King Fahd University of Petroleum & MineralsMechanical Engineering Department

ME 205 – 01&02 : MATERIALS SCIENCE Fall Semester 2006-2007 (061)

Instructor: Mr. Muhammad Younas

Office: 22-206

Phone: 3049

Office Hours: SMW ( 9:00-9:50 AM ) & UT ( 11:00-11:50 AM ) E-mail: myounasa@kfupm.edu.sa

Textbook

Callister, W.D., Materials Science and Engineering

6th Ed., 2003

Lecture ScheduleLecture # Lecture Topic Section#

1 Classification of Materials, Materials of Future 1.4, 1.6

2 The Periodic Table, Bonding Forces and Energies. 2.4,2.5

3 Primary and Secondary Bonds. 2.6, 2.7

4 Crystal Structures, Unit Cells. 3.2,3.3

5 Metallic Crystal Structures, Density Computation. 3.4,3.5

6 Polymorphism, Crystal systems, Point coordinates 3.6,3.7, 3.8

7 Crystallographic Directions, Crystallographic Planes. 3.9, 3.10

8 Linear and Planar Atomic Densities. 3.11

9 Closed Packed Crystal Structures, Single Crystals, Polycrystalline Materials, Anisotropy. 3.12, 3.13, 3.14,3.15

10 Imperfection in Solids, Point Defects, Vacancies and Self-interstitials, Impurities in Solids. Specification of composition

4.2, 4.3, 4.4

11 Dislocations-Linear Defects, Interfacial Defects (external surface & grain boundaries only). 4.5, 4.6

EXAM 1: Sunday October 29, 2006 @ 7:00 – 9:00 PM

12 Diffusion, Introduction, Diffusion Mechanisms. 5.1,5.2

13 Steady-State Diffusion. 5.3

14 Non-Steady State Diffusion. Factors that influence Diffusion. 5.4, 5.5

15 Mechanical Properties of Metals, Elastic Deformation, Concepts of Stress and Strain. 6.2

16 Stress-Strain Behavior, Elastic Properties of Materials. 6.3, 6.5

17 Plastic Deformation, Tensile Properties. 6.6

18 Tensile Properties 6.6

19 True Stress-True Strain, Elastic Recovery During Plastic Deformation. 6.7, 6.8

20 Dislocations and Strengthening Mechanisms, Basic concepts, Characteristics of Dislocations. 7.2, 7.3

21 Slip Systems. 7.4

22 Slip in Single Crystals, Plastic Deformation of Polycrystalline Materials. 7.5, 7.6

Lecture # Lecture Topic Section#23 Strengthening by Grain Size Reduction, Solid Solution Strengthening, Strain

Hardening.7.8, 7.9, 7.10

24 Recovery, Recrystallization and Grain growth. 7.11, 7.12, 7.13

EXAM 2 November 29, 2006 @ 5:30 – 7:30 PM

25 Phase Diagram, Solubility Limit, Phases, Microstructure, Phase Equilibria. 9.1, 9.2, 9.3, 9.4, 9.5

26 Binary Iso-morphous System 9.6,9.7

27 Interpretation of Phase diagram 9.7, 9.8

28 Binary Eutectic Phase Diagrams, Development of Microstructure in Eutectic Alloys

9.10, 9.11

29 Iron-Iron Carbide Phase Diagram, Development of Microstructure in in Iron-Carbon Alloys, The influence of other alloying elements

9.17, 9.18, 9.18

30 Review class

Final Exam

Grading Policy

1) Home works

: 05%

2) Quizzes

: 10%

3) Lab. Work

: 15%

4) Exam # 1

: 15%

5) Exam # 2

: 20%

6) Final Exam

: 35%

Attendance in the class will be strictly observed starting first day of classes. IN CASE OF AN UNEXCUSED ABSENCE, 0.5 POINT WILL BE DEDUCTED FROM FINAL GRADE. A DN grade will be immediately reported for SIX (6) unexcused absences. A DN grade will be immediately reported if both unexcused and excused absences reach TEN (10) absences.

CLASS ATTENDANCE

Materials Science and EngineeringMaterials Science and Engineering

Material ScienceMaterial Science

Involves investigating the relationships that Involves investigating the relationships that exist between the structures and properties exist between the structures and properties of materials.of materials.

Materials EngineeringMaterials Engineering

On the basis of structure-property On the basis of structure-property correlations, involves designing or correlations, involves designing or engineering the structure of a material to engineering the structure of a material to produce a predetermined set of properties.produce a predetermined set of properties.

Materials Science and Engineering (Contd.)Materials Science and Engineering (Contd.)

The The structure of a materialstructure of a material usually relates to the usually relates to the arrangement of its internal components.arrangement of its internal components.

Subatomic structureSubatomic structure involves electrons within the involves electrons within the individual atoms and interactions with their nuclei.individual atoms and interactions with their nuclei.

