Students Learn About:
classification of materials
properties of materials
– physical and mechanical properties
structure of materials
– atomic structure
– bonding
– crystalline and non-crystalline structure
metals
– ferrous metals including mild steels
– non-ferrous metals including copper, brass,
bronze and aluminium
basic forming processes suitable for materials
– casting
– rolling
– extruding – cutting
– joining
– fabricating
polymers
– thermo softening
– thermosetting
ceramics
– common types used
– forming and shaping
composites
– timber
– concrete
Students Learn To:
classify a variety of materials
identify the properties of materials and explain the reason for their selection
describe the structure and bonding of materials
distinguish between and explain reasons for the use of ferrous and non-ferrous metals as components in engineering
describe the suitability of basic forming processes used on materials
distinguish between thermo softening polymers and thermosetting polymers
identify the types of engineering ceramics
identify forming and shaping methods
outline the properties and uses of composites in engineering
Materials can be classified according to their properties, or the way they occur in nature (e.g. iron ore), the way they are prepared (e.g. mild steel), the atomic/crystal structure (e.g. thermosetting polymer) or the industrial application of the material (e.g. refractory brick). In the next section materials have been grouped by their properties and how they occur or are manufactured.
All materials regardless of their state may be classed as elements, solutions, compounds or mixtures, depending on their chemical composition and their structure.
Elements: These are the basic building blocks of all matter. Elements cannot be broken down to simpler material. Most materials do not exist naturally as pure elements. The Periodic Table of Elements shows all the elements so far known to humanity.
Solutions: A solution is where one substance dissolves in another, such as sugar in tea or salt in water. Similarly many metals will dissolve in one another to form solutions. Solutions can exist as liquids or as solids, and are made up of a solute (the substance added) and the solvent (the material the solute is added to). Steels (carbon in iron) and brasses (zinc in copper) are both examples of a solid solution.
Compounds: Are a result of two or more elements that combine chemically in a fixed proportion. Unlike elements, compounds can be broken down into the elements that make them up. Examples of compounds are NaCl (salt), HO (water) and ALO; (alumina).
Mixtures: Are the result of two or more pure substances (elements OR compounds) mixed together mechanically without regard to any fixed proportion, that can be separated. Examples are ferrite and cementite (in steels) or salt and pepper. Here these can be mixed together in any ratio.
Strength: is the ability of a material to withstand applied loads without failure. Strength varies according to the type of load, tensile, compressive, shear or torsional.
Hardness: is the ability of a material to resist scratching, abrasion or indentation. Moh's scale of hardness lists 10 minerals in ascending order of hardness from 1 (talc)to 10 (diamond). Nowadays hardness is determined by special hardness tests that then assign a hardness number
Elasticity: is the ability of a material to return to its original shape and dimensions after being subjected to a load.
Stiffness: is the ability of a material to resist elastic deformation under load. This is also measured using Young's modulus (sometimes referred to as the modulus of elasticity).
Plasticity: is the ability of a material to undergo some degree of permanent deformation without rupture. Processes such as rolling, extruding, pressing, forging, and spinning depend upon plastic deformation and the ability of a material to alter its shape under load. Plasticity usually increases with temperature and this is why many processes are carried out at elevated temperatures. Glass and many other ceramics have no plasticity at room temperature, and therefore behave in a brittle manner.
Malleability: is the ability of a material to be hammered and rolled into thin sheets.
Ductility: is the ability of a material to be drawn out into thin wire. Not all materials that are ductile are malleable, e.g. lead is very malleable but not very ductile. Another use of the term ductility is a measure of the percentage elongation of a material when undergoing a tension test.
Fatigue: is the tendency of a material to break when subjected to repeated cyclic loading where the induced stress is well below the elastic limit.
Notch Toughness: is a measure of the amount of energy required to cause failure.
Chemical composition largely determines the behaviour of a material in all types of chemical reactions. With metals, the alloying elements and impurities present must be known if the expected performance of the metal is to be predicted with any accuracy. Metals that are found in nature in the forms of oxides, sulphides or carbonates are usually metastable in the metallic form. In the presence of aqueous solutions and atmospheric gases, they tend to revert to one of their more stable forms. This is the process of corrosion. Although polymers and ceramics do not suffer from corrosion as metals do, they too can undergo chemical changes in certain situations. Ultraviolet light, for example, often causes the chemical breakdown of some polymers.
