Engineering Materials

Why study materials?

• applied scientists or engineers must make material choices
• materials selection
• in-service performance
• deterioration
• economics
BUT…really, everyone makes material choices!
aluminum glass plastic
What is material?
• Material is nothing but a matter of substance used to create a certain
thing.
• Engineering materials are the materials used to for the application of
engineering works.
• Based on the mechanical, physical, chemical and manufacturing
properties materials are selected according to the application.
Factors for selection of materials
The selection of material for the required functioning application is
based on some of the following factors:
• Stresses to which the work piece or component will be subjected.
• Corrosion resistance.
• Temperature, wear and tear resistance.
• Flexibility and rigidity.
• Easiness of the manufacturing process.
• Cost effectiveness for the product development.
• Availability of the material.
Classification of Engineering Materials
 Common type of materials

Metals Non-Metals

Ferrous Non-Ferrous Polymers Ceramics

Hybrids (Composites)
Classification of Materials
Metals Ceramics & Glasses Polymers
• good conductors of • thermally and • low density, low weight
electricity and heat electrically insulating • maybe extremely
• lustrous appearance • resistant to high flexible
• susceptible to temperatures and
corrosion harsh environments
• strong, but • hard, but brittle
deformable
Classification of Materials
Biomaterials Semiconductors Composites
• implanted in human • electrical properties • consist of more than
body between conductors one material type
• compatible with and insulators • designed to display
body tissues • electrical properties a combination of
can be precisely properties of each
controlled component

Hip replacement Intel Pentium 4 Fiberglass surfboards

Metals

 Metals are polycrystalline bodies which are having number of

differentially oriented fine crystals.
 Normally major metals are in solid states at normal temperature.
 However, some metals such as mercury are also in liquid state at normal
temperature.
 All metals are having high thermal and electrical conductivity.
 All metals are having positive temperature coefficient of resistance.
 Means resistance of metals increases with increase in temperature.
 Examples of metals – Silver, Copper, Gold, Aluminum, Iron, Zinc, Lead, Tin
etc.
Metals can be further divided into two groups
Ferrous Metals
 All ferrous metals are having iron as common element.
 All ferrous materials are having very high permeability which makes these
materials suitable for construction of core of electrical machines.
 Examples: Cast Iron, Wrought Iron, Steel, Silicon Steel, High Speed Steel,
Spring Steel etc.
 Non-Ferrous Metals
 All non-ferrous metals are having very low permeability.
Example: Silver, Copper, Gold, Aluminum etc.
Metals
• Ferrous Metals • Non-ferrous metals
• Cast irons • Aluminum and its alloys
• Steels • Copper and its alloys
• Wrought iron • Magnesium and its alloys
• Super alloys • Nickel and its alloys
• Iron-based • Titanium and its alloys
• Nickel-based • Zinc and its alloys
• Cobalt-based • Lead & Tin
• Refractory metals
• Precious metals
Carbon steels
1. Low-carbon steel or mild steel, < 0.2%C,
bolts, nuts and sheet plates.
2. Medium-carbon steel, 0.2% ~ 0.6%C,
machinery, automotive and agricultural
equipment.
3. High-carbon steel, > 0.60% C, springs,
cutlery, cable.
Alloy Steels
• Steels containing alloys in specifiable amounts
• 1.65% or more manganese
• 0.60% silicon
• 0.60% copper
• Most common alloying elements are chromium, nickel,
molybdenum, vanadium, tungsten, cobalt, boron and
copper
• Low alloy steels contain less than 8% alloy additions
• High alloy steels contain more than 8% alloy additions
Common Nonferrous Metals and Alloys
Alloy
• Alloy is a combination of two or more metals. It is named based on metallic bonding character. It is
of two types’ ferrous metal alloy and non ferrous metal alloy. Cast iron is an alloy made from iron,
carbon and silicon. Brass is an alloy of copper and zinc.

