RJM, 8/7/06All photos and figures - Copyright, Prentice Hall What is this Class??? Applied material selection course –Some material science (text) Chemistry and Metallurgy –Some material selection software (lab using CES software) –A little corrosion and failure analysis (text and lab) –+ Capstone Projects!! Goal: Intelligently select materials for design!!!

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Chapter 1 – The Importance of Engineering Materials Chapter 2 – Forming Engineering Materials from the Elements Origin of Engineering Materials The Periodic Table of Elements Overview: Metals, Ceramics, Polymers and Composites

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall History – the evolution of materials

The expansion of the materials world James Stuart, Professor of Engineering at Cambridge No polymers – now over 45,000 Today: > 160,000 engineering materials Creates two needs: 1 Education – how best to teach materials? 2 Industry – how manage materials information, consistency, etc.. ? No light alloys – now several thousand No composites – now hundreds …… In his day: a few hundred materials Think about how materials impacted your life today, quality of life, drive to work/school, etc… Composite wood, new thin glass for LCD/phone displays, semiconductors, diamond composite rock drills for deep sea drilling, new Mg alloys for automotive wheels, new inconel alloys for Yucca Mountain nuclear waste site, etc……………….

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall A Study in Polymers!! Football Helmet – 7 layers of various polymers: Butyl elastomer bonded to g/f nylon Composite mask (RTM)

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Flight bars – PUR, abrasion resistance in extremely hostile environment Drill Bit Isolators – high strength elastomer bonded to 4140 HT, carbide bit Caster wheel – perfect marriage of steel, thermoplastic and elastomer

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Seismic Mount (QC-19191) Bearing Plate Upright Box Fabrication (Fail Safe) Cross-Aisle Down-Aisle Seismic Isolation System:

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Teaching materials to engineering students  Engineers make things. They make them out of materials, using processes. The philosophy  The CES EduPack provides the resources to achieve this and gives students a tool they can use in their later profession (like CAD or FE tools)  What do they need to know to do this successfully? A perspective of the world of materials and processes An ability to select those that best meet requirements of a design Access to information and tools for comparison and selection An understanding material properties and their origins

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Mechanical properties illustrated (Ashby, 2005) Stiff Strong Tough Light Not stiff enough (need bigger E) Not strong enough (need bigger  y ) Not tough enough (need bigger K ic ) Too heavy (need lower  ) All OK ! Need to improve on the selection of materials

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Material Classifications (4 basic families): MetalsCeramics Polymers Composites Applications: building frame, autos, heavy equipment, etc. Key: cheap, strong and ductile, easily fabricated!! Applications: Electronics, cutting tools, glass, building materials, etc. Key: Extremely hard w/ high temp capability (little thermal expansion) Applications: packaging, medical equipment, moderate load carrying applications, etc. Key: Cheap, reasonably strong, variety of materials Applications: Autos, aerospace, etc. Key: high strength to weight ratio

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Mechanical engineering Ceramics, glasses Hybrids, composites Polymers, elastomers Metals, alloys

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Aerospace and motorsport Hybrids, composites Polymers, elastomers Metals, alloys Ceramics, glasses

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Civil engineering and architecture Hybrids, composites Polymers, elastomers Metals, alloys Ceramics, glasses

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Bio-engineering Ceramics, glasses Polymers, elastomers Metals, alloys Hybrids, composites

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Product & industrial design Hybrids, composites Polymers, elastomers Metals, alloys Ceramics, glasses

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Glass, stone, silicone carbide SiC Wood/leather CFRP, GFRP, aluminum silicone carbide Al/SiC

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall CES: Organising information: the MATERIALS TREE Kingdom Materials Family Ceramics & glasses Metals & alloys Polymers & elastomers Hybrids Class Steels Cu-alloys Al-alloys Ti-alloys Ni-alloys Zn-alloys Member A material record Attributes Density Mechanical props. Thermal props. Electrical props. Optical props. Corrosion props. Supporting information -- specific -- general Density Mechanical props. Thermal props. Electrical props. Optical props. Corrosion props. Supporting information -- specific -- general Structured information Unstructured information

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Optimized selection using charts 2 3 Results 22 pass Material Material Material etc... Ranked by Index 1 Search area

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Metals Polymers Ceramics Composites Chapter 1 Summary:

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Chemistry Review (yuck) Just know basics…………………..

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Basic Chemical Terms: Atom – smallest part of an element that retains the property of that element. Composed of neutrons, electrons, and protons. All matter composed of atoms bonded together in different patterns and different types of bonds. Elements – pure substance that CAN NOT be broken down to a simpler substance. 90 elements occur naturally in the earth’s crust. 120 total elements including laboratory synthesized elements.

