Chapter 1
Introduction
to
Materials Science
1
Course Objectives
Introduce fundamental concepts in Materials
Science
Provide the interrelationships among structure,
properties & processing.
2
Learning Outcomes
At the end of this course the students should be able to:
1.Describe the classifications, structures &
applications of metals, ceramics and polymers
correctly.
2.Analyse deformations behavior and
strengthening mechanisms relying to its
structure & properties of materials clearly.
3.Apply Fick’s Law in calculating the diffusion
process and its mechanism in solids properly.
3
Learning Outcomes
At the end of this course the students should be able to:
4.Demonstrate appropriate test methods in
determining mechanical properties.
5.Apply the relation between composition,
microstructure and properties of metallic
materials by using apposite phase diagram and
heat treatment process.
4
Course Synopsis
This course comprises the fundamentals of
Materials Science and its applications, atomic
structure, crystal structure, solidification,
imperfections and solid diffusion, mechanical
and physical properties, phase diagrams and
transformation, synthesis, types and applications
of materials.
5
Course References
1.Callister W. D., 2008, Fundamentals of
Materials Science and Engineering, 3rd Edition,
John Wiley & Sons.
2. Smith W. F., 2004, Foundation of Materials Science and
Engineering, 4th Edition, McGraw Hill.
3. Shackleford J. F. , 2000, Introduction to Materials
Science for Engineers, 5th Edition, Prentice Hall.
4. Budinski K. G. and Budinski M.G., 1999, Engineering
Materials: Properties and Selection, 6th Edition,
Butterworth-Heinemann UK.
5. Askeland D. R., 1994, The Science and Engineering of
Materials, 3rd Edition, PWS Publication Co.
6
Lectures
Lecturer: Wan Mohd Farid bin Wan Mohamad
Time: 8 – 10 a.m (Tuesday)
Place: BK 3, Fasa B
Tutorial/Lab. Sections
Group 1
Lecturer: Wan Mohd Farid
Time: 2 – 5 p.m (Tuesday)
Place: BK 1/MSTB
Group 2
Lecturer: Sushiela Edayu
Time: 2 – 5 p.m (Monday)
Place: MCS /MSTB
Technician (G1 & G2)
Mahader bin Muhamad
7
Course Evaluations
Criteria
%
Course work
Test
Assignment
1 Test (1½ hour)
15
1 assignment
Will be submitted 4 weeks after tutorial
15
1 Group presentation (week 15)
Quiz
Laboratory
2 Quizzes
5
5
3 Informal Group Reports (hand written)
Will be submitted 3 days after lab session
12
1 Formal Individual Report (hand written)
Will be submitted 1 week after lab session
8
Final examination
Exam
1 Final Exam (2 ½ hours)
Total
40
100
8
Course Schedules
Week
Topic
Chapter
1,2 General Intro; Atomic Structure & Bonding
1,2
3,4
Crystalline Structures; Polymers
3,4
5,6
Defects; Diffusion
5,6
7
Mid-Semester Break
8,9 Mechanical Properties; Strength Mechanisms 7,8
10,11
Failure; Phase Diagrams
9,10
12
Hari Raya Aidilfitri Break
13,14
Phase Transform; Appl. of Materials
11,12
15
Physical Properties
13
16
Revision & Group presentation
17,
Study week
18,19,20
Final exam
Lectures: will highlight important portions of each
9
chapter.
General Introduction
• What is materials science?
• Why should we know about it?
• Materials drive our society
–
–
–
–
Stone Age
Bronze Age
Iron Age
Now?
• Silicon Age?
• Polymer Age?
10
Example – Hip Implant
• With age or certain illnesses joints deteriorate.
Particularly those with large loads (such as hip).
Adapted from Fig. 22.25, Callister 7e.
11
Example – Hip Implant
• Requirements
– mechanical
strength (many
cycles)
– good lubricity
– biocompatibility
Adapted from Fig. 22.24, Callister 7e.
12
Example – Hip Implant
Adapted from Fig. 22.26, Callister 7e.
13
Hip Implant
• Key problems to overcome
– fixation agent to hold
acetabular cup
– cup lubrication material
– femoral stem – fixing agent
(“glue”)
– must avoid any debris in cup
Ball
Acetabular
Cup & Liner
Femoral
Stem
Adapted from chapter-opening photograph,
Chapter 22, Callister 7e.
14
Structure, Processing, & Properties
• Properties depend on structure
ex: hardness vs structure of steel
martensitic
(d)
Hardness (BHN)
600
tempered
martensite
500
400
300
200
100
spheroidite
(a)
30 mm
0.01 0.1
pearlite +
proeutectoid
(c)
ferrite
(b)
4 mm
30 mm
30 mm
Data obtained from Figs. 11.31(a)
and 11.33 with 4 wt% C composition,
and from Fig. 14.8 and associated
discussion, Callister & Rethwisch 3e.
