Lecture 2

An Overview of Engineering Materials

16 August 2022

Dr Shantanu V. Madge
Attendance

• Refer to section 4.9 of the UG rules and regulations

(https://iitjammu.ac.in/academics-rules-and-regulations)
• At least 75% attendance is expected.

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 Definition of Materials

• Substances of which something is made.

• The definition is very broad indeed – covers subjects from Astronomy to
Zoology!
• Even if we restrict the term to materials that make "useful products”, that
would include materials like acids or textiles – clearly not in the purview of
“Materials Engineering”.
• Materials Engineering usually deals with solid materials used by
engineers to create products.
• Hence, it draws upon concepts from solid state physics and solid
state chemistry.

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Classification of Materials
Metallic Materials/Alloys
• Inorganic substances largely made of metals and at times may contain nonmetallic elements.
• High thermal and electrical conductivity.
• Malleable or ductile.
• Relatively strong.
Ceramics & Glasses
• Inorganic compounds made of metallic and nonmetallic elements.
• Strong but brittle.
• Heat-resistant.
• Relatively low electrical/thermal conductivity.
Polymers
• Organic compounds based on C, H and O, N, or Si.
• Large molecular structures, often chainlike having a “backbone” of C atoms.
• Low density – high strength-to-weight ratio
• Very pliable – easy formability, weak at higher temperatures!
• Chemically inert.
Composites
Mixture of the above classes to obtain desired properties, e.g. Co-WC metal matrix composites.
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Examples of these classes

Metals & Alloys: Al, steel, Mg, Cu, Ni, iron…

Ceramics & Glasses: Alumina, SiO2, SiC, Si3N4, porcelain,

glass…

Polymeric Materials: Nylon, polyethylene, poly-vinyl chloride,

polycarbonate etc..

Callister & Rethwisch, Mater. Sci. Engg.

(2013)

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Historical Perspective

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M. F. Ashby, Materials Selection in Mechanical Design, Butterworth-Heinemann, (2011)
Development in Materials
Driven by the need for ever-greater performance

M. F. Ashby, Materials Selection in Mechanical Design, Butterworth-Heinemann, 7(2011)

Materials Engineering Today
Composition/
Chemical
Makeup

Performance/
Processing Structure Properties
Applications

Sustainability

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Modern Processing
Casting Forging

https://www.thomasnet.com/articles/custom-manufacturing-fabricating/types-of-casting-processes/
https://www.scotforge.com/Customized-Services/Forging-For-Cost-Reduction
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 Cold/Hot-
rolling

Welding

https://www.indiamart.com/proddetail/cold-rolling-machine-17178415497.html

https://newsroom.posco.com/en/ask-expert-makings-posco-master-korea/

https://www.metalsupermarkets.com/what-type-of-welding-is-used-for-aluminum/
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Additive Manufacturing

https://www.eos.info/en/industrial-3d-printing/advantages/complex-geometries

https://www.businesstoday.in/current/corporate/additive-manufacturing-am-revolution-technology-3d-printers-sustainability-production-process/story/346048.html
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What is Structure of Materials?

Macrostructure: Visible with the naked eye.

Microstructure: Visible with optical/electron microscopy.

Crystal Structure: The internal atomic arrangement.

Atomic Structure: Constitution of individual atoms - the nucleus and arrangement

of electrons.

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 External shapes of crystals
Macrostructure
Steel with large grains

Metals 2018, 8, 884

https://www.yogajournal.com/lifestyle/what-kind-of-crystal-do-you-need

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Microstructure Grains or crystals in a Ti alloy,
observed using a microscope.

