Course

MATERIALS SCIENCE
Course code
MEE1002A

GOPINATH T
Assistant Professor
School of Mechanical Engineering
MIT World Peace University, Pune
Maharashtra
INDIA
[email protected]
[email protected]

4th Feb 2022

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Corrections and suggestions, if any, with respect to the

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GT
 UNIT 3

Application of polymers, ceramics, composites and metals

Polymers
 Polymers

• Polymers is derived from Greek word in which (poly means

many, mer means units) is composed of a large number of
repetitive called monomers (mono means one) or simple
molecules

• Thus a polymer is made up of thousands of monomers joined

chemically together to form a large molecule

• It has been observed that each molecule of polymer is either a

long chain or a network of repetitive units or monomers. It
consists of chain of molecules
Polymers
Polymers
Polymers
Polymers
Polymers
Polymers
 Classification of Polymers
Polymers are classified into two main groups as below

(1) Thermoplastic polymers

(2) Thermosetting polymers

Thermoplastic Polymers

Thermoplastic polymers are the polymers which become

soft and deformable when heated, which is characteristic of
linear polymeric molecules.
 Classification of Polymers
Thermoplastic Polymers

• The high temperature plasticity is due to the ability of the

molecules to slide past one another which is another
example of a thermally activated.

• Most thermoplastics have a high molecular weight

 Thermoplastic Polymers
• Thermoplastic materials are similar to metals that gain
ductility a high temperatures

• It has been noted that, as with metals, the ductility of

thermoplastic polymers is reduced by cooling

• The key distinction between thermoplastics and metals is

what we mean by high temperatures

• The secondary bonding, which must be overcome to

deform thermoplastic, may allow substantial
deformation around 100 C for common thermoplastics
 Thermoplastic Polymers
• However, metallic bonding generally restricts creep deformation to
temperatures closer to 1000 C in typical alloys

• Although polymers cannot, in general, be expected to duplicate

fully the mechanical behavior of traditional metal alloys

• A major effort is made to produce some polymers with sufficient

strength and stiffness to be serious candidates for structural
applications once dominated by metals

• These polymers are noted in engineering polymers, which retain

good strength and stiffness up to 150–175 C
Thermoplastic Polymers
 Thermosetting Polymers

• Thermosetting polymers are the polymers which are the opposite of

thermoplastics

• They become hard and rigid when heating

• Unlike thermoplastic polymers, this phenomenon is not lost by

cooling, which is characteristic of network molecular structures
formed by the step-growth mechanism

• The chemical reaction steps are enhanced by higher temperatures

and are irreversible; that is, the polymerization remains upon
cooling
 Thermosetting Polymers
• Thermosetting products can be removed from the mould at the
fabrication temperatures from 200 to 300 C

• By contrast, thermoplastics must be cooled in the mould to prevent

distortion

• Common thermo-setting polymers which is subdivided into two

categories, thermosetting and elastomers

• In this case, thermosets refers to materials that share with the

engineering polymers

• Significant strength and stiffness so as to be common. Metal

substitutes
Thermosetting Polymers
 Polymerization techniques

There are four types of polymerization techniques

1. Bulk Polymerization

2. Solution Polymerization

3. Suspension Polymerization

4. Emulsion Polymerization
 Bulk Polymerization
Bulk polymerization or mass polymerization is carried out by
adding a soluble initiator to pure monomer in liquid state. The
initiator should dissolve in the monomer. The reaction is initiated
by heating or exposing to radiation.
 Solution Polymerization
This method is used to solve the problems associated with the bulk
polymerization because the solvent is employed to lower the.
Viscosity of the reaction, thus help in the heat transfer and reduce
auto acceleration. It requires the correct selection of the solvents.
Both the initiator and monomer be soluble in each other and that the
solvent are suitable for boiling points, regarding the solvent-removal
steps.
 Suspension Polymerization
In this system, the monomer must be either 1) insoluble in water or 2)
only slightly soluble in water, so that when it polymerizes it becomes
insoluble in water. The behaviour inside the droplets is very much like the
behaviour of bulk polymerization, but since the droplets are only 10 to
1000 microns in diameter, more rapid reaction rates can be tolerated
(than would be the case for bulk polymerization) without boiling the
monomer. The advantages are better heat control of the
reaction, and separation is much easier than in solution
polymerization. The disadvantage is that few monomers are water
soluble.
 Emulsion Polymerization
The "ingredients" for an emulsion polymerization include 1) a water
soluble initiator, 2) a chemical emulsifier, and 3) a monomer that is only
slightly soluble in water, or completely insoluble.

