Fundamentals of Materials

Science (MNF 212)

Dr. Gamal Abdou

Department of Manufacturing Engineering and Production

Fundamentals of Material Science Dr. Gamal Abdou

1
Fundamentals of Materials Science

Course Outline
Lecturer: Dr. Gamal Abdou
Course Outline:
1. Introduction to Engineering Materials
2. Atomic Structure and Interatomic Bonding
3. Structure of Crystalline Materials
4. Imperfections in Solid
5. Diffusion
6. Strengthening Mechanisms
7. Mechanical Properties
8. Electrical, Thermal, Optical, and Magnetic Properties
9. Fracture, Fatigue, and creep
Exams, Projects, Practices:
• Workshop and/or classroom practices (10%)
• Midterm Exam (10%)
• Practical Exam (20)
• Term Exam (60%)
 Fundamentals of Materials Science

Course Resources
• Lectures Notes Dr. Gamal Abdou
• Labs experiments
• Tutorials exercises
• Text Book References
• W.D. Callister “Fundamentals of Materials Science and Engineering”
” , 5th edition, Wiley
.
Fundamentals of Material Science

CHAPTER 1
Introduction to Engineering Materials

Fundamentals of Material Science Dr. Gamal Abdou

Why Materials ???
Introduction to Engineering Materials
Properties of materials

Mechanical properties of materials

Strength, Toughness, Hardness, Ductility,
Elasticity, Fatigue and Creep

Physical properties
Density, Specific heat, Melting and boiling point,
Thermal expansion and conductivity,
Electrical and magnetic properties

Chemical properties
Oxidation, Corrosion, Flammability, Toxicity, …
General properties of Ceramics:
1. High melting points and high chemical stabilities.
2. High hardness and high temperature strength.
3. Very brittle.
4. Poor electrical conductors.
5. High strength on compression.
6. They can be crystalline (ceramics), non-crystalline
(glass) or mixture of both glass- ceramics).
7. Ceramics specific gravity(density) = 2.5 gm/mm2
General properties of Polymers:
1. Non-crystalline, but some consist of mixtures of both
crystalline and non-crystalline regions.
2. Low densities and low rigidity.
3. Poor electrical conductors due to the nature of the
atomic bonding.
4. High corrosion resistant but not used at high
temperatures.
5. Good strength to weight ratio.
6. Polymer specific gravity(density) ≈ 1.2 gm/mm2
 Composites
A number of composite materials have been engineered that
consist of more than one material type. Usually they consist of:
a) Reinforcement phase(e. g. fiber)
b) Binder phase (e.g. compliant matrix)
Advantage of composite:
1. High strength and stiffness.
2. High corrosion resistance.
3. High wear resistance.
4. High thermal insulation.
5. Low weight ratio.
General Properties and Applications of
Ferrous Alloys
• Ferrous alloys are useful metals in terms of
mechanical, physical and chemical
properties.
• Alloys contain iron as their base metal.
• Carbon steels are least expensive of all
metals while stainless steels is costly.
Carbon and alloy steels
Carbon steels
• Classified as low, medium and high:
1. Low-carbon steel or mild steel, < 0.3%C,
bolts, nuts and sheet plates.
2. Medium-carbon steel, 0.3% ~ 0.6%C,
machinery, automotive and agricultural
equipment.
3. High-carbon steel, > 0.60% C, springs,
cutlery, cable.
Carbon and alloy steels
Alloy steels
• Steels containing significant amounts of
alloying elements.
• Structural-grade alloy steels used for
construction industries due to high strength.
• Other alloy steels are used for its strength,
hardness, resistance to creep and fatigue,
and toughness.
• It may heat treated to obtain the desired
properties.
Carbon and alloy steels

High-strength low-alloy steels

• Improved strength-to-weight ratio.
• Used in automobile bodies to reduce weight
and in agricultural equipment.
• Some examples are:
1. Dual-phase steels
2. Micro alloyed steels
3. Nano-alloyed steels
 Stainless steels
• Characterized by their corrosion resistance,
high strength and ductility, and high
chromium content.
• Stainless as a film of chromium oxide protects
the metal from corrosion.
Stainless steels

• Five types of stainless steels:

1. Austenitic steels
2. Ferritic steels
3. Martensitic steels
4. Precipitation-hardening (PH) steels
5. Duplex-structure steels
Typical Selection of Carbon and Alloy Steels
for Various Applications

TABLE 5.1
Product Steel Product Steel
Aircraft forgings, 4140, 8740 Differential gears 4023
tubing, fittings Gears (car and truck) 4027, 4032
Automobile bodies 1010 Landing gear 4140, 4340, 8740
Axles 1040, 4140 Lock washers 1060
Ball bearings and races 52100 Nuts 3130
Bolts 1035, 4042, 4815 Railroad rails and wheels 1080
Camshafts 1020, 1040 Springs (coil) 1095, 4063, 6150
Chains (transmission) 3135, 3140 Springs (leaf) 1085, 4063, 9260, 6150
Coil springs 4063 Tubing 1040
Connecting rods 1040, 3141, 4340 Wire 1045, 1055
Crankshafts (forged) 1045, 1145, 3135, 3140 Wire (music) 1085
Mechanical Properties of Selected Carbon
and Alloy Steels in Various Conditions

