MTS 226

Materials and Manufacturing

Processes

Instructor: Dr. Hamid Jabbar

Hamid.jabbar@ceme.nust.edu.pk
Lecture Slides Courtesy of Dr.
Danish Hussain

Department of Mechatronics Engineering, EME, NUST

 Engineering Materials
Ceramics
• Ceramics are compounds
between metallic and nonmetallic
elements; they are most
frequently oxides, nitrides and
carbides.
• For example: aluminum oxide
(alumina, AL2O3), silicon dioxide
(or silica, SIO2), silicon carbide
(SIC), silicon nitride (SI3N4),
porcelain, cement and glass. Properties

• Typically insulative to the passage of electricity and heat

• More resistant to high temperatures and harsh environments
than metals and polymers
• In general, they are hard, corrosion-resistant and brittle

Department of Mechatronics Engineering, EME, NUST

 WHAT ARE CERAMİCS?

http://www.ts.mah.se/utbild/mt7150/051212%20ceramics.pdf

Periodic table with ceramics compounds indicated by a combination

of one or more metallic elements (in light color) with one or more
nonmetallic elements (in dark color).

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Advanced Materials

Semiconductors
• Materials having electrical
properties that are intermediate Silicon
between those of electrical
conductors and insulators. Electrical
properties of these materials are
extremely sensitive to small
concentrations of impurities
Germinium
https://en.wikipedia.org/wiki/Silicon

Department of Mechatronics Engineering, EME, NUST

 Advanced Materials
Biomaterials
• Materials employed in
components implanted into
the human body to replace
diseased or damaged body
parts. Must be non-toxic and
compatible with body tissues.
Smart Materials
• State of the art materials such Multiple roles for biomaterials in stem cell Tissue Engineering
as shape-memory alloys, https://www.researchgate.net/publication/6539385_Biomaterials_Approach
_to_Expand_and_Direct_Differentiation_of_Stem_Cells/figures?lo=1
piezoelectric ceramics.
(a) Illustration drawing of an EAP gripping device.
(b) A voltage is applied and the EAP fingers deform
in order to surround the ball. (c) When the voltage is
removed, the EAP fingers return to their original
shape and grip the ball.

Department of Mechatronics Engineering, EME, NUST

 Summary:

Metals

Polymers

Ceramics

Composites

Department of Mechatronics Engineering, EME, NUST

 GENERAL COMPARİSON OF
MATERİALS
Property Ceramic Metal Polymer

Hardness Very High Low Very Low

Elastic modulus Very High High Low

Thermal expansion High Low Very Low

Wear resistance High Low Low

Corrosion resistance High Low Low

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22.02.2020
 The Lockheed SR-71 "Blackbird"

Department of Mechatronics Engineering, EME, NUST

 GENERAL COMPARİSON OF
MATERİALS
Property Ceramic Metal Polymer

Ductility Low High High

Density Low High Very Low

Electrical conductivity Depends High Low

on material

Thermal conductivity Depends High Low

on material

Magnetic Depends High Very Low

on material

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22.02.2020
 Engineering Properties of Materials
Physical Properties
A physical property is an aspect of matter that can be observed
or measured without changing it.
A common means of distinguishing one material from another is
through their physical properties
• These include such features as density (weight); melting point;
optical properties (transparency, opaqueness, or color); the
thermal properties of specific heat, coefficient of thermal
expansion, and thermal conductivity: electrical conductivity;
and magnetic properties
• In some cases, physical properties are of prime importance
when selecting a material, however, material selection is
dominated by the properties that describe how a material
responds to applied loads or forces

Department of Mechatronics Engineering, EME, NUST

 Mechanical properties
Mechanical properties are defined as those material properties that
measure a material’s reaction to applied force, like wear resistance,
tensile strength, elongation, Young’s modulus, fracture toughness,
and fatigue strength.

Department of Mechatronics Engineering, EME, NUST

 Mechanical Properties
• Stiffness - Elastic Modulus or Young’s Modulus (MPa)
• Strength - Yield, Ultimate, Fracture, Proof, Offset Yield.
Measured as stress (MPa)
• Ductility - Measure of ability to deform plastically without
fracture - Elongation, Area Reduction, Fracture Strain -
(no units or mm/mm)
• Toughness, Resilience - Measure of ability to absorb
energy (J/m3).
• Hardness - Resistance to indentation/abrasion (Various
scales, e.g.; Rockwell, Brinell, Vickers.)