On an On an atomicatomic level, structure encompasses the level, structure encompasses the organization of atoms or molecules relative to one organization of atoms or molecules relative to one another.another.

Microscopic structureMicroscopic structure contains large groups of atoms contains large groups of atoms that are normally agglomerated together and subject to that are normally agglomerated together and subject to direct observation using some type of microscope.direct observation using some type of microscope.

Macroscopic structureMacroscopic structure meaning structural elements meaning structural elements that may be viewed with naked eye.that may be viewed with naked eye.

Materials Science and Engineering Materials Science and Engineering (Contd.)(Contd.)

Property is a materialProperty is a material trait in terms of the kind and magnitude trait in terms of the kind and magnitude of response to a specified imposed stimulus. It is independent of of response to a specified imposed stimulus. It is independent of shape and size.shape and size.

Six categoriesSix categories of material properties: of material properties:

1.1. Mechanical Mechanical properties relate deformation to an applied load or properties relate deformation to an applied load or force; examples include elastic modulus and strength.force; examples include elastic modulus and strength.

2.2. For For electrical electrical properties, such as electrical conductivity and properties, such as electrical conductivity and dielectric constant, the stimulus is an electric field.dielectric constant, the stimulus is an electric field.

3.3. The The thermalthermal behavior can be represented in terms of heat behavior can be represented in terms of heat capacity and thermal conductivity.capacity and thermal conductivity.

4.4. MagneticMagnetic properties demonstrate the response of a material to properties demonstrate the response of a material to the application of a magnetic field. the application of a magnetic field.

5.5. For For opticaloptical properties, the stimulus is electromagnetic or light properties, the stimulus is electromagnetic or light radiation; index of refraction and reflectivity are representative radiation; index of refraction and reflectivity are representative optical properties. optical properties.

6.6. DeteriorativeDeteriorative characteristics indicate the chemical reactivity of characteristics indicate the chemical reactivity of materials.materials.

Materials Science and Engineering Materials Science and Engineering (Contd.)(Contd.)

Four componentsFour components involved in the science and involved in the science and engineering of materials, and their interrelationship:engineering of materials, and their interrelationship:

ProcessingProcessing ===>===> StructureStructure ===>===> PropertiesProperties ===> ===> PerformancePerformance

CLASSIFICATION OF CLASSIFICATION OF MATERIALSMATERIALS

Major Classes Of MaterialsMajor Classes Of Materials

• 1.   METALS1.   METALS• 2.   CERAMICS2.   CERAMICS• 3.   POLYMERS3.   POLYMERS• 4.   COMPOSITES4.   COMPOSITES• 5.   ELECTRONIC MATERIALS5.   ELECTRONIC MATERIALS• 6. BIO MATERIALS6. BIO MATERIALS

BASIS OF MATERIAL BASIS OF MATERIAL CLASSIFICATIONSCLASSIFICATIONS

Chemical MakeupChemical Makeup Atomic BondingAtomic Bonding Atomic Arrangement Atomic Arrangement Characteristic Physical PropertiesCharacteristic Physical Properties Characteristic Mechanical PropertiesCharacteristic Mechanical Properties

METALSMETALS

Distinguishing FeaturesDistinguishing Features

oo            Atoms arranged in a regular repeating Atoms arranged in a regular repeating manner.manner.

oo      Relatively High Strength.      Relatively High Strength.oo      High Density.      High Density.oo      Ductile.      Ductile.oo      Excellent conductors of Electricity and       Excellent conductors of Electricity and

Heat.Heat.oo      Opaque to visible light.      Opaque to visible light.oo      Shiny appearance.      Shiny appearance.

APPLICATIONS OF METALSAPPLICATIONS OF METALS Electrical wiringElectrical wiring Buildings, Structures, Bridges etc.Buildings, Structures, Bridges etc. Automobiles: body, chassis, engine block, Automobiles: body, chassis, engine block,

springs, etc.springs, etc. Air planes: engines, fuselage (airplane body), Air planes: engines, fuselage (airplane body),

landing gears, etc.landing gears, etc. Trains: rails, engines, body, wheelsTrains: rails, engines, body, wheels MachinesMachines Machine tools: drills, hammers, saw blades, Machine tools: drills, hammers, saw blades,

nuts, bolts, etc.nuts, bolts, etc. Industrial Plant components, structuresIndustrial Plant components, structures MagnetsMagnets

METALLIC MATERIAL METALLIC MATERIAL EXAMPLESEXAMPLES

Pure MetalsPure Metals Cu, Fe, Zn, Al, Ag, Au, Cr, Ni, Sn, etcCu, Fe, Zn, Al, Ag, Au, Cr, Ni, Sn, etc

Alloys Alloys

Steel, Brass, Stainless Steels, etc.Steel, Brass, Stainless Steels, etc.

