Fundamentals of

Engineering Materials

Syed Wilayat Husain

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Interdisciplinary gathering
Designers, Users, analysts

Points to Ponder
Brushing the Memory
Organization of thoughts
Discussions and sharing of Knowledge

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Advancement in Technology limited by Materials

Materials Science: Understand the Relation

Processing - Structure – Property

Select – Use - Study failures – Analyze -

feed back for improvement.

Or Design the Material for your requirement.

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 Classification of
Engineering materials
Grouping of materials
to make study easy
Grouping based on Atomic Structure
characteristics
Metals Metallic Bonding

Ceramics Covalent, Ionic

Polymers
Covalent

Composites 4
 Advanced Materials

Smart Materials
Materials which sense and respond

Shape memory Alloys

Nanomaterials

FGM – Functionally Graded Materials

Increasing use of semi-metals

Ga, In, Se, Te, Tl

Here we are interested in Structural

Materials 5
 Metallic materials
Major characteristics :
Crystallinity*, conductivity, fabricability and
relatively high strength & toughness

Generally classified as Ferrous and Nonferrous

Ferrous materials - iron base,

range from plain carbon steels (>98% Fe) to
high alloy steel (<50% alloying elements)

Nonferrous materials - the rest

Nickel, Copper, Aluminum, Magnesium,
Titanium & their alloys
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Within each group of alloy, classification can be made
according to:

Chemical composition, e.g. carbon content or alloys

content in steels

Method of production, e.g. cast, wrought alloys

Finishing method, e.g. hot rolled or cold rolled

Product form, e.g. bar, plate, sheet, tubing,

structural shape

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Designation: identification of each class by a
number, letter, symbol, name or a combination.
Normally based on chemical composition or
mechanical properties.

For steels : System used by AISI & SAE

4 or 5 digits which designate the alloy
composition.
1st two digits indicate Alloy system
Last two or three digits - nominal carbon%

1040 Plain carbon Steel – 0.4%C

4340 Ni-Cr-Mo Steel - 0.4% C
10100 ????? 8
350 Maraging Steel

In Aluminum Alloys
6061 T6 Al-Mg-Si alloy – age hardened
7075 O Al-Zn-Mg-Cu - Annealed
2024 H Al-Cu-Mg - cold worked

In Titanium Alloys
Ti - 6Al - 4V

In Magnesium Alloys
AZ92A
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Load carrying capacity of component can be related
to the yield strength, fatigue strength or creep
strength depending on loading & service condition.

All are structure sensitive.

Changed by changing chemical composition of the

alloy, method and condition of manufacturing, as
well as heat treatment

Increasing the strength generally causes metal

ductility to decrease*.

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Design and selection for metals

One of the major issues for structural components

is deflection (Elastic) under service load.
A function of the applied forces and
geometry, and also stiffness of material.

Stiffness of material is difficult to change

(structure insensitive). Change shape or material
to achieve a large change in the stiffness of a
component.
( Fe Ti Al Be)
30 18 10 40 106 psi
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Electrical & thermal conductivities

Al & Cu- Manufacture of components where

conductivity is primary requirement

Corrosion resistance may limit the materials

usage.
Ti Al Stainless Steels

Specific gravity limits the materials usage

W Pb Cu Steel Ti Al Be Mg 12
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Powder Metallurgy
Weldability – a function of material composition.
So, critical in structures involving joining.
FSW!!
Machinability:
Important if large amounts of material have
to be removed
improvement by heat treatment or by
alloying

Fabricability:
Room temperature formability – a blessing
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 Design for polymer
Monomers vs polymers
Mers may be same or different
Most important source of HC mers is naphtha cracking

General:
Polymer – low density, good thermal & electrical
insulation, high resistance to most chemicals and ability
to take colours and opacities.
But unreinforced bulk polymer are mechanically weaker,
lower elastic moduli & high thermal expansion
coefficients.
Improvement: Reinforced variety of fibrous materials
- Composites (PMC).
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Advantages : ease of manufacturing & versatility.
Can manufacture into complicated shapes in one step
with little need for further processing or surface
treatment.
Versatility : ability to produce accurate component,
with excellent surface finish and attractive color, at
low cost and high speed
Application: automotive, electrical & electronic
products, household appliance, toys, container,
packaging, textiles
Basic manufacturing processes for polymer parts are
extrusion, molding, casting and forming of sheet.
Now talking about magnetic, conducting and Shape
Memory polymers (Smart Polymers)
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Types of Polymers

Thermoplastic-little cross bonding between

polymers, soften when heated & harden when
cooled
Thermoset-strong intermolecular bonding (cross-
linking) which prevents fully cured materials
from softening when heated
Elastomers, like Rubber, are similar to plastic in
structure and the difference is largely based on
the degree of extensibility or stretching.

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Design consideration for polymer
Structural part - When the parts is to carry load

Should remember the strength and stiffness

of plastics vary with temperature.
Long term properties cannot be predicted
from short term prop. e.g. Creep behavior
Many Engineering plastics are brittle, hence
avoid stress raiser

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 Design for ceramics
Ceramic Materials
Inorganic compounds of one or more elements. e.g.
Diamond, Graphite, Al2O3, SiO2, SiC, BN , B4C3, Si2N3,
Crystal structures of ceramics are complex
accommodating various element of widely different
atomic size.
The interatomic forces generally alternate
between ionic & covalent which leave few free
electrons
usually heat & electrical insulators
Strong ionic & covalent bonds give high hardness,
stiffness & stability (thermal & hostile environ.).