Micrographs adapted from (a) Fig.
11.19; (b) Fig. 10.34;(c) Fig. 11.34;
and (d) Fig. 11.22, Callister &
Rethwisch 3e.
1
10 100 1000
Cooling Rate (ºC/s)
• Processing can change structure
ex: structure vs cooling rate of steel
15
Types of Materials
• Metals:
– Strong, ductile
– High thermal & electrical conductivity
– Opaque, reflective.
• Polymers/plastics: Covalent bonding  sharing of e’s
– Soft, ductile, low strength, low density
– Thermal & electrical insulators
– Optically translucent or transparent.
• Ceramics: ionic bonding (refractory) – compounds of metallic
& non-metallic elements (oxides, carbides, nitrides, sulfides)
– Brittle, glassy, elastic
– Non-conducting (insulators)
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The Materials Selection Process
1. Pick Application
Determine required Properties
Properties: mechanical, electrical, thermal,
magnetic, optical, deteriorative.
2. Properties
Identify candidate Material(s)
Material: structure, composition.
3. Material
Identify required Processing
Processing: changes structure and overall shape
ex: casting, sintering, vapor deposition, doping
forming, joining, annealing.
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ELECTRICAL
• Electrical Resistivity of Copper:
6
Adapted from Fig. 12.8, Callister &
Rethwisch 3e. (Fig. 12.8 adapted
from: J.O. Linde, Ann Physik 5, 219
(1932); and C.A. Wert and R.M.
Thomson, Physics of Solids, 2nd
edition, McGraw-Hill Company, New
York, 1970.)
(10-8 Ohm-m)
Resistivity, r
5
4
3
2
1
0
-200
-100
0
T (°C)
• Adding “impurity” atoms to Cu increases resistivity.
• Deforming Cu increases resistivity.
18
THERMAL
-- Silica fiber insulation
offers low heat conduction.
• Thermal Conductivity
of Copper:
Adapted from chapteropening photograph,
Chapter 17, Callister &
Rethwisch 3e. (Courtesy
of Lockheed
Missiles and Space
Company, Inc.)
100 mm
Adapted from
Fig. 19.4W, Callister
6e. (Courtesy of
Lockheed Aerospace
Ceramics Systems,
Sunnyvale, CA)
(Note: "W" denotes
fig. is on CD-ROM.)
-- It decreases when
you add zinc!
Thermal Conductivity
(W/m-K)
• Space Shuttle Tiles:
400
300
200
100
0
0
10
20 30 40
Composition (wt% Zinc)
Adapted from Fig. 17.4, Callister & Rethwisch
3e. (Fig. 17.4 is adapted from Metals
Handbook: Properties and Selection:
Nonferrous alloys and Pure Metals, Vol. 2, 9th
ed., H. Baker, (Managing Editor), American
19
Society for Metals, 1979, p. 315.)
OPTICAL
• Transmittance:
-- Aluminum oxide may be transparent, translucent, or
opaque depending on the material structure.
single crystal
polycrystal:
low porosity
transparent translucent
polycrystal:
high porosity
opaque
Adapted from Fig. 1.2,
Callister & Rethwisch 3e.
(Specimen preparation,
P.A. Lessing; photo by S.
Tanner.)
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DETERIORATIVE
• Stress & Saltwater...
crack speed in salt water!
crack speed (m/s)
-- causes cracks!
• Heat treatment: slows
10 -8
10 -10
Adapted from chapter-opening photograph,
Chapter 16, Callister & Rethwisch 3e.
(from Marine Corrosion, Causes, and
Prevention, John Wiley and Sons, Inc., 1975.)
“as-is”
“held at
160ºC for 1 hr
before testing”
Alloy 7178 tested in
saturated aqueous NaCl
solution at 23ºC
increasing load
Adapted from Fig. 11.20(b), R.W. Hertzberg, "Deformation and
Fracture Mechanics of Engineering Materials" (4th ed.), p. 505, John
Wiley and Sons, 1996. (Original source: Markus O. Speidel, Brown
Boveri Co.)
-- material:
4 mm
7150-T651 Al "alloy"
(Zn,Cu,Mg,Zr)
Adapted from chapter-opening
photograph, Chapter 11, Callister & Rethwisch 3e.
(Provided courtesy of G.H. Narayanan and A.G. Miller,
Boeing Commercial Airplane Company.)
21
SUMMARY
Course Goals:
• Use the right material for the job.
• Understand the relation between properties,
structure, and processing.
• Recognize new design opportunities offered
by materials selection.
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End of
Chapter
1
23