National Institute of Technology

Hamirpur
UNIT 2
Brief Introduction of
Engineering Materials

Dr. P. K. Sood
Associate Professor
 Engineering Materials
Materials that are used as raw material for any sort of
construction or manufacturing in an organized way of
engineering application are known as Engineering Materials.

• Over 70,000 different kinds and grades of engineering

materials
• This number grows daily
• 1,000 different materials
make up an automobile
Material Classification
 Metals
1Copper 2. Bronze 3. Brass 4. Cast iron 5. Steel 6. Aluminum 7.
Titanium 8. Alloys
Polymers
1Rubber 2. Plastic 3. Leather 5. Nylon 6. Acrylics 7. Polyesters
8. Advanced Polymers
Ceramics
1. Stone 2. Pottery 3. Glass 4. Cement 5. Portland Cement 6.
Fused Silica 7. Advanced Ceramics
Composite
• 1. Bricks 2. Paper 3. Fiberglass 4. Kevlar 5. C arbon F iber R
einforced P lastics 6. M etal M atrix C omposites 7. P
olymer M atrix C omposites 8. C eramic M atrix C omposites
 Classification of Engineering Materials
• There are thousands of materials available for use in
engineering applications.
• Most materials fall into one of three classes that are based on
the atomic Classification of Engineering MaterialsDr.
Abdel-Wahab El-Morsy Faculty of Engineering - Rabigh
• Most materials fall into one of three classes that are based on
the atomic bonding forces of a particular material. These three
classifications are metallic, ceramic and polymeric. Additionally,
different materials can be combined to create a composite
material.
• Within each of these classifications, materials are often further
organized into groups based on their chemical composition or
certain physical or mechanical properties.
• Composite materials are often grouped by the types of
materials combined or the way the materials are arranged
together.
 PROPERTIES
• Many materials, when in service, are subjected to forces or
loads; examples includethe aluminum alloy from which an
airplane wing is constructed and the steelin
anautomobileaxle.INTRODUCTIONMechanical PropertiesDr.
Abdel-Wahab El-Morsy Faculty of Engineering -
Rabighautomobileaxle.
• In such situations it is necessary to know the characteristics
of the material and todesign the member from which it is
made such that any resulting deformation willnot be
excessive and fracture will not occur.
• The mechanical behavior of a material reflects the
relationship betweenits responseor deformation to an applied
load or force.
• Important mechanical properties are strength, hardness,
ductility, and stiffness
 Engineering Materials

Metals
Polymers

metals
polymers
ceramics
composites

Ceramics
 Metals
• Metals are usually characterized by a well defined crystal structure.
They are bonded together by means of metallic bonds which maintain
an electron cloud. This electron cloud is crucial for the high electrical
and thermal conductivity characteristic to metals.
• Metals consist of alkaline, alkaline earth, metalloids and transition
metals
• Metal alloys are mixtures of two or more metal and nonmetal
elements (for example, aluminum and copper, Cu-Ni alloy, steel)
• Bonding: Metallic
– No particular sharing or donating occurs. Electron cloud is formed (that
is, free electrons)
– Strong bonds with no hybridization or directionality
• Properties:
– Electrically conductive (free electrons)
– Thermally conductive
– High strength – large capacity to carry load over x-section area (stress)
– Ductile – endure large amounts of deformation before breaking.
– Magnetic – ferromagnetism, paramagnetic
– Medium melting point
 Metal Application
• Electrical wire: aluminum, copper, silver
• Heat transfer fins: aluminum, silver
• Plumbing: copper
• Construction beams (bridges, sky scrapers, rebar, etc.): steel
(Fe-C alloys)
• Cars: steel (Fe-C alloys)
• Consumer goods:
– soup cans
– appliances (stainless steel sheet metal)
– utensils
– tools
– Many, many, many more…
 Alloys of metals
• Many things that are made of metals may, in fact,
be made of mixtures of at least one metal with
either other metals, or with non-metals. These
mixtures are called alloys. Some common alloys
are:

• Steel (iron and carbon) (Carbon is a non-metal)

• Brass (copper and zinc)
• Bronze (copper and tin)
• Duralumin (aluminum and copper)
• Gunmetal (copper, tin, and zinc)
 CERAMICS
• To be most frequently silicates, oxides, nitrides
and carbides

• Typically insulative to the passage of electricity

and heat

• More resistant to high temperatures and harsh

environments than metals and polymers

• Hard but very brittle

 CERAMICS
ceramics that are predominantly ionic in nature have crystal structures
comprised of charged ions, where positively-charged (metal) ions
are called

where positively-charged (metal) ions are called

cations, and negatively-charged (non-metal) ions
are called anions – the crystal structure for a given
ceramic depends upon two characteristics:
1. The magnitude of electrical charge on eachcomponent ion,
recognizing that the overallstructure must be electrically neutral

2. The relative size of the cation(s) and anion(s),which determines the

type of interstitial site(s) for the cation(s) in an anion lattice
 Properties Of Ceramic

Low ductility
– Very brittle
– High elastic modulus
Low toughness
– Low fracture toughness
– Indicates the ability of a crack or flaw to
produce a catastrophic failure
Low density
– Porosity affects properties
High strength at elevated temperatures
 Classification of Ceramics
• Traditional Ceramics
✔ the older and more generally known types
(porcelain, brick, earthenware, etc.)
✔ Based primarily on natural raw materials of clay
and silicates
✔ Applications;
building materials (brick, clay pipe, glass)
household goods (pottery, cooking ware)
manufacturing ( abbrasives, electrical devices,
fibers)
 Classification of Ceramics
• Advanced Ceramics
✔ have been developed over the past
half century
✔ Include artificial raw materials, exhibit
specialized properties, require more
sophisticated processing
✔ Applied as thermal barrier coatings to
protect metal structures, wearing
surfaces,
✔ Engine applications (silicon nitride
(Si3N4), silicon carbide (SiC), Zirconia
(ZrO2), Alumina (Al2O3))
 Classification of Ceramics

• Oxides: Alumina, zirconia

• Non-oxides: Carbides, borides, nitrides,
silicides
• Composites: Particulate reinforced,
combinations of oxides and non-oxides
 Oxide Ceramics:
• Oxide Ceramics:
Oxidation resistant
chemically inert
electrically insulating
generally low thermal
conductivity
slightly complex
manufacturing
low cost for alumina
more complex manufacturing
higher cost for zirconia.
 Non-Oxide Ceramics:

• Non-Oxide Ceramics:
Low oxidation resistance
extreme hardness
chemically inert
high thermal conductivity
electrically conducting
difficult energy dependent
manufacturing and high cost.
Silicon carbide cermic foam filter (CFS)
 Classification of Materials (Ceramics)
• Ceramics are compounds
of metallic and
non-metallic elements,
examples include;

• Oxides (alumina –
insulation and abrasives,
zirconia – dies for metal
extrusion and abrasives)
• Carbides
(tungsten-carbide tools)
• Nitrides (cubic boron
nitride, 2nd in hardness to
diamond)
 Ceramic-Based Composites:

• Ceramic-Based Composites:
Toughness
low and high oxidation resistance
(type related)
variable thermal and electrical
conductivity
complex manufacturing processes
high cost.
• Ceramic Matrix Composite (CMC)
rotor
 Use of ceramics in engineering and
technology
• Ceramic products are hard, porous, and brittle. As
a result, they are used to make pottery, bricks,
tiles, cements, and glass.

• Ceramics are also used at many places in gas

turbine engines.

