1. Materials Science & Selection Integrated Science & Technology 431 Fall 2003

2. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 20032 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.

3. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 20033 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)

4. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 20034 Manufacturing Manufacturing. –Manus (Hand). –Factus (make). No longer true. –Most items of value are mass made by automated systems.

5. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 20035 Manufacturing 2 Technologically –Application of chemical and physical processes to materials to alter; Geometry Properties Appearance

6. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 20036 Manufacturing 3 Economically –Transformation of materials into items of greater value By processing By assembly

7. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 20037 Manufacturing 4 –Production control –Support services –Marketing –Sales –Shipping –Customer service A complex process involving… –Product design –Machinery and tooling –Process planning –Purchasing –Manufacturing

8. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 20038 Manufacturing 5 ProductNumber of parts Rotary lawn mower300 Grand piano12,000 Automobile15,000 C-5B transport plane>4,000,000 Boeing 747-400>6,000,000

9. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 20039 Manaufacturing 5 Manufacturing is a process which uses material. Three primary types of manufacturing, and all use different material.

10. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 200310 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

11. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 200311 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

12. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 200312 Materials Can be anything of substance in the known universe. For our purposes we will restrict the discussion essentially to solids

13. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 200313 Engineering Materials Metals Non-metals (Ceramics) Polymers Natural stuff

14. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 200314 Engineering Materials 2 Metals Non-metals (Ceramics) Polymers Natural stuff Blends produce unique materials called: Composites

15. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 200315 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,

16. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 200316 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

17. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 200317 Evolution of Engineering Materials

18. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 200318 Material and Civilization Timeline

19. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 200319 Evolution of material normalized strength

20. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 200320 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

21. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 200321 Metallic Materials Substances composed of one or more metallic elements –For example: Iron (Fe) Copper (Cu) Aluminum (Al) Nickel (Ni) ….

22. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 200322 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

23. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 200323 Metallic Materials 3 Two Classes –Ferrous metals and alloys Contain a large percentage of iron –Non-ferrous Usually softer and used at lower temperatures.

24. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 200324 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

25. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 200325 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

26. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 200326 Polymerics Two major constituents –Carbon –Silicon Polymers generally are giant molecules consisting of long chains –Structures may be one, two, or three dimensional.

27. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 200327 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

28. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 200328 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

29. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 200329 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

30. Dr. Ken Lewis ISAT-431 Module 1 Overview Fall 200330 Competition amongst six major materials