FUNDAMENTALS OF

Materials Science and Engineering

AN INTEGRATED APPROACH Fourth Edition

William D. Callister, Jr. and David G. Rethwisch

Chapter 1

Introduction

Copyright © 2012 by John Wiley & Sons, Inc. All rights reserved.

Chapter 1 -

CHEN313: Introduction to Materials Science & Engineering

Course Objective...

Introduce fundamental concepts in Materials Science & Engineering

You will learn about:

• material structures • how structure dictates properties • how processing can change structure

This course will help you to:

• use materials properly • realize new design opportunities with materials Chapter 1 2

COURSE MATERIALS (with text)

Textbook:

•

Fundamentals of Materials Science and Engineering,

W.D. Callister, Jr. and D.G. Rethwisch, 4th edition, John Wiley and Sons, Inc. (2012). Chapter 1 3

Chapter 1 -

Chapter 1 -

COURSE MATERIALS (with WileyPLUS)

Textbook:

• WileyPLUS for

Fundamentals of Materials Science and Engineering,

W.D. Callister, Jr. and D.G. Rethwisch, 4th edition, John Wiley and Sons, Inc. (2012).

Website:

http://www.wileyplus.com/xxxxxxxxxxx • Can be bought online at wileyplus.com for 40% of textbook price • Includes complete online version of textbook • Or comes bundled with textbook at bookstore • $5 more than textbook alone • Homework assignments with instant feedback and hints • Computer graded self-help problems • Hotlinks in homework to supporting text sections • Quizzes Chapter 1 6

WEBSITES

Course Website:

See Syllabus in the web page

Text Website:

http://www.wiley.com/college/callister • VMSE for 3D interactive simulations and animations of material structures, characteristics, and properties • Mechanical Engineering online support module • Case studies of materials usage • Extended learning objectives • Self-assessment exercises Chapter 1 7

Virtual Materials Science & Engineering (VMSE)

Website: http://www.wileyplus.com/college/callister

Student Companion Site  VMSE • Comprised of 8 interactive modules • Atomic/molecular stuctures - 3D perspectives (better visualizations) using click-and-drag rotations • Demonstrations of defects and phenomena that exist/occur in materials • Demonstrations of material tests - performance and results • Database of material property values and costs Chapter 1 8

Virtual Materials Science & Engineering (VMSE)

• This is a screenshot of the VMSE opening window • Available in Student Companion Site at www.wiley.com/college/callister and in WileyPLUS Chapter 1 9

Chapter 1 - Introduction

• What is

materials science

?

– Structure-properties – Applications • Why should we know about it?

–

All fields make use of materials

• Materials drive our society

– Stone Age – Bronze Age – Iron Age – Now?

• Silicon Age?

• Polymer Age?

• Nano age Chapter 1 - 10

Example – Hip Implant

• With age or certain illnesses joints deteriorate. Particularly those with large loads (such as hip).

Adapted from Fig. 22.25,

Callister 7e.

Chapter 1 - 11

Example – Hip Implant

• Requirements – mechanical strength (many cycles) – good lubricity – biocompatibility

Adapted from Fig. 22.24,

Callister 7e.

Chapter 1 - 12

Example – Hip Implant

Adapted from Fig. 22.26,

Callister 7e.

Chapter 1 - 13

Hip Implant

• Key problems to overcome – fixation agent to hold acetabular cup – cup lubrication material – femoral stem – fixing agent – must avoid any debris in cup Ball Acetabular Cup and Liner Femoral Stem Adapted from chapter-opening photograph, Chapter 22,

Callister 7e.

Chapter 1 - 14

Example – Develop New Types of Polymers

• Commodity plastics Ex.

– large volume ca. $0.50 / lb Polyethylene Polypropylene Polystyrene etc.

• Engineering Resins Ex.

Nylon etc.

– small volume > $1.00 / lb Polycarbonate Polysulfone Can polypropylene be “ upgraded ” those of engineering resins?

to properties (and price) near Chapter 1 - 15

Structure, Processing, & Properties

• Properties depend on structure ex: hardness vs structure of steel (d) 600 30 m m 500 (c) 400 300 200 (a) 30 m m (b) 30 m m 4 m m 100 0.01 0.1

1 10 100 1000 Cooling Rate ( ºC/s) • Processing can change structure ex: structure vs cooling rate of steel Data obtained from Figs. 11.31(a) and 11.33 with 4 wt% C composition, and from Fig. 14.8 and associated discussion,

Callister & Rethwisch 4e

.