Density: the amount of matter packed into a given volume. Some materials are more dense than others, which means that within equal volumes one material has a greater amount of matter present. Water and mercury, for example, are both liquid at room temperature, but a given volume of mercury will be considerably heavier than an equal volume of water. This is because mercury is denser, i.e. there is more matter packed into the same volume. The same is true for solids; compare equal volumes of aluminium and mild steel. Density is found by the formula:
𝝆 = 𝑚/𝑽
𝝆 = density (kg/m³)
𝑚 = mass (kg)
𝑽 = volume (m³)
Note that the symbol for density (the Greek letter rho, p) is the same symbol used for electrical resistivity, covered later. There should be little confusion between the two as they are used in vastly different contexts.
Porosity: is a measure of the amount of voids or pores that a material has. Porosity may naturally occur (timber) or be introduced in manufacture (porous bearings made by powder metallurgy).
Moisture content: is a measure of the amount of moisture present in the structure of a material. It is of great importance to timber where high moisture content reduces strength, and increases thermal and electrical conductivities. Some polymers can also absorb moisture, which has an impact on strength and electrical properties.
Thermal conductivity: the ability of a material to conduct heat. Generally, metals conduct heat well, and non-metals conduct heat poorly.
Heat Resistance: is determined by the melting point of a material, as well as how stable it is at elevated temperatures. An example is titanium that isn't stronger than an equivalent volume of chrome molybdenum steel at room temperature, but at 500°C has better strength due to its stability at elevated temperatures.
Electrical conductivity: is the ability of a material to conduct electricity. Metals and carbon are good conductors, pure water and timber are poor conductors, and air, glass, most polymers and ceramics are good insulators. Semiconductors are materials that are manufactured to be poor conductors. They allow small amounts of current to flow through them and are the basis for most modern electronic components. Materials such as silicon and germanium are infused with either boron or arsenic to produce either a small deficiency or small surplus of electrons. This then allows a small amount of electrons to flow through the structure, producing a low current flow.
Magnetism in metals is a result of unpaired electrons. When electrons are paired they spin in opposite directions and cancel out any magnetism. Some materials have unpaired electrons and so demonstrate permanent magnetism. There are three types of magnetism:
Diamagnetic magnetism, found in materials that are ionic and molecular materials;
Paramagnetic magnetism, found in materials with a single valence electron;
Ferromagnetic magnetism, found in materials which have large amounts of unpaired electrons and can become permanent magnets; only iron, nickel and cobalt (and their alloys) belong to this group.
Metals are one of the most important materials used by engineers. Societies and individuals have used metals since before the Bronze Age when copper was used before 4000 BC. Although the Iron Age was around 1000 BC, our society is still highly dependent on iron (now alloyed with carbon to form steel) due to the many desirable and varied properties it offers. Metals can occur naturally, e.g. gold, silver, platinum and copper. However most are in the form of ores that are extracted from the Earth's crust and refined to their pure form e.g. iron, aluminium, copper, lead and titanium.
Most metals used by people today are alloys that generally provide more desirable properties than the pure metal. Alloys are mixtures of two or more materials, one of which must be a metal, and the alloy generally has metallic properties e.g., steel (iron and carbon), brass (copper and zinc), bronze (copper and tin), aluminium bronze (copper and aluminium), duralumin (aluminium and copper) and solder (tin and lead).
Some publications call all aluminum alloys simply 'alloy'; however this term is misleading, as steel is an alloy as well.
Of the 92 naturally occurring elements, 70 are metals. However, most of these are nor of any use industrially. Metals can be loosely grouped into two groups, ferrous and nonferrous. Ferrous metals contain only those with iron as a primary constituent, and although there is less variety than in non-ferrous metals, they are used more frequently. For example, mild steel is extensively used in the building industry for reinforced concrete.
