An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

CHAPTER 5
Engineering Materials

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Mechanical components;

• It has a mass,

• They carry loads,

• They have a shape,

• They conduct electricity and heat,

• They are subjected to wear (corrosive environment, friction)

• They may consist of one or more components.

What is «Material»?

• Anything with volume and mass is considered as «matter».

• But we need to shape matters to produce objects.
• Objects are made of materials, which are malleable, machinable,
castable or can be shaped by any other manufacturing method.
• «Material» is the matter from which a thing is or can be made!!!

• The discipline of materials science involves investigating the

relationships that exist between the structures and properties of
materials.
Crystalline and Amorphous Solids
• Solid materials may be classified according to the regularity with which
atoms or ions are arranged with respect to one another.
• A crystalline material is one in which the atoms are situated in a repeating or
periodic array over large atomic distances.
• Amorphous materials are characterized by a short-range order, and atoms
are bonded in disordered, random spatial positions, because of factors that
do not allow the formation of a regular arrangement. Most polymers and
inorganic glasses can have an amorphous structure.

The three general types of solids: amorphous ; single crystal ; polycrystalline (with
multiple ordered domains called grains separated by a grain boundary).

4
 Evolution of Engineering Materials
• The amount of material that can be used for engineering is
around 160,000.
• How to choose the best material for the purpose?
Evolution of Engineering Materials (prehistoric)
Evolution of Engineering Materials (16. century)
Evolution of Engineering Materials (20. century)
Evolution of Engineering Materials (Present Day)
 Evolution of Engineering Materials

A Teapot 4000 years ago;

• In direct contact with fire

• Good conductor of heat (iron, copper, bronze)

Today's kettle;

• With electricity, not with fire

• Safer
• More practical
• Heat non-conducting body
• Easy to shape
• Aesthetic appearance
• Inexpensive to produce
Evolution of Engineering Materials
• Low density boards
• Steel wires
• Silk fabrics
• The bigger it is, the more useless it is.

• Aluminium-based
• High bending stiffness
• High strength at low weight

• Large scale manufacturability

• High fuel cost
• Due to the low carbon emission
requirement;
• 80% carbon-fiber reinforced plastic
construction
• 30% lighter
 Engineering Materials

Composites
Metals Ceramics Polymers
(based on matrix)

Ferrous Nonferrous Thermoplastic Polymer Matrix

Steels Heavy metals Thermoset Metallic Matrix

Cast Iron Light metals Elastomer Ceramic Matrix

12
An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

Engineering Materials
• Mechanical engineers select materials in the context of both the
product’s purpose and the processes that will be used during its
manufacture.
• The more manufacturing steps that are required to produce a
material, the greater the material’s cost.
• In selecting the materials to be used in a product, an engineer:

• First decides on the class of materials that will be used (for

instance, metals and their alloys).

• Then determines which material within the class is most

appropriate (for instance, steel or aluminum).

© 2017 Cengage Learning®. May not be scanned, copied or duplicated, or posted to a publicly accessible website, in whole or in part.
 1. Metals and their alloys
• The word 'metal' is derived from the Word 'Metallon,
which means' to obtain from the earth's crust' in
Greek.

• Three -quarter of the elements in the periodic table are

metal.

• Metals are divided into lower classes such as transition

metals, alkali metals, soil alkali metals, rare soil lantanid
and actinides.
1. Metals and their alloys
An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

1. Metals and their alloys

• Metals are relatively stiff and heavy materials with large elastic
modulus and density values.
• The strength of metals can be increased by mechanical and heat
treatments and by alloying.
• Metals are a good choice to use in structures and machines that
must carry large forces.
• Metals are, however, susceptible to corrosion, and can
deteriorate and weaken over time.

© 2017 Cengage Learning®. May not be scanned, copied or duplicated, or posted to a publicly accessible website, in whole or in part.
1. Metals and their alloys

• Elastic modulus quantifies a material's resistance to non-permanent,

or elastic, deformation.
• The E modulus is a characteristic property of a material.
• E modulus is affected by chemical composition and ambient
temperature, not by heat treatment.
Differences between pure metals and alloys

Pure Metals Alloys

• Consist of only one type of atom • A mixture of different atoms
• Softer • better formability and higher
• Better thermal and electrical strength
conductivity • can provide better corrosion
resistance (stainless steels)
An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

1. Metals and their alloys

• Metals can be manufactured by casting, extrusion, forging,
rolling, cutting, drilling, and grinding.
• The ability of a material to withstand a significant amount of
stretching before it fractures is called ductility.
• Some metals, by virtue of their processing and alloys, have high
degrees of ductility.
• A ductile material has a wide region over which plastic
deformation occurs.