Applications
• Due to their toughness and ability to sterilize at high temperatures metals are used as needles,
surgical blades.
• Due to their strength and ability to withstand heavy weights metals like iron and steel are used in
construction.
• Metals like gold, silver, platinum, etc are used in jewellery.
• Metals are used in machines and automobiles as they can withstand high temperature, pressure
and workloads.
• Aluminium and titanium play important role in light weight category for aircraft alloys.
• Tungsten is used in high temperature applications.
CERAMICS
• A particle or fibrous which are used in terms of making ceramic
products.
• Ceramics have regular atomic structure and crystal structure.
Ceramics are mainly oxides, nitrides and carbides.
• They are non conducting materials, due to its insulating property they
are used as insulators.
• They are very hard and brittle in nature.
Eg: alumina, silica, silicon carbide, diamond, bricks, etc.
Applications:
• Due to the compressive strength bricks are used in construction
• Because of their good thermal insulation ceramic tiles are used in
ovens.
• Some ceramics are transparent to radar and other electromagnetic
waves are used in radomes and transmitters.
• Glass ceramics have high temperature capabilities so they are used in
optical equipment and fiber insulation.
• Alumina, silica, silicon carbide are used in making tools.
• Diamond is used in ornaments and cutting tool applications.
Non-Metals
• Non-Metal materials are non-crystalline in nature.
• These exists in amorphic or mesomorphic forms.
• These are available in both solid and gaseous forms at normal
temperature.
• Normally all non-metals are bad conductor of heat and electricity.
Examples: Plastics, Rubber, Leathers, Asbestos etc.
• As these non-metals are having very high resistivity which makes them
suitable for insulation purpose in electrical machines.
POLYMERS
• Polymers have chain molecule structure of carbon as back bone
atoms. They are mainly made up of tough organic materials.
• They are low density materials and also flexible. In some cases
polymers are not flexible.
• Polymers are not only used as structural materials, they can be used
as fiber and resins in the matrix of composite materials.
Eg : polyester as fibers, phenolic and epoxides as resins.
• Elastomers are also polymers but they are considered separately due
to their specific design for certain purposes like shock and vibration
absorption.
• Natural polymers :
• Eg : wool, silk, DNA, cellulose, proteins, etc.
• Synthetic polymers:
• Thermoplastics
• Thermosetting plastics
• Eg: nylon, polyethylene, polyester, Teflon, epoxy, Bakelite, etc.
• Applications:
• Polyethylene is used for making carry bags.
• Polypropylene is used for making high temperature resistance products like feeding
bottle.
• Polyether ether ketone and polyethylene ketone are used in mineral water bottle
concept.
• Poly carbonate is used to make high performance polymers like transparent polymers
• Polyaniline is a conducting polymer.
• Bakelite used for making insulating materials.
COMPOSITE

• Composite material is the composition of two or more constituent

materials with different physical and chemical properties to produce a
different characteristic material.
• Composite material may be both metals or metal and ceramic or metal
and polymer, depending upon the application requirement the
combination is made.
• Eg : wood, concrete, fiber glass, CFRP (carbon fiber reinforced plastic),
GFRP (glass fiber reinforced plastic), etc.
Composite Materials
• Nonuniform solid consisting of two or more different
materials
• Mechanically or metallurgically bonded
• Each of the constituent materials maintains its identity
• Properties depend on:
• Properties of individual components
• Relative amounts
• Size, shape, and distribution
• Orientation
• Degree of bonding
Fiber-Reinforced Composites
• Discontinuous thin fibers of one material are embedded in
a matrix
• Wood and bamboo are naturally occurring fiber composites
• Bricks of straw and mud
• Automobile tyres
• Fibers of nylon, rayon, Kevlar, or steel to reinforce the
rubber
• Glass fibers
• Ceramic fibers, metal wires, whiskers
• Common objective is high strength and lightweight
Applications:
• CFRP and GFRP are used for automotive body parts.
• CRPF and honeycomb composites are used for chassis.
• Some fuel tanks are made up of Kevlar reinforced fiber.
• Reinforced thermosets are used in springs and bumper system.
• Fiberglass reinforced plastic has been used for boat hulls, fishing rods,
tennis rackets, helmets, bows and arrows.
 SEMICONDUCTORS
• Semiconductor is an intermediate conducting material.
• Their conductivity is not high as like metals and low as like insulating
ceramic materials.
• In these materials' resistance decreases as their temperature increases.
• The unique atomic structure allows to control the conductivity.
Eg : silicon, germanium, gallium arsenide, selenium, etc.
• Applications:
• Gallium arsenide is widely used in low noise, high gain and weak signal
amplifying devices.
• A semi conductor device can perform the function of a vacuum tube having
hundreds of times its volume.
 BIOMATERIALS
• Biomaterials are non-viable materials.
Eg : alumina, zirconia, titanium, tantalum, niobium, carbon, etc.
Applications:
• Metals are used in medicine to cure any micronutrient metal
deficiency diseases in humans and animals, like iron is a part of
hemoglobin a bio molecule which can be used as ferrous sulphate to
cure some forms of anemia.
• Implants in the body to repair or replace the damaged tissue.
NOTE: Area of
trapezium is
half of sum of
two parallel
lines
multiplied by
the width b/w
them.
MECHANICAL PROPERTIES
Strength Elasticity
Hardness Plasticity
Toughness Rigidity
Brittleness Machinability
Ductility Resilience
Malleability Fatigue
Creep
 MECHANICAL PROPERTIES
The characteristics of material that describe the behavior under the
action of external loads are referred as its mechanical properties. The
common mechanical properties are as follows
STRENGTH :
It is defined as the ability of a material to resist loads without failure.
It is usually expressed or measured in terms of maximum load per unit
area (i.e. maximum stress or ultimate strength) that a material can
withstand failure and it varies according to the type of loading .
Further the strength is divided into three types:
1. Tensile Strength:
The tensile strength or tenacity is defined
as the ability of material to resist a stretching
(tensile) load without fracture.
2. Compressive strength:
The ability of a material to resist squeezing
(compressive) load without fracture is called
compressive strength.

