Introduction to Materials Science & Engineering

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1 Introduction to Materials Science & Engineering Course Objective... Introduce fundamental concepts in Materials Science & Engineering You will learn about: material structures how structure dictates properties how processing can change structure This course will help you to: use materials properly realize new design opportunities with materials Chapter 1-1

about: material structures how structure dictates properties how processing can change

2 COURSE MATERIALS (with WileyPLUS) Required text: WileyPLUS for Fundamentals of Materials Science and Engineering, W.D. Callister, Jr. and D.G. Rethwisch, 4th edition, John Wiley and Sons, Inc. (2012). Website: Can be bought online at wileyplus.com for 40% of textbook price Includes complete online version of textbook Or comes bundled with textbook at bookstore $5 more than textbook alone Homework assignments with instant feedback and hints Computer graded self-help problems Hotlinks in homework to supporting text sections Quizzes Chapter 1-2

com for 40% of textbook price Includes complete online version of textbook Or comes bundled with textbook at bookstore $5 more than textbook

3 Course Website: Syllabus Lecture notes Solution manual Grades WEBSITES Text Website: VMSE for 3D interactive simulations and animations of material structures, characteristics, and properties Mechanical Engineering online support module Case studies of materials usage Extended learning objectives Self-assessment exercises Chapter 1-3

com/college/callister VMSE for 3D interactive simulations and animations of material structures,

4 Virtual Materials Science & Engineering (VMSE) Website: Student Companion Site VMSE Comprised of 8 interactive modules Atomic/molecular stuctures - 3D perspectives (better visualizations) using click-and-drag rotations Demonstrations of defects and phenomena that exist/occur in materials Demonstrations of material tests - performance and results Database of material property values and costs Chapter 1-4

- 3D perspectives (better visualizations) using click-and-drag rotations Demonstrations of defects and phenomena

5 Virtual Materials Science & Engineering (VMSE) This is a screenshot of the VMSE opening window Available in Student Companion Site at and in WileyPLUS Chapter 1-5

Available in Student Companion Site at www.wiley.

6 Chapter 1 - 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? Chapter 1-6

7 Example Hip Implant With age or certain illnesses joints deteriorate. Particularly those with large loads (such as hip). Adapted from Fig , Callister 7e. Chapter 1-7

8 Example Hip Implant Requirements mechanical strength (many cycles) good lubricity biocompatibility Adapted from Fig , Callister 7e. Chapter 1-8

9 Example Hip Implant Adapted from Fig , Callister 7e. Chapter 1-9

10 Hip Implant Key problems to overcome fixation agent to hold acetabular cup cup lubrication material femoral stem fixing agent must avoid any debris in cup Ball Acetabular Cup and Liner Femoral Stem Adapted from chapter-opening photograph, Chapter 22, Callister 7e. Chapter 1-10

must avoid any debris in cup Ball Acetabular Cup and Liner Femoral

11 Example Develop New Types of Polymers Commodity plastics large volume ca. $0.50 / lb Ex. Polyethylene Polypropylene Polystyrene etc. Engineering Resins small volume > $1.00 / lb Ex. Polycarbonate Nylon Polysulfone etc. Can polypropylene be upgraded to properties (and price) near those of engineering resins? Chapter 1-11

Engineering Resins small volume > $1.00 / lb Ex.

12 Structure, Processing, & Properties Properties depend on structure ex: hardness vs structure of steel Hardness (BHN) (a) 30 μm (b) 30 μm (c) 4 μm Cooling Rate (ºC/s) Processing can change structure ex: structure vs cooling rate of steel (d) 30 μm Data obtained from Figs (a) and with 4 wt% C composition, and from Fig and associated discussion, Callister & Rethwisch 4e. Micrographs adapted from (a) Fig ; (b) Fig ;(c) Fig ; and (d) Fig , Callister & Rethwisch 4e. Chapter 1-12

1 1 10 100 1000 Cooling Rate (ºC/s) Processing can change structure ex: structure vs cooling rate of steel (d) 30 μm Data obtained from Figs.

13 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) Chapter 1-13

$Ceramics: ionic bonding (refractory) compounds of metallic & non-metallic elements (oxides, carbides, nitrides,$

14 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. Chapter 1-14

optical, deteriorative. 2. Properties Identify candidate Material(s) Material: structure, composition. 3.

