ENGINEERING MATERIALS Thanks to Dr.

Ravindra for the

original slides

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MATERIAL APPLICATIONS

Firecrackers

Aerospace
Applications Semiconductors

Sports Equipment

Automobiles Buildings

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 MATERIALS CLASSIFICATIONS BASED ON PROPERTIES
Material
Classification

Metals Polymers Ceramics Composites Semiconductors

• High thermal • Low thermal • Thermal insulators • High strength • Variable resistivity
conductivity conductivity • Brittle • Low density • P-type doping
• High Density • Low Density • Electrical insulators • Electrical insulators • N-type doping
• Ductile • Low electrical • High stiffness • High stiffness
• High electrical conductivity • Stronger in • High strength
conductivity • Lower stiffness compression than • Ductile
• High stiffness • Lower strength tension
• High strength • Chemically inert
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PROPERTIES OF MATERIALS
Case Study: Soft-drink bottle
Properties need to be considered
▪Low density
▪Stiffness
▪Chemically inert
▪Formable
▪Recyclable
▪Inexpensive
Examples: Aluminium, Glass,
Polyethylene terephthalate (PET)

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 PROPERTIES OF MATERIALS
1. Physical Properties
 Density, Melting point
2. Mechanical Properties
 Strength, Stiffness, Hardness, Wear resistance
3. Electrical Properties
 Resistivity, Conductivity, Capacitance
4. Thermal Properties
 Heat capacity, Thermal conductivity, Melting point
5. Optical Properties
 Refractive index, Transmittivity
6. Chemical Properties
 Corrosion resistance, Solvent resistance
7. Magnetic Properties
 Magnetization, Permeability

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MECHANICAL PROPERTIES
• Tensile strength
• Yield stress
• Elastic modulus
• Poisson’s ratio
• Ductility
• Hardness
• Toughness The mechanical properties are defined in such a way that they are
independent of the size and geometry of the material specimen.

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[Link]
WHAT IS STRESS?

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TYPES OF LOADS AND STRESSES

Tensile Loading

Compressive Loading

Shear Loading
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[Link]
 STRESS AND STRAIN
▪When any solid body is subjected to external load, resisting forces are set-up within the body. These
internal resistances are called stresses.
▪A body subjected to tensile load, the corresponding resistance set-up in the body is known as tensile
stress.
▪When a material is subjected to a compressive load, the corresponding stress is known as
compressive stress.
▪When a section is subjected to the shear loading, the body is in a state of shear, the corresponding
stress is known as shear stress.
▪Strain is defined as the ratio of change in dimension to original dimension.

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 STRESS AND STRAIN
𝐸𝑥𝑡𝑟𝑒𝑛𝑎𝑙 𝐹𝑜𝑟𝑐𝑒 (𝐹) 𝐹
𝑆𝑡𝑟𝑒𝑠𝑠 𝜎 = 𝑆𝑡𝑟𝑒𝑠𝑠 𝜎 = 𝜋
𝐶𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 (𝐴) 2
𝐷 0
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𝐶ℎ𝑎𝑛𝑔𝑒 𝑖𝑛 𝑙𝑒𝑛𝑔𝑡ℎ (∆𝐿) 𝐿1 − 𝐿0

𝑆𝑡𝑟𝑎𝑖𝑛 𝜀 = 𝑆𝑡𝑟𝑎𝑖𝑛 𝜀 =
𝑂𝑟𝑖𝑔𝑖𝑛𝑎𝑙 𝑙𝑒𝑛𝑔𝑡ℎ (𝐿0 ) 𝐿0

The strain in the direction of the applied load is known as linear strain or axial strain.
𝐿1 − 𝐿0
𝐿𝑖𝑛𝑒𝑎𝑟 𝑠𝑡𝑟𝑎𝑖𝑛 𝜀𝑙𝑖𝑛𝑒𝑎𝑟 =
𝐿0

