiley and Sons, 1996. (Original source: Markus O. Speidel, Brown Boveri Co.) “held at 160ºC for 1 hr before testing” increasing load crack speed (m/s) “as-is” 10 -10 10 -8 Alloy 7178 tested in saturated aqueous NaCl solution at 23ºC

29.  http://chemistry.about.com/od/metalsalloys/Metals_Alloys.htm http://chemistry.about.com/od/metalsalloys/Metals_Alloys.htm  http://www.engr.sjsu.edu/WofMatE/Metals&Alloys.htm http://www.engr.sjsu.edu/WofMatE/Metals&Alloys.htm  http://www.sigmaaldrich.com/etc/medialib/docs/Aldrich/Brochure/al_mater ial_matters_v2n4.Par.0001.File.tmp/al_material_matters_v2n4.pdf http://www.sigmaaldrich.com/etc/medialib/docs/Aldrich/Brochure/al_mater ial_matters_v2n4.Par.0001.File.tmp/al_material_matters_v2n4.pdf  http://www.engineeringtoolbox.com/metal-alloys-densities- d_50.html http://www.engineeringtoolbox.com/metal-alloys-densities- d_50.html  http://www.google.com.my/search?q=metals+and+alloys&hl=en&cl ient=firefox-a&hs=zlq&sa=G&rls=org.mozilla:en- US:official&channel=s&prmd=ivb&source=univ&tbs=vid:1&tbo=u&ei =btI7TOvJCdG4rAfO3ZDKCg&oi=video_result_group&ct=title&resnu m=16&ved=0CFsQqwQwDw http://www.google.com.my/search?q=metals+and+alloys&hl=en&cl ient=firefox-a&hs=zlq&sa=G&rls=org.mozilla:en- US:official&channel=s&prmd=ivb&source=univ&tbs=vid:1&tbo=u&ei =btI7TOvJCdG4rAfO3ZDKCg&oi=video_result_group&ct=title&resnu m=16&ved=0CFsQqwQwDw  http://www.google.com.my/search?q=metals+and+alloys&hl=en&cl ient=firefox-a&hs=zlq&sa=G&rls=org.mozilla:en- US:official&channel=s&prmd=ivb&source=univ&tbs=vid:1&tbo=u&ei =btI7TOvJCdG4rAfO3ZDKCg&oi=video_result_group&ct=title&resnu m=16&ved=0CFsQqwQwDw http://www.google.com.my/search?q=metals+and+alloys&hl=en&cl ient=firefox-a&hs=zlq&sa=G&rls=org.mozilla:en- US:official&channel=s&prmd=ivb&source=univ&tbs=vid:1&tbo=u&ei =btI7TOvJCdG4rAfO3ZDKCg&oi=video_result_group&ct=title&resnu m=16&ved=0CFsQqwQwDw 29