INTRODUCTION

industrial Materials
Lecture 1
 MATERIAL
• A physical substance from which things can be made e.g. building
materials, such as stone
• Crude oil is used as the raw (basic) material for making plastics

• In the industrial sense, materials are inputs

to manufacturing processes
• They are often raw – that is, unprocessed –but are sometimes
processed before being used in more advanced manufacturing
processes
 Classification of materials
Engineering materials can be classified into four basic
categories:

1. Metals
2. Ceramics
3. Polymers
4. Composites

Their chemistries are different, their mechanical and physical

properties are dissimilar.
 1.Metals
A metal (from Greek métallon) is a material that is typically hard,
opaque (not transparent), shiny, and has
good electrical and thermal conductivity.

Metals are generally 

• Malleable: able to be be hammered or pressed permanently
out of shape without breaking or cracking
• Fusible: able to be fused or melted at high temperature
• Ductile: able to be drawn out into a thin wire
 1.Metals
The use of metals in manufacturing are usually in alloys ,which
are composed of two or more elements, with at least one being
metallic element. Metals can be divided into two basic
categories:
(a) Ferrous
(b) Non-ferrous
 1.Metals (Ferrous Metals)
• Ferrous is used to indicate the presence of iron.

• Ferrous metals include steel and pig iron (with a carbon content of a

few percent) and alloys of iron with other metals (such as stainless
steel).

• Pure Iron has limited commercial use, but when alloyed with carbon,
iron has more uses and greater commercial value than any other metal.

• Stainless steel is an alloy of Iron with a minimum of 10.5% Chromium

and 1.2% Carbon by mass. Increasing the amount of Chromium gives
an increased resistance to corrosion.
 1.Metals (Ferrous Metals)
Pig iron
Pig iron has carbon content, typically 3.5–4.5%, along with silica
(SiO2) and other constituents, which makes it very brittle and
not useful directly as a material except for limited applications.

The main use of smelting is to produce a base metal from

its ore. This includes production of silver, iron, copper and other
metals from their ores.

An ore is a type of rock that contains sufficient minerals with

important elements including metals that can be economically
extracted from the rock.
 Pig iron

A type of pig iron used to make ductile iron, stored in a bin

Iron ore
 1.Metals (Non-ferrous Metals)
• The term non-ferrous is used to indicate metals other than
iron and alloys that do not contain an appreciable amount
of iron.

Non ferrous metals are:

• generally more expensive than ferrous metals
• are used because of desirable properties such as low
weight (e.g. aluminum)
• have higher conductivity (e.g. copper)
• have non-magnetic property 
• has resistance to corrosion (e.g. zinc)
 1.Metals (Non-ferrous Metals)
Aluminum Alloy: An alloy of aluminium, copper and manganese.
Very lightweight and easily worked. Used in aircraft manufacture,
window frames and some kitchen ware.

Copper: is a natural occurring substance. The fact that it conducts

heat and electricity means that it is used for wiring, tubing and pipe
work.

Brass: A combination of copper and zinc, usually in the proportions

of 65% to 35%, respectively. Is used for ornamental purposes and
within electrical fittings.

Lead: Lead is a naturally occurring substance. It is heavy and very

soft and is often used in roofing, batteries and to make pipes.
 2.Ceramics
A ceramic is an inorganic solid material comprising metal, non-
metal or metalloid atoms primarily held in ionic and covalent
bonds.
General properties are
• high melting temperature,
• high hardness,
• poor conductivity,
• high modulus of elasticity,
• chemical resistance low ductility

Many composites, such as fiberglass and carbon fiber, while

containing ceramic materials, are not considered to be part of the
ceramic family.
 2.Ceramics
Ceramics generally can withstand (bear up) very high
temperatures, such as temperatures that range from
1,000 °C to 1,600 °C (1,800 °F to 3,000 °F).

Cutting disks made of silicon carbide

 2.Ceramics
Porcelain is used for a wide range of household and
industrial products.

Porcelain high-voltage insulator

 2.Ceramics
Boron Oxide is used in body armor.
Earthenware used for domestic ware such as plates
and mugs.
Uranium oxide (UO2), used as fuel in nuclear
reactors.
Titanium carbide, used in space shuttle and
scratchproof watches.
 3.Polymer
A polymer (Greek poly "many”, mer, "parts") is a large molecule,
or macromolecule, composed of many repeated subunits.

Polymers range from familiar synthetic plastics such as polystyrene

(C8H8)n to natural biopolymers such as DNA and proteins that are
fundamental to biological structure and function.

Polymers, both natural and synthetic, are created

via polymerization of many small molecules, known as monomers.
 3.Polymer
The process by which monomers combine end to
end to form a polymer is called polymerization.

Ethylene gas (H2C=CH2) is the precursor monomer

for polyethylene.
 3.Polymer
Thermoplastic Polymers

A thermoplastic is a plastic material (polymer) that

becomes pliable (bendable, malleable) or moldable
above a specific temperature and solidifies upon cooling.

