What are Engineering Materials?

Their Types and

Selection (Notes with PDF)
learnmechanical.com/engineering-materials/

Atul Singla August 22, 2022

Knowledge of materials and their properties is very important for designers. Mechanical
elements should be made of materials with suitable properties for the operating conditions.
Additionally, designers need to know how manufacturing processes and heat treatments
affect material properties. This article describes construction materials commonly used in the
manufacture of machinery and their properties.

Contents

What are Engineering Materials?

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 Classification of Engineering Materials
Metals
Ferrous Metals
Non-Ferrous Metals
Alloys
Typical Uses & Applications of Alloys
Ceramics
Uses & Applications of Ceramics as Engineering Materials
Polymers
Thermoplastic Polymers
Thermosetting Polymers
Elastomers
Uses & Applications of Elastomers
Composite Materials
Fibrous Composites
Particulate Composites
Laminated Composites
Uses & Applications of Composites
Semiconductors
Uses & Applications of Semiconductors
Biomaterials
Uses & Applications of Biomaterials
Advanced Engineering Materials
Material Selection for Engineering Purposes

What are Engineering Materials?

Engineering materials refer to a group of materials used in the construction of man-made
structures and components. The main function of engineering materials is to withstand the
applied loading without failure (breaking and excessive deflection). Carbon steel, Aluminum,
Cast Iron, Stainless Steel, Copper alloys, Plastics, Composites, Nickel alloys, DSS, etc all
are examples of engineering materials.

Classification of Engineering Materials

Engineering materials are generally grouped into two parts i.e., Metals & Non-Metals. Metals
include Ferrous, Non-Ferrous, and Non-Metals include Glass, Rubber, Plastic, etc. However,
there are many other engineering materials which are Ceramics, Polymers, Semiconductors,
Composite, Biomaterials, and Advance Materials. Let’s understand these materials one by
one:

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 Material Classifications

Metals

Metals have a large number of delocalized electrons. That is, these electrons are not
attached to any specific atom. Metals are very good conductors of electricity and heat and
are opaque to visible light. The polished metal surface has a glossy appearance.

 In addition, the metal is fairly strong yet malleable, making it widely used in structural
applications. Metals are classified into ferrous metals (carbon steel, alloy steel, stainless
steel, tool/mild steel, etc.) and nonferrous metals (Al, Mg, Cu, Ni, Ti, refractory metals, Be, Zr,
superalloys, etc. Alloying elements together have created a wide variety of metallic materials
that can be engineered for specific properties.

Ferrous Metals

Iron and Carbon are the main constituents of Ferrous metals and due to the presence of
Iron, ferrous metals are having magnetic properties. For example, Cast Iron, Wrought Iron,
Steel, etc.,

Non-Ferrous Metals
Non-Ferrous metals do not have Iron content and thus these are non-magnetic and rust
resistant. For example, Aluminium, Copper, Lead, Brass, Bronze, Gold, Zinc, etc.

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Alloys

Alloys are the combination of two or more alloying elements. For example, Brass is an alloy
of Copper and Zinc. Bronze is an alloy of Copper and Tin.

Typical Uses & Applications of Alloys

For making Needles & Surgical Blades due to the toughness property and ability to
sterilize at elevated temperature.
Metals like Gold, Silver in Jewellery making.
Used in Machines & Automobiles and other construction work.

Ceramics

Ceramics are compounds of metallic and non-metallic elements. They are mainly oxides,
nitrides, and carbides. A wide range of materials that fall into this category includes ceramics
composed of clay minerals, cement, and glass. These materials typically insulate the
passage of electricity and heat and are more tolerant of high temperatures and harsh
environments than metals or polymers. Regarding mechanical behavior, ceramics are hard
but very brittle. MgO, SiC, BaTiO3, silica, glass, concrete, cement, ferrite, garnet, Al2O3,
granite, calcite, magnesite, etc. Ceramics.

Uses & Applications of Ceramics as Engineering Materials

In the making of Ceramic Tiles and Bricks.

Silicon Carbide, Alumina, and Silica are used in making tools.
In the making of Insulations and Optical Instruments.

Polymers
Polymers are large molecules made up of repeating small simple chemical units. In some
cases, the iterations are linear, like a chain made up of its links. In other cases, the chains
are branched or linked to form a 3D network. The repeating units of the polymer are usually
the same or nearly the same as the monomers or starting materials from which, the polymer
is formed.

Polymers include familiar plastic and rubber materials. Many of them are chemically organic
compounds based on carbon, hydrogen, and other non-metallic elements. Moreover, they
have a very large molecular structure. These materials are typically low density and very
flexible. PVC, PTFE, polyethylene, terylene, nylon, rubber, etc. are polymers.

Polymers are generally divided into three types:

Thermoplastic Polymer
Thermosetting Polymer

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 Elastomers

Thermoplastic Polymers

The classification of thermoplastics and thermosets is based on their thermal behavior. When
heat is applied to thermoplastics, they soften and melt. When cooled, it returns to its original
solid state. Thermoplastics can be repeatedly heated and cooled without undergoing a
chemical change (unless the temperature is hot enough to break molecular bonds).
Therefore, it is very suitable for injection molding.

