Module 1

Introduction to Engineering Materials

Dr. S. Singh, Dean, SME, KIIT University

Introduction
Stone Age: Naturally accessible materials, i.e. stone, wood, bone, fur
Gold was the 1st metal used by the mankind followed by copper

Bronze Age: Copper and its alloy like bronze

Iron Age: Iron (sponge iron & later pig iron)
1960s

Engineering Materials

Design

Choice of Material

New Materials

Metals

New Products

Number of Materials

40 80,000!

General Definition of Material

According to Websters dictionary, materials are defined as
substances of which something is composed or made
Dr. S. Singh, Dean, SME, KIIT University

Engineering Material: Part of inanimate matter, which is useful to

engineer in the practice of his profession (used to produce
products according to the needs and demand of society)
Material Science: Primarily concerned with the search for basic
knowledge about internal structure, properties and processing of
materials and their complex interactions/relationships
Material

Engineering:

Mainly

concerned

with

the

use

of

fundamental and applied knowledge of materials, so that they may

be converted into products, as needed or desired by the society
(bridges materials knowledge from basic sciences to engineering
disciplines)
Note: Material science is the basic knowledge end of materials knowledge
spectrum, where as, material engineering is applied knowledge end and
there is no demarcation line between the two subjects of interest
Dr. S. Singh, Dean, SME, KIIT University

Evolution of Engineering Materials

Dr. S. Singh, Dean, SME, KIIT University

Why Material Science & Engineering is important to technologists?

Examples:
Mechanical engineers search for high temp material so that gas
turbines, jet engines etc can operate more efficiently and wear
resistance materials to manufacture bearing materials
Electrical engineers search for materials by which electrical
devices or machines can be operated at a faster rate with minimum
power losses
Aerospace & automobile engineers search for materials having
high strength-to-weight ratio
Electronic engineers search for material that are useful in the
fabrication & miniaturization of electronic devices
Chemical engineers search for highly corrosion-resistant materials
Note: All these demands may be fulfilled when the internal structure
and engineering properties are known to an engineer or technologist

Dr. S. Singh, Dean, SME, KIIT University

Classification
It is the systematic arrangement or division of materials into
groups on the basis of some common characteristic
1. According to General Properties
2. According to Nature of Materials
3. According to Applications

Dr. S. Singh, Dean, SME, KIIT University

1. According to General Properties

(a). Metals (e.g. iron, aluminium, copper, zinc, lead, etc)
Iron as the base metal, and range from plain carbon (> 98 % Fe) to
(i). Ferrous: high alloy steel (< 50 % alloying elements), e.g. cast
iron, wrought iron, steel, alloys like high-speed steel, spring steel,
etc
(ii). Non-Ferrous: Rest of the all other metals and their alloys, e.g.
copper, aluminium, zinc lead, alloys like brass, bronze, duralumin,
etc
(b). Non-Metals (e.g. leather, rubber, asbestos, plastics, etc)

Dr. S. Singh, Dean, SME, KIIT University

2. According to Nature of Materials

(a). Metals: e.g. Iron & Steel, Alloys & Superalloys, Intermetallic
Compounds, etc
(b). Ceramics: e.g. Structural Ceramics (high-temperature load
bearing), Refractories (corrosion-resistant, insulating), Whitewares
(porcelains), Glass, Electrical Ceramics (capacitors, insulators,
transducers), Chemically Bonded Ceramics (cement & concrete)
(c).Polymers: e.g. Plastics, Liquid Crystals, Adhesives
(d).

Electronic

Materials:

e.g.

Silicon,

Germanium,

Photonic

materials (solid-state lasers, LEDs)

Dr. S. Singh, Dean, SME, KIIT University

(e). Composites: e.g. Particulate composites (small particles

embedded in a different material), Laminate composites (golf club
shafts, tennis rackets), Fiber reinforced composites (fiberglass)
(f). Biomaterials: e.g. Man-made proteins (artificial bacterium),
Biosensors, etc
(g). Advanced / Smart Materials: e.g. materials in computers
(VCRs,

CD

Players,

etc),

fibreoptic

systems,

spacecrafts,

aircrafts, rockets, shape-memory alloys, piezoelectric ceramics,

magnetostrictive

materials,

optical

fibres,

microelectromechanical (MEMs) devices, electrorheological /

magnetorheological fluids, Nanomaterials, etc

Dr. S. Singh, Dean, SME, KIIT University

3. According to Applications
(a). Electrical Materials: e.g. conductors, insulators, dielectrics,
etc
(b). Electronic Materials: e.g. conductors, semi-conductors, etc
(c). Magnetic Materials: e.g. ferromagnetic, paramagnetic &
diamagnetic materials, etc
(d). Optical Materials: e.g. glass, quartz, etc
(e). Bio Materials: e.g. man-made proteins, artificial bacterium

