CHAPTER

1
Introduction to Materials Science
and
Engineering

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 LEARNING OBJECTIVES

By the end of this chapter, students will be able to:

1. Describe the subject of materials science and engineering as a
scientific discipline
2. Cite the primary classification of solid materials.
3. Give distinctive features of each group of materials.
4. Cite one material from each group. Give some applications of
different types of materials.
5. Evaluate how much you know, how much you do not know
about materials.
6. Establish the importance of materials science and engineering
in selection of materials for various application
 What are Materials?

• Materials may be defined as substance of which

something is composed or made.
• We obtain materials from earth crust and
atmosphere.
• Examples :-
 Silicon and Iron constitute 27.72 and 5.00 percentage of weight
of earths crust respectively.
 Nitrogen and Oxygen constitute 78.08 and 20.95 percentage of
dry air by volume respectively.

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Table 1.1
Materials are...
engineered structures...not blackboxes!
Structure...has many dimensions...

Structural feature Dimension (m)

atomic bonding < 10 -10
missing/extra atoms 10-10
crystals (ordered atoms) 10 -8 -10-1
second phase particles 10 -8 -10-4
crystal texturing > 10 -6
 Materials Science and Materials Engineering

Materials Science
and Engineering
Materials Resultant Material
Science knowledge of the Engineering
structure,
Basic Applied
properties,
knowledge knowledge of
processing,
of materials materials
performance of
engineering
materials
 Figure 1.4: This diagram illustrates how materials science and
engineering form a bridge of knowledge from the basic sciences to
the engineering disciplines (Reprinted with permission from
National Academy of sciences, courtesy of National Academic
Press.)
 Materials Science and Engineering

• Materials science deals with basic knowledge

about the internal structure, properties and
processing of materials.
• Materials engineering deals with the application of
knowledge gained by materials science to convert
materials to products.

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 Structure, Processing, & Properties
• Properties depend on structure
ex: hardness vs structure of steel
(d)
600
Hardness (BHN)

30m
500 (c)
Data obtained from Figs. 10.21(a)
400 (b)
(a) and 10.23 with 4wt%C composition,
4m and from Fig. 11.13 and associated
300 discussion, Callister 6e.
30m Micrographs adapted from (a) Fig.
200 30m 10.10; (b) Fig. 9.27;(c) Fig. 10.24;
and (d) Fig. 10.12, Callister 6e.

100
0.01 0.1 1 10 100 1000
Cooling Rate (C/s)

• Processing can change structure

ex: structure vs cooling rate of steel
 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.
 ELECTRICAL
• Electrical Resistivity of Copper:

Adapted from Fig. 18.8, Callister 6e.

(Fig. 18.8 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.)

• Adding “impurity” atoms to Cu increases resistivity.

• Deforming Cu increases resistivity.
• Space Shuttle Tiles: THERMAL
• Thermal Conductivity
--Silica fiber insulation
of Copper:
offers low heat conduction.
--It decreases when
you add zinc!

Fig. 19.0, Callister

6e.
(Courtesy of
Lockheed
Missiles and
Space
Company, Inc.)

Adapted from
Fig. 19.4W, Callister
6e. (Courtesy of Adapted from Fig. 19.4, Callister 6e.
Lockheed Aerospace (Fig. 19.4 is adapted from Metals
Ceramics Systems, Handbook: Properties and Selection:
Sunnyvale, CA) Nonferrous alloys and Pure Metals, Vol.
(Note: "W" denotes 2, 9th ed., H. Baker, (Managing Editor),
fig. is on CD-ROM.) American Society for Metals, 1979, p.
315.)
 MAGNETIC
• Magnetic Storage: • Magnetic Permeability
--Recording medium vs. Composition:
is magnetized by --Adding 3 atomic % Si makes
recording head. Fe a better recording medium!

Adapted from C.R. Barrett, W.D. Nix, and

Fig. 20.18, Callister 6e.
(Fig. 20.18 is from J.U. Lemke, MRS Bulletin,
Vol. XV, No. 3, p. 31, 1990.)
A.S. Tetelman, The Principles of
Engineering Materials, Fig. 1-7(a), p. 9,
1973. Electronically reproduced
by permission of Pearson Education, Inc.,
Upper Saddle River, New Jersey.
 OPTICAL
• Transmittance:
--Aluminum oxide may be transparent, translucent, or
opaque depending on the material structure.
polycrystal: polycrystal:
single crystal low porosity high porosity

Adapted from Fig.