Thermosetting Polymers

Thermosets are typically heated during initial processing and then permanently hardened.
Thermosets do not melt when reheated. However, if the heat applied becomes extreme, the
thermoset will degrade due to the breaking of molecular bonds. Thermosets are typically
harder and stronger than thermoplastics. They are also typically more dimensionally stable
than thermoplastics, retaining their original dimensions better when exposed to changes in
temperature and humidity.

Elastomers
Elastomers are highly elastic polymers with rubber-like mechanical properties. Elastomers
are widely used in seals, adhesives, hoses, belts, and other flexible parts. The strength and
stiffness of rubber can be increased through a process called vulcanization. Vulcanization is
the addition of sulfur and subjecting the material to high temperature and pressure. This
process forms crosslinks between polymer chains.

Uses & Applications of Elastomers

In the making of carrying Bags.

In the making of Pipes and Plumbing items.
Used as an Insulation

Composite Materials

Many composite materials have been developed that consist of multiple types of materials.
Glass fibers are a well-known example of glass fibers embedded in polymeric materials.
Composite materials are designed to have the best combination of properties from each
constituent material. Fiberglass gets its strength from glass and its flexibility from polymer.
Many recent materials developments involve composite materials.

Generally, composites are the following types:

Fibrous Composites

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A fiber composite is a material in which the fibers of the material are embedded in a matrix.
The fibers carry most of the stress and the matrix holds them in place and serves to transfer
stress between them. The fibers can be short and randomly oriented or long and continuous.

Particulate Composites

Particulate composites are made by adding particles of the material to a matrix (filler).
Particles typically occupy less than 15% of the total volume of the material. Particles are
added to remedy some deficiencies of the matrix material.

Laminated Composites

Laminated composites are made by combining layers of composite materials. The layers
usually have different fiber orientations or are different materials themselves. Sandwich
materials are common, where a lightweight material (such as foam or honeycomb) is placed
between layers of strong, rigid material.

Uses & Applications of Composites

Glass Fiber Reinforced Plastics are used in Automotive Parts and in GRP Piping
systems.
Carbon Fiber Reinforced Plastics are used in Chasis of Vehicle.
Bumper systems of Automobiles are also made up of Composite materials.

Semiconductors

Semiconductors have electrical properties intermediate between those of conductors and

insulators. Moreover, the electrical properties of these materials are highly sensitive to the
presence of trace concentrations of impurities. Semiconductors have enabled the emergence
of integrated circuits and have completely revolutionized the electronics and computer
industry over the past few decades. Semiconductor materials include Si, Ge, CdS, CdSe,
and GaAs.

Uses & Applications of Semiconductors

Semiconductors are widely used in Mother Board of Electronic devices.

Biomaterials

Biomaterials are used for components that are implanted in the human body to replace
diseased or damaged body parts. These materials must not produce toxic substances and
must be compatible with body tissue (ie, not cause adverse biological reactions). All the
materials mentioned above (metals, ceramics, polymers, composites, and semiconductors)
can be used as biomaterials.

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Uses & Applications of Biomaterials

Used in implantation of Damaged Body parts or damaged Tissues.

Advanced Engineering Materials

Materials used in high-tech (or hi-tech) applications are sometimes called advanced
materials. Advanced technology means devices or products that operate or function
according to relatively complex and sophisticated principles. Examples include electronic
devices (VCRs, CD players, etc.), computers, fiber optic systems, spacecraft, aircraft, and
military missiles.

 These advanced materials are typically either conventional materials with improved
properties or newly developed high-performance materials. Additionally, they can be made of
all sorts of materials (metals, ceramics, polymers, etc.) and are usually relatively expensive.

These materials are used in thermal protection systems for lasers, integrated circuits,
magnetic information storage, liquid crystal displays (LCDs), optical fibers, and space shutter
orbiters. This category includes materials such as process electricals, ferroelectrics, high-
temperature superconductors, super refractory materials, magnetic alloys, and shape
memory alloys.

Material Selection for Engineering Purposes

Choosing the right material for engineering purposes is one of the most difficult problems for
designers. The best materials are those that serve their intended purpose at the lowest cost.

The choice of material for a particular application is determined by the working conditions to
which it will be exposed, ease of manufacture, and cost considerations. Pure metal has very
few applications in engineering, firstly because it is difficult to manufacture in its pure state,
and secondly, it generally has low strength in its pure state. can achieve a variety of
desirable special properties. Alloys consist of a base metal (usually a content of 50% or
more) and one or more alloying elements. Typical properties related to working conditions
are toughness, elasticity, toughness, and hardness, and typical properties related to the
manufacturing process are ductility, deformability, and plasticity.

 Various properties can be determined by test methods. Tensile strength is a tensile test,
ductility is a bending test, wear resistance is a hardness test, toughness is an impact test,
and fatigue and creep tests determine other special properties such as fatigue and creep.

 Materials can be manipulated in a number of ways. The choice depends on the material, the
desired properties, the shape to be manufactured, the accuracy required, the quantity to be
manufactured, and the cost aspect.

The following factors should be considered when choosing materials:

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 Material Availability
Suitability of the Engineering material for the required working conditions
The load to which a workpiece or component is exposed.
The resistivity of the Engineering Material against Corrosion
The resistivity of the Engineering Materials against Temperature, Wear & Tear.
Flexibility and Rigidity are required for the material.
Ease in manufacturing.
Cost-effectiveness to manufacture.

The key properties that determine a material’s usefulness are its physical, chemical, and
mechanical properties which we will discuss separately.

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