Motilal Nehru National Institute of Technology Allahabad,

Prayragraj
Department of Applied Mechanics

Materials Science and Engineering

AM
 Course Code: AM-
Materials Science and Engineering
• Core Course. By Department of Applied Mechanics.
• Contact Hours/week - 3L. Credit – 3.
• Teacher’s Assessment (25).
• 10 marks for Home Assignments.
• 05 marks for Attendance.
• 10 marks for Teachers Appraisal.
• Mid Semester Examination (25).
• Written Exam
• End Semester Examination (50).
• Written examination.
• Students are requested to check “ACADEMIC CALENDAR”.

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 Course Code: AM-
Materials Science and Engineering
• Course Outcomes
• Students will be able to
• Understand role of structure at different level on properties,
• Apply concepts of Materials Science to analyze engineering problems,
• Select material for engineering application

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 Course Code: AM-13103
Materials Science and Engineering
Day Details Reference Materials
Unit 1. Introduction-Historical perspective of Materials Science, Structure and properties relationship of Engineering Materials,
Classification of materials, Introduction of Ceramics, Composite materials, Processing and Applications, Advanced Materials
Historical perspective of Materials Science, Structure and properties relationship of Engineering
1 Callister 9E: 1.1-1.4, 1.7
Materials, Classification of materials,
Requirement of materials and important applications, Classification of engineering materials with
2 the brief introduction of composite materials, smart/intelligent materials, functionally graded Callister 9E: 1.5-1.6
materials, biomaterials, nano-materials and polymeric materials
Unit 2. Structure of Solids and Characterization of Materials: Introduction to crystal structures and systems, Metallic structures,
Ceramic crystal Structures, Crystallographic directions and planes, Miller indices, Density computations, Crystallography,
Diffraction methods, Metallography, Introduction to electron microscopy and Thermal characterization techniques.
Crystalline vs non-crystalline solids, Space lattice, Unit cell, Bravais crystal system, Primitive cell, Coordination
3 number, Relation between r and a, Effective number of atoms, APF, Voids, Calculation of density,
Callister 9E: 3.2-3.5
4 Miller indices for Cubic System, Miller indices for Hexagonal System, Callister 9E: 3.7-3.10
Callister 9E: 3.11-3.12,
5 HCP & DC structure, Inter-planer spacing, Linear density and planer density,
12.4
6 Different methods of crystallography, Bragg’s diffraction law, Structure determination,
Callister 9E: 3.16
7 X-ray powder method and numerical
Metallography: Microscopy, Preparation of test specimen, Optical microscope- working, ASTM No for grain size
8 determination. Callister 9E: 4.9-4.11
9 Electron microscopy. Thermal analysis: TGA, DTA, DSC, TMA

AM13103 MSE, AMD, MNNITA, Prayagraj 4

 Course Code: AM-13103
Materials Science and Engineering
Day Details Reference Materials
Unit 3. Imperfections in Crystals: Types of imperfections, Point defects, Dislocations, Surface and Bulk defects
Classification of imperfections, Point imperfections: types, effects origin; Line
10 Callister 9E: 4.1-4.5
imperfections (Dislocation): edge, screw and mixed types
Berger vector, characteristics of dislocations, energy of dislocations; Frank-Read
11 Raghavan 5E: 6.2, 11.6
source, effects and remedies of dislocations, Related numerical.
Phenomena related to behaviour of dislocations such as glide motion, climb-up,
12 climb-down, cross-slip, jogs. Surface imperfections: grain boundary, twinning, Raghavan 5E: 6.3-6.4
low angle tilt boundary, stacking fault; Volume imperfections, Whiskers.
Unit 4. Diffusion: Diffusion mechanisms, steady and non-steady state diffusion, Factors that influence diffusion,
Law’s of diffusion, Applications of Diffusion.
Different types of diffusion such as self, inter, grain-boundary etc. and their
13 Callister 9E: 5.1-5.5
mechanism. Laws of diffusion: Fick’s 1st and 2nd law and their limitation,
Solution to 2nd law, Diffusion controlled applications: Carburizing, Nitriding
14 Callister 9E: 5.6-5.7
Decarburization, Corrosion, case hardening etc.
Experimental determination of diffusivity; Facts affecting diffusivity; Kirkendall
15 Raghavan 5E: 8.3-8.6
Effect; Activation energy for lattice, pipe, grain boundary and surface diffusion

