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Materials inEveryday Lives

Dr. Deni Ferdian, M.ScDr. Andi Rustandi, MT

Weeks Subject Note1 Class Intro; Types of engineering materials and their

applications

2 Atomic structure, atomic interatomic and material structure

3 Imperfection in solids and properties of materials

4 Phase diagram and phase transformation

6 Application and processing of metal alloys

7 Polymer, ceramic and composite processing and application

8 Mid semester exam9 Corrosion and degradation of materials

10 Corrosion and degradation of materials

11 Corrosion and degradation of materials

12 Corrosion and degradation of materials

13 Corrosion and degradation of materials

14 Corrosion and degradation of materials

15 Final exam

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What is Material?

• Material (n): the substance from whicheverything is composed or made.

• Materials can easily be foundeverywhere in everyday lives.

• Materials have played a major role inthe development of our civilizations.

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Metals

Ceramics

Electronic and Photonic Materials

Materials in Everyday Lives

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Types of Materials• Metals:

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

• Polymers/plastics: Covalent bonding sharing of e’s– Soft, ductile, low strength, low density– Thermal & electrical insulators– Optically translucent or transparent.

• Ceramics: ionic bonding (refractory) – compounds of metallic & non-metallic elements (oxides, carbides, nitrides, sulfides)– Brittle, glassy, elastic– Non-conducting (insulators)

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Iron and Steel• Has been used for thousand

years, since 200 AD.

• The main material for cars,buses, aircraft andChallenger fuel tank.

• The main material forconstruction of the ThamesBarrier, the Channel Tunnel,the Eiffel Tower, etc.

• Materials for our daily life:shave blade, paper clips, dll.

Rubber• Arrived in Europe in 1740’s.

• The use increases with thefinding of bicycle in 1880’s.

• The main use of rubber is fortire, also used for shoes,hoses, shock absorber, etc.

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Polymer• Light

• Easily shaped

• Not corroded

• Relatively cheap

Ceramic• High strength and hardness.

• High temperature resistance

• Wear resistance

• Glasses is a type of ceramic.Lenses were found in 1500’s andthen used as the main parts inmicroscope and telescope,because of its transparency andstrength.

• Modern telecommunication usesfiber optics that ultra transparentwith the thickness not more that apiece of hair!

• Fiberglass is also used forcomposite materials.

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Engineering Materials

Composites

Metals

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Engineering Materials Expanded

Aluminum BodySteel Body

Technology DevelopmentFord 1958 Ford GT 2004

Material andprocessing !!!!

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Komputer

IBM Univac (Remington Rand)Memory: 1000 buah kata dgn 12 huruf 2 halaman A4 = 40 kBBesar: 288 m3 = 288 juta cm3

US $ 750,000 + $ 185,000 printer

1951

Motion LS800Memory: 30 GB,Video, audio, modem, DVD-CD-RW, double-layer DVDburber, infrared, bluetooth,built-in webcam, wifiBerat 500 grUS $ 2,234

2012

Material andprocessing !!!!

Properties

Structure

Processing

Performance

Processing Structure Properties Performance

Materials EngineeringScope

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Aluminium : Engine Block

Properties- What’s the hardness of

the material?

Processing:• How to cast to

reduce reject?• What heat

treatment isneeded?

Structure:• What’s the role of Sr?• What second phase has

negative impact?

Performance:- Cost of adding Sr vs

reject rate?

Can materials have the same composition butposses different properties?

Graphite, is a black,lustrous solidthat is completely opaque.

Pure diamonds areclear and colorless

In solution buckminsterfullerenedeep red color is revealed

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Material’s properties are determined by its structure!

graphite diamond buckyball

Material structure describes the arrangement of atoms or ions in materialand profoundly influences the material properties

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ex: hardness vs structure of steel• Properties depend on structure

Data obtained from Figs. 10.30(a)and 10.32 with 4 wt% C composition,and from Fig. 11.14 and associateddiscussion, Callister & Rethwisch 8e.Micrographs adapted from (a) Fig.10.19; (b) Fig. 9.30;(c) Fig. 10.33;and (d) Fig. 10.21, Callister & Rethwisch8e.

ex: structure vs cooling rate of steel• Processing can change structure

Structure, Processing, & Properties

Har

dnes

s (B

HN

)

Cooling Rate (ºC/s)