3. Shear strength:
The ability of a material to resist transverse
loads i.e. loads tending to separate (or cut)
the material is called shear strength. It is applied parallel to
parallel to the area of cross-section of material.

STIFFNESS:
It is the ability of material to resist deformation or deflection
under load. Within the elastic limit, stiffness is measured by
the modulus of elasticity. The best example is spring constant.
ELASTICITY:
The ability of a material to deform under load and return to
its original shape when the load is removed is called elasticity.

PLASTICTY:
The ability of a material to deform under load and retain its
new shape when the load is removed is called plasticity.

DUCTILITY:
It is the ability of a material to be deformed
plastically without rupture under tensile load.
Due to this property material can drawn out
into fine wire without fracture.
MALLEABILTY:
It is the ability of a material to be deformed
plastically without rupture under compressive load.
Due to this property metals are hammered and
rolled into thin sheets.
TOUGHNESS:
 It describes a material’s resistance to fracture under impact
loading. It is often expressed in terms of the amount of
energy a material can absorb before fracture.
 Toughness is not a single property but rather a combination
of strength and ductility. It is the area under stress-strain
curve up to breaking point.
BRITTLENESS:
It is the property of sudden fracture without any visible
permanent deformation.
HARDNESS:
It is defined as the ability of a material to resist scratching or indentation by
another hard body. Hardness is directly related to strength.
CREEP:
• It is the progressive deformation of a material under a constant static
load maintained for a long period of time. It is a slow, temperature-aided,
time-dependent deformation.
FATIGUE:
Failure of material under repeated or reversal stresses is called fatigue.
RESILIENCE:
It is a property of material to absorb energy and to resist shock and impact
loads. It is measured by the amount of energy absorbed per unit volume
within the elastic limit. Also it is the area under stress-strain curve up to
elastic limit.
MACHINABILITY:
The ease with which a given material may be worked or
shaped with a cutting tool is called machinability.
Machinability depends on chemical composition, structure
and mechanical properties.
WELDABILITY:
It is the ability of material to be joined by welding. Weldability
depends on chemical composition, physical properties and
heat treatment to which they are subjected.
CASTABILITY:
Castability of metal refer to the ease with which it can be cast
into different shapes and is concerned with the behavior of
metal in its molten state.
 What is Macro Material?
 In a component, if any one of the dimensions i.e.(length, Dia, thickness etc.) is
of the order equal to 5 mm (or) If a grain size in a material is of the order of
equal to 5 mm is known as macro material.

What is Micro Material?

 In a component, if any one of the dimensions i.e.(length, Dia, thickness etc.) is
of the order equal to 5 Micrometer (or) If a grain size in a material is of the
order of equal to 5 Micrometer is known as micro material.
 Note: As size decreases, defect size decreases and that results to the increment
of strength. It means Strength is inversely proportional to Defect size.
Micro-Manufacturing Examples

This preserved housefly is sporting a pair of two-millimeter-wide eyeglasses,

engineered with ultra-precise fast-pulse laser technology.

[Source: Micreon GmbH]

Micro-Manufacturing Examples

This two-millimeter-tall camel was made of gold foil.

Posed here passing through the eye of a needle 300 microns wide.