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 Course Code: AM-13103
Materials Science and Engineering
Day Details Reference Materials
Unit 5. Phase Diagrams and Phase Transformations: Unary, Binary, Equilibrium phase diagrams, Eutectic, Eutectoid, Peritectic and peritectoid reactions,
Transformation rate effects and TTT diagrams. Microstructure and property changes in iron-carbon system, Iron-Carbon (Fe-C or Fe-Fe3C) Diagram
16 Different types of Phases, Solid solution, Hume-Rothery rule, Gibbs phase rule. Unary phase diagram of steel, Callister 9E: 9.1-9.6
Binary phase diagram, Eutectoid, Eutectic, Peritectic and Peritectoid, reaction, Phase diagrams of Pb-Sn, Pt-Ag, Al-Si to
17 Callister 9E: 9.7-9.14
be given as case study.
18 Iron – carbon equilibrium diagram, Micro-structural changes and Lever rule and related numerical, Effect of coring. Callister 9E: 9.17-9.19
Different types of heat treatment process and their purpose, Microstructure of steel and iron, T-T-T curve, Heating Callister 9E: 10.1-10.2,
19
temperature range of different processes: annealing, normalizing 10.5, 11.7
20 Precipitation Hardening, Age Hardening. Introductory idea of hardening, quench hardening, hardenability, tempering. Callister 9E: 11.8-11.9
Unit 6. Mechanical Behaviour of Materials: Elastic and Plastic properties, Creep, Fracture., Fatigue
Explanation of stress, strain and Young’s modulus, Elastic constants; Isotropy, anisotropy and orthotropy; stress- strain
21
diagrams of various materials in tension, compression, shear, bending etc.,
Stress-strain diagram of structural steel, Linearly and nonlinearly elastic properties: Bi-modulus material, secant and
22 Callister 9E: 6.2-6.10
tangent modulus, damping property;
Elasticity and plasticity; resilience, proof resilience and toughness; Ductility and brittleness, Malleability; True stress-
23
strain diagram in tension and compression.
24 Plastic Deformation: slip system
25 Critical resolved shear stress Callister 9E: 7.1-7.10
26 Yielding: mechanism of continuous and discontinuous yielding, strain hardening: its mechanism and effects;
Fracture; Ductile fracture: mechanism, types; Brittle fracture: Griffith’s theory and its salient features; Method of
27
protection against fracture; Ductile-brittle transition.
28 Fatigue: fatigue limit and S-N diagram, mechanism improving the fatigue life. Callister 9E: 8.1-7.13
29 Creep: creep curves, creep laws, factors affecting creep, mechanism, creep-resistant materials.

AM13103 MSE, AMD, MNNITA, Prayagraj 6

 Course Code: AM-13103
Materials Science and Engineering
Day Details Reference Materials
Unit 7. Thermal, Electrical, Magnetic, Optical Properties: Thermal behavior of materials, Electrical conduction,
Semi conductivity, Super conductivity, Dielectric behavior, Ferro electricity, Piezoelectricity, Magnetic
behavior of materials, Optical properties of materials and their applications
Electrical Conduction, Semi-conductivity, Classification of semiconductor
Callister 9E: 18.3, 18.10-
37 materials, super conductivity and special super-conducting materials, Ferrites.
8.11, 20.12
Photonic materials,
Dielectric materials. Piezoelectric and Ferro-electric materials,
38 Electromechanical materials, Mechanism of polarization and its Callister 9E: 18.19-18.25
measurements
Diamagnetism, Paramagnetism, ferromagnetism, Antiferromagnetism,
39 Ferrimagnetism, Domain and Hysterisis, Soft and hard magnetic materials, Callister 9E: 20.2-20.11
magnetic storage, Influence of temperature on magnetic behaviour
Thermal and Optical Properties

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 Course Code: AM-13103
Materials Science and Engineering
• Text/References Books:
• Callister Jr. W. D., and Rethwisch, D.G., “Materials Science and Engineering”: An
Introduction , Wiley, 99th edition.
• Raghavan V., “ Materials Science and Engineering: A First Course, PHI, 5th edition”.
• Van Vlack L.H., “Elements of Material Science and Engineering, Pearson, 6th edition”.
• Dieter Jr. G. E., “Mechanical Metallurgy”.

