Module 1

The Importance of Engineering Materials

Engineering Materials: properties and selection, 9th ed.

Kenneth G. Budinski, Michael K. Budinski
Goals
 This module is intended to stimulate interest on the part of students in engineering
materials.
 It also contains most of the information that material users will need to know about
inspecting materials for incipient failures (cracks) or manufacturing defects (NDE*).
 Our reason for putting NDE information in the introduction is that it applies to all
materials.
 It is important and yet most curricula cannot afford a complete lecture on just this
topic.

Upon completion of this Module, the student should:

 Have a feel for materials used to make things

 Understand the importance of using the “right” material for an application

 Have knowledge of the reasons why products fail

 Understand of NDE and how to apply it

*NDE = Non-Destructive Evaluation
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 2
What is Materials Engineering?
 Multidisciplinary Field:
 Materials Engineering is a multidisciplinary branch that combines principles

from physics, chemistry, and engineering to study and manipulate the

properties of materials.

 Design and Development:

 It involves the design, development, and optimization of materials to meet

specific performance criteria for diverse applications in industries such as

aerospace, automotive, and healthcare.

 Material Types:
 Mechanical/materials engineers work with a variety of materials, including

metals, polymers, ceramics, and composites, tailoring their properties to

achieve desired characteristics.
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 3
What is Materials Engineering?
 Applications Across Industries:
 The field finds applications in a wide range of industries, from creating

lightweight and durable materials for aircraft to developing biocompatible

materials for medical implants.

 Understanding Material Properties:

 Mechanical/Materials engineers focus on understanding the fundamental

properties of materials, such as strength, elasticity, conductivity, and

corrosion resistance, to control and enhance their performance.

 Innovation and Sustainability:

 The field drives innovation by developing new materials and technologies,

while also addressing sustainability concerns by exploring eco-friendly and

renewable material alternatives.
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 4
Timeline of materials development
from the Stone Age to the present day
 Stone Age (2.5 million years ago - 3000 BCE):
 Materials: Flint, obsidian, and other natural stones.
 Development: Humans use stones for tools, weapons, and basic implements.
 Bronze Age (3300 BCE - 1200 BCE):
 Materials: Bronze (copper and tin alloy).
 Development: Introduction of metalworking, leading to the creation of stronger and more durable
tools and weapons.
 Iron Age (1200 BCE - 1 CE):
 Materials: Iron and steel.
 Development: Iron smelting becomes widespread, enabling the production of stronger and more
versatile materials.
 Middle Ages (500 CE - 1500 CE):
 Materials: Wrought iron, glass, and early ceramics.
 Development: Advancements in metallurgy, glassmaking, and ceramics contribute to improved
construction, weaponry, and artistry.

Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 5
Timeline of materials development
from the Stone Age to the present day…….
 Renaissance (14th - 17th centuries):
 Materials: Improved steel, glass, and early polymers.
 Development: Renaissance-era innovations in metallurgy and glassmaking contribute to the production of finer
tools and artistic materials.
 Industrial Revolution (18th - 19th centuries):
 Materials: Cast iron, steel, and early synthetic materials (e.g., vulcanized rubber).
 Development: Mass production and advancements in metallurgy lead to the widespread use of iron and steel in
industry. The first synthetic materials emerge.
 20th Century:
 1900s - 1930s: Plastics (e.g., Bakelite) and stainless steel.
 1940s - 1950s: Nylon, polyester, and Teflon.
 1960s - 1970s: High-performance polymers, carbon fiber, and advanced ceramics.
 1980s - 1990s: Smart materials, composites, and biocompatible materials.
 21st Century (2000s - Present):
 Materials: Graphene, nanomaterials, and advanced alloys.
 Development: Continued innovation in nanotechnology, materials science, and sustainable materials. Emphasis on
environmentally friendly and energy-efficient materials.

Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 6
1.2 The Language of Materials

 Figure 1-1 Relationship between the basic sciences and applied fields of study

Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 7
Materials Science Tetrahedron

Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 8
1.3 The Role of Materials in Product Success
 Materials selection is a critical factor in determining the success of a product.
 Influence on Design:
 Material properties directly impact design elements such as strength, weight, and aesthetics.
 The right materials enhance product functionality, durability, and user experience.
 Performance and Durability:
 Proper material selection contributes to overall product performance and longevity.
 Materials influence how well a product withstands environmental factors and everyday use.
 Innovation and Competitive Edge:
 Innovative materials drive product differentiation and provide a competitive edge in the market.
 Continuous material innovation is essential for staying ahead in a rapidly evolving business landscape.
 Environmental Considerations:
 Materials play a crucial role in the sustainability of a product.
 Choosing eco-friendly and recyclable materials aligns with modern consumer expectations.
 The success of a product is intricately tied to the thoughtful selection and application of materials.
 Strategic materials choices contribute to functionality, aesthetics, and the overall value proposition of a
product.
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 9
 1.3 The Role of Materials in Product Success
 Failure of the products attributed to just two factors:
 (i) Insufficient design and/or (ii) Insufficient properties

Figure 1-2 Example of a design flaw in a beverage container

Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 10
Example of a design flaw

Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 11
1.3 The Role of Materials in Product Success

 Figure 1-3 Examples of chemical, physical, and mechanical properties of materials

Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 12
1.4 Inspection to Prevent Failures

 Figure 1-4 Example of a forging burst flaw in the center of a

stainless steel bar

Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 13
Importance of Inspection in Preventing Failures
 Quality Assurance: Ensures products meet standards, preventing substandard releases.
 Safety Compliance: Identifies hazards early, ensuring adherence to safety regulations.
 Risk Mitigation: Proactively addresses vulnerabilities, minimizing potential consequences.
 Early Defect Detection: Identifies and corrects defects in early stages, reducing system-wide
issues.
 Cost Savings: Prevents costly consequences, making proactive measures cost-effective.
 Increased Reliability: Regular inspections enhance confidence in system and machinery
reliability.
 Enhanced Productivity: Minimizes unplanned downtime, ensuring a smoother workflow.
 Regulatory Compliance: Meets legal requirements and builds trust with customers and
stakeholders.
 Extended Equipment Life: Maximizes ROI through preventive maintenance and extended
equipment life.
 Customer Satisfaction: Ensures quality, enhancing customer satisfaction and loyalty.
 In summary, inspection is a proactive strategy for quality, safety, and reliability,
preventing failures and contributing to long-term success.
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 14
1.4 Inspection to Prevent Failures

Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 15
Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 16
1.4 Radiography

Radiography - nondestructive testing techniques

Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
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1.4 Dye Penetrant Testing

Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 18
Ultrasonic Testing

Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 19
Magnetic Particle Testing

Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
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1.5 Evolution of Engineering Materials

Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 21
1.6 A Materials Repertoire
 There are 50,000 plastics, 50,000 metals, hundreds of ceramics, and an infinite number of
composites.
 Nobody can know them all, this course will provide a usable repertoire in each material
category.

Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 22
Reading Assignment
 Chapter 1

Engineering Materials: properties and selection, 9th ed. © 2010 Pearson Higher Education,
Upper Saddle River, NJ 07458. • All Rights Reserved.
Kenneth G. Budinski, Michael K. Budinski 23