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Classification of Matter: (contain carbon) (not derived from living things)

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Atomic number – Total number of protons in the nucleus of an atom. Periodic Table:

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Periodic Table: Best: Elements can be broadly classified as: metals, metalloids and nonmetals. Metals – solid at room temperature (Except mercury), malleable, ductile, strong, conduct electricity, 1/2/3 valence electrons in outer shell – much more! Nonmetals (total of 17) – poor conductors of heat, mostly insulators, tend to be brittle and fracture easily. Metalloids or semimetals – have some properties like metals (i.e. conduct electricity) but share other properties with non-metals. See suplemental notes on course data disk for elements!!

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall *

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Oxygen Atom

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall What we really care about are material properties!! From CES Unit 3 – The elements: Elements  127 records for 111 elements  52 fields  Periodic table properties  Structural properties  Mechanical properties  Thermal properties  Diffusion data  Surface energies  Electrical and superconducting props.  Magnetic properties  Nuclear properties  Approximate cost The Periodic Table

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Using the Elements DB  Explore how properties change across the Periodic Table

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Relationships between properties (1)  Modulus and melting point

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Engineering materials – the same dependence

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Relationships between properties (2)  Expansion coefficient and melting point

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Engineering materials – the same dependence

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Relationships between properties (3)  Electrical and thermal conductivities Electrical and thermal conduction Wiedemann-Franz law

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Engineering materials – the same dependence Wiedemann-Franz law CERAMICS ARE THE EXCEPTION!!!

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall 1.3 Forming Engineering Materails from the Elements Atoms must be balanced! 2 Recall: atoms tend to combine so their outer electron shell contains 8 electrons!!

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall 1.4 The Solid State Crystalline structures (i.e. metals) atoms are arranged in unit cells – 4 common cells shown above

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Several cells form a crystal, if many crystals are growing in a melt at the same time, where they meet = grain boundry as shown below:

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall 1.5 The Nature of Metals: Characterized by: 1.Valence electrons of 1,2 or 3 – see periodic table 2.Primary bonding between electrons called metallic bonding: Valence electrons not “bonded” to particular atom but shared and free to drift through the entire metal 3. Properties include: good conductors of electricity and heat, not transparent, quite strong yet deformable!

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall How do metals fail??? If bonds are strong and metal is brittle get cleavage failure a. Cleavage:

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall How do metals fail??? b. Slip due to dislocations

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall b. Slip due to dislocations

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall b. Slip due to dislocations

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall How to Strengthen Metals Alloying (aka: Solid Solution Strengthening) – larger impurity atoms impede dislocation motion. Cold working – adding more dislocations actually impedes motion of all dislocations!! Heat Treating (aka: Precipitation hardening) impurity atoms coalesce in matrix and form barrier to dislocation movement. Dispersion Hardening (aka: Quench hardening) – fine particles impede dislocation movement.

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall How to strengthen metals:

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall 1.6 Nature of ceramics: Characterized by: 1.Compounds between metallic and non-metallic elements. 2.Frequently oxides, nitrides and carbides (i.e. silicon carbide – SpinWorks) 3.Very strong covalent (sharing of electrons) or ionic (transfer of electrons) bonds. 4.Properties include: Strong but brittle Low fracture toughness Good insulators of electricity BUT good conductor of heat (i.e. comparable to metals have reasonably high thermal conductivity, k) – this is unique to ceramics. Excellent high temp properties Low coef of thermal expansion

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Electrical Resistance: Ceramics = good electrical insulators, but…

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall Selection: one-property indices Good conductors: metals and ceramics Good insulators: polymer foams, cork, wood, cardboard…. Good thermal conductors!

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall 1.6 Nature of ceramics: Example: Aluminum Oxide, Al 2 O 3

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall 1.7 Nature of polymers: Characterized by: 1.Organic compound (i.e. chemically based on carbon, hydrogen or other nonmetallic element) 2.Covalent bond between atoms 3.Long chain repeating molecular structures 4.Properties include low density, highly flexible 5.Broadly classified into three groups: thermosets, thermoplastics and elastomers.

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall

RJM, 8/7/06All photos and figures - Copyright, Prentice Hall 1.8 Nature of Composites: Characterized by: 1.Combination of two or more materials 2.Designed to display a combination of the best characteristics of each material i.e. fiberglass acquires strength from glass and flexibility from the polymer. 3.Can have: High strength to weight ratio Excellent corrosion resistance 4.Used in aircraft, boats, automotive, fishing pools, tennis rackets, etc