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• Introduction to Materials Sc & Engineering
https://nptel.ac.in/courses/113/101/113101002/
https://nptel.ac.in/courses/113/106/113106032/

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Unit 1 - Introduction
• Outline
• Historical perspective of Materials Science,
• Structure and properties relationship of Engineering Materials,
• Classification of materials,
• Brief introduction of Advanced Materials
 Ceramic Materials
 Polymeric materials
 Composite materials,
 Functionally graded materials,
 Nano-materials and
 Biomaterials,
 Smart/intelligent materials,
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Importance of Material?
• Living in Material World
• Most human activities require materials
• Transportation,
• Housing,
• Clothing,
• Communication,
• Recreation, and
• Food production (front page of book or the first slide)…
• Services, like
• Online virtual classes
• Banking and Finance…
• Virtually every segment of our everyday lives is influenced to one degree or another
by materials.
• Materials are probably more deep seated in our culture than most of us realize.
Ref. - MS&E, WDC & DGR, 9E, Sec. 1.1 AM13103 MSE, AMD, MNNITA, Prayagraj 11
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Historical Perspective of Materials Science

• Historically, the development and advancement of societies/nations have
been intimately associated to the members’ ability to access the natural
resources, manipulate or process materials to produce suitable materials
and products to fill their needs.
• In fact, early civilizations have been designated by the level of their materials
development…..
• Stone Age (2.5 million BC),
• Bronze Age (3500 BC),
• Iron Age (1000 BC)…

• Polymer Age?
• Silicon Age?
• Nano/bio-materials?
Ref. - MS&E, WDC & DGR, 9E, Sec. 1.1 AM13103 MSE, AMD, MNNITA, Prayagraj 12
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Scope of Present Course

• How many different types of materials do we know today?
• Solid, liquid, gas, powders, chemical, pharmaceutical, fibers, fabric, food, biomaterial etc.
• Scope of the Present Course
• Solid Materials used by engineers
• A very limited number of natural materials…..
• Stone,
• Wood,
• Clay,
• Skins, and so on…..
• Tens of thousands of different materials have evolved with rather specialized
characteristics that meet the needs of modern and complex society, including….
• Metals,
• Plastics,
• Glasses, and
• Composites (To name a few)

Ref. - MS&E, WDC & DGR, 9E, Sec. 1.1 AM13103 MSE, AMD, MNNITA, Prayagraj 13
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Why do we study materials?

• Engineers are associated with design and production of goods and services
for which they require material.
• Materials utilization was totally a selection process (Readymade) that
involved deciding from a limited set of materials based on its known
properties.
• The one best suited for an application by virtue of its characteristics.
• Understand the relationships between the structural elements of materials
and their properties.
• This knowledge, acquired over approximately the past 100 years, has
empowered them to fashion/design (Tailor-made), to a large degree, the
characteristics of materials.

Ref. - MS&E, WDC & DGR, 9E, Sec. 1.1 AM13103 MSE, AMD, MNNITA, Prayagraj 14
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Materials Science and Engineering

• Materials Science involves investigating the relationships that exist between the
structures and properties of materials.
• Materials Engineering involves, on the basis of these structure–property
correlations, designing or engineering the structure of a material to produce a
predetermined set of properties.
• The role of a Materials Scientist is to develop or synthesize new materials in small
quantities in lab
• The role of a Materials Engineer is to produce bulk material, to develop techniques
for processing of materials and/or create new products or systems using existing
materials
• Most engineering graduates are thus trained to be both Material Scientist and
Materials Engineers
• Materials Scientists and Engineers are specialists who are totally involved in the
investigation and design of materials.
Ref. - MS&E, WDC & DGR, 9E, Sec. 1.2 AM13103 MSE, AMD, MNNITA, Prayagraj 15
 Structure and Properties Relationship of U1

Engineering Materials
• Structure of a material usually relates to the arrangement of its internal
components.
• Classified in terms of (and with increasing) dimensionality
• Subatomic structure involves electrons within the individual atoms and interactions
with their nuclei.
• Atomic structure encompasses the organization of atoms or molecules relative to
one another.
• Microscopic structure contains large groups of atoms that are normally
agglomerated together. It is subject to direct observation using some type of
microscope.
• Macroscopic structure that can be viewed with the naked eye

Ref. - MS&E, WDC & DGR, 9E, Sec. 1.2 AM13103 MSE, AMD, MNNITA, Prayagraj 16
 Structure and Properties Relationship of U1

Engineering Materials
• The property refers to external stimuli subjecting on material that evoke some type
of response.
• A specimen subjected to forces experiences deformation.
• A polished metal surface reflects light.
• A property of a material is the kind and magnitude of response to a specific
imposed stimulus.
• Generally, properties are made independent of material shape and size.
• Virtually all main properties of solid materials may be grouped into six categories:
• Mechanical,
• Electrical,
• Thermal,
• Magnetic,
• Optical, and
• Deteriorative over time.

