JASHORE UNIVERSITY OF SCIENCE AND TECHNOLOGY

IPE 1101: Engineering Materials (3 credit hours)

Dr. Md Mahfuzur Rahman

Assistant Professor, Dept. of IPE
19th FEB, 2022
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Introduction

What do you mean by engineering materials?

 The substances which are useful in the field of engineering are called Engineering materials.
Materials are an important aspect of engineering design and analysis.

What is Materials Science?

 Materials science involves investigating the relationships that exist between the structures
and properties of materials.

What is Materials Engineering?

 Materials engineering is, on the basis of these structure–property correlations, designing or
engineering the structure of a material to produce a predetermined set of properties.

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Introduction

Why do we Study Materials?

 To solve a design problem involving materials.

 The more familiar an engineer or scientist is with the various characteristics and
structure–property relationships, as well as processing techniques of materials, the
more proficient and confident he or she will be in making judicious materials
choices based on these criteria.

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Course Syllabus
Ceramic:
 Preparation and characterization of ceramic raw materials.
 Principles and mechanisms of ceramic drying and firing processing, defects and properties of
ceramics: glazing and decoration.
 Conventional and engineering ceramics, industrial Ceramics.
Glasses:
 Kinetics of crystallization and phase separation of glass transition, viscosity.
 Chemical durability and thermal, electrical, optical, and mechanical properties of commercial
glasses, relation of physical properties to glass structure and composition.
Polymers:
 Structure and properties of polymers and copolymers, thermoplastics and thermosets,
commercial processing of polymers.
 Properties and testing polymers and the environment.
 Composites: theory of composites, fabrication.

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Course Syllabus
Plastic:
 Fundamental characteristics, classification, raw materials and manufacture of plastics, some
typical examples of plastics and their uses.
Rubber:
 Source of natural rubber, chemical treatment of latex, synthesis and properties of synthetic
rubber.
Fibers:
 Types of fibers, synthesis and application of synthetic fibers.
Cement:
 Types, Portland cement, raw materials, method of manufacture, setting and hardening.
Refractories:
 Definition, classifications, characteristics, fire clay bricks its manufacture and uses.
Lubricants:
 Functions, classification.
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Intended Learning Outcomes
ILO1: Identify the meaning an the Classification of Engineering Materials.
Engineering Materials

 The substances which are useful in the field of engineering are called Engineering
materials.
 Materials Engineering refers to selecting the correct materials for the application in which
the engineered part is being used.

Selection of Engineering Materials

 Primarily selected based on their mechanical, physical, chemical and

manufacturing properties.
 The secondary points to be considered are the cost and availability, appearance,
service life and recyclability.
 In the present day, strict environmental legislations have forced the designers and
engineers to select the environment friendly materials which have minimum
environmental impact.

Materials are often selected for their mechanical, physical, chemical and manufacturing
properties for ensuring proper functioning under desired conditions. When several materials
are suitable for a particular design requirement, the cheapest one is usually selected. 6
Classification of Engineering Materials

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Metals

Metals
 Metals are the elements, which occupy the left hand side of the periodic table with one, two
or three electrons in the outer most shell that takes part in bonding and chemical reactions.
 Materials in this group are composed of one or more metallic elements (e.g., iron, aluminum,
copper, titanium, gold, and nickel), and often also nonmetallic elements (e.g., carbon,
nitrogen, and oxygen) in relatively small amounts.

 Atoms in metals and their alloys are arranged in a very orderly manner, and in comparison to
the ceramics and polymers, are relatively dense.

Properties
 Relatively stiff and strong, yet are ductile, and are resistant to fracture

 Metallic materials have large numbers of nonlocalized electrons; that is, these electrons are
not bound to particular atoms. Thus, metals are extremely good conductors of electricity and
heat
 Metals are not transparent to visible light; a polished metal surface has a lustrous appearance.
 Some of the metals (i.e., Fe, Co, and Ni) have desirable magnetic properties.
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Ceramics
Ceramics
 Ceramics are compounds between metallic and nonmetallic elements; they are most frequently oxides,
nitrides, and carbides.
 Ceramics can be defined as solid compounds that are formed by the application of heat, and sometimes
heat and pressure, comprising at least two elements provided one of them is a non-metal or a nonmetallic
elemental solid. The other element(s) may be a metal(s) or another nonmetallic elemental solid(s). It is
neither a metal, a semiconductor nor a polymer is a ceramic.

