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Electrical Engineering Materials (Em) 1

This document provides an introduction to engineering materials. It discusses that engineering materials are raw materials used for construction and manufacturing. It then classifies materials into metals, non-metals, and composites. Within metals, it distinguishes between ferrous and non-ferrous materials. The document also discusses factors that influence material properties such as heat treatment, processing, and environmental reactions. Material selection considers properties, cost, processing requirements, and environmental impacts.

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57 views26 pages

Electrical Engineering Materials (Em) 1

This document provides an introduction to engineering materials. It discusses that engineering materials are raw materials used for construction and manufacturing. It then classifies materials into metals, non-metals, and composites. Within metals, it distinguishes between ferrous and non-ferrous materials. The document also discusses factors that influence material properties such as heat treatment, processing, and environmental reactions. Material selection considers properties, cost, processing requirements, and environmental impacts.

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Hezron gibron
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Electrical Engineering Materials

EE 8212

Course Tutor: Mr. Mlay J. J


Assistant Lecturer
(MSc: Power Engineering and Engineering Thermophysics)
joshmlay@gmail.com

Department of Electrical and Power Engineering (EPE)


College of Engineering and Technology (CET)
Mbeya University of Science and Technology (MUST)
Mbeya-Tanzania,
2021/2022
INTRODUCTION TO ENGINEERING MATERIALS
(EM)
• Engineering materials are materials that are used as raw
material for any sort of construction or manufacturing
in an organized way of engineering application.

 Material Engineering:
Mainly concerned with the use of fundamental and applied
knowledge of materials, so that they may be converted into
products, as needed or desired by the society

• bridges materials knowledge from basic sciences to


engineering disciplines
INTRODUCTION TO (EM) CONT.
 Nowadays we use many types of materials, fashioned in
many different ways, To satisfy our requirements for
• housing,
• heating,
• furniture,
• clothes,
• transportation,
• entertainment,
• medical care,
• defense and all the other
trappings/accessories/trimmings of a modern, civilised
society.
INTRODUCTION TO (EM) CONT.

 Most materials doesn't exist in its pure shape , it is


always exist as ores (a naturally occurring solid material from which a
metal or valuable mineral can be extracted).

 Understanding of the materials resources and nature


enables engineers
• to select the most appropriate materials
• to use them with greatest efficiency in minimum
quantities
• to reduce pollution in their extraction, refinement
and manufacture.
INTRODUCTION TO (EM) CONT.
 Material Selection
When we talk about choosing materials for a
component, we take into account many different
factors. These factors are
i. Material Properties
The expected level of performance from the material

ii. Material Cost and Availability


Material must be priced appropriately (not cheap
but right) Material must be available (better to have
multiple sources)
Material Selection Cont.
iii. Processing
Must consider how to make the part, for example:
Casting ,Machining and Welding.

iv. Environment
 The effect that the service environment has on
the part .
 The effect the part has on the environment
 The effect that processing has on the
environment
Classifications of EM

The most convenient way to classify (EM) as shown


in figure below:
Classifications of EM
1.0: Metals

1 .1 Ferrous metals
• These are metals and alloys containing a high
proportion of the element iron.

• They are the strongest materials available


• Used for applications where high strength is
required at relatively low cost and where
weight is not of primary importance.
Ferrous metals
An example of ferrous metals including:
• bridge building,
• the structure of large buildings,
• railway lines,
• locomotives and rolling stock and the
bodies
• highly stressed engine parts of road
vehicles.
Classification of Ferrous Metals.
1.2 Non – ferrous metals
• These materials refer to the remaining metals known to
mankind.
• The pure metals are rarely used as structural materials
as they lack mechanical strength.
• They are used where their special properties such as
corrosion resistance, electrical conductivity and thermal
conductivity are required.
• Copper and aluminum are used as electrical conductors
and, together with sheet zinc and sheet lead, are use as
roofing materials.
• They are mainly used with other metals to improve their
strength.
Classification of Non-ferrous Metals and Alloys.
2.0: Non – metallic materials
2.1: Synthetic materials
• These are non – metallic materials that do not
exist in nature, although they are manufactured
from natural substances such as oil, coal and clay.
• They combine good corrosion resistance with
ease of manufacture by molding to shape and
relatively low cost.
• Synthetic adhesives are also being used for the
joining of metallic components even in highly
stressed applications.
Classification of Synthetic Materials.
2.2: Natural Materials

 Such materials are so diverse that only a few can be


listed here to give a basic introduction to some typical
applications.