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 Structure:
(1) Amorphous or glass-short range order, (2)
crystalline (long range order) & (3) crystalline
material bonded by glassy matrix.
Classification:
Glasses, refractories, structural clay products &
enamels.
Characteristics:
Hard & brittle,
low mechanical & thermal shock resistance
High melting points
Thermal conductivities between metal & polymer

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Design consideration for ceramics
Brittle, low mechanical & thermal shock resistance
- need special consideration
Ratio between tensile strength, modulus of
rupture & compressive strength ~ 1:2:10. In
design, load ceramic parts in compression & avoid
tensile loading
Sensitive to stress concentration
Avoid stress raiser during design.
Dimensional changes take place during drying and
firing, should be considered
Large changes in thickness of product can lead to
nonuniform drying and cracking.
Dimensional tolerances should be generous to
avoid machining 21
 Design for composite

Introduction
A composite material can be broadly defined as an
assembly of two or more chemically distinct
materials, having distinct interface between them
and acting to produce desired set of properties
The composite constituent divided into two
Matrix
Structural constituent / reinforcement

Composites – MMC, PMC

& CMC
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Properties / behavior depends on properties, size
& distribution, volume fraction & shape of the
constituents, & the nature and strength of bond
between the constituents.
Mostly developed to improve mechanical
properties i.e. strength, stiffness, creep
resistance & toughness.
Three types of composites
(1) Dispersion-strengthened,
(2) Fiber Reinforcement – continuous &
discontinuous
(3) Laminated (consist of more than 2 layers
bonded together).
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Designing with composite
Composite materials usually are more expensive.
Used when weight saving is possible when the relevant
specific property (property/density) of the composite
is better than conventional material
e.g. specific strength (strength/density), specific
elastic modulus ( elastic modulus/density)
Efficient use of composite can be achieved by tailoring
the material for the application
e.g., to achieve max. strength in one direction in a
fibrous composite, the fibers should be well aligned
in that direction
Sometimes making a brittle material usable,
e.g. WC + Co
Sometimes increasing strength without affecting physical
properties, e.g. TD Ni, OD metals 25
 If composite is subjected to tensile loading,
important design criterion is the tensile
strength in the loading direction
Under compression loading, failure by buckling
become important
Fatigue behavior:
Steel- show an endurance limit or a stress
below which fatigue does not occur
Composite-may fatigue at low stress level
because fibrous composites may have many
crack, which can be growing simultaneously and
propagate through the matrix

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PMC
• Strength, Stiffness, Fatigue, Corrosion resistance
• Fibers (Glass, Carbon, Aramid)
• Matrix (Polyesters, Epoxies, Phenolics)

MMC
• Strength, Stiffness, high temperature resistance, wear
resistance, conductivity
• SiC or Al2O3 in Al
• SiC in Mg
• SiC in Ti

CMC
• Strength, Stiffness, high temperature resistance, wear
resistance, Insulator, Corrosion Resistance
• Addition to Improve toughness
• Carbon in Carbon 27
• Whiskers in glass, Alumina, SiC
Some Limitations of Composite

Repair of a component in use

In many cases Temperature limitations
In many cases Fabrication limitations
In many cases Anisotropic properties
Recycling Problem:
Combination of different types of materials
Now talking about green composites (back to
nature)

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 Physical Properties

Density MP Conductivity 1 / Thermal

Expansion
Tungsten Tungsten Copper Tungsten
Copper Titanium Aluminum Glass
Steel Steel Tungsten Titanium
Titanium Glass Steel Steel
Aluminum Copper Titanium Copper
Glass Aluminum Glass Aluminum
Plastic Plastic Plastic Plastic

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 Mechanical Properties

Strength Toughness Stiffness Specific

Strength
Fibers Ductile Metal Carbides Reinforced
Plastics
Carbides Reinforced Steel Titanium
Plastics
Steel Ceramics Aluminum Steel
Titanium Glass Reinforced Aluminum
Plastics
Aluminum Plastic
Plastic
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 C. Q. I.
Continual Quality Improvement

Most significant is improved toughness

Others may be specific requirements

Decrease Impurities
Control specifications
Process Improvement

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 PSM - CQI
Grade 60 steel bars for power plants
Control of carbon and manganese
Vacuum degassing for low inclusions
Low residual elements

316L/304L stainless steel for power plants

Very low cobalt required

Super alloys in Pakistan

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Thanks for Patience

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Selection of metal in Engg. Applications:

1) Product shape: a) sheet, strip, plate, (b) bar, rod,

wire, (c) tubes, (d) forging (e) casting
2) Mechanical properties: tensile, fatigue, hardness,
creep, impact strength
3) Physical & chemical properties: Density, conductivity,
corrosion
4) Metallurgical consideration: anisotrophy,
hardenability, grain size, inclusions
5) Processing:
castability, formability, machinability
6) Sales appeal: color, luster
7) Cost & availability
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