Engineering Materials: An Overview
Engineering Materials: An Overview
Engineering Materials: An Overview
Engineering Materials
Materials
Ferrous metals: carbon-, alloy-, stainless-, tool-and-die steels Non-ferrous metals: aluminum, magnesium, copper, nickel, titanium, superalloys, refractory metals, beryllium, zirconium, low-melting alloys, gold, silver, platinum, Plastics: thermoplastics (acrylic, nylon, polyethylene, ABS,) thermosets (epoxies, Polymides, Phenolics, ) elastomers (rubbers, silicones, polyurethanes, ) Ceramics, Glasses, Graphite, Diamond, Cubic Boron Nitride Composites: reinforced plastics, metal-, ceramic matrix composites Nanomaterials, shape-memory alloys, superconductors,
Properties of materials
Mechanical properties of materials Strength, Toughness, Hardness, Ductility, Elasticity, Fatigue and Creep Physical properties Density, Specific heat, Melting and boiling point, Thermal expansion and conductivity, Electrical and magnetic properties Chemical properties Oxidation, Corrosion, Flammability, Toxicity,
Material Specification Chemical composition Mechanical properties Strength, hardness (under various conditions: temperature, humidity, pressure) Physical properties density, optical, electrical, magnetic Environmental green, recycling
Metals
Ferrous Metals
Cast irons Steels
Non-ferrous metals
Aluminum and its alloys Copper and its alloys Magnesium and its alloys Nickel and its alloys Titanium and its alloys Zinc and its alloys Lead & Tin Refractory metals Precious metals
Super alloys
Iron-based Nickel-based Cobalt-based
Carbon and alloy steels Carbon steels Classified as low, medium and high: 1. Low-carbon steel or mild steel, < 0.3%C, bolts, nuts and sheet plates. 2. Medium-carbon steel, 0.3% ~ 0.6%C, machinery, automotive and agricultural equipment. 3. High-carbon steel, > 0.60% C, springs, cutlery, cable.
Carbon and alloy steels Alloy steels Steels containing significant amounts of alloying elements. Structural-grade alloy steels used for construction industries due to high strength. Other alloy steels are used for its strength, hardness, resistance to creep and fatigue, and toughness. It may heat treated to obtain the desired properties.
Carbon and alloy steels High-strength low-alloy steels Improved strength-to-weight ratio. Used in automobile bodies to reduce weight and in agricultural equipment. Some examples are: 1. Dual-phase steels 2. Micro alloyed steels 3. Nano-alloyed steels
Stainless steels Characterized by their corrosion resistance, high strength and ductility, and high chromium content. Stainless as a film of chromium oxide protects the metal from corrosion.
Stainless steels Five types of stainless steels: 1. Austenitic steels 2. Ferritic steels 3. Martensitic steels 4. Precipitation-hardening (PH) steels 5. Duplex-structure steels
S t e l
4 1 4 0 , 8 7 4 0 1 0 1 0 1 0 4 0 , 4 1 4 0 5 2 1 0 1 0 3 5 , 4 0 4 2 , 4 8 1 5 1 0 2 0 , 1 0 4 0 3 1 3 5 , 3 1 4 0 4 0 6 3 1 0 4 0 , 3 1 4 1 , 4 3 4 0 1 0 4 5 , 1 4 5 , 3 1 3 5 , 3 1 4 0
P r o d u c t
D i f e r n t i a l g e a r s G e a r s ( c a r a n d t r u c k ) L a n d i n g e a r L o c k w a s h e r s N u t s R a i l r o a d r a i l s a n d w h e l s S p r i n g s ( c o i l ) S p r i n g s ( l e a f ) T u b i n g W i r e W i r e ( m u s i c )
S t e l
4 0 2 3 4 0 2 7 , 4 0 3 2 4 1 4 0 , 4 3 4 0 , 8 7 4 0 1 0 6 0 3 1 3 0 1 0 8 0 1 0 9 5 , 4 0 6 3 , 6 1 5 0 1 0 8 5 , 4 0 6 3 , 9 2 6 0 , 6 1 5 0 1 0 4 0 1 0 4 5 , 1 0 5 1 0 8 5
1 0 2 0
1 0 8 0
3 1 4 0 4 3 4 0 8 6 2 0
A s r o l e d N o r m a l i z e d A n e a l e d A s r o l e d N o r m a l i z e d A n e a l e d N o r m a l i z e d A n e a l e d N o r m a l i z e d A n e a l e d N o r m a l i z e d A n e a l e d
MPa 240 275 310 350 415 485 550 690 830 970
550590
210290
6055
480520
240310
3525
480520
275
3020
Tool and die steels Designed for high strength, impact toughness, and wear resistance at a range of temperatures.