Department of Mechatronics Engineering, EME, NUST

 Comparison of densities

Bar-chart of room temperature density values for various metals, ceramics,

polymers, and composite materials.

Department of Mechatronics Engineering, EME, NUST

 Comparison of elastic modulus

Bar-chart of room temperature Stiffness (i.e., elastic modulus)

values for various metals, ceramics, polymers, and composite materials.
Department of Mechatronics Engineering, EME, NUST
 Comparison of tensile strength

Bar-chart of room temperature Strength (i.e., tensile strength) values for

various metals, ceramics, polymers, and composite materials

Department of Mechatronics Engineering, EME, NUST

 Resistance to fracture

Bar-chart of room-temperature resistance to fracture

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 Electrical Conductivity

Bar-chart of room temperature electrical conductivity ranges

Department of Mechatronics Engineering, EME, NUST
 Engineering Stress and Strain
• Engineering stress, σ is defined as
the instantaneous load divided by the
original specimen cross-sectional
area
σ = F/A
• Engineering strain, ε is expressed as
the change in length (in the direction
of load application) divided by the
original length.
ε = ∆l /l

Compressive forces tend to shorten the material

and produce compressive stresses and strains
Shear stresses and strains result when two forces
acting on a body are offset with respect to one
another

Department of Mechatronics Engineering, EME, NUST

 Hooke’s Law
Elastic Deformation
• Elastic deformation is not permanent; it means that when
the load is removed, the part returns to its original shape
and dimensions.
• For most metals, the elastic region is linear. For some
materials, including metals such as cast iron, polymers, and
concrete, the elastic region is non-linear.
• If the behavior is linear elastic, or nearly linear-elastic,
Hooke’s Law may be applied:
σ = εE
• Where E is the modulus of elasticity (MPa)

Department of Mechatronics Engineering, EME, NUST

 Tensile Test

• Tensile testing, is also known

as tension testing, is a
fundamental materials science test in
which a sample is subjected to a
controlled tension until failure
• The results from the test are
commonly used to select a material
for an application, for quality control,
and to predict how a material will Schematic representation of
the apparatus used to conduct
react under other types of forces tensile stress– strain tests.

A standard tensile specimen

with circular cross section.

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 Tensile Test

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 Tensile Test
• The point of yielding may be determined as the
initial departure from linearity of the stress–
strain curve; this is sometimes called the yield strength
proportional limit
• Elastic limit: beyond the elastic limit, permanent
deformation will occur. The elastic limit is
therefore the lowest stress at which permanent
deformation can be measured.
• Yield point: the point in the stress-strain curve at
which the curve levels off and plastic
deformation begins to occur.
• Offset yield point: when a yield point is not easily
defined based on the shape of the stress-strain
curve an offset yield point is arbitrarily defined.
The value for this is commonly set at 0.1 or 0.2% (a) Typical stress–
plastic strain. strain behavior for a metal showing
• Breaking strength: the greatest stress especially elastic and plastic deformations, (b)
in tension that a material is capable of Representative stress–strain behavior
withstanding without rupture found for some steels demonstrating
the yield point phenomenon

Department of Mechatronics Engineering, EME, NUST

 Tensile Strength
• Maximum possible engineering stress in tension.
This corresponds to the
maximum stress that can be
sustained by a structure in
tension; if this stress is applied
and maintained, fracture will
result.

Metals: occurs when noticeable necking

starts
Ceramics: occurs when crack Typical engineering stress–strain behavior to fracture,
propagation starts point F. The tensile strength TS is indicated at point
•Polymers: occurs when polymer M. The circular insets represent the geometry of the
deformed specimen at various points along the curve.
backbones are aligned and about to
break

Department of Mechatronics Engineering, EME, NUST

TENSILE STRENGTH: COMPARISON

TS (ceram)
~TS (met)
~ TS (comp)
>> TS (poly)
Room T values
Based on data in Table B4,
Callister 6e.
a = annealed
hr = hot rolled
ag = aged
cd = cold drawn
cw = cold worked
qt = quenched & tempered
AFRE, GFRE, & CFRE =
aramid, glass, & carbon
fiber-reinforced epoxy
composites, with 60 vol%
fibers.