The strain in the perpendicular direction is known as lateral strain or perpendicular strain.
𝐷1 − 𝐷0
𝐿𝑎𝑡𝑒𝑟𝑎𝑙 𝑠𝑡𝑟𝑎𝑖𝑛 𝜀𝑙𝑎𝑡𝑒𝑟𝑎𝑙 =
𝐷0
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POISSON'S RATIO
Poisson's ratio : The ratio of lateral strain to linear strain

+𝜀𝑧
= 𝑛𝑜𝑟𝑚𝑎𝑙 𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑠𝑡𝑟𝑎𝑖𝑛 𝑖𝑛 𝑡ℎ𝑒 𝑙𝑜𝑛𝑔𝑖𝑡𝑢𝑑𝑖𝑛𝑎𝑙 𝑑𝑖𝑟𝑒𝑐𝑡𝑖𝑜𝑛
−𝜀𝑥
= 𝑛𝑜𝑟𝑚𝑎𝑙 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 𝑠𝑡𝑟𝑎𝑖𝑛 𝑖𝑛 𝑡ℎ𝑒 𝑙𝑎𝑡𝑒𝑟𝑎𝑙 𝑑𝑖𝑟𝑒𝑐𝑡𝑖𝑜𝑛

For isotropic material:

𝑙𝑎𝑡𝑒𝑟𝑎𝑙 𝑠𝑡𝑟𝑎𝑖𝑛 𝜀𝑥
ν=− =
𝑙𝑜𝑛𝑔𝑖𝑡𝑢𝑑𝑖𝑛𝑎𝑙 𝑠𝑡𝑟𝑎𝑖𝑛 𝜀𝑧
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 STRESS STRAIN GRAPH
Elastic Elastic Plastic
Region + Region
U
Plastic
Region

YU F
𝑆𝑡𝑟𝑒𝑠𝑠 𝜎

YL
P

P = Proportionality limit
C B YU = Upper Yield Point
YL = Lower Yield Point
U = Ultimate Strength
F = Fracture Point

𝑆𝑡𝑟𝑎𝑖𝑛 𝜀 12
[Link]
STRESS-STRAIN CURVE CHARACTERISTICS
▪The maximum stress from which the bar can return to its original length is the material's elastic limit
→ mostly proportional limit
▪ elastic limit is the maximum stress a material can withstand without permanent deformation
▪ proportional limit is the highest stress at which stress and strain remain directly proportional

▪The stress-strain relation is linear in the elastic region and the ratio of stress to strain, in the linear elastic region, is called
Young’s modulus of elasticity, E
𝜎 𝐹𝐿0
𝐸= =
𝜀 𝐴0 ∆𝐿
▪Physical significance of the Young's modulus (elastic modulus): It is a measure of the interatomic bonding forces and, therefore,
the stiffness of the material.
▪ A stiff material exhibits small deformation under large applied load.

▪Yield point is defined as the first stress in the material at which an increase in strain occurs without an appreciable increase in
stress. This behavior is known as yielding.
▪The maximum stress that a bar will withstand before failing is the measure of its tensile strength → ultimate tensile strength.
▪The stress at which the bar breaks is its breaking strength or rupture strength.

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 MECHANICAL PROPERTIES
Ductility of a material is measured by ▪A material that undergoes very little plastic
percentage elongation or reduction in area of a deformation before rupture is called brittle.
specimen after fracture → gradual failure ▪ no yielding no necking phenomenon
𝑓𝑖𝑛𝑎𝑙 𝑙𝑒𝑛𝑔𝑡ℎ − 𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑙𝑒𝑛𝑔𝑡ℎ ▪ ruptures suddenly, without warning → catastrophic failure
% 𝑒𝑙𝑜𝑛𝑔𝑎𝑡𝑖𝑜𝑛 = × 100
𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑙𝑒𝑛𝑔𝑡ℎ
𝑙 − 𝑙0 ▪Brittle materials are weak and unreliable in
= × 100
𝑙0 tension.
𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑎𝑟𝑒𝑎 − 𝑓𝑖𝑛𝑎𝑙 𝑎𝑟𝑒𝑎
%𝑟𝑒𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑖𝑛 𝑎𝑟𝑒𝑎 =
𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑎𝑟𝑒𝑎
× 100 ▪Cast iron, glass, and ceramics are the few
examples of brittle materials.
𝐴0 − 𝐴𝑓
= × 100
𝐴0
Material %elongation
Mild steel 20%
Cast iron 1%
Thermoplastics 50% - 500%
Thermosets 0.1% - 1% 14
SAMPLE STRESS-STRAIN GRAPHS
Brittle
Ductile
𝑆𝑡𝑟𝑒𝑠𝑠 𝜎