• Bio-ceramics are used as dental implants and

synthetic bones. Given below are some other
important uses of ceramic
 POLYMERS
• Polymers are usually long chain organic
macro-molecules with covalent bonds. Each molecule is
formed from a large number of unitary molecules
known as Monomer. For this reason, the polymers can
be bent and stretched easily. In certain polymers some
of the molecules cross link with each other there by
increasing the strength across the molecules.
• Main characteristics
• Ductile / soft
• Translucency
• Low thermal stability
• Lightweight (But high molecular weight)
• Poor conductor of heat and electricity (With exception
of PPV, etc.)
 PoPOLYMERSlymers
• Polymers consist of various hydro-carbon (organic
elements) with select additives to elucidate specific
properties
• Polymers are typically disordered (amorphous) strands
of hydrocarbon molecules.
• Bonding: Covalent-London Dispersion Forces
• Properties:
– ductile: can be stretched up to 1000% of original length
– lightweight: Low densities
– medium strength: Depending on additives
– chemical stability: inert to corrosive environments
– low melting point
 POLYMERS
• Monomer
– The basic building block
of a polymer
– The smallest repeating
unit in a polymer chain
– A polymer has a linear,
branched, or network
structure of chained
monomers
 Classification of Polymers

□ Linear polymer - Any polymer in which

molecules are in the form of spaghetti-like
chains.
□ Thermoplastics - Linear or branched polymers
in which chains of molecules are not
interconnected to one another.
□ Thermosetting polymers - Polymers that are
heavily cross-linked to produce a strong three
dimensional network structure.
□ Elastomers - These are polymers
(thermoplastics or lightly cross-linked
thermosets) that have an elastic deformation >
200%.
 Properties of Polymers
• Physical Properties
• As chain length and cross-linking increases the tensile strength of the polymer increases.
• Polymers do not melt, they change state from crystalline to semi-crystalline.
• Chemical Properties
• Compared to conventional molecules with different side molecules, the polymer is enabled with
hydrogen bonding and ionic bonding resulting in better cross-linking strength.
• Dipole-dipole bonding side chains enable the polymer for high flexibility.
• Polymers with Van der Waals forces linking chains are known to be weak, but give the polymer a low
melting point.
• Optical Properties
• Due to their ability to change their refractive index with temperature as in the case of PMMA and
HEMA: MMA, they are used in lasers for applications in spectroscopy and analytical applications.
• Some Polymers and their Monomers
• Polypropene, also known as polypropylene, is made up of monomer propene.
• Polystyrene is an aromatic polymer, naturally transparent, made up of monomer styrene.
• Polyvinyl chloride (PVC) is a plastic polymer made of monomer vinyl chloride.
• The urea-formaldehyde resin is a non-transparent plastic obtained by heating formaldehyde and urea.
• Glyptal is made up of monomers ethylene glycol and phthalic acid.
• Bakelite or polyoxybenzylmethylenglycolanhydride is a plastic which is made up of monomers phenol
and aldehyde.
 Properties
• Car tires: vulcanized polymer (added sulfur)
• Ziploc bags
• Food storage containers
• Plumbing: polyvinyl chloride (PVC)
• Kevlar
• Aerospace and energy applications: Teflon
• Consumer goods:
– calculator casings
– TV consuls
– shoe soles
– cell phone casings
– Elmer’s Glue (adhesives)
– contact lenses
– Many, many. many more…
 COMPOSITES
Composite materials are engineered materials made
from two or more constituent materials that remain
separate and distinct while forming a single component

-Generally, one material forms a continuous matrix while

the other provides the reinforcement

- The two materials must be chemically inert with

respect to each other so no interaction occurs upon
heating until one of the components melts, an exception
to this condition is a small degree of inter diffusion at the
reinforcement-matrix interface to increase bonding
 Why are composites used in
engineering?
• Weight saving (High strength to Weight ratio)!
• High corrosion resistance!
• High toughness & High Strength at elevated
temp! Better Fatigue Properties!
• Manufacturing advantages!
• low cost tooling!
• Design ,Freedoms.
• continuous property spectrum.
• anisotropic properties
• Easy to, repair
 COMPOSITES
• Composite materials are generally used for
buildings, bridges, and structures such as boat
hulls, swimming pool panels, bathtubs,
storage tanks, imitation granite and cultured
marble sinks and countertops. The most
advanced examples perform routinely on
spacecraft and aircraft in demanding
environments.
 COMPOSITES
• Matrix rule
• The matrix material surrounds and supports the reinforcement materials
by maintaining their relative positions.
• The matrix material largely determines the processing method.