100

200

300

400

500

600

0.01 0.1 1 10 100 1000

(d)

30 µm(c)

4 µm

(b)

30 µm

(a)

30 µm

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Scale

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Structure of materialsMacroscopicLevel

MicroscopicLevel

Atomic,Molecular Level

Unaided Eyes

OpticalMicroscope

SEM, TEM, AFM

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200 nm

Optical microstructure

SEM

TEM

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Properties of materials• Mechanical• Physical• Electrical• Magnetic• Optical and Dielectric• Thermal• Environmental Related• Deformation and Failure Related

Processing of materials

• Extraction and refining• Foundry / casting• Powder processing• Thermal and thermo-mechanical processing

• Deposition processing• Deformation processing

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Performance of materials

Design andMaterials Selection

Failure Analysis

Non Destructive EvaluationCorrosion Control

Failure Analysis

Titanic sink

Pesawat Mandala, 6 Sept 2005

Azerbaijan Airlines, 23 Des2005

200 nm

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1. Pick Application Determine required Properties

Processing: changes structure and overall shapeex: casting, sintering, vapor deposition, doping

forming, joining, annealing.

Properties: mechanical, electrical, thermal,magnetic, optical, deteriorative.

Material: structure, composition.2. Properties Identify candidate Material(s)

3. Material Identify required Processing

The Materials Selection Process

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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.

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Example – Hip Implant

• Requirements• mechanical strength (many

cycles)• good lubricity• biocompatibility

Adapted from Fig. 22.24, Callister 7e.

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Example – Hip Implant

Adapted from Fig. 22.26, Callister 7e.

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Hip Implant• Key problems to overcome

• fixation agent to holdacetabular cup

• cup lubrication material• femoral stem – fixing agent (“glue”)• must avoid any debris in cup

FemoralStem

Ball

AcetabularCup and Liner

Adapted from chapter-opening photograph,Chapter 22, Callister 7e.

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ELECTRICAL• Electrical Resistivity of Copper:

• Adding “impurity” atoms to Cu increases resistivity.

• Deforming Cu increases resistivity.

Adapted from Fig. 18.8, Callister &Rethwisch 8e. (Fig. 18.8 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.)

T (ºC)-200 -100 0

1

2

3

4

5

6

Res

istiv

ity,ρ

(10-

8O

hm-m

)

0

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THERMAL• Space Shuttle Tiles:

-- Silica fiber insulationoffers low heat conduction.

• Thermal Conductivityof Copper:-- It decreases when

you add zinc!

Adapted fromFig. 19.4W, Callister 6e.(Courtesy of LockheedAerospace CeramicsSystems, Sunnyvale, CA)(Note: "W" denotes fig. ison CD-ROM.)

Adapted from Fig. 19.4, Callister & Rethwisch 8e.(Fig. 19.4 is adapted from Metals Handbook:Properties and Selection: Nonferrous alloys andPure Metals, Vol. 2, 9th ed., H. Baker, (ManagingEditor), American Society for Metals, 1979, p. 315.)

Composition (wt% Zinc)

Ther

mal

Con

duct

ivity

(W/m

-K)

400

300

200

100

00 10 20 30 40

100µm

Adapted from chapter-opening photograph,Chapter 17, Callister &Rethwisch 3e. (Courtesyof LockheedMissiles and SpaceCompany, Inc.)

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MAGNETIC• Magnetic Permeability

vs. Composition:-- Adding 3 atomic % Si

makes Fe a betterrecording medium!

Adapted from C.R. Barrett, W.D. Nix, andA.S. Tetelman, The Principles ofEngineering Materials, Fig. 1-7(a), p. 9,1973. Electronically reproducedby permission of Pearson Education, Inc.,Upper Saddle River, New Jersey.

Fig. 20.23, Callister & Rethwisch 8e.

• Magnetic Storage:-- Recording medium

is magnetized byrecording head.

Magnetic Field

Mag

netiz

atio

n Fe+3%Si

Fe

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• Transmittance:-- Aluminum oxide may be transparent, translucent, or

opaque depending on the material structure.

Adapted from Fig. 1.2,Callister & Rethwisch 8e.(Specimen preparation,P.A. Lessing; photo by S.Tanner.)

single crystalpolycrystal:low porosity

polycrystal:high porosity

OPTICAL

Evolution of Materials