Plastic Elastomer

0.2%
𝑆𝑡𝑟𝑎𝑖𝑛 𝜀
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 MECHANICAL PROPERTIES
Toughness is a measure of the energy per unit Resilience is the capacity of a material to
volume a material can absorb before it fractures absorb energy elastically.
 area under the stress-strain curve up to point of fracture ▪ On removal of the load, the energy stored is given off
 Indicates good strength and ductility exactly as in spring when the load is removed.
▪ measured by the triangular area under the elastic portion
of the stress-strain curve.
▪ Greater resilience → Capable of absorbing greater
impact energy without any plastic deformation.
▪ Applications: shock absorbers, springs.

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 MECHANICAL PROPERTIES
Malleability of a material is its ability to be Hardness is a surface property measuring
flattened (deformed) into thin sheets without resistance to abrasion and indentation
cracking  Mohs scale: Qualitative hardness indexing scale.
 Ductility is a tensile quality → ability to deform under  1 for talc (soft) and 10 for diamond (hard)
tensile stress
 whereas malleability is a compressive quality → ability to
deform under compressive stress Techniques:
✓Rockwell hardness tests
Materials like aluminum, lead, copper, and tin ✓Brinell hardness test
have good malleability.
✓Vickers microhardness test
✓Knoop microhardness test

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COMMON ENGINEERING MATERIALS
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CAST IRON
▪Ferrous metal: Alloy of Iron with 2.1 to
4.5% carbon and 3.5% silicon.
▪Hard and Brittle
▪Advantages
▪ Good vibration damping
▪ High compressive strength
▪ Wear resistance

▪Applications:
▪ Machine beds and frames
▪ Knobs
▪ Impellers
▪ Pipe flange
▪ Railway wheel rim and brake shoes

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[Link]
STEEL
Alloy of Iron and Carbon in addition to
manganese, silicon, chromium and copper.

Types
1. Low carbon steel or mild steel (0.05 to 0.3%C)
2. Medium carbon steel (0.3 to 0.7%C)
3. High carbon steel (0.7 to 1.5%C).

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[Link]
ALUMINIUM AND COPPER

Aluminium Copper
 Non-ferrous material  Non-ferrous material
 High thermal conductivity  High thermal conductivity
 High electrical conductivity  High electrical conductivity
 Good corrosion resistance
Brass: Alloy of Cu and Zn
 Low density
Bronze: Alloy of Cu and Sn
Applications: utensils, decorative things,
Applications: utensils, electrical valves, bearings
appliances, airplanes, jet engines
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[Link]
ZINC AND TIN

Zinc and zinc alloy Tin

 Low melting point  Soft and ductile
 Brittle at room temperature  Good malleability
 Ductile at 110°C to 150°C  Good corrosion resistance
 4th most used industrial material  Good fatigue resistance

Applications: carburettors, fuel pumps, Applications: bearings, cans, solder wire

automobile parts

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SELECTION OF MATERIALS

Define • Properties of the component

Requirements • Cost, durability, strength, life-span, etc.

Possible • List all materials that satisfy the material requirements

Materials • List all the properties of the material(s)

• Final material selection

Make a Choice • Selection factors: availability of raw material, cost,
processing steps, environmental factors, etc.

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PROBLEM
A timber post having a rectangular cross-
section, has one side of section twice the
other.
The post is subjected to a compressive load
of 10 kN.
The load compresses the post by 0.05 mm
for 1 m length.
If the modulus of elasticity of timber is 10
GPa, calculate the dimensions of the post.

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