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Surface Technology Part 1 Introduction

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Presentation on theme: "Surface Technology Part 1 Introduction"— Presentation transcript:

1 Surface Technology Part 1 Introduction
Professor Kenneth W Miller Office A108 Phone Surface Technology

2 Topics for Today Course Syllabus Introductions
My background What is your background What are your areas of interest Automobile Parts of Interest Materials of Interest What is Not Covered Fundamentals of Materials Science Surface Technology

3 Automotive Parts of Interest
Body in White Suspension Components Brake Components Steering Components Space Frames Accessories Mirrors Antenna Surface Technology

4 Enemies List Metal to metal contact Sun Water Salt Rocks Grocery carts
Time Surface Technology

5 Body and Frame Functions
Strength Frame A, B, and C Pillars Suspension and Steering Components Braking Components Cosmetic Body panels hood Surface Technology

6 Automotive Materials of Interest
Steel Carbon Steel HSLA Stainless Steel New Alloys Aluminum Magnesium Polymers Composites Surface Technology

7 What is Not Covered Engine and engine components Tires
Polymers will get limited coverage underbody impact protection body parts Surface Technology

8 Summary Body in White is the Primary Topic
Steel is the Primary Material Aluminum is Becoming Significant Magnesium is of Limited Interest What are the factors in material selection? Surface Technology

9 Material Structure Atomic Level
Patterns of Atoms Unit Cells Body-Centered Cubic (BCC) Face-Centered Cubic (FCC) Hexagonal Close Pack (HCP) Surface Technology

10 Material Structure - FCC
Surface Technology

11 Material Structure -BCC
Surface Technology

12 Material Structure - HCP
Surface Technology

13 Energy and Packing • Non dense, random packing
• Dense, regular packing Surface Technology 2

14 Material Structure - APF
Atomic Packing Factor APF = Volume of atoms / Volume of cell APF = 0.74 for FCC APF = 0.68 for BCC APF = 0.74 for HCP Surface Technology

15 Material Structure Coordination Number
Nearest neighbors and touching atoms Coordination Number = 12 for FCC Coordination Number = 8 for BCC Coordination Number = 12 for HCP Surface Technology

16 Material Structure - FCC
Metal Atomic Radius (nm) Aluminum 0.1431 Copper 0.1278 Gold 0.1442 Nickel 0.1246 Platinum 0.1387 Silver 0.1445 Surface Technology

17 Material Structure - BCC
Metal Atomic Radius (nm) Chromium 0.1249 Iron (α) 0.1750 Molybdenum 0.1363 Tantalum 0.1430 Tungsten 0.1371 Surface Technology

18 Material Structure - HCP
Metal Atomic Radius (nm) Cadmium 0.1490 Cobalt 0.1253 Titanium (α) 0.1445 Zinc 0.1332 Surface Technology

19 Strength of Materials Determined by bond strength
Limited by slip planes Slip planes and dislocations Split planes and inclusions Atomic separation (distances) Surface Technology

20 Crystalline Defects Surface Technology

21 Bond Strength Surface Technology

22 Energy and Packing • Non dense, random packing
• Dense, regular packing Surface Technology 2

23 Granular Structure Pure metals are rarely used
Practical limits to crystalline structure Can create anisotropy Reflects heterogeneous composition Caused and changed through Forming operations such as casting Working operations e.g. rolling, drawing Heat treatment Surface Technology

24 Granular Structure Polycrystalline lead ingot Magnified 7x
Surface Technology

25 Granular Structure Size – effects strength Size – effects toughness
Orientation – affects directional strength Orientation at surface – corrosion opportunities Can be seen through a small microscope Crystalline structure requires special equipment Surface Technology

26 Strain Engineering Strain True Strain Surface Technology

27 Stress Engineering Stress True Stress Surface Technology

28 Stress and Strain These are point functions
>0 for tension, <0 for compression Both are directional Both depend on plane considered Normal stress and strain Shear stress and strain Full stress or strain state is represented as a 3x3 matrix Surface Technology

29 Stress and Strain Surface Technology

30 Material Properties Tensile strength Yield strength Toughness Hardness
Fracture toughness Modulus of Elasticity Poisson’s Ratio Toughness – resistance to fracture, area under stress strain curve Surface Technology

31 Stress and Strain Elastic Range – linear Plastic Range – non-linear
E is the modulus of elasticity or Young’s Modulus Full recovery, no permanent change Plastic Range – non-linear Varies with material Work hardening Necking Permanent change to size and strength Surface Technology

32 Modulus of Elasticity Surface Technology
True or engineering stress and strain Surface Technology

33 Modulus of Elasticity Surface Technology

34 Yield Point Surface Technology

35 Necking Surface Technology

36 Stress Strain Power law relationship Typical for steel and aluminum
Assumes slow strain Assumes uniform temperature Surface Technology

37 Stress Strain Material n K (MPa) Low Carbon Steel 0.21 600
4340 Steel Alloy 0.12 2650 304 Stainless Steel 0.40 1400 Aluminum A2024-T3 0.17 780 Magnesium AZ-31B 0.16 450 Surface Technology

38 Poisson’s Ratio Pull it and it gets thinner Squish and it gets thicker
Consider a tensile specimen pulled in z Upper limit is 0.5 for no material volume change Surface Technology

39 Material Properties Material Elasticity Yield Poisson’s GPa MPa Ratio
Tungsten 407 0.28 Steel 207 180 0.30 Nickel 138 0.31 Titanium 107 450 0.34 Copper 110 69 Brass 97 75 Aluminum 35 0.33 Magnesium 45 0.35 Surface Technology

40 Discussion - Surfaces Appearance Cover minor flaws
Hide difference materials Protection from Corrosion Protection from scratches or impacts Increase / decrease friction Improve scratch resistance (hardness) Surface Technology

41 Manufacturing Considerations
Cost Speed – timing for production Downstream effects Value to the consumer Weight Appearance Safety Surface Technology

42 Manufacturing Cost Materials Time Equipment
Flexibility (changeover time and cost) Labor Waste disposal (toxic?) Surface Technology

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