Materials Science and Engineering

Ninth Edition

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

Chapter 1
Introduction

Copyright © 2014 John Wiley & Sons, Inc. All rights reserved. Chapter 1 -
 ANNOUNCEMENTS
 Reading: Chapter 1 & Chapter 6

 HW 1: on Folio, under Assessment-

Quizzes, “HW1”

Chapter 1 - 2
 Ask Yourself
Why choose this material for specific application?

• Tony stark- iron man’s armor

• Diesel engine head- compacted graphite iron

• F-150 pickup truck body- aluminum alloy

• Steel so widely used in the structural component

• 3rd-Gen high strength steel

Chapter 1 - 3
 Chapter 1: Introduction to
Materials Science & Engineering

ISSUES TO ADDRESS...
• What is materials science and engineering?

• Why are materials important?

• Why is it important for engineers to understand

materials ?

Chapter 1 - 4
What is Materials Science & Engineering?

• Materials science
– Investigate relationships between structures and
properties of materials
– Design/develop new materials

• Materials engineering
– Create products from existing materials
– Develop materials processing techniques

Chapter 1 - 5
 Why Are Materials Important?
• Materials drive advancements in our society
– Stone Age
– Bronze Age
– Iron Age

• What is today’s material age?

– Silicon (Electronic Materials) Age?
– Nanomaterials Age?
– Polymer Age?

Chapter 1 - 6
 Why is it Important for Engineers to
Understand Materials?
• Products/devices/components that engineers
design are all made of materials

• To select appropriate materials and

processing techniques for specific
applications engineers must
– have knowledge of material properties and
– understand the structure-property relationships

Chapter 1 - 7
 Relationships Among Processing,
Structure, & Properties
• Processing (e.g., cooling rate of steel from high
temperature) affects structure (microstructure)
• Structure in turn effects hardness

Structure (d)
Property
600
Hardness (BHN)

30 μm
500 (c)
Data obtained from Figs. 10.32(a) and
400 (b) 10.33 with 0.4 wt% C composition, and
(a) from Fig. 11.18, Callister & Rethwisch 10e.
Micrographs adapted from (a) Fig. 10.19;
4 μm
300 (b) Fig. 9.30; (c) Fig. 10.34; and (d) Fig.
10.22, Callister & Rethwisch 10e. (Figures
30 μm 10.19, 10.22, & 10.34 copyright 1971 by United
200 30 μm States Steel Corporation. Figure 9.30 courtesy
of Republic Steel Corporation.)

100
0.01 0.1 1 10 100 1000 Processing
Cooling Rate (ºC/s)
Chapter 1 - 8
 Types of Materials
• Metals:
– Strong, ductile
– High thermal & electrical conductivities
– Opaque, reflective

• Polymers/plastics: compounds of non-metallic elements

– Soft, ductile, low strengths, low densities
– Low thermal & electrical conductivities
– Opaque, translucent or transparent

• Ceramics: compounds of metallic & non-metallic elements

(oxides, carbides, nitrides, sulfides)
– Hard, Brittle
– Low thermal & electrical conductivities
– Opaque, translucent, or transparent

Chapter 1 - 9
 Materials Selection
Engineers often solve materials selection problems.
Procedure:
1. For a Specific Application Determine Required Properties
• Properties: mechanical, electrical, thermal,
magnetic, optical, deteriorative.

2. From List of Properties Identify Candidate Material(s)

3. Best Candidate Material Specify Processing technique(s)

• To provide required set of properties
• To produce component having desired shape and size
• Example techniques: casting, mechanical forming, welding,
heat treating

Chapter 1 - 10
 Material Property Types

Properties of materials fall into six categories as

follows:
• Mechanical
• Electrical
• Thermal
• Magnetic
• Optical
• Deteriorative

Chapter 1 - 11
 Mechanical Properties
Effect of carbon content on the hardness of a
common steel:
Fig. 10.31, Callister & Rethwisch 10e.
[Data taken from Metals Handbook: Heat
320 Treating, Vol. 4, 9th edition, V. Masseria
(Managing Editor), 1981. Reproduced by
Brinell hardness

permission of ASM International, Materials Park,

OH.]

240

160

80
0 0.5 1 wt%C

• Increasing carbon content increases hardness of steel.

Chapter 1 - 12
 Electrical Properties
Factors that affect electrical resistivity – for copper:
6 Fig. 18.8, Callister & Rethwisch 9e.
t%Ni [Adapted from: J.O. Linde, Ann Physik 5, 219

5 3 .3 2a (1932); and C.A. Wert and R.M. Thomson,

Physics of Solids, 2nd edition, McGraw-Hill

C u+ Ni
Company, New York, 1970.]
Resistivity, ρ

t%
(10-8 Ohm-m)

4 2 . 16 a t %Ni
+ 2 a
Cu +1 . 1
3 C u
e d
e fo rm % N i
d 2 a t
2 . 1
u +1
C
1 r e ” Cu
“Pu
0
T (°C)
-200 -100 0
• Increasing temperature increases resistivity.
• Increasing impurity content (e.g., Ni) increases resistivity.
• Deformation increases resistivity.
Chapter 1 - 13
 Thermal Properties
Thermal Conductivity – measure of a material’s ability to
conduct heat

400
Thermal Conductivity

300 Fig. 19.4, Callister & Rethwisch 10e.

(W/m-K)

[Adapted from Metals Handbook: Properties

and Selection: Nonferrous alloys and Pure

200 Metals, Vol. 2, 9th ed., H. Baker, (Managing

Editor), ASM International, 1979, p. 315.]

