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ENGINEERING
Material science Engineering can be subdivided into materials science and
materials engineering.
Materials Science involves investigating the relationships that exist between the
structures and properties of materials.
Classification of materials
Metals
Metals are composed of one or more metallic elements, and often also
nonmetallic elements in small amounts. Such metals having a homogeneous
mixture of metallic and non-metallic elements in pre-defined amounts are called
alloys. Atoms in metals and their alloys are arranged in very orderly manner and
in comparison to the ceramics and polymers, are relatively dense. They are stiff
and strong and yet are ductile, and are resistant to fracture, which accounts for
their widespread use in structural applications.
Metal alloys, by virtue of their composition are classified into two types- ferrous
and non-ferrous.
Ferrous alloys are those alloys in which iron is the prime constituent. These
include steels and cast iron.
Most steels contain less than 1.0% Carbon. Plain low-carbon steels and high-
strength low-alloy, medium-carbon, tool, and stainless steels are the most
common types.
Cast irons contain a higher carbon content, normally between 3% and 4.5% wt.
Gray, ductile(or nodular), malleable, and compacted graphite irons are the four
most widely used cast irons.
Applications
Non-Ferrous Alloys
All other alloys fall within the non-ferrous category, which is further subdivided
according to the base metal or some distinctive characteristic that is shared by a
group of alloys. Typical types are alloys of copper, aluminum, magnesium,
titanium, nickel, lead, tin and zinc.
Magnesium alloys are very lightweight and are fairly corrosion resistant in dry to
slightly humid atmosphere conditions but fail miserably in highly humid
atmosphere like marine environments.
Applications
1. Some of the common copper alloys are, brass which is used in lamp stands
and lamp fixtures, and bronze which is used in making coins.
2. Aluminum alloys are used in food storage equipment, heat exchangers,
light reflectors, fuel tanks, rivets, and high tension wires.
3. Tin alloys are used in storage cans as they do not react with organic acids
present in foodstuffs.
4. Magnesium alloys are used in audio-video-computer-communications
equipment (e.g. laptops, cellular phones, TV sets etc.)
Ceramics
Ceramics are compounds between metallic and non-metallic elements; they are
most frequently oxides, nitrides, and carbides. Ceramic materials are relatively
stiff and strong, and are comparable to metals in terms of stiffness and strength.
In addition, ceramics are very hard. On the other hand, they are extremely brittle
(lack ductility) and are highly susceptible to fracture. These materials are typically
insulative to the passage of heat and electricity, and are more resistant to higher
temperature than metals or polymers. There are two broad categories of
ceramics: Traditional ceramics and advanced ceramics.
Traditional Ceramics
Glass
Glasses are noncrystalline silicates containing other oxides like CaO,Na2O,K2O, and
Al2O3 which influences the glass properties. Most inorganic glasses can be made
to transform from a noncrystalline state to crystalline state by high temperature
heat treatment. This process is called crystallization, and the product is a fine-
grained polycrystalline material called glass-ceramic.
Glass finds a wide range of uses from window panes to high quality gorilla glass
on your smartphones.
Refractories
Typical applications of bricks include furnace linings for metal refining, glass
manufacturing, metallurgical heat treatment, and power generation. Tiles are
used both on floors and roofs.
There are three types of refractories: Fireclay refractories, Silica refractories, and
Basic refractories.
Abrasives
Abrasive ceramics are used to wear, grind, or cut away other material, which are
softer. Therefore, the prime requirement is hardness or wear-resistance and a
high degree of toughness so that the abrasive particles do not fracture easily.
The most common types of abrasives are Silicon Carbide, Tungsten Carbide,
aluminum Oxide, Silica, Boron Carbide, etc.
Ceramic Coatings
Ceramic coatings, which offer the excellent properties of ceramics such as high
hardness and wear resistance, electrical insulation, low thermal conductivity, are
used for surface protection.
The most common materials are aluminum oxide, titanium oxide, zirconium oxide
and chromium oxide.
They are coated using a process called plasma spraying wherein oxide ceramic
powders or powder mixtures are melted in a plasma flame at approx. 10,000
degree Celsius and sprayed on a previous sandblasted material. It is necessary
before plasma spraying that a fissured surface is created through sandblasting to
which the ceramic particles can cling as they arrive. Multiple coats are achieved
for high quality surface finish.
Cements
The characteristic feature of cements is that when mixed with water, they form a
paste which subsequently sets and hardens. The different types of cement are:
Portland cement, plaster of Paris, and lime.
Advanced Ceramics
The processing of MEMS is virtually same as that for the production of silicon
based integrated circuits; this includes photolithographic, ion implantation, ion
etching, and deposition techs. In addition, some mechanical components are
fabricated using micromachining techniques.
Optical Fibers
The optical fiber is made of extremely pure silica, which must be free of even
minute quantities of contaminants and other defects that absorb, scatter, and
attenuate a light beam.