Its common type is an oil-in-water emulsion. The droplets of monomer

(the oil) are emulsified (with surfactants) in a continuous phase of water.
Water-soluble polymers, such as certain polyvinyl alcohols
Hydroxyethyl celluloses are used to act as emulsifiers/stabilizers
 Characteristics of Polymers
The followings are the 7. Polymers can be produced
characteristics of polymers : with close dimensional
1. Poor tensile strength tolerances
2. Poor temperature 8. Good mouldability
resistance 9. Low coefficient of friction
3. Low mechanical 10. Good corrosion resistance
properties. 11. Low density
4. Economical
5. Polymers can be produced
transparent or in different
colours
6. Excellent surface finish
can be obtained
25
Applications of Engineering Polymers
• The rear quarter panel on this sports car was a pioneering
application of an Engineering polymer in a traditional
structural metal application

• In automotive industry Engineering polymers are used

• Consumer and industrial products made of polymers include

food and beverage containers. Packing, housewares, textiles,
medical devices foam, paints, safety shields and toys
 Special Purpose Plastics
Polymethyl methacrylate (PMMA) Contact lenses, glazing (best
known in this form by its various trade names around the world; e.g.,
Perspex, Oroglas, Plexiglas), aglets, fluorescent light diffusers, rear
light covers for vehicles. It forms the basis of artistic and commercial
acrylic paints when suspended in water with the use of other agents

Polytetrafluoroethylene (PTFE) Heat-resistant, low-friction

coatings, used in things like non-stick surfaces for frying pans,
plumber's tape and water slides. It is more commonly known as
Teflon

Polylactic acid (PLA) A biodegradable, thermoplastic found

converted into a variety of aliphatic polyesters derived from lactic acid
which in turn can be made by fermentation of various agricultural
products such as corn starch, once made from dairy products
Composites
 Composites
• Composite materials comprising two or more different materials
bonded together having combined properties of constituents are
called as composites

• In its simplest form composite consists of two independent and

dissimilar materials

• The common examples of composites used in everyday life are

plywood, vehicle tyres etc.

• Plywood is the composites of thin sheets of wood with grains of

alternate sheets perpendicular to each other and bonded together
by a polymer in between them.

• R.C.C has steel rods embedded in the concrete mix, which itself, is
a composite of cement, sand aggregate and water.
 Composites
• The resulting R.C.C. structure can take loads which otherwise
cannot be carried by the concrete alone. Steel rods can be of
different shape, size and provided in various directions
• Vehicle tyres are rubber reinforced with woven cards
• All these and many more composites have properties which
are impossible to achieve in conventional materials
• Each of the materials in the composites serves one or more
specific functions
• The properties of composites are affected by the size and
distribution of the constituents in relation to each other; the
bond strength between them, shape, size, amount and
properties of each material
 Composites
• The base material surrounding other materials is normally, present in
higher percentage and is called matrix

• Other material which reinforce the properties of base material are called
reinforcements

• Cohesion between the matrix and reinforcement is essential and may take
place in any or combination of the following ways,

(i) Chemical reaction at the interfaces of the constituents

(ii) Mechanical keying between the matrix and the reinforcement

(iii) Physical bonding between the matrix and the reinforcement by van
der waals forces acting between the surface molecules of the various
constituents
Classification of Composites
 Particle Reinforced Composites
• The dispersed phase for particle reinforced composites is
equiaxed

• Particle dimensions are approximately the same in all

directions

• 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
 Fiber Reinforced Composites
• The most important composites are those in which the
dispersed phase is in the form of a fibre. Goals of fibre
reinforced composites often include high strength and/or
stiffness on a weight basis those characteristics are
expressed in terms of specific strength and specific modulus
parameters which correspond, respectively, to the ratios of
tensile strength to specific gravity and modulus of elasticity to
specific gravity

• Fiber reinforced composites with exceptionally high specific

strengths and moduli have been produced that utilize low-
density fiber and matrix materials
 Fiber Reinforced Composites

(a) Continuous and aligned (b) Discontinuous and (c) Discontinuous and randomly
fiber reinforced composites aligned fiber reinforced oriented fiber reinforced
composites composites
 Properties of Composite Materials

• The properties such as strength, resistance to heat or some other

properties of composite materials are better than the properties of
the individual materials from which they are made

• Specific strength is sometimes referred to as the strength to weight

ratio

• Composites have stiffness, toughness, creep resistance, etc.

• Properties like density and heat capacity depend on the amount of

each phase and are independent of microstructure
 Applications of Composite Materials

• Composite materials are preferred in certain applications like

space vehicles
• Aircrafts
• Rockets
• High pressure vessels
• Building construction
• Aerospace
• Fuel efficient automobiles
 Iso-stress-Iso-strain condition of composite
The Young’s modulus of the composite is between that of the matrix and the
reinforcement
Let us consider two extreme cases.
(A) Isostrain the matrix and the reinforcement (say long fibres) are under identical
strain. This is known as Voigt averaging
(B) Isostress the matrix and fibre are under identical stress. This is known as Reuss
averaging
Let the composite be loaded in uniaxial tension and the volume fraction of the fibre be
Vf (automatically the volume fraction of the matrix is Vm = (1− Vf))
 Iso-stress-Iso-strain condition of composite