• Reinforcement Rule
• The reinforcements impart their special mechanical and physical
properties to enhance the matrix properties.

• If the composite is designed and fabricated correctly, it combines the

strength of the reinforcement with the toughness of the matrix to achieve
a combination of desirable properties not available in any single
conventional material.
• polymer/ceramic composites have a higher modulus than the polymer
component,
• but are not as brittle as ceramics.
 COMPOSITES
• Considerations for $electing the reinforcements %
Matrix
• There are certain considerations for selecting the
reinforcements and the matrix such as& melting
point, volatility 'instability, density, elastic
modulus, coefficient of thermal expansion,
strength, creep characteristics, fracture toughness
% compatibility between fiber % matrix.
• The last consideration of compatibility is divided
into three categories, namely& chemical
compatibility, #thermal compatibility %
compatibility with the environment
 Reinforcements Types

• Reinforcing phase, is in the form of:

• fibers,
• Whiskers,
• Sheets
• particles
• and is embedded in the other materials #the
matrix phases.
 Metal Matrix Composites ‘(MMCs)

• Fibre: boron* carbon, graphite, $iC, alumina.

• Matrix: aluminium* magnesium* titanium
and copper
• Fibres improve high temperature creep and
thermal expansion.
 Polymer Matrix Composites (PMCs)

• Thermoplastics
Tough; high melt viscosity; and recyclable
• Thermo sets
Brittle; low viscosity before cure; not
recyclable
 CeramicMatrix Composites (CMCs)

• Fibre:
$iC alumina Silicon Nitride
• Matrix:
SiC alumina glass-ceramic Silicon Nitride
Fibres improve toughness
 $trength of Composites
• The strength of the composite depends primarily
on the amount, arrangement and type of fiber for
particles reinforcement in the resin.
• . Typically, the higher the reinforcement content,
the greater the strength.
• In some cases, glass fibers are combined with
other fibers, such as carbon or aramid composite
that combines the properties of more than one
reinforcing material.
 Particle Reinforcement
• Particles used for reinforcing include:
• ceramics (SIC) and glasses particles,
• metal particles such as aluminum,
• polymers and
• carbon.
The Rule of Particles
• Particles are used to Increase the modulus of the
matrix,
• To decrease the ductility of the matrix.
• Particles are also used to produce inexpensive
composites.
 Example of Particle Composite
• ‘ An example of particle reinforced composites
is car tire which has carbon particles in a
matrix of the elastomeric polymer poly- iso
-butylene.
• Another example for particlereinforced
composite is concrete where the aggregates
(sand and gravel ) are the particles and
cement is the matrix. PRCs support higher
tensile, compressive and shear stresses.
 Fiber-reinforced Composites
• Reinforcing fibers can be made of metals,
ceramics, glasses, or polymers graphite or carbon
fibers. Fibers increase the modulus of the matrix
material.
• Practically any material ' polymers, metals, glass
or ceramics can be transformed into a
fibrous form. An important attribute of fine fibers
is their flexibility.
• A high degree of flexibility is really a
charectertsitic of a material having a low modulus
and a small diameter.
 Glass Fiber

• Glasses or amorphous materials show

the phenomena of time dependent-strain,
called visco-elasticity. above the glass
transition temperature, such materials show
normal viscosity, i.e. the stress is proportional
to the strain rate. This property is exploited in
the drawing of fiber and sheet forms.
 Examples of Composite
• Reinforced concrete and masonry
• Composite wood such as plywood
• Reinforced plastics, such as fiber-reinforced
polymer or fiberglass
• Ceramic matrix composites (composite
ceramic and metal matrices)
• Metal matrix composites
• and other Advanced composite materials