 Examples, aluminum oxide (or alumina, Al2O3), silicon dioxide (or silica, SiO2), silicon carbide (SiC),
silicon nitride (Si3N), and, in addition, what some refer to as the traditional ceramics—those composed of
clay minerals (i.e., porcelain), as well as cement and glass.
Properties
 Relatively stiff and strong—stiffnesses and strengths are comparable to those of the metals.
 They are typically very hard.
 Ceramics brittle (lack of ductility) and are highly susceptible to fracture.

 Typically insulative to the passage of heat and electricity (i.e., have low electrical conductivities), and are
more resistant to high temperatures and harsh environments than metals and polymers.

 With regard to optical characteristics, ceramics may be transparent, translucent, or opaque, and some of
the oxide ceramics (e.g., Fe3O4) exhibit magnetic behavior. 9
Polymers
Polymers
 Polymers include the familiar plastic and rubber materials. Many of them are organic compounds that are
chemically based on carbon, hydrogen, and other nonmetallic elements (i.e., O, N, and Si).
 Polymers are compounds of very high molecular weights formed by the combination of a large number of
small repeating units.
 Thus, polymers are macromolecules of high molecular weight which are formed by linkage between large
numbers of small molecules called monomers.

 They have very large molecular structures, often chainlike in nature, that often have a backbone of carbon
atoms.
 Examples: polyethylene (PE), nylon, poly(vinyl chloride) (PVC), polycarbonate (PC), polystyrene (PS),
and silicone rubber.
Properties
 These materials typically have low densities.
 They are not as stiff nor as strong as metals.
 Polymers are extremely ductile and pliable (i.e., plastic), which means they are easily formed into complex
shapes.
 Relatively inert chemically and unreactive in a large number of environments.
 One major drawback to the polymers is their tendency to soften and/or decompose at modest temperatures,
which, in some instances, limits their use.
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 They have low electrical conductivities and are nonmagnetic.
Composites
Composites
 A composite is composed of two (or more) individual materials, which come from the categories of
metals, ceramics, and polymers.
 The design goal of a composite is to achieve a combination of properties that is not displayed by any
single material, and also to incorporate the best characteristics of each of the component materials.

 Naturally composites: wood and bone.

 Synthetic composites: fiberglass, in which small glass fibers are embedded within a polymeric
material (normally an epoxy or polyester).
 The glass fibers are relatively strong and stiff (but also brittle), whereas the polymer is more
flexible. Thus, fiberglass is relatively stiff, strong, and flexible. In addition, it has a low density.
 Carbon fiber–reinforced polymer (CFRP) composite—carbon fibers that are embedded within a
polymer.
 These materials are stiffer and stronger than glass fiber–reinforced materials, but more expensive.
CFRP composites are used in some aircraft and aerospace applications, as well as high-tech
sporting equipment (e.g., bicycles, golf clubs, tennis rackets, and skis/snowboards) and recently
in automobile bumpers. The new Boeing 787 fuselage is primarily made from such CFRP
composites.

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Properties of Engineering Materials
ILO2: Identify different properties of materials and describe the importance of learning those.

i. General Physical Properties

 Density: It is defined as the ratio of an objects mass to its volume.
– Density is a function of the mass of the atoms making up the materials and the distance between them.
Closely packed atoms characterize high density materials such as Tungsten or Neptunium. In contrast
light, relatively distant atoms compose low density materials such as Beryllium or Aluminum.
 Availability/Manufacturability
– The importance of a material being available is obvious. Materials which are not available cannot be
used. Any other desirable qualities are useless if a material cannot be processed into the shape required to
perform its function.
 Cost
– A materials cost is also generally a limiting factor. Understanding the entire processing
sequence is critical to accurately evaluating the true cost of a material.
 Appearance

- Because the appearance of many mechanical components seems fairly trivial it is also easy to
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overlook its importance in the marketing and commercial success of a product.
Properties of Engineering Materials