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 (like O, N, and Si). They have very large molecular
structures, often chain-like in nature that has a backbone of carbon atoms. Some
of the common and familiar polymers are polyethylene, nylon 6-6, polyvinyl
chloride, polycarbonate, polystyrene and silicone rubber.
These materials typically have low densities, but many of the polymers are ductile
and pliable, i.e., they can easily be formed into complex shapes.
The polymers which become soft on heating and hard on cooling are called
thermoplastic polymers.
The polymers which undergo chemical changes and crosslinking on heating and
become permanently hard, rigid and infusible mass are called thermosetting
polymers.
Elastomers
Elastomers are polymers having elastic properties. They are usually thermoplastic
polymers and can undergo a high degree of bending and stretching without
permanent change in original dimensions.
The most important elastomer is SBR (styrene butadiene rubber) which is used in
automobile tires, reinforced with carbon black. NBR (acrylonitrile butadiene
rubber), which is highly resistant to degradation and swelling, is another common
synthetic elastomer.
Fibers
The fiber polymers are capable of being drawn into long filaments having at least
100:1 length-to-diameter ratio. Most commercial fiber polymers are utilized in
the textile industry, being woven or knit into cloth or fabric. To be useful as a
textile material, a fiber polymer must have a host of rather restrictive physical and
chemical properties as they are subjected to a variety of mechanical deformations
like stretching, twisting, shearing, and abrasion. Consequently, they must have a
high tensile strength (over a relatively wide temperature range) and a high
modulus of elasticity, as well as abrasion resistance. These properties are
governed by the chemistry of the polymer chains and also by the fiber drawing
process.
The fibers are of nylon-6, nylon 6,6, polyester, acrylic, spandex, polypropylene,
etc.
Coatings
Coatings are frequently applied to the surface of materials for one or more
functions: (1) to protect an item from the environment that may produce
corrosive or deteriorative reactions; (2) to improve the item’s appearance; and
(3) to provide electrical insulation.
Many of the ingredients in coatings are polymer materials, majority of which are
organic in origin. These organic coatings fall into several different classifications
like paint, varnish, enamel, lacquer, and shellac.
Adhesives
Films
Films are used for packaging food products and other merchandise. They are of
low density, have a high degree of flexibility, high tensile and tear strengths, and
are resistant to attack by moisture and other chemicals. These materials include
polyethylene, polypropylene, cellophane, and cellulose acetate.
Foams
Foams are materials that contain a small percentage of small pores and trapped
gas bubbles. These include polyurethane, rubber, polystyrene, and
polyvinylchloride.
Foams are used in sofa settees, car seat and headrests, linings of boxes carrying
fragile glass or other crack able materials.
Particle – Reinforced
Large-particle and dispersion–strengthened composites are the two sub
classifications of particle-reinforced composites. The distinction between these is
based upon reinforcement or strengthening mechanism.
On the basis of diameter and character, fibers are grouped into three different
classifications: whiskers, fibers, and wires.
Whiskers are very thin single crystals that have extremely large length-to-
diameter ratios. They are among the strongest known materials. In spite of these
high strengths, whiskers are not utilized extensively as a reinforcement medium
because they are extremely expensive.
Materials that are classified as fibers are either polycrystalline or amorphous and
have small diameters; fibrous materials are generally either polymers or ceramics.
Carbon fibers have the highest specific modulus and specific strength of all
reinforcing fiber materials.
They retain their high tensile modulus and high strength at elevated
temperatures; high-temperature oxidation, however, may be a problem.
At room temperature, carbon fibers are not affected by moisture or a wide
variety of solvents, acids, and bases.
These fibers exhibit a diversity of physical and mechanical characteristics,
allowing composites incorporating these fibers to have specific engineered
properties.
Fiber and composite manufacturing processes have been developed that
are relatively inexpensive and cost effective.
Their desirable properties include high-tensile moduli and tensile strengths that
are retained to temperatures in excess of 2000 ˚C resistance to creep, and
relatively large fracture toughness values. Furthermore, carbon–carbon
composites have low coefficients of thermal expansion and relatively high
thermal conductivities; these characteristics, coupled with high strengths, give
rise to a relatively low susceptibility to thermal shock. Their major drawback is a
propensity to high temperature oxidation.
Hybrid Composites
A relatively new fiber-reinforced composite is the hybrid, which is obtained by
using two or more different kinds of fibers in a single matrix; hybrids have a better
all-around combination of properties than composites containing only a single
fiber type.
A variety of fiber combinations and matrix materials are used, but in the most
common system, both carbon and glass fibers are incorporated into a polymeric
resin. The carbon fibers are strong and relatively stiff and provide a low-density
reinforcement; however, they are expensive. Glass fibers are inexpensive and lack
the stiffness of carbon. The glass–carbon hybrid is stronger and tougher, has a
higher impact resistance, and may be produced at a lower cost than either of the
comparable all-carbon or all-glass reinforced plastics.