Examples:
• Polystyrene is manufactured in various forms that have
different applications.
• Polyvinyl chloride (PVC) is a tough, lightweight material
that is resistant to acids and bases. Much of it is used by
the construction industry, drainpipes, etc.
 3.Polymer
Elastomers
An elastomer is a polymer with very weak inter-
molecular forces, generally having low Young's modulus.

Each of the monomers which link to form the polymer is

usually made of carbon, hydrogen, oxygen or silicon.

At ambient temperatures, rubbers are thus relatively soft and

deformable.

Application areas for different types of rubber are tires, seals,

shoe soles as well as dampening and insulating elements.
 3.Polymer
Thermosetting Plastic

These are plastics that can be softened on heating but

become permanently hard on cooling.

Examples:
• Bakelite is used in electrical insulators and plasticware.
• Duroplast is light but strong material, similar to Bakelite
used for making car parts.
• Polyimides used in printed circuit boards (PCBs) and in
body parts of modern aircraft.
 4.Composites
Composite materials are:
• multiphase materials obtained by artificial combination of
different materials to attain properties that individual
component cannot attain
• made by combining two or more materials – often ones
that have very different properties.

 The two materials work together to give the composite

unique properties.
 However, within the composite you can easily tell the
different materials apart as they do not dissolve or blend
into each other.
 4.Composites
Natural composites:
• Natural composites exist in both animals and plants.
• Wood is a composite – it is made from long cellulose
fibers (a polymer) held together by a much weaker
substance called lignin. The two weak substances – lignin
and cellulose – together form a much stronger one.
• The bone in our body is also a composite. It is made from
a hard but brittle material called hydroxyapatite (which is
mainly calcium phosphate) and a soft and flexible
material called collagen (which is a protein). Collagen is
also found in hair and finger nails. These two can give the
properties to bone that are needed to support the body.
 4.Composites
Early composites:

• People have been making composites for many thousands

of years. One early example is mud bricks. Mud can be
dried out into a brick shape to give a building material.
• Another ancient composite is concrete. Concrete is a mix
of cement and sand.
• In more recent times it has been found that adding metal
rods or wires to the concrete can increase its
tensile/bending strength. Concrete containing such rods
or wires is called reinforced concrete.
 4.Composites
Making composites:
Most composites are made of just two materials. One
is the binder. It surrounds and binds together fibres of
the other material, which is called the reinforcement.

Modern examples:
The first modern composite material was fiberglass. It
is still widely used today for boat hulls, sports
equipment, building panels and many car bodies. The
matrix is a plastic and the reinforcement is glass that
has been made into fine threads.
 4.Composites
Some advanced composites are now made using carbon
fibres instead of glass. These materials are lighter and
stronger than fibreglass but more expensive to produce.
They are used in aircraft structures and expensive sports
equipment such as golf clubs.

The new Airbus A380, the world’s largest passenger

airliner, makes use of modern composites in its design.
More than 20 % of the A380 is made of composite
materials, mainly plastic reinforced with carbon fibres.
 4.Composites
Why use composites?
• The biggest advantage of modern composite
materials is that they are light as well as strong.
• By choosing an appropriate combination of bind and
reinforcement material, a new material can be made
that exactly meets the requirements of a particular
application.
• Composites also provide design flexibility because
many of them can be moulded into complex shapes.
• The downside is often the cost. Although the
resulting product is more efficient, the raw materials
are often expensive.
Difference b/w Alloy and Composite
In an alloy, the constituent elements do not retain
their original properties after mixing whereas in
a composite, the materials forming the
composite retain their original properties thus
making the composite material suitable for a wider
variety of applications.
Alloy is a homogenous or a heterogeneous mixture
whereas composites are heterogeneous.
There is at least one metal in alloy, but it is not
necessary to have metals in composites.
What is an Alloy?
Alloy is a mixture of two or more elements where at
least one of them is metal.
If only two components are mixed to produce an
alloy, it is known as a binary alloy.
If there are three components, it is known as ternary
alloy.
The amount of element in the alloy is normally
measured and given by mass (as percentages).
What is an Alloy?
 What is an Alloy?
Steel is an example of alloy. It is made out of iron and carbon.
Steel is stronger than iron. The carbon percentage can vary
depending on the grade, and mostly it is between 0.2% and
2.1% by weight. Though carbon is the main alloying material
for iron, some other elements like Tungsten, chromium,
manganese can also be used for the purpose. Different types
and amounts of alloying elements used determine the
hardness, ductility and tensile strength of steel. Alloying
element is responsible for maintaining the crystal lattice
structure of steel by preventing dislocation of iron atoms.
Thus, it acts as the hardening agent in steel. The density of
steel varies between 7,750 and 8,050 kg/m3 and, this is
affected by the alloying constituents too.
 What is an Alloy?
Brass is another alloy which is made out of copper
and zinc, but more durable than copper and
attractive than zinc.
When producing jewelry from gold, silver, and
platinum, they are mixed with other elements, to
make them more ductile and flexible.
 What is a Composite?
Composite is a material made out of two or more
constituent materials which are chemically and
physically different. Constituent materials are the
individual materials which makes the composite.
There are two categories of them as matrix and
reinforcement. Usually matrix material supports the
reinforcement material. The constituent materials
stay separately within the finished structure because
they are chemically and physically different, to mix
with each other.