Micrographs adapted from (a) Fig.

11.19; (b) Fig. 10.34;(c) Fig. 11.34; and (d) Fig. 11.22,

Callister & Rethwisch 4e

.

Chapter 1 - 16

Types of Materials

• Metals : – Strong, ductile – High thermal & electrical conductivity – Opaque, reflective.

• Polymers/plastics : Covalent bonding  – Soft, ductile, low strength, low density – Thermal & electrical insulators – Optically translucent or transparent.

sharing of e ’ s • Ceramics : ionic bonding (refractory) – compounds of metallic & non-metallic elements (oxides, carbides, nitrides, sulfides) – Brittle, glassy, elastic – Non-conducting (insulators) Chapter 1 - 17

The Materials Selection Process

1.

Pick Application Determine required Properties Properties: mechanical, electrical, thermal, magnetic, optical, deteriorative.

2.

Properties Identify candidate Material: structure, composition.

Material(s)

3.

Material Identify required Processing Processing: changes

structure

and overall

shape

ex: casting, sintering, vapor deposition, doping forming, joining, annealing.

Chapter 1 - 18

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ELECTRICAL

• Electrical Resistivity of Copper: 6 5 4 Adapted from Fig. 12.8,

Callister & Rethwisch 4e.

(Fig. 12.8 adapted from: J.O. Linde, Ann Physik 5 , 219 (1932); and C.A. Wert and R.M. Thomson,

Physics of Solids

, 2nd edition, McGraw-Hill Company, New York, 1970.) 3 2 1 0 -200 -100 0

T

( ° C) • Adding “ impurity ” • Deforming atoms to Cu increases Cu increases resistivity .

resistivity .

Chapter 1 - 27

• Space Shuttle Tiles: -- Silica fiber insulation

THERMAL

• Thermal Conductivity of Copper: offers low heat conduction .

-- It decreases when you add zinc!

Adapted from chapter opening photograph, Chapter 17,

Callister & Rethwisch 3e.

(Courtesy of Lockheed Missiles and Space Company, Inc.) 400 300 200 100 m m 100 Adapted from Fig. 19.4W,

Callister 6e.

(Courtesy of Lockheed Aerospace Ceramics Systems, Sunnyvale, CA) (Note: "W" denotes fig. is on CD-ROM.) 0 0 10 20 30 40 Composition (wt% Zinc) Adapted from Fig. 17.4,

Callister & Rethwisch 4e.

(Fig. 17.4 is adapted from

Metals Handbook: Properties and Selection: Nonferrous alloys and Pure Metals

, Vol. 2, 9th ed., H. Baker, (Managing Editor), American Society for Metals, 1979, p. 315.) Chapter 1 - 28

MAGNETIC

• Magnetic Storage : -- Recording medium is magnetized by recording head.

•

Magnetic Permeability vs. Composition: -- Adding 3 atomic % Si makes Fe a better recording medium!

Fe+3%Si Fe Fig. 18.23,

Callister & Rethwisch 4e.

Magnetic Field Adapted from C.R. Barrett, W.D. Nix, and A.S. Tetelman,

The Principles of Engineering Materials

, Fig. 1-7(a), p. 9, 1973. Electronically reproduced by permission of Pearson Education, Inc., Upper Saddle River, New Jersey.

Chapter 1 - 29

OPTICAL

• Transmittance : -- Aluminum oxide may be transparent, translucent, or opaque depending on the material ’s structure (i.e., single crystal vs. polycrystal, and degree of porosity).

single crystal polycrystal: no porosity polycrystal: some porosity Adapted from Fig. 1.2,

Callister & Rethwisch 4e.

(Specimen preparation, P.A. Lessing; photo by S. Tanner.) Chapter 1 - 30

Chapter 1 -

DETERIORATIVE

• Stress & Saltwater...

-- causes cracks! • Heat treatment: slows crack speed in salt water! Adapted from Fig. 16.21,

Callister & Rethwisch 4e.

(from

Marine Corrosion, Causes, and Prevention

, John Wiley and Sons, Inc., 1975.) 10 -8 10 -10 “ as-is ” “ held at 160 ºC for 1 hr before testing ” Alloy 7178 tested in saturated aqueous NaCl solution at 23 ºC increasing load Adapted from Fig. 11.20(b), R.W. Hertzberg, "Deformation and Fracture Mechanics of Engineering Materials" (4th ed.), p. 505, John Wiley and Sons, 1996. (Original source: Markus O. Speidel, Brown Boveri Co.) Chapter 1 - 32

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