By definition, ferrous metals and alloys are those where iron is the primary constituent, e.g. iron, cast iron, carbon steel and stainless steel. Ferrous metals may be further grouped into either pure iron or steels. Pure iron is rarely used nowadays. Steels may be further grouped according to the amount of carbon added, the most common form of steel are mild steels. These have approximately 0.15% to 0.25% carbon and will also contain some manganese. (Steels are covered in more detail in Chapter 3). It should be noted that most steels used now are low alloy steels with various additions along with carbon to improve their performance
Mild steel is useful as it is easily formed, machined and welded, does not harden much if cooled quickly, and is quite ductile. It finds extensive use in construction. manufacturing, fasteners such as screws and bolts, motor shafts (in non-corrosive environments) and for the housings of any sheet steel objects ranging from toasters to cheaper computer towers.
It should be noted that mild steel, like all steels (except stainless steels), readily corrodes, and that the product of corrosion (commonly known as rust) is porous, thus promoting further corrosion. In most situations the steel must be painted or electroplated or galvanised (coated in zinc) to avoid extensive corrosion. Alternatively another ferrous alloy such as stainless steel could be used.
Stainless Steels: it is appropriate to mention stainless steels because in recent times their use has expanded greatly. Stainless steels are ferrous alloys with at least 10% chromium added; the chromium reacts with oxygen to form a chromium oxide layer that prevents the ferrous alloy from corroding further. The most common stainless covered more deeply in chapter 4. steels in use usually have both chromium and nickel added. Stainless steels are
Non-ferrous metals are all metals except iron, and non-ferrous alloys are those in Which iron is not a primary constituent. They may contain iron, but it should not be a major alloying element. The non-ferrous metals of greatest importance here are copper and aluminium. The main non-ferrous alloys of copper are brass (copper and zinc), bronze (copper and tin) and aluminium bronze (copper and aluminium).
Copper: this metal is used extensively in the electrical fields due to its high electrical conductivity (second only to silver). It is a heavy metal of red to orange colour, with high ductility and malleability and good corrosion resistance. Copper is used in applications such as electrical wiring, electrical contacts, and the wiring in electric motor armatures and rotors.
Brass: is a useful alloy of copper and zinc, and perhaps other metals. Brass can contain up to 40% zinc but beyond this the alloy becomes brittle and is of little use. Brass with 70% Cu and 30% Zn is called 70/30 brass or cartridge brass; 60/40 brass is harder and is sometimes called Muntz Metal. All brasses are corrosion-resistant and they are used in electrical appliances as switch gear and contacts. Most outdoor taps are cast using 60/40 brass. Brass is harder than copper and hence more wear resistant in certain applications. Brass finds use in some commercial espresso coffee machines as it as more stable thermal performance than aluminium alloys.
Bronze: is not as widely used as brass nowadays but finds extensive use in marine applications. Bronzes are alloys of copper and tin and may have various additions to improve corrosion resistance. They can be used as bearings and springs and also find use as cymbals. With additions of small amounts (greater than 0.1 % but less than 1 %) of phosphorus phosphor bronze is created; this alloy is quite suitable for spring and switch contacts. Bronzes are often used as low maintenance bearings. By pressing and sintering bronze powder a porous sleeve may be produced. The porous article is then impregnated with oil, graphite or polytetrafluroethylene (PTFE or Teflon™) for lubrication, thus producing a simple bearing that requires little maintenance. Lead is often added in amounts up to 5 % to improve the bearing properties.
Aluminium Bronzes: these alloys exhibit excellent corrosion properties at room temperature, and good wearing properties. They are golden in colour and can be used as brush holders in electric motors, gear wheels and also for moving contacts.
Aluminium: is a highly used metal which has low density and excellent corrosion resistance; however it has low strength and as such is usually used in alloyed form. Aluminum foil is almost pure aluminum, but industrially aluminium is alloyed with materials like copper, zinc, magnesium, lithium and other metals to gain excellent strength, and due to its low density it usually offers strength to weight ratios better than most ferrous alloys. Unfortunately some aluminum alloys lose aluminium's excellent corrosion resistance when they are alloyed, however this is deemed an acceptable compromise to gain the excellent strength to weight ratio.