• The modulus of a real composite will lie between these two extremes (usually closer
to isostrain). The modulus of the composite will depend on the shape of the
reinforcement and the nature of the interface (e.g. in a long aligned fibre composite
having a perfectly bonded interface with no slippage will lead to isostrain conditions

• Purely from a modulus perspective, a larger volume fraction will give a higher
modulus; however, ductility and other considerations typically limit the volume
fraction of reinforcement in a composite to about 30%
Iso-stress-Iso-strain condition of composite
Ceramics
 Ceramics

• The term ceramics is applied to a range of inorganic

materials of widely varying uses

• Generally these materials are non-metallic and in most

cases have been treated at a high temperature at some
stage during manufacturing

• The word ‘ceramic’ is derived from Greek, Keramos

though the group of materials now so described includes
glass products, cements and plasters
 Ceramics

• Keramikos – ‘burnt stuff –Clay Products’

• Ceramics are inorganic compounds of metallic and non-
metallic elements.
• Generally known as ‘Clay products’
Ordinary glass: 74% SiO2, 16% Na2O, 5% CaO, 1% Al2O3 and
4% MgO.
• E.g. Metal and nonmetal: MgO; NMES and nonmetal: SiO2;
Metal and NMES: TiC, ZrB2, MoSi2; Two NMES : SiC,
Si3N4;
 Classification of Ceramics

Clay products
Whiteware
Bricks

Refractories Cements
bricks for high- Composites
temperature furnaces Structural

Abrasives
Glasses Sandpaper
Optical Cutting
Composite reinforce Polishing Advanced Ceramics
Containers Engine rotors
Household Engine valves
Engine Bearings
Sensors
• some abrasives and cutting tool materials, building
materials such as bricks, tiles and drain pipes, various
electrical insulation materials, refractory linings for
furnaces, porcelain & other refractory coatings for metal as
well as the more traditional uses in pottery, crockery and
sanitaryware.

• Ceramics structure can be classified conveniently into four

main groups:
(1) Amorphous ceramics
(2) Crystalline ceramics
(3) Bonded ceramics
(4) Cements
 Amorphous Ceramics (Glass)
These are substances referred to generally as ‘glasses’. They include those
such as obsidian which occur naturally and man-made glasses used for the
manufacture of bottles, windows and lenses.
 Crystalline Ceramics
• A ceramic material is an inorganic, non-metallic, often crystalline oxide,
nitride or carbide material
• Some elements, such as carbon or silicon, may be considered ceramics.
• Ceramic materials are brittle, hard, strong in compression, weak in
shearing and tension
 Cermets
• A cermet is a composite material composed of ceramic (cer) and metal
(met) materials
• The particle size is more than 1.0 micron and their volume fraction is
generally more than 20%. These are also termed as cemented carbides
• Depending on the physical structure of the material, cermets can also
be metal matrix composites, but cermets are usually less than 20%
metal by volume
• The ceramics have high strength, high tensile modulus, high hardness
but are brittle materials by themselves on the other hand, metals are
weaker, less stiff and ductile in nature
• The metal is used as a binder for an oxide, boride, or carbide.
Generally, the metallic elements used are nickel, molybdenum,
and cobalt
• Cermets are used in the manufacture of resistors (esp. potentiometers),
capacitors, and other electronic components which may experience high
temperature
 Applications of Ceramic Materials

Ceramic have numerous consumer and industrial applications!

• Ceramics are used in electrical and electronics industry because

of their high electrical resistivity, dielectric strength and
magnetic properties that suitable for applications such as
magnets in speakers

• The capability of ceramics to maintain their strength and

stiffness at elevated temperatures makes them very attractive
for high temperature applications

• High resistance to wear makes them suitable for applications

such as cylinder liners, bushings, seals, and bearings
 Applications of Ceramic Materials
• Internal combustion engines are only about 30% efficient, but with the
use of ceramic components their operating performance can be
improved by at least 30%

• Ceramics have been used in gasoline and diesel engine components

(rotors) made of silicon nitride, silicon carbide, and partially stabilized
zirconia, etc.

• Ceramics are used to coat over metals to reduce wear, prevent

corrosion, and provide a thermal barrier

• High- speed components for machine tools are ceramics

• Higher elastic modulus of ceramics make them attractive for

improving the stiffness while reducing the weight of machines
Applications of Ceramic Materials
• Silicon nitride ceramics are also used as ball bearings
and rollers. Because of their strength and inertness

• Ceramics are used as biomaterials to replace joints in

the human body, as prosthetic devices and for dental
work

• Commonly used bioceramics include aluminium oxide,

silicon nitride, and various compounds of silica

• Ceramics can be made to be porous, thus allowing bone

to grow into the porous surface and develop a strong
mechanical bond
Questions?
Thank You