1.2,
Callister 6e.
(Specimen
preparation,
P.A. Lessing; photo
by J. Telford.)
 DETERIORATIVE
• Stress & Saltwater... • Heat treatment: slows
--causes cracks! crack speed in salt water!

Adapted from Fig. 11.20(b), R.W. Hertzberg, "Deformation

and Fracture Mechanics of Engineering Materials" (4th
Adapted from Fig. 17.0, Callister 6e. ed.), p. 505, John Wiley and Sons, 1996. (Original source:
(Fig. 17.0 is from Marine Corrosion, Causes, Markus O. Speidel, Brown Boveri Co.)
and Prevention, John Wiley and Sons, Inc.,
1975.)
--material: 4m
7150-T651 Al "alloy"
(Zn,Cu,Mg,Zr)
Adapted from Fig. 11.24,
Callister 6e. (Fig. 11.24 provided courtesy of G.H.
Narayanan and A.G. Miller, Boeing Commercial
Airplane Company.)
 Classification of Materials
* Metals * Composite
* Polymer * Ceramics
* Semiconductor * Biomaterials
* Advanced Materials
* Smart Materials
* Nanotechnology
Materials Properties Examples
Metal • Good conductivity of heat and electricity • Ferrous -
• Not transparent to visible light Iron and
• Polished surface has lustrous appearance Steels
• Strong • Non ferrous
– Aluminum,
• Deformable (machinable) aluminum
• Extensive use in structure alloy, Titanium
alloy etc
Polymer • Large molecular structure • Plastic
• Low densities • Rubber
• Flexible (compare to other material) • Adhesive
• Low electrical and thermal conductivity
Ceramics • Strong and hard • Clay
/ glasses • Low thermal conductivity and electrical conductivity • Cement
(extensive use as refractory material) • Glasses
• Brittle
• Resistant to harsh environment
• Resistant to high temperature
 Material Properties Example

Composite • Combination of more than one material type • Fiberglass

and displays combination of the best • Concrete
characteristics • Plywood
• Light weight
• Hard, strong, very stiff
• high temperature resistance materials
Semiconductor • Electrical properties are intermediate • Germanium;
/ electronic between insulator and conductor • Silicon;
• Able to convert electrical signal • Gallium
arsenide

Biomaterials • Components implanted into the human body • Metal

for replacement of disease or damaged body • Ceramics
parts • Polymer
• Non-toxic • Composite
• Biocompatible with body tissues • Semiconductor
Cha
pter
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20
 Types of Materials
• Metallic Materials
 Composed of one or more metallic elements.
 Example:- Iron, Copper, Aluminum.

 Metallic element may combine with nonmetallic elements.

 Example:- Silicon Carbide, Iron Oxide.

 Inorganic and have crystalline structure.

 Good thermal and electric conductors.

Metals and Alloys

Ferrous Nonferrous
Eg: Steel, Eg:Copper
Cast Iron Aluminum
 Metallic Materials

The aircraft turbine engine shown is made principally of metal alloys. The latest high-
temperature, heat resistant, high-strength nickel-base alloys are used in this engine. This
engine has many advanced, service-proven technologies to enhance operational performance
and durability. These include second-generation single-crystal turbine blade materials, powder
metal disks, and an improved full authority digital electronic control
• Polymeric (Plastic) Materials
 Organic giant molecules and mostly noncrystalline.
 Some are mixtures of crystalline and noncrystalline regions.
 Poor conductors of electricity and hence used as insulators.
 Strength and ductility vary greatly.
 Low densities and decomposition temperatures.

 Examples :- Poly vinyl

Chloride (PVC), Polyester.
 Applications :- Appliances,
DVDs, Fabrics etc.
• Ceramic Materials
 Metallic and nonmetallic elements are chemically bonded together.
 Inorganic but can be either crystalline, noncrystalline or mixture of both.
 High hardness, strength and wear resistance.
 Very good insulator. Hence used for furnace lining for heat treating and
melting metals.
 Also used in space shuttle to insulate it during exit and reentry into
atmosphere.
 Other applications : Abrasives, construction materials, utensils etc.

