Internal structure and material

properties for material selection

Semester 1

Aerospace Engineering Study Program

Faculty of Mechanical and Aerospace Engineering
Institut Teknologi Bandung
 Course Objectives
• This course discuss the relationship between the internal
structures of materials with their mechanical properties.
• The basic principle of strengthening of metallic materials is
introduced together with the application.
• Discuss the major causes of mechanical failure of engineering
components or structure.
• Ref:
1. Callister Chap 1, 22,
2. Ashby Chap 4
Introduction
• Why should we LEARN materials
science & engineering?
• Civilizations are named based
on materials used
• Stone Age (~ 2.5 million BC)
• Bronze Age (~ 3500 BC)
• Iron Age (~ 1000 BC)
• Now?
• Silicon Age?
• Polymer/plastic Age?
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Material science and engineering
• Materials science: Investigating relationship of structures and
properties.

• Materials engineering: Designing or engineering the structure to

produce certain properties.

Sub-atomic Atomic Microscopic Macroscopic

Types of Materials
• Metals: Metallic bonding  free electrons not attracted to
any one particular nucleus
• 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, capable of elastic deformation only
• non-conducting (insulators)
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 Types of Materials
• Composites: a material made from two or more constituent
materials with significantly different physical or chemical
properties that, when combined, produce a material with
characteristics different from the individual components.
• Mortars, concrete
• Reinforced plastics, such as fibre-reinforced polymer
• Metal composites

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Advanced Materials
• Semiconductors:
• having electrical properties intermediate between the
electrical conductors and insulator
• electrical characteristics are extremely sensitive to the
presence of minute concentrations of impurity atoms
 may be controlled
• made possible the advent of integrated circuitry for
electronics and computers

• Biomaterials:
• employed in components implanted into the human
body
• must not produced toxic substances and must be
compatible with body tissues
• metals, ceramics, polymers, composites, and semi
conductors may be used as bio materials

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Advanced Materials https://www.nasa.gov/sites/default/files/
smartrotor_3264x2448_0.jpg

• Smart Materials:
• Able to sense changes in their environments & respond
in a predetermined manner
• Components: sensor & actuator
• Examples: smart systems in helicopters to reduce
cockpit noise created by rotating blades. Use
piezoelectric sensor

• Nanoengineered materials:
• manipulate & move atom, & molecules to form a new
structures & design new materials
• Provide opportunity to develop mechanical, electrical,
magnetic & other properties

https://sbasse.lums.edu.pk/sites/default/files/styles/620_x_350/public/physics_1.jpg?itok=TiXBPkOH

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 Modern Materials’ Need http://cdn.oilprice.com/a/img/content/article/718x300/d69d914bde8bd5d98f82533d383a

• Nuclear Energy
• Save Energy Transportation
• Materials for Solar Panels
• Materials for Hydrogen Fuel Cell
• Materials for pollution control
• Renewable materials with less environmental
impact

http://www.aluminum-plates.com/Automotive_Aluminum_
http://www.energymatters.com.au/wp-content/uploads/ 10
Automotive_Plate_Sheet / 2014/09/solar-panels-australia.png
https://media.treehugger.com/assets/images/2014/11/
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Material Science & Engineering Disciplines

Material Scicence:
• Investigate correlation between structure and
properties

Material Engineering:
• Designing and engineering structure of material to
produce a predetermined set of properties
Design Flow Chart
1. Concept
Design

2. Geometrical
5. Testing
Design

3. Material
4. Manufacturing Selection
The Materials Selection Process

1. Requirements Determine required Properties

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

2. Identification & selection Identify candidate Material(s)

Material: structure, composition.

3. Processing Identify required Processing

Processing: changes structure and overall shape
ex: casting, sintering, vapor deposition, doping
forming, joining, annealing.