ILO2: Identify different properties of materials and describe the importance of learning
those.
ii. Mechanical Properties
– Strength-ability of a material to resist the application of load without rupture.
– Hardness-ability of a material to resist penetration or scratching.
– Hardenability-ability of a material to be hardened by heat treatment.
– Toughness-property of a material where it can absorb energy before actual fracture.
– Brittleness-ability of material to fracture on receiving shock or blow.
– Ductility-ability of a material to be drawn into wires.
– Creep -ability of a material to flow like a viscous liquid under the application of stress and
temperature is called creep. The phenomenon where deformation stops even if the load is
acting.
– Resilience-property of a material to absorb energy within elastic range. This required for
springing action.
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 Properties of Engineering Materials

ILO2: Identify different properties of materials and describe the importance of learning
those.
iii. Thermal Properties
 Thermal conductivity: The thermal conductivity is the rate of heat transfer through a material in steady state.
 Thermal diffusivity : The thermal diffusivity is a measure of the transient heat flow through a material.
 Specific heat: The specific heat is a measure of the amount of energy required to change the temperature of a given mass of
material. Specific heat is measured by calorimetry techniques and is usually reported both as CV, the specific heat measured at
constant pressure, or CP, the specific heat measured at constant pressure.
 Melting point: The melting point is the temperature at which a material goes from the solid to the liquid state at one
atmosphere.
 Glass transition temperature: The glass transition temperature, or Tg is an important property of polymers. The glass
transition temperature is a temperature range which marks a change in mechanical behavior. Above the glass transition
temperature a polymer will behave like a ductile solid or highly viscous liquid. Below Tg the material will behave as a brittle
solid.
 Creep resistance : Creep is slow, temperature aided, time dependent deformation. Creep is typically a factor in materials
above one third of their absolute melting temperature or two thirds of their glass transition temperature. Creep resistance is
an important material property in high temperature design, but it is difficult to quantify with a single value. Creep response is
a function of many material and external variables, including stress and temperature. Often other environmental factors such
as oxidation or corrosion play a role in the fracture process.
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Properties of Engineering Materials
iv. Electrical and magnetic
 Resistivity
 Dielectric constant
 Magnetic permeability
v. Environmental interaction
 Oxidation
 Corrosion
 Wear

vi. Production
 Ease of manufacture
 Joining
 Finishing

vii. Aesthetic
 Color
 Texture
 Feel 15
 Atomic Structure & Bonding
ILO3: Explain different types of primary and secondary bonds that are found in solids
Primary Bonds
 Primary bonds, also known as “strong bonds,” are created when there is direct interaction of
electrons between two or more atoms, either through transfer or as a result of sharing. The more
electrons per atom that take place in this process, the higher the bond “order” (e.g., single,
double, or triple bond) and the stronger the connection between atoms.

 There are four general categories of primary bonds: (i) Ionic, (ii) covalent, (iii) polar covalent,
and (iv) Metallic bond.

 For ionic bonds, electrically charged ions are formed by the transference of valence electrons
from one atom type to another. This type of bonding is found in ceramic materials.
 There is a sharing of valence electrons between adjacent atoms when bonding is covalent.
Polymers and some ceramic materials covalently bond.
 The percent ionic character (%IC) of a bond between two elements (A and B) depends on their
electro-negativities (X’s).
 With metallic bonding, the valence electrons form a “sea of electrons” that is uniformly dispersed
around the metal ion cores and acts as a form of glue for them. Metallic materials exhibit this type
of bonding.

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 Atomic Structure & Bonding
ILO4: Explain different types of primary and secondary bonds that are found in solids

Secondary Bonds

 Secondary bonds, or weak bonds, occur due to indirect interaction of electrons in

adjacent atoms or molecules.

 There are three main types of secondary bonding: hydrogen bonding, dipole–dipole
interactions, and van der Waals forces.

 For hydrogen bonding, highly polar molecules form when hydrogen covalently
bonds to a nonmetallic element such as fluorine.

 The Van der Waals forces arise due to momentary electric dipoles
(regions of positive and negative charge) that can occur in all atoms and
molecules due to statistical variations in the charge density. These
intermolecular forces are common, but very weak, and are found in inert
gases where other types of bonding do not exist. 17
Atomic Structure & Bonding
Ionic Bonds

 An element like sodium with one excess electron will readily give it up so that it has a
completely filled outer shell.
 It will then have more protons than electrons and become a positive ion (charged
atom) with a +1 charge. An atom of chlorine, on the other hand, with seven electrons
in its outer shell, would like to accept one electron and become a negative ion with a -
1 charge.