[Source: Micreon GmbH ]

Micro-Manufacturing Examples

An array of holes, each measuring approximately 125 nanometers in length,

was precision-drilled with a computer-controlled focused ion beam.
 Micro-Manufacturing Examples

The platinum tip of a six-micron-long atom probe –

a device used to analyze the distribution of individual atoms in alloys and other substances
is seen here at 25,000x magnification.

[Source: FEI Company/Tools for Nanotech]

 Micro-Manufacturing Examples

This 4mm long submarine is molded from an acrylic liquid that solidifies
when it comes in contact with a computer-controlled laser beam.
Its expected use is in future medical applications for treating the
body on a microscopic level.

[Source: Eye of Science/Photo Researchers, Inc ]

Micro-Manufacturing Examples

A focused ion beam created this two-micron-wide gear,

seen here at 50,000x magnification

[Source: FEI Company/Tools for Nanotech]

Micro-Manufacturing Examples

This chain of six microscopic gears can be used to drive micro-engines at speeds
of up to 25,000 rpm. Longer chains can also be used in complex
electronic locking mechanisms that are practically unpickable –
each gear has to be precisely aligned in order to activate an electronic switch

[Source: Sandia National Laboratories/SUMMiT Technologies ]

 What is Nanoscience and Nanotechnology?
 In a component, if anyone of the dimensions i.e.(length, Dia, thickness etc.) is of the
order of less than 100 nm (or) if a grain size in a material is of the order of less than
100 nm is known as Nano Material.
 The above words refer to a compound word having two parts ‘Nano’ and ‘Science’.
 Nanoscience is the branch of science which deals with the objects within the size
regime of nanometres.
 This is the size regime within which matter exhibits the unusual properties which
makes this science unique.
 The properties of different materials vary differently with size of the particles.
 However, in general it is taken as science of matters where constituent units range
between 1nm to 100nm.
 The particles which are present in the material having one or more dimensions less
than 100nm and there is some change in one or more properties is called
nanomaterial.
 Nanotechnology is the technology using objects or structures or phenomena at the
nanometer scale.
 Nanoeffect
 I am calling it nano effect because at certain size range the impact of size on
the property is dramatically significant.
 Suddenly you see very significant change in the value of the property because
you have now come into a certain size range and only where it happens that
you are actually seeing the nano effect.
 That since you came to the nanometer scale the same material is now showing
you completely different properties and because of that you can take the same
material and put it for completely new applications.
 This combination where a size change leads to a dramatic change in properties
and therefore, it enables you to use it for new applications.
 This concept which seems to happen in the nanometer scale, i.e. 100
nanometers scale or less is the whole idea between behind this topic of
nanomaterials or nanoscience or nanotechnology.
 So, that is the nano effect.
 Why Nanomaterials?
 Various macroscopically measured properties (i.e. electrical conductivity,
magnetic properties, mechanical properties, etc.) are based on phenomena that
occur at an altogether different size range.
 Manipulating materials at or near this characteristic size range often results in
new control on material properties which is why the nanomaterial becomes
interesting because now with the exact same material we are getting different
properties but in olden days this control was not there.

Types of Nanomaterials
 Natural Nanomaterials:- Existing in nature. Example- smoke, volcanic dust,
bacteria, etc.
 Incidental Nanomaterials:- Unintended by product of human activity. Example-
Diesel exhaust, coal combustion, welding fumes, etc.
 Engineered Nanomaterials :- Intentionally created. Example – Nanotubes,
fullerenes, etc.
 Applications of Nano Material:
 Nanomedicine
 Energy applications of nanotechnology
 Potential applications of carbon nanotubes
 Industrial applications of nanotechnology
 Nanoart
 Nanobiotechnology
 Green nanotechnology
 Nano-technology: Silicon composite structures

Nano-technology is used to produce materials with feature sizes below 1, typically
in the range 1-100nm. The fabricated objects may have many uses, including catalysts,
coating for clothes, medicine, etc.

[Source: Univ of Cambridge Nanoscale science labs, Mark Welland & Ghim Wei Ho ]
Summary

Micro and Nano-manufacturing methods:

Chemistry-based
Electron-beam lithography, Molecular beam epitaxy, …

Micro- and Nano-sensors:

Atomic force microscope,

Scanning Tunneling Electron Microscope, …

Many scientists consider the first half of this century to be the age
of
Nanotechnology