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 Structure, Processing, & Properties
• Properties depend on structure
Microstructure: ex: hardness vs structure of steel
a) Spherodite (d)
b) Perlite 600
c) Tempered

Hardness (BHN)
30 mm
500 (c)
Martensite Data obtained from Figs. 10.30(a)
400 (b) and 10.32 with 4 wt% C composition,
d) Martensite (a)
4 mm
and from Fig. 11.14 and associated
discussion, Callister 7e.
300 Micrographs adapted from (a) Fig.
10.19; (b) Fig. 9.30;(c) Fig. 10.33;
30 mm
and (d) Fig. 10.21, Callister 7e.
200 30 mm

100
0.01 0.1 1 10 100 1000
Cooling Rate (ºC/s)
• Processing can change structure
ex: structure vs cooling rate of steel
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Important Material Properties
• Torsinally stressed shaft
• Material selection criteria : Light, strong, affordable
• Develop performance index: strength/mass, strength/cost
Material Selection in Design – Strength/Mass
Consideration

Safe Performance
operation
Mechanical
Properties

Design Guidelines

Strength versus density materials selection chart. Design guidelines for performance indices of 3, 10, 30, and 100 (MPa) 2/3m3 /Mg have been constructed, all having a slope of (Adapted from
M. F. Ashby, Materials Selection in Mechanical Design. Copyright 1992. Reprinted by permission of Butterworth-Heinemann Ltd.)
Strength
Constraint >
300 MPa
Performace Index of Engineering Materials
Cost Index of Engineering Materials
 Electrical Properties
Wademan-Franz
Relation:

λ: Thermal conductivity
ρe: Resistivity
κ : conductivity

Non Metal = ?
Thermal conductivity, plotted against electrical resistivity. For metals the two are related
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Ashby, Material Selection, Chapter 4. Figure 4.10
 Thermal Properties

• Metal: linear relationship

• Foam – Porous material

deviate – good for
insulation Thermal conductivity, plotted against thermal diffusivity
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Ashby, Material Selection, Chapter 4. Figure 4.11
Optical Properties
Transmittance: Aluminum oxide may be transparent,
translucent, or opaque depending on the material structure.

Aluminum Oxide:
• Single crystal : transparent
• Connected small single
crystal: Translucent
• Interconnected small single,
small pores/void spaces:
Opaque

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

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 Deteriorative Properties: Friction & Wear

Tribology: Study of Friction and

Wear
• Cost problem due to lost of
energy and worn equipment
• Low Friction  More efficient
system
• Less wear  Equipment last
longer

Ka : wear constant
H : Hardness
P : Pressure
Best Design: Lowest ka.H From Fig 4.16: Ashby, Material Selection 24
 The History of Aircraft Materials

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Material Selection: Aircraft material
 Material used in the Boeing 787

http://www.1001crash.com/index-page-composite-lg-2.html
The History of Aircraft Materials
• Questions to answer in this module…

• What is the brief history of the materials used to construct aircraft?

• Why were these materials adopted?
• Why did some materials replace others?
• What is the future for materials in aircraft?

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1903 - First flight - Wright Brothers

Aluminum engine block

Spruce & steel wire structure
Fabric skin

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1903 - Wright Brothers
• Why wood and wire structure?
• Why fabric skin?

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1903 – Aluminum Engine Block
Most internal combustion engines of the time were of cast iron
construction

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1915 – All Metal Airplane
Hugo Junkers
Steel tubing
Sheet iron skin

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1916 - Stressed Skin Construction
LFG Roland C.II

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Stressed-Skin Construction
• Why stressed-skin?

Skeleton-like space frame

construction used for
non-stressed skin aircraft.

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1930’s – Increased Aluminum Use
Duralumin and Alclad

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1931 - Stainless Steel Construction

Budd BB-1 Pioneer

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Steel/ Stainless Steel vs. Aluminum

So why not build all aircraft out of stainless steel?

Corrosion resistance
Weight
Cost
Buckling failure

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1936 - Plastics Use Expands
Plexiglas

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1942 - Composites- Fiberglass
Cockpit components for war effort

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1940’s – 1950’s Superalloys
Before World War II iron based alloys were developed for high temperture work.
The war increased demand of performance materials for turbochargers and jets.

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1969 - Carbon Fiber Composites
Rolls-Royce RB211 jet turbofan engine

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1970 – Boron Fiber Composites
F-14 Tomcat

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1981 - Ceramics
Space Shuttle Thermal Protection Tiles

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1998 - Aluminum-Lithium
• Space Shuttle external fuel tank

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2005- GLARE
“GLAss-Reinforced” Fiber Metal Laminate (FML)

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2009 – Boeing 787 Dreamliner
Large scale composite use

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Future- Intelligent Materials
Inbedded sensors and monitoring systems
Materials change properties and configurations

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Future- Nanotechnology
Ultra-strength Composites
Locally tailored materials for
specific requirements

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Summary
• What is the brief history of the materials used to construct aircraft?
• Why were these materials adopted?
• What is the future for materials in aircraft?

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