CERAMICSCERAMICS Distinguishing FeaturesDistinguishing Features

Most have a regular arrangement of Most have a regular arrangement of atoms (except glasses)atoms (except glasses)Compounds of Metallic and Non-Compounds of Metallic and Non-Metallic elementsMetallic elementsDensity lower than MetalsDensity lower than MetalsStronger than MetalsStronger than MetalsLow resistance to FractureLow resistance to FractureBrittle (low ductility)Brittle (low ductility)High Melting PointsHigh Melting PointsPoor Conductors of Electricity and Poor Conductors of Electricity and HeatHeat

APPLICATIONS OF CERAMICSAPPLICATIONS OF CERAMICS

Electrical InsulatorsElectrical Insulators Thermal Insulations and CoatingsThermal Insulations and Coatings AbrasivesAbrasives Glasses (windows, TV screens, Optical Glasses (windows, TV screens, Optical

fibersfibers Cement, ConcreteCement, Concrete Ceramic tiles for space shuttlesCeramic tiles for space shuttles Furnace Lining bricksFurnace Lining bricks

CERAMIC MATERIAL CERAMIC MATERIAL EXAMPLESEXAMPLES

Diamond, GraphiteDiamond, Graphite GlassesGlasses Building MaterialsBuilding Materials Oxides (SiOOxides (SiO22, Al, Al22OO33))

Carbide Tools (WC, TiC)Carbide Tools (WC, TiC)

POLYMERSPOLYMERS

Distinguishing FeatureDistinguishing Feature Composed Primarily of C and H Composed Primarily of C and H

(hydrocarbons)(hydrocarbons) Low Melting PointsLow Melting Points Some partly crystalline, Most are notSome partly crystalline, Most are not Most are poor conductors of Electricity and Most are poor conductors of Electricity and

HeatHeat Many have high plasticityMany have high plasticity Some are transparent, most are opaqueSome are transparent, most are opaque

APPLICATIONS OF POLYMERSAPPLICATIONS OF POLYMERS

Adhesives and GluesAdhesives and Glues Plastic products (plastic pipes, bottles, Plastic products (plastic pipes, bottles,

house hold utensils, etc.)house hold utensils, etc.) Coatings and PaintsCoatings and Paints Solid Lubricants (Teflon)Solid Lubricants (Teflon) Rubber Products (gaskets, seals, and o-Rubber Products (gaskets, seals, and o-

rings)rings) Clothing and furniture coverings (leather, Clothing and furniture coverings (leather,

nylon)nylon)

EXAMPLES OF POLYMER EXAMPLES OF POLYMER MATERIALSMATERIALS

PVC (Poly Vinyl Chlorides)PVC (Poly Vinyl Chlorides) PE (Poly ethylene)PE (Poly ethylene) PC (Poly Carbonates)PC (Poly Carbonates) TeflonTeflon NylonNylon

COMPOSITESCOMPOSITES

Distinguishing FeaturesDistinguishing Features Composed of Two or More Different MaterialsComposed of Two or More Different Materials Strong, Light weight, Good resistance to Strong, Light weight, Good resistance to

fracturefracture High stiffness and good deformabilityHigh stiffness and good deformability Collection of good Properties of each Collection of good Properties of each

material usedmaterial used

APPLICATIONS OF COMPOSITE APPLICATIONS OF COMPOSITE MATERIALSMATERIALS

Aerospace, Marine, AutomotiveAerospace, Marine, Automotive Sporting GoodsSporting Goods Storage Tanks (water, fuel, chemicals)Storage Tanks (water, fuel, chemicals) Transport Piping (oil, seawater, Transport Piping (oil, seawater,

sewage)sewage)

EXAMPLES OF COMPOSITE EXAMPLES OF COMPOSITE MATERIALSMATERIALS

PMCs (polymer matrix composites)PMCs (polymer matrix composites)

Fiber Glass, Concrete)Fiber Glass, Concrete) MMCs (Metal Matrix Composites)MMCs (Metal Matrix Composites) CMCs (Ceramic Matrix Composites)CMCs (Ceramic Matrix Composites)

The bridge in the picture is built entirely from composite material. Weighs one-tenth of the conventional concrete bridge. It took only 18 hours to assemble the bridge.

MATERIALS OF FUTUREMATERIALS OF FUTURE

SMART MATERIALSSMART MATERIALS Shape Memory AlloysShape Memory Alloys Piezoelectric ceramicsPiezoelectric ceramics MEMS MEMS (Micro-Electrical Mechanical Systems)(Micro-Electrical Mechanical Systems)

NANOTECHNOLOGYNANOTECHNOLOGY

Materials by designMaterials by design

Carbon Nanotubes Carbon Nanotubes (500 atom diameters)(500 atom diameters)