• Wood: This is naturally occurring fibrous composite


material used for the manufacture of casting patterns.

• Rubber :This is used for hydraulic and compressed air


hoses and oil seals. Naturally occurring latex is too soft
for most engineering uses but it is used widely for
vehicle tires when it is compounded with carbon black.
• Glass :This is a hardwearing, abrasion-resistant material
with excellent weathering properties. It is used for
electrical insulators, laboratory equipment, optical
components in measuring instruments eta and, in the
form of fibers, is used to reinforce plastics.

• It is made by melting together the naturally occurring


materials: silica (sand), limestone (calcium carbonate )
and soda (sodium carbonate).

• Emery : This is a widely used abrasive and is a naturally


occurring aluminum oxide. Nowadays it is produced
synthetically to maintain uniform quality and
performance.
• Ceramic: These are produced by baking naturally occurring
clays at high temperatures after molding to shape. They are
used for high – voltage insulators and high – temperature –
resistant cutting tool tips.

• Diamonds: These can be used for cutting tools for operation


at high speeds for metal finishing where surface finish is
greater importance. For example, internal combustion
engine pistons and bearings. They are also used for dressing
grinding wheels.

• Oils : Used as bearing lubricants, cutting fluids and fuels.

• Silicon : This is used as an alloying element and also for the


manufacture of semiconductor devices.
Classification of Natural Materials.
Composite materials (composites
• These are materials made up from, or composed of, a
combination of different materials to take overall
advantage of their different properties.

examples are:
• The reinforcement of air-dried bricks by mixing the clay
with straw.
• Horse hair was used to reinforce the plaster used on
the walls and ceiling of buildings.
• Carbon fiber reinforced frames for tennis rackets and
shafts for golf clubs have revolutionized these sports
 The above reinforcement helped to reduce cracking.
Properties of Engineering Materials
 Important factors which can influence the properties
and performance of engineering materials
 Heat treatment
This is the controlled heating and cooling of metals to
change their properties to improve their performance or
to facilitate processing.
After the heat treatment happened on the material it will
be in its best condition for flow forming, during flow
forming (working) the grains will be distorted and this will
result in most metals becoming work hardened if flow
formed at room temperature.
• An example of heat treatment is the hardening of a piece of high
carbon steel rod.
Properties of Engineering Materials Cont.
 Processing
Hot and cold working process will be referred to understand
what is meant by the terms hot and cold working as applied
to metals.

Examples of (a) hot-working and (b) cold-working process.


Processing(cont.)
• Metal is hot worked or cold worked depending upon the
temperature at which it is flow formed to shape . These
temperatures are not easy to define.

 for instance , lead hot works at room temperature and can


be beaten into complex shapes without cracking , but steel
does not hot work until it is red hot.

 When metal are examined under the microscope it can be


seen that they consist of very small grains.

 When most metals are bent or worked at room temperature


(cold worked) these grains become distorted and the metal
becomes hard and brittle then most metals are bent or
worked.
Processing(cont.)
• When metals are hot worked the crystals are also
distorted.

• However, they reform instantly into normal crystals


because the process temperature is above the
temperature of recrystallization for the metal being
used and work hardening does not occur.

• Cold working is the flow forming of metals below the


temperature of the recrystallization,
• Whilst hot working is the flow forming of metals above
the temperature of recrystallization.
Environmental reactions

The properties of materials can also be effected by reaction with


environment in which they are used.

Examples:
• Rusting of steel
Unless steel structures are regularly maintained by rust
neutralization and painting process, rusting will occur.

The rust will eat into the steel, reduce its thickness and,
therefore, its strength.
In extreme cases an entire structure made from steel may be
eaten away.
Environmental reactions(Cont.)

• Dezincification of brass
Brass is an alloy of copper and zinc

When brass is exposed to a marine environment for


along time, the salt in the sea water pray react with the
zinc content of the brass and remove it, leaving it behind
on spongy, porous mass of copper.

This obviously weakness the material which fails under


normal working conditions.
ENVironmental reactions(Cont.)

• Degradation of plastic

 Many plastic degrade and become weak and brittle


when exposed to the ultraviolet content of sunlight.

 Special dye-stuffs have to be incorporated into the


plastic to filter out these harmful rays.

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