15 ELECTRICAL Electrical Resistivity of Copper: 6 5 Resistivity, ρ (10-8 Ohm-m) Adapted from Fig. 12.8, Callister & Rethwisch 4e. (Fig 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.) T (ºC) Adding impurity atoms to Cu increases resistivity. Deforming Cu increases resistivity. Chapter 1-15

M. Thomson, Physics of Solids, 2nd edition, McGraw-Hill Company, New York, 1970.

16 Space Shuttle Tiles: -- Silica fiber insulation offers low heat conduction. THERMAL Adapted from chapteropening photograph, Chapter 17, Callister & Rethwisch 3e. (Courtesy of Lockheed Missiles and Space Company, Inc.) Thermal Conductivity of Copper: -- It decreases when you add zinc! Thermal Conductivity (W/m-K) Composition (wt% Zinc) 100μm Adapted from Fig. 19.4W, Callister 6e. (Courtesy of Lockheed Aerospace Ceramics Systems, Sunnyvale, CA) (Note: "W" denotes fig. is on CD-ROM.) Adapted from Fig. 17.4, Callister & Rethwisch 4e. (Fig is adapted from Metals Handbook: Properties and Selection: Nonferrous alloys and Pure Metals, Vol. 2, 9th ed., H. Baker, (Managing Editor), American Society for Metals, 1979, p. 315.) Chapter 1-16

Thermal Conductivity (W/m-K) 400 300 200 100 0 0 10 20 30 40 Composition (wt% Zinc) 100μm Adapted from Fig. 19.4W, Callister 6e.

17 Magnetic Storage: -- Recording medium is magnetized by recording head. MAGNETIC Magnetic Permeability vs. Composition: -- Adding 3 atomic % Si makes Fe a better recording medium! Magnetization Fe+3%Si Fe Fig , Callister & Rethwisch 4e. Magnetic Field Adapted from C.R. Barrett, W.D. Nix, and A.S. Tetelman, The Principles of Engineering Materials, Fig. 1-7(a), p. 9, Electronically reproduced by permission of Pearson Education, Inc., Upper Saddle River, New Jersey. Chapter 1-17

23, Callister & Rethwisch 4e. Magnetic Field Adapted from C.R. Barrett, W.D. Nix, and A.S.

18 Transmittance: -- Aluminum oxide may be transparent, translucent, or opaque depending on the material s structure (i.e., single crystal vs. polycrystal, and degree of porosity). single crystal OPTICAL polycrystal: no porosity polycrystal: some porosity Adapted from Fig. 1.2, Callister & Rethwisch 4e. (Specimen preparation, P.A. Lessing; photo by S. Tanner.) Chapter 1-18

single crystal OPTICAL polycrystal: no porosity polycrystal: some porosity Adapted from Fig.

19 DETERIORATIVE Stress & Saltwater causes cracks! Heat treatment: slows crack speed in salt water! Adapted from Fig , Callister & Rethwisch 4e. (from Marine Corrosion, Causes, and Prevention, John Wiley and Sons, Inc., 1975.) crack speed (m/s) as-is increasing load held at 160ºC for 1 hr before testing Alloy 7178 tested in saturated aqueous NaCl solution at 23ºC Adapted from Fig (b), R.W. Hertzberg, "Deformation and Fracture Mechanics of Engineering Materials" (4th ed.), p. 505, John Wiley and Sons, (Original source: Markus O. Speidel, Brown Boveri Co.) Chapter 1-19

) crack speed (m/s) 10-8 10-10 as-is increasing load held at 160ºC for 1 hr before testing Alloy 7178 tested in saturated aqueous NaCl solution at 23ºC

20 Course Goals: SUMMARY Use the right material for the job. Understand the relation between properties, structure, and processing. Recognize new design opportunities offered by materials selection. Chapter 1-20

Materials Sciences. Dr.-Ing. Norbert Hort norbert.hort@gkss.de. International Masters Programme in Biomedical Engineering

Materials Sciences. Dr.-Ing. Norbert Hort norbert.hort@gkss.de. International Masters Programme in Biomedical Engineering Materials Sciences International Masters Programme in Biomedical Engineering Magnesium Innovations Center (MagIC) GKSS Forschungszentrum Geesthacht GmbH Dr.-Ing. Norbert Hort norbert.hort@gkss.de Contents