1. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 The contents of this lecture are protected under U.S. copyright law and should not be duplicated or redistributed for commercial purposes. 1 MATSE 259 Properties and Processing of Engineering Materials Christopher L. Muhlstein, Ph.D. Department of Materials Science and Engineering The Pennsylvania State University University Park, PA

2. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 2 Today’s Lecture Administrative issues (syllabus, etc.) Introduction to materials engineering

3. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 3 Instructor and TAs Instructor: E. Ryba –e-mail: ryba@ems.psu.edu –Office: 122 Steidle Bldg. –Office Hours: by appt. TA: Youngho Jin –e-mail: yuj107@psu.edu –Office: 225 Steidle Bldg. –Office Hours: Wed. 1:30- 3:30PM TA: Sameet Nabar –e-mail: ssn116@psu.edu –Office: 211 Steidle Bldg. –Office Hours: Mon. 10AM-12 noon I will be teaching this course through 1/26/07 (when Prof. Ryba is back from China).

4. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 4 Important Information Meeting time and place –12:20 PM – 1:10 PM, 121 Sparks Textbook (recommended) –W.D. Callister, Materials Science and Engineering: An Introduction, 6 th ed. Prerequisites –E MCH 13 or E MCH 210

5. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 5 Administrative Issues http://www.ems.psu.edu/~ryba/ coursework/259/matse%20259.html –For the syllabus, lecture slides, announcements, example problems, etc. Academic integrity –This course adopts the College of Earth and Mineral Science’s academic integrity policy as detailed at: http://www.ems.psu.edu/students/integrity/index.html. http://www.ems.psu.edu/students/integrity/index.html –Sanctions for violating the academic integrity policy will be enforced. Special needs – If you anticipate needing any type of accommodation in this course or have questions about physical access, please tell the instructor as soon as possible.

6. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 6 Administrative Issues Assessment tools –Four exams (each 25% of final grade) First three outside of class 6:30-7:45PM Last exam during class See web site for dates Example Problems –Problems and solutions posted on class web site –No graded homework Make up policy –You must contact the the instructor in advance of the exam

7. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 7 Administrative Issues See web site for –Course objectives –Course outcomes –Relevant book sections Lecture Slides on web site –These slides are not “lecture notes” –Posted slides are provided to facilitate the note taking process –Posted slides are not a substitute for your own, handwritten notes or for attending lecture

8. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 8 Materials and Engineering What is engineering? What is materials engineering? Why should you care about this class? What can we learn about engineering from materials-related failures?

9. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 9 Engineering Design and Failure Aloha Airlines 243 (4/28/1988) 1 killed Stress corrosion cracking/corrosion fatigue failure of structural aluminum after 89,680 flight cycles

10. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 10 Engineering Design and Failure Kansas City Hyatt Regency Bridge Collapse in Kansas City, MO (7/1981) 114 killed, over 200 injured Structural steel design error Deformed 4 th floor box beamScene after collapse

11. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 11 Engineering Design and Failure Pepper Mill (9/3/2002) No fatalities Pepper Mill Condominiums, 710 S. Atherton St., State College, PA Under investigation James Rajotte, The Digital Collegian 9/4/2002 Scene after collapse.

12. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 12 Lecture 1: Key Concepts and References Six different property classifications of materials that determine their applicability The three primary classifications of materials The four components of materials engineering and their interrelationships Steel designations Read in Callister: –sects. 3.12, 4.3, 5.1 –pps. 261-262 –start chapter 6 Reference: Callister, Chapter 1

13. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 13 Engineering Properties of Materials Mechanical Electrical Thermal Magnetic Optical Deteriorative What are some general categories of properties of engineering materials?

14. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 14 Components of Materials Engineering Materials science is the study of the relationships between the structures and properties of materials Materials engineering is the design or engineering of a material to produce the desired properties Components of materials engineering: Callister, Materials Science and Engineering: An Introduction (2003)

15. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 15 Fundamental Principle of MATSE Structure, processing, and properties are interrelated Structure ProcessingProperties

16. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 16 What’s in a rug? What is it, and what is its function? What is it made from?

17. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 17 The Periodic Table Callister, Materials Science and Engineering: An Introduction (2003)

18. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 18 Primary Classes of Materials 1.Metals (e.g. aluminum, iron, and titanium) 2.Ceramics (e.g. Al 2 O 3, Fe 3 C, and SiC) 3.Polymers (e.g. acrylic, polyethylene, and nylon) Other “classes” –Composites –Semiconductors (e.g. silicon, germanium, and SiC)

19. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 19 Metals, Ceramics, and Polymers Composition Structure/Bonding Properties Callister, Materials Science and Engineering: An Introduction (2003)

20. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 20 Is this your design?

21. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 The contents of this lecture are protected under U.S. copyright law and should not be duplicated or redistributed for commercial purposes. 21 Looks like a materials problem! What is the material?

22. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 22 100510061008100910101012101510161017 10181019102010211022102310251026 1030 10341035103810391040104410441045 1046 10501060106410651070107410801090 1095 11081116111711181119113211371141 1144 1211121212131215154715483140 40121330133513401345402340274028 40324037404240474118413041404142 41454147415041614419432043404422 44274615462046264718472048154817 482050465060512051305132 Types of Steels

23. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 23 Low and Medium Carbon Steel Nomenclature Four digit number –First two give alloy –Second two give wt% carbon  100 –UNS number starts with G Some alloy types –10XX, plain carbon –41XX, Cr + Mo –43XX, Ni + Cr + Mo

24. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 24 Tool and Stainless Steel Nomenclature Tool steels –High carbon content (0.6-1.4 wt. %) –AISI code denoted by letter+number e.g. M1, A2, etc. –UNS number starts with T Stainless steels –>11 wt. % Cr –3XX series, austenitic –4XX series, ferritic and martensitic –XX-XPH, precipitation hardened –UNS number starts with S

25. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 25 Does it matter? Properties of hot rolled and normalized steels Type Tensile strength 1020 64.0 ksi 1030 75.5 ksi 1040 85.5 ksi 1050 108.5 ksi 1060 112.5 ksi 1080 146.5 ksi

26. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 26 How else can steel properties be changed? SteelTensile strength 1040 hot rolled and normalized 86 ksi 1040 quenched and tempered at 400 F130 ksi 8640 quenched and tempered at 400 F270 ksi (8640: Fe - 0.5%Cr - 0.5%Ni - 0.2%Mo - 0.4%C)

27. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 27 Tensile Behavior of Steels Features –Elastic response –Yielding behavior –Ultimate strength –Failure Influence of alloy chemistry Popov, Engineering Mechanics of Solids (1991)

28. MATSE 259 Spring 2007, C. Muhlstein© C. Muhlstein, 2007 28 What do these things do in steels? Change C content Mechanical work Heat treat Alloying elements Change “structure” Changing structure changes properties