 Example:- Porcelain, Glass,

Silicon nitride.
 (a) Examples of a newly developed
generation of engineered ceramic
materials for advanced engine
applications. The black items
include engine valves, valve seat
inserts, and piston pins made of
silicon nitride. The white item is a
port-manifold liner made of an
alumina ceramic material
(b) Potential ceramic component
applications in a turbocharged
diesel engine

High-performance ceramic ball bearings and races are

made from titanium and carbon nitride feedstocks through
power metal technology
• Composite Materials
 Mixture of two or more materials.
 Consists of a filler material and a binding material.
 Materials only bond, will not dissolve in each other.
 Mainly two types :-
o Fibrous: Fibers in a matrix
o Particulate: Particles in a matrix
o Matrix can be metals, ceramic or polymer
 Examples :-
 Fiber Glass ( Reinforcing material in a polyester or epoxy matrix)
 Concrete ( Gravels or
steel rods reinforced in
cement and sand)
 Applications:- Aircraft wings
and engine, construction.
Composite materials
Composite materials
• Electronic Materials

 Not Major by volume but very important.

 Silicon is a common electronic material.
 Its electrical characteristics are changed by adding impurities.

 Examples:- Silicon chips,

transistors
 Applications :- Computers, Integrated Circuits, Satellites etc.

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2
 Competition Among Materials
• Materials compete with each
other to exist in new market Example:-

• Over a period of time usage 1600

Aluminum
Iron
of different materials changes 1400 Plastic
Steel
depending on cost and
1200
1000

lb/Car
performance. 800
600

• New, cheaper or better 400

materials replace the old 200

0
materials when there is a 1985 1992 1997
Model Year

breakthrough in technology Figure 1.14

Predictions and use of
materials in US automobiles.
 Competition Among Materials

Breakdown of weight percentage of major materials used in the average 1985 U.S.
automobile
 Recent Advances and Future Trends
• Nanomaterials
 Smaller than 100 nm particle size.
 Materials have special properties.
 Very hard and strong characteristics.
 Research in progress.
 Example: Carbon nanofiber reinforced plastic: very light but stronger
than metals.

http://farm4.static.flickr.com/

www.ml.afrl.af.mil/stories/mlb-00378.html
 Recent Advances and Future Trends
• Smart Materials
 React to environment Stimuli.
 Change their properties by sensing external stimulus.
 Examples: Shape memory alloys – used in the artery stents.
 Microelectromechanical systems (MEMS) devices.
 Future Trends

• Polymeric (Plastic Materials)

 Fastest growing basic material (9% per year).
 After 1995 growth rate decreased due to saturation.
 Different polymeric materials can be blend
together to produce new plastic alloys.
 Search for new plastic continues.

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 Future Trends

• Ceramic Materials
 New family of engineering ceramics are produced last
decade
 New materials and applications are constantly found.
 Now used in Auto and Biomedical applications.
 Processing of ceramics is expensive.
 Easily damaged as they are highly brittle.
 Better processing techniques and high-impact
ceramics are to be found.

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 Future Trends
• Composite Materials
 Fiber reinforced plastics are primary products.
 On an average 3% annual growth from 1981 to 1987.
 Annual growth rate of 5% is predicted for new
composites such as Fiberglass-Epoxy and Graphite-
Epoxy combinations.
 Commercial aircrafts are expected to use more and
more composite materials.

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 Future Trends

• Smart Materials : Change their properties by

sensing external stimulus.
 Shape memory alloys: Strained material reverts
back to its original shape above a critical
temperature.
 Used in heart valves and to expand arteries.

 Piezoelectric materials: Produce electric field

when exposed to force and vice versa.
 Used in actuators and vibration reducers.
 Future Trends

• Electronic Materials
 Use of electronic materials such as silicon increased
rapidly from 1970.
 Electronic materials are expected to play vital role in
“Factories of Future”.
 Use of computers and robots will increase resulting in
extensive growth in use of electronic materials.
 Aluminum for interconnections in integrated circuits
might be replaced by copper resulting in better
conductivity.

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 Recent Advances and Future Trends
• Nanomaterials
 Smaller than 100 nm particle size.
 Materials have special properties.
 Very hard and strong characteristics.
 Research in progress.
 Example: Carbon nanofiber reinforced plastic: very light but stronger
than metals.
 Case Study – Material Selection
• Problem: Select suitable material for bicycle
frame and fork.

Carbon fiber
Steel and Aluminum Ti and Mg
Wood Reinforced
alloys alloys alloys
plastic

Low cost but Light and Very light and Light, moderately Slightly better
Heavy. Less strong. But strong. No Strong. Corrosion Than Al
Corrosion Cannot be corrosion. Resistance. alloys. But much
resistance shaped Very expensive expensive expensive

Cost important? Select steel

Properties important? Select CFRP
The End
Thank You