© 2017 Cengage Learning®. May not be scanned, copied or duplicated, or posted to a publicly accessible website, in whole or in part.
 1. Metals and their alloys
● The most abundant metal in the earth's crust is aluminum
(third element after oxygen and silica!).

● Themost abundant metal in the entire globe is iron. Iron

covers most of the core of our earth.

● Alkalimetals such as lithium, sodium, potassium are so

reactive that they ignite and explode even in water.
 1. Metals and their alloys
● Noble metals such as silver, gold and platinum show excellent
resistance to oxidation and corrosion, even under harsh
atmospheric conditions.
● Tungsten is the metal with the highest melting point.
● All metals except mercury are solid at room temperature.
GENERAL PROPERTIES OF METALS AND
ALLOYS

High thermal and electrical

conductivity

Ductility

Good formability properties (plastic

deformation)

Adequate for structural applications

(load-bearing materials)
An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

2. Ceramics
• Ceramics are hard, brittle, crystalline materials that can comprise
metals and nonmetals.
• They are not appropriate for supporting large tensile forces.
• Ceramics are capable of withstanding extreme temperatures and
are widely used for insulation.
• Space shuttles use tens of thousands of lightweight ceramic tiles
for insulation.

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 GENERAL PROPERTIES OF CERAMICS
• Bricks, glass, refractories and abrasives
• Commonly used as insulator.
• Their optical and electrical properties can be enhanced for microchips and
fiber-optic applications
Hard

Corrosion
Brittle
resistant

Properties of
High melting
ceramics High
compressive
point
strength

Low
Low thermal
electrical
conductivity
conductivity
An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

3. Polymers
• Polymers are organic compounds, with a
chemical formulation based on the properties
of the element carbon.
• Rubber and silk are two naturally occurring
polymers.
• Polymers are classified into three groups:

• Thermosetss
• Thermoplastics
• Elastomers

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An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

3. Polymers cont.

• Polymers are not well suited for

applications where strength is
required or for operations at
elevated temperatures.

• They are however, relatively

inexpensive, lightweight, good
insulators against heat and
electricity, and easy to shape and
mold into complex parts.

© 2017 Cengage Learning®. May not be scanned, copied or duplicated, or posted to a publicly accessible website, in whole or in part.
GENERAL PROPERTIES OF POLYMERS
• Polymers: plastics, rubbers, binders
• They are produced by forming large molecular structures from organic
molecules by the polymerization process.
• Not suitable for high temperature applications (creep behaviour even at
low stress conditions)
• Low electrical conductivity
• Low strength
• Lightweight and easy to form
• UV radiation causes photooxidative degradation which results in breaking
of the polymer chains. Useless after an unpredictable time!!!
An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

4. Composite Materials

• Composites are mixtures of several different materials, and

their formulation can be customized for specific applications.

• Composite materials are a type of material produced by

combining two or more macroscopically separate materials.

• Composite materials are compatible with each other but do

not react excessively with each other.

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4. Composite Materials cont.

• There are two main constituent in each matrix

composite; matrix and reinforcement.
These materials have different physical
properties from each other, and the
composite material formed by
combining them gains different
properties from both.
• The reinforcement acts as load-bearing
material, and the surrounding matrix
phase holds the reinforcements
together and supports them.
reinforcement
• The matrix is a relatively ductile
material.
An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

Composite Materials cont.

• They tend to be made very stiff, strong, and lightweight.
• The additional processing steps that are necessary to produce
these materials raise their costs.

Most substances in nature are composite. (tree, bone, leaf, leather..)

© 2017 Cengage Learning®. May not be scanned, copied or duplicated, or posted to a publicly accessible website, in whole or in part.
An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

Composite Materials cont.

© 2017 Cengage Learning®. May not be scanned, copied or duplicated, or posted to a publicly accessible website, in whole or in part.
Material Charts
• Material charts reveal correlations between material properties that
aid in checking and estimating data; they are tools for materials
selection, for exploring the effect of processing on properties, etc.