TABLE 5.2 Typical Mechanical Properties of Selected Carbon and Alloy Steels in the Hot-Rolled,
Normalized, and Annealed Condition
AISI Condition Ultimate Yield Elongation in Reduction of Hardness
tensile Strength 50 mm(%) area (%) (HB)
strength (MPa)
(MPa)
1020 As-rolled 448 346 36 59 143
Normalized 441 330 35 67 131
Annealed 393 294 36 66 111
1080 As-rolled 1010 586 12 17 293
Normalized 965 524 11 20 293
Annealed 615 375 24 45 174
3140 Normalized 891 599 19 57 262
Annealed 689 422 24 50 197
4340 Normalized 1279 861 12 36 363
Annealed 744 472 22 49 217
8620 Normalized 632 385 26 59 183
Annealed 536 357 31 62 149
AISI Designation for High-Strength Sheet Steel

TABLE 5.3
Yield Strength Chemical Deoxidation
Composition Practice
3
psi x 10 MPa
35 240 S = structural alloy F = killed plus sulfide inclusion control
40 275
45 310
50 350 X = low alloy
60 415 K = killed
70 485 W = weathering
80 550 O = nonkilled
100 690 D = dual phase
120 830
140 970
Room-Temperature Mechanical Properties and
Applications of Annealed Stainless Steels
TABLE 5.4 Room-Temperature Mechanical Properties and Typical Applications of Selected Annealed
Stainless Steels
Ultimate
tensile Yield Elongation
AISI strength strength in 50 mm
(UNS) (M Pa) (M Pa) (%) Characteristics and typical applications
303 550–620 240–260 53–50 Screw machine products, shafts, valves, bolts,
(S30300) bushings, and nuts; aircraft fittings; bolts; nuts;
rivets; screws; studs.
304 565–620 240–290 60–55 Chemical and food processing equipment,
(S30400) brewing equipment, cryogenic vessels, gutters,
downspouts, and flashings.
316 550–590 210–290 60–55 High corrosion resistance and high creep strength.
(S31600) Chemical and pulp handling equipment,
photographic equipment, brandy vats, fertilizer
parts, ketchup cooking kettles, and yeast tubs.

410 480–520 240–310 35–25 Machine parts, pump shafts, bolts, bushings, coal
(S41000) chutes, cutlery, tackle, hardware, jet engine parts,
mining machinery, rifle barrels, screws, and
valves.
416 480–520 275 30–20 Aircraft fittings, bolts, nuts, fire extinguisher
(S41600) inserts, rivets, and screws.
Tool and die steels
• Designed for high strength, impact
toughness, and wear resistance at a range of
temperatures.
Aluminium and aluminium alloys
• Factors for selecting are:
1. High strength to weight ratio
2. Resistance to corrosion
3. High thermal and electrical conductivity
4. Ease of machinability
5. Non-magnetic
Magnesium and magnesium alloys
• Magnesium (Mg) is the lightest metal.
• Alloys are used in structural and non-
structural applications.
• Typical uses of magnesium alloys are aircraft
and missile components.
• Also has good vibration-damping
characteristics.
Copper and copper alloys

• Copper alloys have electrical and mechanical

properties, corrosion resistance, thermal
conductivity and wear resistance.
• Applications are electronic components,
springs and heat exchangers.
• Brass is an alloy of copper and zinc.
• Bronze is an alloy of copper and tin.
Nickel and nickel alloys
• Nickel (Ni) has strength, toughness, and
corrosion resistance to metals.
• Used in stainless steels and nickel-base
alloys.
• Alloys are used for high temperature
applications, such as jet-engine components
and rockets.
Superalloys

• Superalloys are high-temperature alloys use

in jet engines, gas turbines and reciprocating
engines.
Titanium and titanium alloys

• Titanium (Ti) is expensive, has high strength-

to-weight ratio and corrosion resistance.
• Used as components for aircrafts, jet-
engines, racing-cars and marine crafts.
Refractory metals

• Refractory metals have a high melting point

and retain their strength at elevated
temperatures.

• Applications are electronics, nuclear power

and chemical industries.

• Molybdenum, columbium, tungsten, and

tantalum are referred to as refractory metal.
Other nonferrous metals

1. Beryllium
2. Zirconium
3. Low-melting-point metals:
- Lead
- Zinc
- Tin
4. Precious metals:
- Gold
- Silver
- Platinum
 Special metals and alloys

1. Shape-memory alloys (i.e. eyeglass frame, helical

spring)
2. Amorphous alloys (Metallic Glass)
3. Nanomaterials
4. Metal foams
 Ceramics

•Traditional ceramics
• clays: kaolinite
• silica: quartz, sandstone
• alumina
• silicon carbide
•New ceramics
• oxide ceramics : alumina
• carbides : silicon carbide, titanium carbide, etc.
• nitrides : silicon nitride, boron nitiride, etc.
 Polymers
• Thermoplastics - reversible in phase by heating and cooling. Solid phase
at room temperature and liquid phase at elevated temperature.
• Thermosets - irreversible in phase by heating and cooling. Change to
liquid phase when heated, then follow with an irreversible exothermic
chemical reaction. Remain in solid phase subsequently.
• Elastomers - Rubbers

Composite
• Metal Matrix Composites (MMC)
Mixture of ceramics and metals reinforced by strong, high-stiffness fibers
• Ceramic Matrix Composites (CMC)
Ceramics such as aluminum oxide and silicon carbide embedded with fibers for
improved properties, especially high temperature applications.
• Polymer Matrix Composites (PMC)
Thermosets or thermoplastics mixed with fiber reinforcement or powder.
Materials Science and Materials Engineering

Fig. 1 The role of Materials Science and Materials

Engineering