To be able to use metals effectively in engineering, it's important to have an understanding of how they are structured at the atomic level.
In this video we'll explore metals, their microstructure, and various techniques like grain boundary strengthening, solid solution strengthening, precipitation hardening and work hardening that can be used to improve their properties.
We'll also cover phase diagrams, focusing on the diagram for Iron-Carbon atoms, that shows us the different phases like ferrite, austenite and cementite that can be found in steels for equilibrium conditions.
Casting is a forming process that involves heating up a material, such as a metal alloy and then placing it into a mould, either by gravity pouring or through the use of pressure. Moulds may be permanent moulds made of metal or they may be expendable moulds made of sand. Die casting uses permanent moulds and is extensively used for non-ferrous alloy casting. Sand casting is used for a lot of ferrous alloy casting.
Investment casting is an interesting casting process that has existed since Roman times. It involves making a pattern of the object in way, creating a mould around this, then melting out the wax to leave a cavity to receive the molten metal. This is what investment casting is also known as lost wax casting.
Polymers are formed in their molten state also, but this is called moulding not casting. Many polymers are made using injection moulding which is where molten polymer is injected into a mould. This allows very rapid production of polymers. Other moulding processes like blow moulding are used to crate containers like polymer bottles.
Many metals can be cast in the form of ingots or bars, but these are of little use industrially, often we want metal in long lengths with certain cross sections, for example, circular or square bar. To achieve this metal is passed through rollers. By passing the metals through rollers we can change the thickness and cross section of the metal. For example we can take square or rectangular cross section bar and roll it to be thinner or into a circular cross section.
Rolling may be done at high temperature (hot rolling) or at room temp or only slightly elevated temperature (cold rolling). Hot rolling is easier to do and the resulting bar is unstressed by the deformation, but they are less dimensionally accurate and they are usually covered in scale, and oxide that forms at the elevated temperature. Cold rollins is harder to do and the final metal's structure will be stressed and deformed, but it will have a better surface finish and be more dimensionally accurate.
Extruding may be likened to squeezing toothpaste from a tube. The final structure will take the form of the die through which the metal is passed. Extruded metals are usually passed through a die at an elevated temperate. Aluminium alloy window frames are generally made up from extruded sections.
Welding is a fabrication process that joins materials, usually metals or thermoplastics, by using high heat to melt the parts together and allowing them to cool, causing fusion. Welding is distinct from lower temperature techniques such as brazing and soldering, which do not melt the base metal.
If two pieces of the same metal touch in space, they will permanently bond together as there’s nothing separating like-atoms in a vacuum. An effect known as 'cold welding'.
this is the use of a tin-lead alloy (although other alloys are now available) to join two pieces of metal together, with little or no microstructural change. The solder forms an alloy at the surfaces of the materials which gives the join Steneth. The surface must be chemically cleaned by some type of flux to ensure good joint.
Solder melts at around 183°C and the amount of tin in an alloy is determined by the application of the solder and how it is used. The more fin, the more expensive the solder. For household appliances soldering is used in joining electrical wires together. This Solder is 60% tin and 40% lead and is perfect for electrical work due to its near single temperature change from solid to liquid (other solders go through a pasty par-liquid part-solid cooling range). The solder in wire form usually has a resin in the centre of the wire to 'wet' the joint and chemically clean it. This is called a flux.
Brazing and silver soldering: these processes use higher temperatures than soft soldering and produce stronger joints. Brazing uses a brass that is melted onto a ferrous metal at temperatures of around 860°C. For brazing the surfaces must be clean and the joint design must use capillary action (where the molten filler metal is drawn into a small gap) to draw the molten brazing alloy into the joint to maximise joint strength.
Silver soldering is similar but the joining material contains silver to allow the molten alloy to flow more smoothly. The alloys used in silver soldering usually melt around 620-750°C. Silver soldering is often used when joining dissimilar parent metals. For both processes a flux must be used to allow alloying at the interface as for soft soldering.