Dr. S. Singh, Dean, SME, KIIT University

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Engineering Materials

Metals

Ceramics

Alumina
Diamond
Magnesia
Cast Iron
Silicon
Carbon Steels Carbide
Alloy Steels
Zirconia
Stainless Steels
Ferrous

NonFerrous
Aluminium
Brass
Bronze
Copper
Lead
Magnesium
Nickel
Tin
Zinc
Titanium

Composites

Polymers
Thermoplastic
ABS
Acrylic
Nylon
Polyethylene
Polystyrene
Vinyl

Carbon Fiber
Ceramic
Matrix
Glass Fiber
Metal Matrix

Electronic
Materials
Silicon
Germanium
Photonic
Materials
Solid-State
Lasers
LEDs

BioMaterials
Man-Made
Proteins
Artificial
Bacterium
Biosensors

Advanced /
Smart
Materials
Shape-Memory Alloys
Piezoelectric Ceramics
Magnetostrictive Materials
Optical Fibres
Electrorheological Fluids
Nanomaterials

Thermosetting
Elastomers
Epoxy
Phenolic
Polyester

Butyl
Fluorocarbon
Neoprene
Rubber
Silicone

Classification of Engineering Materials

Dr. S. Singh, Dean, SME, KIIT University

11

Difference between Metals & Non-Metals

Property
Structure
State
Luster

Metals
Crystalline
Generally solids
temp.
Metallic luster

Non-Metals
at

Amorphic
room Gaseous & solid at ordinary temp.
No metallic luster (except iodine &
graphite)

Conductivity

Good conductors of heat & Bad conductors

electricity

Malleability
Ductility
Hardness
Electrolysis
Excitation of
valence electron
by e.m.f.
Density

Malleable
Ductile
Generally hard
Form anions
Easy

Not malleable
Not ductile
Hardness varies
Form anioins
Difficult

High

Low

Dr. S. Singh, Dean, SME, KIIT University

12

Procedure for Selection of Materials (Engineering Applications)

Analysis of material application problem

Translation of material application requirements to material
property values

Selection of candidate materials

Evaluation of candidate materials

Decision making

Dr. S. Singh, Dean, SME, KIIT University

13

Factors Affecting Material Selection

1. Material Performance (depend upon material properties):

Adequate properties for anticipated operating conditions /
performance
2. Constraints : Design, Availability, Cost etc

Dr. S. Singh, Dean, SME, KIIT University

14

1. Material Performance
Physical: e.g. appearance, shape, weight, boiling point, melting
point, freezing point, density, glass transition temperature,
permeability
Mechanical: e.g. strength (tensile, compressive, shear, torsion,
bending), elasticity, plasticity, ductility, malleability, rigidity,
toughness, hardness, brittleness, impact, fatigue, creep, strain
hardening, Bauschinger effect, strain rate effect, vibration
resistance, wear
Thermal:

e.g.

thermal

conductivity,

expansion

coefficient,

resistivity, thermal shock resistance, thermal diffusivity

Dr. S. Singh, Dean, SME, KIIT University

15

Types of Force / Stress System

Dr. S. Singh, Dean, SME, KIIT University

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 Electrical: e.g. conductivity, resistivity, dielectric strength,

thermoelectricity, superconductivity, electric hysteresis
Magnetic: e.g. ferromagnetism, paramagnetism, diamagnetism,
magnetic permeability, coercive force, curie temperature,
magnetic hysteresis
Chemical: e.g. reactivity, corrosion resistance, polymerization,
composition, acidity, alkalinity
Optical: e.g. reflectivity, refractivity, absorptivity, transparency,
opaqueness, color, luster
Metallurgical: e.g. grain size, heat treatment done / required,
anisotropy, hardenability
Dr. S. Singh, Dean, SME, KIIT University

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2. Constraints
Design Requirements
Existing Facilities
Availability
Compatibility
Marketability
Manufacturability (Fabricability / Castability / Formability /
Machinability / Weldability)
Cost (Material + Fabrication / Manufacturing)

Dr. S. Singh, Dean, SME, KIIT University

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Others Factors Affecting Material Performance

Structure-property -Processing Relationships
Hot Work, Cold Work,
Solid Solution Strengthening
Precipitation Hardening
Inclusions
Imperfections (Number of Dislocations)
Crystal structures: Crystalline vs Amorphous
Toughening
Heat treatment (Annealing, Normalizing, Quenching)
Residual Stresses

Dr. S. Singh, Dean, SME, KIIT University

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Investigating relationship between Structure & Properties

Materials Engineering
Designing the structure
to achieve the specific
properties of the
materials
Processing
Materials Science
Investigating the
relationship between
structure and
properties of the
materials

Structure
Properties
Performance

Dr. S. Singh, Dean, SME, KIIT University

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Competition among Materials

Factors causing material replacement: Cost (breakthrough in
processing cost) & development of new materials with specific
properties for some specific applications
Usage of material in US automobiles

Dr. S. Singh, Dean, SME, KIIT University

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