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Elasticity & Plasticity
Elasticity is the ability of material to
return to its original condition whenever
the force applied, is released
The greater the resistance to change,
the greater is the elasticity of the
material and the faster it comes back to
its original shape or configuration when
the deforming force is removed. If this
definition is followed then definitely
steel will win the race of elasticity.
Plasticity is the ability of material to
deform under pressure and remain in its
new shape whenever the pressure is
released
Plastic deformation will take only after
the elastic limit is exceeded
Department of Mechatronics Engineering, EME, NUST
 Ductility & Brittleness
• Ductility is the ability of material to
deform plastically without fracture
• Indication of ductility can be given by
percent reduction in the area or percent
elongation
If a material fails with little or no ductility
then it is said to be brittle
Brittleness can be seen as opposite to
ductility

Department of Mechatronics Engineering, EME, NUST

 Toughness
Toughness is the ability of a
material to absorb energy and
plastically deform before
fracturing. The area under the
stress strain graph represents the
toughness of the test specimen

It is indicative of a material’s resistance to fracture

when a crack (or other stress-concentrating defect)
is present

Department of Mechatronics Engineering, EME, NUST

 Resilience
• Resilience is the ability of a material to
absorb energy when it is deformed
elastically, and release that energy upon
unloading.
• The modulus of resilience is defined as the
maximum energy that can be absorbed per
unit volume without creating a permanent
distortion.
• It can be calculated by integrating the stress-
strain curve from zero to the elastic limit.

Schematic representation showing

• In uni-axial tension, how modulus of resilience
(corresponding to the shaded area) is
Ur = σ 2y / 2 E determined from the tensile stress–
• Where Ur is the modulus of resilience, σy is strain behavior of a material.
the yield strength, and E is the young's
modulus.
Department of Mechatronics Engineering, EME, NUST
 Hardness
• Hardness is a measure of a material’s resistance
to localized plastic deformation (e.g, a small
dent or a scratch)
Hardness Test

• In typical hardness tests, a small indenter is forced into the

surface of a material to be tested under controlled
conditions of load and rate of application.
• The depth or size of the resulting indentation is measured
and related to a hardness number
• The softer the material, the larger and deeper the
indentation, and the lower the hardness index number

Department of Mechatronics Engineering, EME, NUST

2nd Lecture

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 Hardness Tests

Commonly used hardness

tests are:
1. Brinell hardness test
2. Vickers hardness test
3. Rockwell hardness test

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 Hardness Tests

Department of Mechatronics Engineering, EME, NUST

Brinell Hardness Testing

Measures the materials resistance to indentation or scratching

The Brinell hardness test

uses a hardened steel or
tungsten carbide ball of
10mm, 5mm or 1mm
diameter. The diameter of
the indentation is measured
and it is used to indicate the
hardness of the material

Department of Mechatronics Engineering, EME, NUST

Department of Mechatronics Engineering, EME, NUST
 Rockwell hardness test

Measures the materials resistance to indentation or scratching

A square conical shaped

indenter is forced into the
specimen. The diagonal length
of the indented
square is measured. This
measurement is taken by a
special microscope for accuracy.
It is then converted into a
Rockwell hardness number

Department of Mechatronics Engineering, EME, NUST

 Vickers Hardness Testing

Measures the materials resistance to indentation or scratching

A square pyramid shaped

indenter (point angle 136°) is
forced into the specimen. The
diagonal length of the indented
square is measured. This
measurement is taken by a
special microscope for accuracy.
It is then converted into a
Vickers hardness number

Department of Mechatronics Engineering, EME, NUST

Department of Mechatronics Engineering, EME, NUST
Suggested reading
Section-A (compulsory)

• Chapter 1 and 6 from Materials Science and Engineering, An

Introduction by William D. Callister, Jr. David G. Rethwisch
• Chapter 1, all and section 1-1 and 1.-2 from chapter 8 from Elements of
Material Science and Engineering by Van Vlack, Addison Wesley Publishing
Co., Latest Edition.

Department of Mechatronics Engineering, EME, NUST

References

• Fundamentals of Modern Manufacturing

Mikell P. Groover. 4th Edition.

• Materials and Processes in Manufacturing

E. Paul Degarmo, J. Black, Ronald A. Kosher. 10th Edition.

• Manufacturing Processes
H.N. Gupta, R.C. Gupta, Arun Mittal. 2nd Edition

• Lecture Notes: ME-832 Adv. Manufacturing Processes

Dr. Waheed-ul-Haq, Dept. of Mechanical Engineering, CEME

Department of Mechatronics Engineering, EME, NUST