C o l d w o r k S h o c k r e s i s t i n g M o l d s t e l s S p e c i a l p u r p o s e W a t e r h a r d e n i n g
Source: Adapted from Tool Steels, American Iron and Steel Institute, 1978.
Copper and copper alloys Copper alloys have electrical and mechanical properties, corrosion resistance, thermal conductivity and wear resistance. Applications are electronic components, springs and heat exchangers. Brass is an alloy of copper and zinc. Bronze is an alloy of copper and tin.
Nickel and nickel alloys Nickel (Ni) has strength, toughness, and corrosion resistance to metals. Used in stainless steels and nickel-base alloys. Alloys are used for high temperature applications, such as jet-engine components and rockets.
Superalloys Superalloys are high-temperature alloys use in jet engines, gas turbines and reciprocating engines.
Titanium and titanium alloys Titanium (Ti) is expensive, has high strengthto-weight ratio and corrosion resistance. Used as components for aircrafts, jet-engines, racing-cars and marine crafts.
Refractory metals Refractory metals have a high melting point and retain their strength at elevated temperatures. Applications are electronics, nuclear power and chemical industries. Molybdenum, columbium, tungsten, and tantalum are referred to as refractory metal.
Other nonferrous metals 1. Beryllium 2. Zirconium 3. Low-melting-point metals: - Lead - Zinc - Tin 4. Precious metals: - Gold - Silver - Platinum
Special metals and alloys 1. Shape-memory alloys (i.e. eyeglass frame, helical spring) 2. Amorphous alloys (Metallic Glass) 3. Nanomaterials 4. Metal foams
Surface hardening
Carburizing Nitriding Carbonitriding Chromizing and Boronizing
Precipitation Hardening
Electric furnaces
batch furnaces
box furnaces - door car-bottom furnaces - track for moving large parts bell-type furnaces - cover/bell lifted by gantry crane
continuous furnaces
Furnaces for Heat Treatment Vacuum furnaces Salt-bath furnaces Fluidized-bed furnaces Some of the furnaces have special atmosphere requirements, such as carbon- and nitrogen- rich atmosphere.
Surface Hardening Methods Flame hardening Induction heating High-frequency resistance heating Electron beam heating Laser beam heating
Induction heating
New ceramics
oxide ceramics : alumina carbides : silicon carbide, titanium carbide, etc. nitrides : silicon nitride, boron nitiride, etc.
Classification of Polymers
Thermoplastics Thermosets Elastomers
Polymers Thermoplastics - reversible in phase by heating and cooling. Solid phase at room temperature and liquid phase at elevated temperature. Thermosets - irreversible in phase by heating and cooling. Change to liquid phase when heated, then follow with an irreversible exothermic chemical reaction. Remain in solid phase subsequently. Elastomers - Rubbers
Thermoplastics
Acetals Acrylics - PMMA Acrylonitrile-Butadiene-Styrene - ABS Cellulosics Fluoropolymers - PTFE , Teflon Polyamides (PA) - Nylons, Kevlar Polysters - PET Polyethylene (PE) - HDPE, LDPE Polypropylene (PP) Polystyrene (PS) Polyvinyl chloride (PVC)
Composite Materials Metal Matrix Composites (MMC) Mixture of ceramics and metals reinforced by strong, high-stiffness fibers Ceramic Matrix Composites (CMC) Ceramics such as aluminum oxide and silicon carbide embedded with fibers for improved properties, especially high temperature applications. Polymer Matrix Composites (PMC) Thermosets or thermoplastics mixed with fiber
Composite Materials
1D fibre
Woven fabric
Random fibre
Composite Materials