Principal applications for hybrid composites are lightweight land, water, and air
transport structural components, sporting goods, and lightweight orthopedic
components.
Structural Composites
A structural composite is normally composed of both homogeneous and
composite materials, the properties of which depend not only on the properties
of the constituent materials but also on the geometrical design of the various
structural elements. Laminar composites and sandwich panels are two of the
most common structural composites.
Laminar Composites
A laminar composite is composed of two-dimensional sheets or panels that have a
preferred high-strength direction such as is found in wood and continuous and
aligned fiber-reinforced plastics. The layers are stacked and subsequently
cemented together such that the orientation of the high-strength direction varies
with each successive layer. Laminar composite has relatively high strength in a
number of directions in the two-dimensional plane; however, the strength in any
given direction is, of course, lower than it would be if all the fibers were oriented
in that direction.
For example, adjacent wood sheets in plywood are aligned with the grain
direction at right angles to each other.
Sandwich Panels
Sandwich panels, considered to be a class of structural composites, are designed
to be light-weight beams or panels having relatively high stiffness and strength. A
sandwich panel consists of two outer sheets, or faces, that are separated by and
adhesively bonded to a thicker core.
The outer sheets are made of a relatively stiff and strong material, typically
aluminum alloys, fiber-reinforced plastics, titanium, steel, or plywood; they
impart high stiffness and strength to the structure, and must be thick enough to
withstand tensile and compressive stresses that result from loading. The core
material is lightweight, and normally has a low modulus of elasticity. Core
materials typically fall within three categories: rigid polymeric foams (i.e.,
phenolics, epoxy, polyurethanes), wood (i.e., balsa wood), and honeycombs.
Sandwich panels are used in a wide variety of applications including roofs, floors,
and walls of buildings; and, in aerospace and aircraft (i.e., for wings, fuselage, and
tailplane skins).
Smart Materials
Smart materials are designed materials that have one or more properties that can
be significantly changed in a controlled fashion by external stimuli, such as stress,
temperature, moisture, pH, electric or magnetic fields.
There are a number of types of smart material, some of which are already
common. Some examples are as following:
Piezoelectric materials are materials that produce a voltage when stress is
applied. Since this effect also applies in the reverse manner, a voltage across the
sample will produce stress within the sample. Suitably designed structures made
from these materials can therefore be made that bend, expand or contract when
a voltage is applied.
Magnetic shape memory alloys are materials that change their shape in response
to a significant change in the magnetic field.
pH-sensitive polymers are materials that change in volume when the pH of the
surrounding medium changes.
Halochromic materials are commonly used materials that change their colour as
a result of changing acidity. One suggested application is for paints that can
change colour to indicate corrosion in the metal underneath them.
Dielectric elastomers (DEs) are smart material systems which produce large
strains (up to 300%) under the influence of an external electric field.
Biomaterials
Biomaterials are employed in components implanted into the human body for
replacement of diseased or damaged body parts. These materials must not
produce toxic substances and must be compatible with body tissues (i.e., must
not cause adverse biological reactions). All of the above materials—metals,
ceramics, polymers, composites, and semiconductors—may be used as
biomaterials. For example, some of the biomaterials that are utilized in artificial
hip replacements.
The musculoskeletal tissues bone, cartilage and ligament/tendon are highly
structured nanocomposites consisting of nanofibres embedded in a matrix of
different composition. Carbon fibers also show high cell adhesion and specific and
interesting biological reactions.
Nanosphere is commercializing a molecular diagnostics platform using an optical
detection system.
The technology platform is based on functionalized gold nanoparticles. When
there are binding events, the optical properties of the gold nanoparticles change
and can be detected. The primary benefit of the system over existing testing
platforms is that the system is simple and accessible.
Hospital laboratories can rapidly perform sensitive and accurate tests without
substantial technical and operational expertise.
Alpha Szensor (carbon nano tube) was recently formed to commercialize medical
sensors using carbon nanotube networks. The company, located in Woburn,
Massachusetts, has licensed Nantero Inc.’s intellectual property for solution
coating of random networks of carbon nanotubes. These nanotubes have a range
of applications from cancer marking to heart stent making.
Nanomaterials
Nanostructured Materials are a new class of materials which provide one of the
greatest potentials for improving performance and extended capabilities of
products in a number of industrial sectors, including the aerospace, tooling,
automotive, recording, cosmetics, electric motor, duplication, and refrigeration
industries. Encompassed by this class of materials are multilayers, nano-
crystalline materials and nano-composites. Their uniqueness is due partially to the
very large percentage of atoms at interfaces and partially to quantum
confinement effects.
Optically Transparent Conductive Coatings: Indium tin oxide (ITO) and antimony
tin oxide (ATO) are well known, optically transparent, electrically conductive
materials. Nanoparticles of these materials can be painted on surfaces such as
interactive touch screens to create a conductive, transparent screen.
Bio-conjugates