This method is used instead of metallurgical joining processes because metallurgical joining processes incur structural changes. Bolts and nuts, screws, studs and rivets may be used to fasten metals together. Special types of nuts and washers resist being undone. The drawback is the weakening of the joined materials due to hole drilling, and the possibility of corrosion around the joint due to dissimilar metals being used, or varying oxygen levels.
Cutting of metals is the removal of unwanted material. The cutting operation most familiar is cutting with a hacksaw. Some cutting and machining processes are summarised in Table 1.S. This list is not complete but shows the importance of cutting and machining processes.
Fabricating is the process of assembling an item from various components. Students may have experienced metal fabrication when mild steel components were welded together in class. Many components may be too difficult to manufacture using casting so fabrication from cut material becomes the better option. For example aluminium alloy and steel bicycle frames are fabricated from tubes of varying lengths and diameters welded together.
Polymers (better known as plastics) are generally solid materials made up of long molecular chains that are created by adding or connecting smaller molecules together. The name polymer comes from the terms poly (many) and mer (the smallest repeating unit of the polymer).
Due to their molecular nature polymers are usually covalently bonded (van der Waal's forces also are used in bonding) and as a result are good insulators of electricity and heat but are weak and have low temperature stability. These properties along with their strengths make them so widely used in the engineering. However polymers are primarily manufactured from crude oil, so any discussion of oil reserves and oil scarcity must take into account our dependence of polymers and how sustainable they are long term.
Polymer is a term that encompasses a large and diverse group of materials that has had a big impact on industrial and consumer applications since World War II. Polymers are often termed organic, due to carbon being the primary constituent. Although most polymers are synthetic, there are some natural polymers, such as shellac, natural rubber and cellulose fibres. However all other polymers that are used by the engineer are synthetic.
The importance of polymers to the modern engineer is obvious. One needs only to look at the various applications to modern devices as varied as cars, phones and electronic equipment to see that polymers are used in more and more applications.
The term polymer is a very broad term. The field has a wide group of materials, each having distinct structures and properties, which makes them useful in a wide range of applications. Similarly, the term steel is very general due to the wide range of steels available. However, we should try to refer to a specific polymer when describing a particular material for a certain application.
These polymers cannot be re-softened by heating. Once they are formed, heat cannot reshape them. Unlike thermoplastics, thermosets often have a stronger network structure that results in better rigidity and less elasticity than the thermoplastics.
During polymerisation covalent bonds form along the chains and also across it. The result is a rigid structure that cannot be softened, since the energy required to break the covalent bonds would burn the material.
It is possible to control the amount of cross-linking in thermosets, allowing different properties to be produced. Cross-linking can be controlled by heat or pressure as in formaldehyde or by catalytic action (also called cold setting) as in Epoxy or GRP resins.
Examples of thermosets used in industry are epoxy resins, vinyl ester resins and polyester resins. Polymers are dealt with further in Volume 2 Chapters 2, 3 and 4.
Of all the fields we have studied so far the field of ceramics has a wide range. In Some fields ceramics have been supplanted due to developments in polymer technology. However their combination their electrical insulation, stability at elevated temperatures thermal insulation properties, and resistance to chemicals make them useful many applications.
Ceramics have been used for centuries and are now finding new uses due to their hardness and good thermal properties. Ceramics occur naturally as rocks, such as granite (igneous - formed by volcanic activity), sandstone and shale (sedimentary formed by the settling and compaction of sediment), and slate and marble (metamorphic - formed by igneous or sedimentary rocks being exposed to extreme temperature and pressure and converting to another structure). They also occur naturally as clays. Any ceramic material that requires some form of purification, mixing or firing is a synthetic ceramic, e.g. clay-body ceramics, glass, refractories and cement.
Ceramics are important to the modern engineer. Ceramic materials are used in many situations where metals are unsuitable (e.g. furnace linings). Most new structures incorporate concrete of which ceramic materials are the predominant component. Modern ceramics are now being tested for use in turbine and diesel engines, as their high temperature stability and low thermal expansion allow improved fuel efficiency.
Porcelain and china are two of the clay body ceramics used widely in engineering seen around the home.
