1. Types of Material IE 351 Lecture 3

2. Engineering Materials

3. Classification of Materials Metals Ceramics Polymers Composite Materials

4. Further Classification Metals –Ferrous –Non-ferrous –Super alloys Ceramics –Traditional ceramics –New ceramics –Glass

5. Further Classification Polymers –Thermoplastics –Thermosets –Elastomers Composite Materials –Metal Matrix Composites –Ceramic Matrix Composites –Polymer Matrix Composites

6. Metals Ferrous Metals –Cast irons –Steels Non-ferrous metals –Aluminum and its alloys –Copper and its alloys –Magnesium and its alloys –Nickel and its alloys –Titanium and its alloys

7. Metals Ferrous Metals –Cast irons –Steels Superalloys –Iron-based –Nickel-based –Cobalt-based Non-ferrous metals –Aluminum and its alloys –Copper and its alloys –Magnesium and its alloys –Nickel and its alloys –Titanium and its alloys –Zinc and its alloys –Lead & Tin –Refractory metals –Precious metals

8. Heat Treatment of Metals Annealing –Full annealing –Normalising (faster rate of cooling) –Recovery annealing (longer holding time, slower rate of cooling,) –Stress relieving (lower temperature) Martensite formation in steel –Austenitizing (conversion to austenite) –Quenching (control cooling rate –Tempering (reduce brittleness)

9. Heat Treatment of Metals Precipitation hardening –Solution treatment (  -phase conversion) –quenching –precipitation treatment (aging) Surface hardening –Carburizing –Nitriding –Carbonitriding –Chromizing and Boronizing

10. Heat Treatment of Steel

11. Precipitation Hardening Solution treatment Quenching Precipitation treatment

12. Furnaces for Heat Treatment Fuel fire furnaces –gas –oil Electric furnaces –batch furnaces box furnaces - door car-bottom furnaces - track for moving large parts bell-type furnaces - cover/bell lifted by gantry crane –continuous furnaces

13. Furnaces for Heat Treatment Vacuum furnaces Salt-bath furnaces Fluidized-bed furnaces Some of the furnaces have special atmosphere requirements, such as carbon- and nitrogen- rich atmosphere.

14. Surface Hardening Methods Flame hardening Induction heating High-frequency resistance heating Electron beam heating Laser beam heating

15. Surface Hardening Methods Induction heating High frequency resistance heating

16. Ceramics Traditional ceramics –clays: kaolinite –silica: quartz, sandstone –alumina –silicon carbide New ceramics –oxide ceramics : alumina –carbides : silicon carbide, titanium carbide, etc. –nitrides : silicon nitride, boron nitiride, etc.

17. Glass Glass products –window glass –containers –light bulb glass –laboratory glass –glass fibers –optical glass Glass ceramics - polycrystalline structure

18. Polymers Thermoplastics - reversible in phase by heating and cooling. Solid phase at room temperature and liquid phase at elevated temperature. Thermosets - irreversible in phase by heating and cooling. Change to liquid phase when heated, then follow with an irreversible exothermic chemical reaction. Remain in solid phase subsequently. Elastomers - Rubbers

19. Thermoplastics –Acetals –Acrylics - PMMA –Acrylonitrile-Butadiene-Styrene - ABS –Cellulosics –Fluoropolymers - PTFE, Teflon –Polyamides (PA) - Nylons, Kevlar –Polysters - PET –Polyethylene (PE) - HDPE, LDPE –Polypropylene (PP) –Polystyrene (PS) –Polyvinyl chloride (PVC)

20. Thermosets Amino resins Epoxies Phenolics Polyesters Polyurethanes Silicones

21. Elastomers Natural rubber Synthetic rubbers –butadiene rubber –butyl rubber –chloroprene rubber –ethylene-propylene rubber –isoprene rubber –nitrile rubber –polyurethanes –silicones –styrene-butadiene rubber –thermoplastic elastomers

22. Composite Materials Metal Matrix Composites (MMC) Mixture of ceramics and metals reinforced by strong, high-stiffness fibers Ceramic Matrix Composites (CMC) Ceramics such as aluminum oxide and silicon carbide embedded with fibers for improved properties, especially high temperature applications. Polymer Matrix Composites (PMC) Thermosets or thermoplastics mixed with fiber reinforcement or powder.

23. Composite Materials 1D fibre Woven fabric Random fibre

24. Composite Materials

25. Material Selection Ashby,: Material Selection in Mechanical Design

26. Taxonomy of Materials Selection Ashby,: Material Selection in Mechanical Design

27. Material Specification Chemical composition Mechanical properties – Strength, hardness (under various conditions: temperature, humidity, pressure) Physical properties – density, optical, electrical, magnetic Environmental – green, recycling

33. Typical Selection of Carbon and Alloy Steels for Various Applications

34. Mechanical Properties of Selected Carbon and Alloy Steels in Various Conditions

35. AISI Designation for High-Strength Sheet Steel

36. Room-Temperature Mechanical Properties and Applications of Annealed Stainless Steels

37. Basic Types of Tool and Die Steels

38. Processing and Service Characteristics of Common Tool and Die Steels