100

0
0 10 20 30 40
Composition (wt% Zinc)

• Increasing impurity content (e.g., Zn in Cu) decreases

thermal conductivity.
Chapter 1 - 14
 Thermal Properties (continued)
Highly porous materials are Material used for space
poor conductors of heat shuttle

Courtesy of Lockheed Aerospace Ceramics

Courtesy of Lockheed Missiles and Space

Systems, Sunnyvale, CA

Company, Inc.
100 μm

• Ceramic Fibers: • Demonstration:

– significant void space – low thermal conductivity
– low thermal conductivity of this material

https://www.youtube.com/watch?v=Pp9Yax8UNoM
Chapter 1 - 15
 Magnetic Properties
• Magnetic Storage: • Magnetic Permeability
-- Recording medium is vs. Composition:
magnetized by recording -- Adding 3 atomic % Si makes
write head. Fe a better recording medium!
Fe+3%Si

Magnetization
Fe

Magnetic Field
Adapted from C.R. Barrett, W.D. Nix, and
Fig. 20.23, Callister & Rethwisch 10e. A.S. Tetelman, The Principles of Engineering
(Courtesy of HGST, a Western Digital Company.) Materials, Fig. 1-7(a), p. 9, 1973.
(Electronically reproduced by permission of Pearson
Education, Inc., Upper Saddle River, New
Jersey.)

Chapter 1 - 16
 Optical Properties
• The light transmittance of some materials depend on their
structural characteristics:
Aluminum oxide Aluminum oxide
Aluminum oxide single
polycrystalline material polycrystalline
crystal (high degree of
(having many small material having some
perfection)—is optically
grains)—is optically porosity—is optically
transparent
translucent opaque
(Specimen preparation, P.A. Lessing)

Chapter 1 - 17
 Deteriorative Properties
• Small cracks formed in steel bar that was simultaneously
stressed and immersed in sea water
- Form of stress-corrosion cracking

Cracks

Fig. 17.21, Callister & Rethwisch 10e.

(from Marine Corrosion, Causes, and Prevention, John Wiley and Sons, Inc., 1975.)
Chapter 1 - 18
 Deteriorative Properties (cont.)
• For stress-corrosion cracking, rate of crack growth is
diminished by heat treating
Adapted from Fig. 11.20(b), R.W.

“as-received” Hertzberg, "Deformation and

Crack Growth Rate (m/s)

10-8 Fracture Mechanics of Engineering

Materials" (4th ed.), p. 505, John
Wiley and Sons, 1996. (Original
source: Markus O. Speidel, Brown
“heat treated” Boveri Co.)

10-10

load
For Aluminum alloy 7178 that is stressed while immersed in a
saturated aqueous NaCl solution, crack growth rate is reduced by
heat treating (160C for 1 h prior to testing).
Chapter 1 - 19
 Example: Carbonated Beverage
Contains
• Materials requirements
- CO2 pressure
- non-toxic
- relative strong
- inexpensive
- packing colors and labels
• Glass bottle
• Aluminum can
• Plastic bottle

Chapter 1 - 20
 Example: Artificial Hip Replacement

• Damaged and diseased hip joints can

be replaced with artificial ones
• Materials requirements for artificial
Head
joints (Ball)
– Biocompatible – minimum rejection by
surrounding body tissues
– Chemically inert to body fluids
– Mechanical strength to support forces
generated
– Good lubricity and high wear resistance
between articulating surfaces Schematic diagram of an
artificial hip

Chapter 1 - 21
 Materials: Artificial Hip Replacement
(cont.) Shell

• Materials used
- Femoral stem — titanium or Liner
CoCrMo alloy
Head
- Head (Ball) — CoCrMo alloy (Ball)
or Al2O3 (ceramic)
- Shell — titanium alloy Femoral
Stem
- Liner — polyethylene
(polymer) or Al2O3 (ceramic)

Chapter 1 - 22
 Failure Example : Liberty Ship
• Fractured ships
- Ductile to brittle transition temperature of steels
- Sharp corners (square) of hatches
- Assembled by welding (crack propagation)
- Weld defects and discontinuities

Chapter 1 - 23
 SUMMARY
• Appropriate materials and processing decisions
require engineers to understand materials and their
properties.
• Materials' properties depend on their structures;
structures are determined by how materials are
processed
• In terms of chemistry the three classifications of
materials are metals, ceramics, and polymers
• Most properties of materials fall into the following six
categories: mechanical, electrical, thermal, magnetic,
optical, and deteriorative.
• An important role of engineers is that of materials
selection.

Chapter 1 - 24