The clay- based ceramics are produced by moulding wetnexaterthe required shape This is then fired to a temperature that allows some of the material to "cement" the remaining material. This cement fills in the spaces around the solid material. The result is solid particles in a glassy matrix.
Porcelain has low porosity (less than 1%). This is important for crockery such as cups and plates which are used to hold beverages and food. It is a good thermal and electrical insulator. However it is brittle and heavier than polymers. Porcelain is glazed to improve aesthetics and reduce surface porosity to zero; your toilet is porcelain, a place where a porosity of zero is crucially important!
There is a wide variety of glasses available. The most used is the soda-lime glass. Glasses are inorganic fusion products that have cooled to rigidity without crystallising (thus they are amorphous).
Of all the ceramics, glass finds the greatest use in modern applications. Glass resists scratching and staining better than most polymers. However it is more expensive, so only better quality household equipment will use glass ahead of a polymer.
Ceramic cooktops also use special glass-ceramic tops which prevent the saucepan from directly contacting the heating element; these can be used as bench space when hotplates are not in use. They are durable, can withstand sudden temperature changes and have moderate impact resistance. These properties are achieved by using a medium alumina/silica glass that is 90% crystalline and virtually pore free. Adding a nucleation agent such as TiO2, and then heat-treating to promote recrystallisation, achieves this. Glass-ceramic has good mechanical strength and toughness, and a very low thermal expansion rate.
Refractories are materials that display stability at very high temperatures. Most refractory materials are ceramics and these refractory ceramics find use in ovens and furnaces.
A number of forming processes can be used with ceramics. The humble potter's wheel is still used for small batch production or one off items made of clay body ceramics. Automated versions now exist to mass produce plates, cups and bowls.
Toilets and porcelain bath ware may be manufactured using the slip casting technique where the liquid ceramic (slip) is poured into a porous mould. The mould draws out moisture which makes the slip nearest the mould dry out. The liquid slip is poured out leaving a shell which is the desired item. It is the fired in a kiln.
Glass sheets are rolled at an elevated temperature when the glass is more elastic and window glass is floated on molten tin to ensure a flat pane is created.
Spark plugs used in petrol engines use an ceramic insulator made of alumina. This ceramic insulator is manufactured using hot isostatic pressing where the alumin powder is placed in a rubber mould which is then compressed by a fluid surrounding the rubber mould. This compresses the powder greatly and ensures a dense ceramic product.
Ceramics are dealt with in further detail in Volume 2 Chapters 2 and 4.
Composite materials are made of different materials combined together, to capitalise on the desirable properties in each. Fibreglass™ is a good example. It uses very fine glass fibre with high tensile strength in a thermosetting resin matrix. The glass fibre provides good tensile strength, while the resin provides a toughness usually absent in glass. Other examples of composites are carbon fibre reinforced polymer, concrete and cemented tungsten carbide.
Timber is a natural composite that is composed of cellulose fibres, the tracheids, are held together by the lignin, a natural resin. This type of structure humanity has mittored with composites such as glass reinforced and carbon fibre reinforcer polymers.
Timber has excellent specific strength (strength to weight ratio) and reasonable performance in bending. It is adversely affected by the weather and is prone to attack from pests, such as timber. While it is very useful and renewable resource especially when using plantation timber, many hardwoods are not easily replaced once felled. And while new timber can be grown its removal can greatly damage fragile ecosystems.
These are polymers that have some fibre added to improve their rigidity and impact resistance. Glass and carbon fibre in polyester or epoxy resins are examples of this. These are used in a wide range of applications and have found extensive use in aeronautical fields. Carbon fibre composites now find extensive use in sporting applications, with sporting equipment such as kayaks now being made from these high strength composites.
Concrete is a composite that consists of cement, sand and aggregate (some type of ceramic usually basalt). The sand fills the gaps between the larger aggregate particles and the cement acts as a binder that holds it all together. Portland cement, the binder, is a man made ceramic that reacts with water and sets to a hard but brittle solid Concrete is a stronger and more efficient way to make large structures or paths than it is to use cement alone. Concrete is normally 4 parts aggregate, 2 parts sand and 1 part cement. Concrete is usually reinforced with steel to improve its resistance to bending.