50 µm

https://www.azom.com/article.aspx?ArticleID=13545
NATURE COMMUNICATIONS | (2018)9:3426 | DOI: 10.1038/s41467-018-05819-9 |
www.nature.com/naturecommunications
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Crystal Structure Often probed using X-ray diffraction
(XRD) and Transmission Electron
Microscopy (TEM)

https://en.wikipedia.org/wiki/Crystal_structure
https://www.binghamton.edu/adl/equipment/electron_microscopy/tem.html

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An illustration of structure & properties
• Two forms of carbon: Diamond Graphite
Diamond and Graphite.
• Remarkably different
properties, all thanks to a
slight tweak in the crystal
structure.
• And vastly different cost
and “prestige” – who
would buy a graphite
necklace!!

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https://www.scienceabc.com/pure-sciences/graphite-soft-diamond-structure-properties-hard-carbon-allotrope-tetrahedral-layers.html
Properties of Materials

Mechanical Properties
• Strength
• Hardness
• Toughness
• Fatigue resistance https://www.pesmedia.com/dormer-pramet-high-speed-steel-cutting-tools/ https://en.wikipedia.org/wiki/Crankshaft
• Creep resistance.

Functional Properties
• Electrical
• Thermal
• Magnetic
• Optical
http://copper-wire-manufacturer.blogspot.com/2012/05/qualities-
that-make-copper-wire-ideal.html
https://appliedmagnets.com/alnico-2-inch-horseshoe-
Chemical Properties magnet-with-keeper-p-488.html

• Corrosion
• Oxidation resistance.
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 Application-based classification
Materials can also be classified based
on their end use. Metals Ceramics Polymers

Most applications do in fact use a

variety of material classes.

Examples: Engineering Materials

Cars, Aeroplanes: Metals, ceramics

& polymers.

Electric Kettle: Metals and Structures Machines Devices

polymers.
Bridges, towers, Aeroplanes, Transistors,
Computers: Plastics, Metals, Si, melting furnaces turbines.. batteries,
Materials for data storage. pressure gauges
etc.
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Examples of contemporary challenges in Materials Engineering

• Space applications are perhaps THE most demanding in terms

of materials properties!
• Newer materials for additive manufacturing is also an area of
immense interest.

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The Titanic Incident

• Normally ductile metals can

become like glass – breaking
into pieces below a certain
temperature!
• The Titanic ship is a prime
example.
• So, space would be much
worse (cryogenic
temperatures). How do we
tackle those applications?
• Herein comes the development
and use of especially robust
materials.

https://en.wikipedia.org/wiki/Sinking_of_the_Titanic

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Materials for cryogenic temperatures

• The Mars Exploration

Rover(MER).
• Materials must survive at less
than −100oC.
• As you can imagine with say
rubber, it tends to get brittle
at low T (breaks easily).
• What happens to metals &
alloys at low temperatures..?
• Certain special materials are
being investigated/used.

https://en.wikipedia.org/wiki/Mars_Exploration_Rover

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 Metallic glass gears being deployed by NASA

https://www.nasa.gov/directorates/spacetech/game_changing_development/projects/BMGG 22
Challenges in Metal 3D Printing

• 3D printing: Layer-by-
layer solidification.
• Many advantages.
• Alas, not all metals are
suitable, e.g. cracking
etc.
• The challenge is how to 3D printed parts are flown
make high-strength, on aircraft including the
lightweight materials A350 XWB
more suitable for 3D
printing?

https://www.theengineer.co.uk/metal-printing-processes-aircraft-parts

https://www.machinedesign.com/3d-printing-cad/media-gallery/21835191/metal-3d-printing-to-shape-the- 23
aerospace-industry
The last pillar of Materials Engineering - Sustainability

• Environmental impact of
materials engineering
• Processes involved in
producing metals. Are
they polluting?
• Are the materials/product
toxic?
• Availability of resources -- are
the raw materials scarce?
• These issues also affect the
final application of materials
to engineering problems.

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www.google.com
How a “bad” combination of materials is a recipe for disaster!
Summary

In this class, we considered the following:

• Definition & classes of materials.

• Brief history of materials.
• The five pillars of Materials Engineering with relevant examples:
• Processing
• Structure
• Properties
• Performance (Applications)
• Sustainability.
• Examples of advanced materials and current challenges.

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