Fundamentals of Materials
Science (MNF 212)
Dr. Gamal AbdouDepartment of Manufacturing Engineering and Production
1
Fundamentals of Material Science Dr. Gamal Abdou
Course Outline
Lecturer: Dr. Gamal Abdou
Course Outline:1. Introduction to Engineering Materials
2. Atomic Structure and Interatomic Bonding
3. Structure of Crystalline Materials
4. Imperfections in Solid
5. Diffusion
6. Strengthening Mechanisms
7. Mechanical Properties
8. Electrical, Thermal, Optical, and Magnetic Properties
9. Fracture, Fatigue, and creep
Exams, Projects, Practices:• Workshop and/or classroom practices (10%)
• Midterm Exam (10%)
• Practical Exam (20)
• Term Exam (60%)
Fundamentals of Materials Science
Course Resources
• Lectures Notes Dr. Gamal Abdou
• Labs experiments
• Tutorials exercises
• Text Book References
• W.D. Callister “Fundamentals of Materials Science and Engineering”
” , 5th edition, Wiley
.
Fundamentals of Materials Science
Fundamentals of Material Science
CHAPTER 1
Introduction to Engineering Materials
Fundamentals of Material Science Dr. Gamal Abdou
Why Materials ???
Introduction to Engineering Materials
Properties of materials
Mechanical properties of materialsStrength, Toughness, Hardness, Ductility,
Elasticity, Fatigue and Creep
Chemical propertiesOxidation, Corrosion, Flammability, Toxicity, …
Physical propertiesDensity, Specific heat, Melting and boiling point,
Thermal expansion and conductivity,
Electrical and magnetic properties
General properties of Ceramics:
1. High melting points and high chemical stabilities.
2. High hardness and high temperature strength.
3. Very brittle.
4. Poor electrical conductors.
5. High strength on compression.
6. They can be crystalline (ceramics), non-crystalline
(glass) or mixture of both glass- ceramics).
7. Ceramics specific gravity(density) = 2.5 gm/mm2
General properties of Polymers:
1. Non-crystalline, but some consist of mixtures of both
crystalline and non-crystalline regions.
2. Low densities and low rigidity.
3. Poor electrical conductors due to the nature of the
atomic bonding.
4. High corrosion resistant but not used at high
temperatures.
5. Good strength to weight ratio.
6. Polymer specific gravity(density) ≈ 1.2 gm/mm2
Composites
A number of composite materials have been engineered that
consist of more than one material type. Usually they consist of:
a) Reinforcement phase(e. g. fiber)
b) Binder phase (e.g. compliant matrix)
Advantage of composite:
1. High strength and stiffness.
2. High corrosion resistance.
3. High wear resistance.
4. High thermal insulation.
5. Low weight ratio.
General Properties and Applications of
Ferrous Alloys
• Ferrous alloys are useful metals in terms of
mechanical, physical and chemical
properties.
• Alloys contain iron as their base metal.
• Carbon steels are least expensive of all
metals while stainless steels is costly.
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
Typical Selection of Carbon and Alloy Steels
for Various Applications
TABLE 5.1
Product Steel Product Steel
Aircraft forgings,
tubing, fittings
Automobile bodies
Axles
Ball bearings and races
Bolts
Camshafts
Chains (transmission)
Coil springs
Connecting rods
Crankshafts (forged)
4140, 8740
1010
1040, 4140
52100
1035, 4042, 4815
1020, 1040
3135, 3140
4063
1040, 3141, 4340
1045, 1145, 3135, 3140
Differential gears
Gears (car and truck)
Landing gear
Lock washers
Nuts
Railroad rails and wheels
Springs (coil)
Springs (leaf)
Tubing
Wire
Wire (music)
4023
4027, 4032
4140, 4340, 8740
1060
3130
1080
1095, 4063, 6150
1085, 4063, 9260, 6150
1040
1045, 1055
1085
Mechanical Properties of Selected Carbon
and Alloy Steels in Various Conditions
TABLE 5.2 Typical Mechanical Properties of Selected Carbon and Alloy Steels in the Hot-Rolled,
Normalized, and Annealed Condition
AISI Condition Ultimate
tensile
strength
(MPa)
Yield
Strength
(MPa)
Elongation in
50 mm (%)
Reduction of
area (%)
Hardness
(HB)
1020
1080
3140
4340
8620
As-rolled
Normalized
Annealed
As-rolled
Normalized
Annealed
Normalized
Annealed
Normalized
Annealed
Normalized
Annealed
448
441
393
1010
965
615
891
689
1279
744
632
536
346
330
294
586
524
375
599
422
861
472
385
357
36
35
36
12
11
24
19
24
12
22
26
31
59
67
66
17
20
45
57
50
36
49
59
62
143
131
111
293
293
174
262
197
363
217
183
149
AISI Designation for High-Strength Sheet Steel
TABLE 5.3
Yield Strength Chemical
Composition
Deoxidation
Practice
psi x 103
MPa
35
40
45
50
60
70
80
100
120
140
240
275
310
350
415
485
550
690
830
970
S = structural alloy
X = low alloy
W = weathering
D = dual phase
F = killed plus sulfide inclusion control
K = killed
O = nonkilled
Room-Temperature Mechanical Properties and
Applications of Annealed Stainless Steels
TABLE 5.4 Room-Temperature Mechanical Properties and Typical Applications of Selected Annealed
Stainless Steels
AISI
(UNS)
Ultimate
tensile
strength
(MPa)
Yield
strength
(MPa)
Elongation
in 50 mm
(%) Characteristics and typical applications
303
(S30300)
550–620 240–260 53–50 Screw machine products, shafts, valves, bolts,
bushings, and nuts; aircraft fittings; bolts; nuts;
rivets; screws; studs.
304
(S30400)
565–620 240–290 60–55 Chemical and food processing equipment,
brewing equipment, cryogenic vessels, gutters,
downspouts, and flashings.
316
(S31600)
550–590 210–290 60–55 High corrosion resistance and high creep strength.
Chemical and pulp handling equipment,
photographic equipment, brandy vats, fertilizer
parts, ketchup cooking kettles, and yeast tubs.
410
(S41000)
480–520 240–310 35–25 Machine parts, pump shafts, bolts, bushings, coal
chutes, cutlery, tackle, hardware, jet engine parts,
mining machinery, rifle barrels, screws, and
valves.
416
(S41600)
480–520 275 30–20 Aircraft fittings, bolts, nuts, fire extinguisher
inserts, rivets, and screws.
Tool and die steels
• Designed for high strength, impact
toughness, and wear resistance at a range of
temperatures.
Aluminium and aluminium alloys
• Factors for selecting are:
1. High strength to weight ratio
2. Resistance to corrosion
3. High thermal and electrical conductivity
4. Ease of machinability
5. Non-magnetic
Magnesium and magnesium alloys
• Magnesium (Mg) is the lightest metal.
• Alloys are used in structural and non-
structural applications.
• Typical uses of magnesium alloys are aircraft
and missile components.
• Also has good vibration-damping
characteristics.
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 strength-
to-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
Ceramics
•Traditional ceramics
• clays: kaolinite
• silica: quartz, sandstone
• alumina
• silicon carbide
•New ceramics
• oxide ceramics : alumina
• carbides : silicon carbide, titanium carbide, etc.
• nitrides : silicon nitride, boron nitiride, etc.
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
• 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 reinforcement or powder.
Composite
Fig. 1 The role of Materials Science and Materials
Engineering
Materials Science and Materials Engineering