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Historically, development and advancement of societies have been intimately tied to the members ability to
produce and manipulate materials to fill their needs. In fact, early civilizations have been designated by
the level of their materials development (Bronze, Steel, Iron)

Chapter 1 - Introduction

Example Hip Implant

With age or certain illnesses joints deteriorate.
Particularly those with large loads (such as hip).

What is materials science?

Why should we know about it?
Materials drive our society

Stone Age
Bronze Age
Iron Age
Now?
Silicon Age?
Polymer Age?

Adapted from Fig. 22.25, Callister 7e.

Chapter 1 - 1

Chapter 1 - 2

The earliest humans had access to only a very limited number of materials, those that occur naturally: stone,
wood, clay, skins, and so on. With time they discovered techniques for producing materials that had properties
superior to those of the natural ones.

Furthermore, it was discovered that the properties of a material could be altered by heat treatments and by
the addition of other substances. At this point, materials utilization was totally a selection process that
involved deciding from a given, rather limited set of materials the one best suited for an application by
virtue of its characteristics

Example Hip Implant

Example Hip Implant

Requirements
mechanical
strength (many
cycles)
good lubricity
biocompatibility

Adapted from Fig. 22.24, Callister 7e.

Chapter 1 - 3

Adapted from Fig. 22.26, Callister 7e.

Chapter 1 - 4

At this point, materials utilization was totally a selection process that involved deciding from a given,
rather limited set of materials the one best suited for an application by virtue of its characteristics.

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

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

Example Develop New Types of

Polymers

Hip Implant
Key problems to overcome
fixation agent to hold
acetabular cup
cup lubrication material
femoral stem fixing agent
must avoid any debris in cup

Commodity plastics large volume ca. $0.50 / lb

Ex.
Polyethylene
Polypropylene
Polystyrene
etc.

Ball

Acetabular
Cup and Liner

Femoral
Stem

Engineering Resins small volume > $1.00 / lb

Ex.
Polycarbonate
Nylon
Polysulfone
etc.
Can polypropylene be upgraded to properties (and price) near
those of engineering resins?

Adapted from chapter-opening photograph,

Chapter 22, Callister 7e. (Photograph
courtesy of Zimmer, Inc., Warsaw, IN, USA.)
Chapter 1 - 5

Chapter 1 - 6

Processing:
Structure:
Properties:
Performance:

Types of Materials

Structure, Processing, & Properties

Metals:

Properties depend on structure

ex: hardness vs structure of steel

Strong, ductile
High thermal & electrical conductivity
Opaque, reflective.

(d)

Hardness (BHN)

600
500
400

(a)

(b)
4 m

300
200

30 m

100
0.01 0.1

Polymers/plastics: Covalent bonding sharing of electrons

30 m

(c)

30 m

Data obtained from Figs. 10.31(a) and

10.32 with 4 wt% C composition, and from
Fig. 11.15, Callister & Rethwisch 9e.
Micrographs adapted from (a) Fig. 10.19;
(b) Fig. 9.30; (c) Fig. 10.33; and (d) Fig.
10.21, Callister & Rethwisch 9e. (Figures
10.19, 10.21, & 10.33 copyright 1971 by United
States Steel Corporation. Figure 9.30 courtesy
of Republic Steel Corporation.)

Soft, ductile, low strength, low density

Thermal & electrical insulators
Optically translucent or transparent.

Ceramics: ionic bonding (refractory) compounds of metallic

& non-metallic elements (oxides, carbides, nitrides, sulfides)
Brittle, glassy, elastic
Non-conducting (insulators)

1
10 100 1000
Cooling Rate (C/s)

Processing can change structure

ex: structure vs cooling rate of steel
Chapter 1 - 7

Chapter 1 - 8

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Processing -> Structure -> Properties -> Performance

The Materials Selection Process

Determine required Properties

Properties: mechanical, electrical, thermal,

magnetic, optical, deteriorative.

Fig. 18.8, Callister & Rethwisch 9e.

[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.]

Identify candidate Material(s)

Material: structure, composition.

3. Material

Resistivity,

2. Properties

Electrical Resistivity of Copper:

Identify required Processing

(10-8 Ohm-m)

1. Pick Application

ELECTRICAL

4
3
2
1

Processing: changes structure and overall shape

ex: casting, sintering, vapor deposition, doping
forming, joining, annealing.

-200

-100

T (C)

Adding impurity atoms to Cu increases resistivity.

Deforming Cu increases resistivity.
Chapter 1 - 9

THERMAL
Thermal Conductivity
of Copper:

Chapter-opening
photograph, Chapter 17,
Callister & Rethwisch 3e.
(Courtesy of Lockheed
Missiles and Space
Company, Inc.)

100m

-- It decreases when
you add zinc!

MAGNETIC
Magnetic Storage:
-- Recording medium
is magnetized by
recording head.

400
300
200
100
0

0
10
20 30 40
Composition (wt% Zinc)

Fig. 19.4W, Callister 6e.

Fig. 19.4, Callister & Rethwisch 9e.

(Courtesy of Lockheed
Aerospace Ceramics
Systems, Sunnyvale, CA)
(Note: "W" denotes fig. is on
CD-ROM.)

[Adapted from Metals Handbook: Properties

and Selection: Nonferrous alloys and Pure
Metals, Vol. 2, 9th ed., H. Baker, (Managing
Editor), ASM International, 1979, p. 315.]

Chapter 1 - 11

Magnetic Permeability
vs. Composition:
-- Adding 3 atomic % Si
makes Fe a better
recording medium!
Magnetization

-- Silica fiber insulation

offers low heat conduction.

Thermal Conductivity
(W/m-K)

Space Shuttle Tiles:

Chapter 1 - 10

Fe+3%Si
Fe

Magnetic Field
Fig. 20.23, Callister & Rethwisch 9e.
(Courtesy of HGST, a Western Digital Company.)

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

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.

Chapter 1 - 12

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OPTICAL

DETERIORATIVE

Transmittance:

Stress & Saltwater...

-- Aluminum oxide may be transparent, translucent, or

opaque depending on the materials structure (i.e.,
single crystal vs. polycrystal, and degree of porosity).
polycrystal:
no porosity

polycrystal:
some porosity

Heat treatment: slows

crack speed in salt water!

crack speed (m/s)

single crystal

-- causes cracks!

10-8

as-is
held at
160C for 1 hr
before testing

10-10

Alloy 7178 tested in

saturated aqueous NaCl
solution at 23C

increasing load
Fig. 17.21, Callister & Rethwisch 9e.
(from Marine Corrosion, Causes, and Prevention,
John Wiley and Sons, Inc., 1975.)

Fig. 1.2, Callister &

Rethwisch 9e.

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

Fracture Mechanics of Engineering Materials" (4th ed.), p. 505, John
Wiley and Sons, 1996. (Original source: Markus O. Speidel, Brown
Boveri Co.)

(Specimen preparation,
P.A. Lessing)

Chapter 1 - 13

Chapter 1 - 14

SUMMARY
Course Goals:
Use the right material for the job.
Understand the relation between properties,
structure, and processing.
Recognize new design opportunities offered
by materials selection.

Chapter 1 - 15