 When sodium and chlorine atoms are placed together, there is a transfer of electrons
from the sodium to the chlorine atoms, resulting in a strong electrostatic attraction
between the Na+ and Cl- ions and forming the compound sodium chloride.

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Atomic Structure & Bonding
Covalent Bonds

Atoms of some elements may attain a stable electron structure by sharing one or more
electrons with adjacent atoms. Nitrogen (atomic number 7) has 5 electrons in the outer
shell and needs 3 more to complete that shell.

A nitrogen atom shares the electrons of three hydrogen atoms and in turn shares three of
its electrons with the three hydrogen atoms to form the compound ammonia (NH3).

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Atomic Structure & Bonding
Metallic Bonds

Each of the atoms of the metal contributes its valence electrons to the formation of a negative
electron "cloud." These electrons are not associated with a particular ion but are free to move
among the positive metallic ions in definite energy levels.

The metallic ions are held together by virtue of their mutual attraction for the negative electron
cloud.

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Metal Structure

Macrostructure
 Some structural elements are of macroscopic dimensions, that is, are large enough to be
observed with the unaided eye.

 For example, the shape and average size or diameter of the grains for a polycrystalline
specimen are important structural characteristics.

 Macroscopic grains are often evident on aluminum streetlight posts and also on garbage cans.
Relatively large grains having different textures are clearly visible on the surface of the
sectioned lead ingot.
 Macrostructure of material is the external appearance of material which is due to the internal
symmetry of crystals forming it.

 Length of scale for this level is approximately greater than 1000 nm at which features like
porosity, surface coatings, internal or external cracks, fractured surfaces slag inclusions,
materials' flow lines, segregation, heat affected zone, etc. can be observed.

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Metal Structure

Microstructure
 Microstructure is a larger scale than the atomic level definition.

 In most materials the constituent grains are of microscopic dimensions, having diameters that
may be on the order of microns, and their details must be investigated using some type of
microscope.

 Grain size and shape are only two features of what is termed the microstructure.

 Microstructure is subject to direct microscopic observation, using optical or electron

microscopes.

 In metal alloys, microstructure is characterized by the number of phases present,

their proportions, and the manner in which they are distributed or arranged. The
microstructure of an alloy depends on such variables as the alloying elements
present, their concentrations, and the heat treatment of the alloy (i.e., the
temperature, the heating time at temperature, and the rate of cooling to room
temperature).
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Metal Structure

Substructure

 This refers to the structure obtained by using a microscope with much higher
magnification and resolution than the optical one.

 In an electron microscope a magnification of 106 times the linear is possible. Here,

due to the very small wavelength of electrons compared to visible light, the resolving
power also increases so that much finer details is shown up.

 With the help of electron microscope, one can get information on very fine particles
or crystal imperfection like dislocations. The length of the scale is considered as up to
1010m.

 By study of substructure one can understand processes/phenomena occurring

at such a small scale.

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Metal Structure

Crystal Structure

 In crystallography, crystal structure is a description of the ordered arrangement

of atoms, ions or molecules in a crystalline material.

 Ordered structures occur from the intrinsic nature of the constituent particles to
form symmetric patterns that repeat along the principal directions of three-
dimensional space in matter.

 i.e. the crystal structure of the material is the manner in which atoms, ions, or
molecules are spatially arranged.

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Metal Structure
 Since atoms tend to assume relatively fixed positions, this
gives rise to the formation of crystals in the solid state.

 The atoms oscillate about fixed locations and are in

dynamic equilibrium rather than statically fixed.

 The three-dimensional network of imaginary lines

connecting the atoms is called the space lattice, while
the smallest unit having the full symmetry of the crystal
is called the unit cell.

 The specific unit cell for each metal is defined by its

parameters, which are the edges of the unit cell a, b, c
and the angles α (between b and c), β (between a and
c), and γ (between a and b).

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 Metal Structure
 There are only 14 possible types of space lattices, and they
fall into seven crystal systems.

 Fortunately, most of the important metals crystallize in

either the cubic or hexagonal systems,

 and only three types of space lattices are commonly

encountered: the b.c.c. (body-centered cubic), the f.c.c.
(face-centered cubic), and the c.p.h. (close-packed
hexagonal). HCP

BCC FCC 26