1. Bar Chart
2. Material Property Chart
Comparison of Materials

1.5-10g/cm3
1-30g/cm3
1.5-3g/cm3
0.3-3g/cm3
Comparison of Materials

700-1500MPa
50-1200MPa
20-1300MPa
10-100MPa
Comparison of Materials
Comparison of Materials
Comparison of Materials
EXAMPLE: Materials for transmission lines

• Since towers (pylon) are expensive, it is desired that the distance between
the towers be as large as possible, but besides, it is desired that the losses
due to electrical resistance are minimal. The distance between the towers
must be able to withstand the stresses caused by oscillations caused by
wind or icing.
EXAMPLE: Materials for transmission lines

Let’s assume that:

Minimum σf should be 80 Mpa for the specified constant «L»
value. (constraint).
The objective: a material with a low electrical resistance (ρe)
EXAMPLE: Materials for transmission lines

• Strength is used as the elimination strategy

• Resistance is used as the ranking strategy.
EXAMPLE: Materials for transmission lines
EXAMPLE: Materials for transmission lines
EXAMPLE: Materials for transmission lines
STEELS AND CAST IRONS
 FERROUS ALLOYS

microalloyed
steels
General Classification of Carbon Steel and
Alloy Steel Grades
• The 1000 series are carbon steels.
• The 2000 series are nickel steels.
• The 3000 series are nickel-chromium steels.
• The 4000 series are molybdenum steels.
• The 5000 series are chromium steels.
• The 6000 series are chromium-vanadium steels.
• The 7000 series are tungsten steels.
• The 8000 series are nickel-chromium-molybdenum steels.
• The 9000 series are silicon-manganese steels.
Some subclasses of the steel grades
• 10XX = plain carbon steel
• 13XX = manganese steels

• 41XX = chromium-molybdenum steels

• 43XX = nickel-chromium-molybdenum steels
• 46XX = nickel-molybdenum steels
Example of steel grade definations

• AISI 1045 or SAE 1045

• The "10" indicates a plain carbon steel, and the "45" signifies
a carbon content of 0.45%.

«Code of plain carbon steel»

1045 «Weight percent of carbon (45/100)»

*The American Iron and Steel Institute (AISI)/Society of Automotive Engineers (SAE)
Example of steel grade definations

• AISI 4140
• The "41" indicates a chromium-molybdenum steel, and the
"40" signifies an average carbon content of 0.40%.

• Also can be defined as (equivalent materials of 4140):

• 42CrMo4
• 1.7225
Example of steel grade definations
Stainless Steel Grades

• The 100 series are general-purpose austenitic alloys.

• The 200 series are austenitic chromium-nickel-manganese alloys.
• The 300 series are austenitic chromium-nickel alloys.
• The 400 series are chromium alloys that are ferritic or martensitic
(containing martensite, which is formed by rapid cooling austenite to
make it extremely hard).
• The 500 series are chromium alloys that are extremely heat-resistant
due to exceptionally high levels of chromium.
• The 600 series designations were used for proprietary alloys that are
austenitic and/or martensitic. Precipitation hardening stainless steels
are found for the most part in the 600 series.
Tool Steel Grades
Each grade of tool steel features a letter followed by a one or two-digit
number. The initial letters represent the class and attributes of each type.
• The A series are cold worked steels that are air hardening.
• The D series are cold worked steels that are high carbon and high chromium.
• The F series are special purpose steels that are carbon and tungsten based.
• The H series are hot worked steels.
• The L series are special purpose steels that are low alloy.
• The M series are high speed steels that are molybdenum based.
• The O series are cold worked steels that are oil hardening.
• The P series are steels that are used for making plastic molds.
• The S series are shock resisting steels.
• The T series are high speed steels that are tungsten based.
• The W series are water hardening steels.
Example of steel grade definations

• AISI A2 : air hardening-cold work tool steel (X100CrMoV5)

• AISI H22 : hot work tool steel (X30WCrV9-3)

• AISI P20 : tool steel for mold (35CrMo4)

• AISI D2 : cold work tool steel (X153CrMoV12)

Example of steel grade definations
ALUMINUM ALLOYS
Defination of Cast Aluminum Alloys
Defination of Wrought Aluminum Alloys
Defination of Wrought Aluminum Alloys

• The 6463 aluminum alloy is an aluminum alloy in the wrought

aluminum-magnesium-silicon family (6000 or 6xxx series). It is
related to 6063 aluminum alloy, but unlike 6063 it is generally not
formed using any processes other than extrusion.