Ref. - MS&E, WDC & DGR, 9E, Sec. 1.2 AM13103 MSE, AMD, MNNITA, Prayagraj 17
 Structure and Properties Relationship of U1

Engineering Materials
• Mechanical properties relate deformation to an applied load or force; examples
include elastic modulus (stiffness), strength, and toughness.
• Electrical properties relate the stimulus is an electric field, such as electrical
conductivity and dielectric constant.
• Thermal behavior of solids can be represented in terms of heat capacity and
thermal conductivity.
• Magnetic properties demonstrate the response of a material to the application of a
magnetic field.
• Optical properties relate the stimulus is electromagnetic or light radiation; index of
refraction and reflectivity are representative optical properties.
• Deteriorative characteristics relate to the chemical reactivity of materials
(corrosion) and fatigue

Ref. - MS&E, WDC & DGR, 9E, Sec. 1.2 AM13103 MSE, AMD, MNNITA, Prayagraj 18
 Structure and Properties Relationship of U1

Engineering Materials
• An example of processing-structure-properties-performance principles in Figure is
showing three thin disk specimens placed over some printed matter.

Transparent
(Single Crystal)
Translucent (numerous
very small crystals
having boundaries)
Opaque (numerous
small crystals with
voids and pores)
Figure: Three thin disk specimens of aluminum oxide that have different structures obtained through
different processing in order to demonstrate their differences in light-transmittance characteristics.
Ref. - MS&E, WDC & DGR, 9E, Sec. 1.2 AM13103 MSE, AMD, MNNITA, Prayagraj 19
 Structure and Properties Relationship of U1

Engineering Materials
• All of these specimens are of the same material, Aluminum
Oxide, but the leftmost one is a single crystal (high degree of perfection).
• Center one is composed of numerous and very small single connected crystals, the
boundaries between these small crystals scatter a portion of the light reflected
from the printed page.
• Specimen on the right is composed not only of many small, interconnected crystals,
but also of a large number of very small pores or void spaces. These pores
effectively scatter the reflected light and render this material opaque.

• Thus, the structures of these three specimens are different in terms of crystal
boundaries and pores, which affect the optical transmittance properties.
• Furthermore, each material was produced using a different processing technique.

Ref. - MS&E, WDC & DGR, 9E, Sec. 1.2 AM13103 MSE, AMD, MNNITA, Prayagraj 20
 Structure and Properties Relationship of U1

Engineering Materials
• In addition to structure and properties, two other important components are
involved in the science and engineering of materials—namely, processing and
performance.
• The interrelationship among processing, structure, properties, and performance is
as depicted in the schematic illustration shown in Figure.

Figure: The four components of the discipline of materials

science and engineering and their interrelationship.

• Attention is required for relationships among these four components in terms of the
design, production, and utilization of materials.

Ref. - MS&E, WDC & DGR, 9E, Sec. 1.2 AM13103 MSE, AMD, MNNITA, Prayagraj 21
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Structure, Processing, & Properties

• Properties depend on structure
ex: hardness vs structure of steel
(d)
6 00
30 μm
5 00 (c)
BHN)
Hardness (BHN

4 00 (b)
(a)
4 μm
3 00
30 μm
2 00 30 μm

100
0.01 0.1 1 10 100 1000
Cooling Rate (ºC/s)
• Processing can change structure
ex: structure vs cooling rate of steel
Ref. - MS&E, WDC & DGR, 9E, Sec. 1.7 AM13103 MSE, AMD, MNNITA, Prayagraj 22
22
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Selection of Materials
• Many an Applied Scientist or Engineer, are exposed to a design problem involving
materials, such as (few)…..
• A transmission gear,
• The superstructure for a building,
• An oil refinery component, or
• An integrated circuit chip.
• Selecting the right material from the thousands available, the decision is based on
several criteria.
• In-service conditions must be characterized, that dictates the properties required
including deterioration of material properties that may occur during service
operation.

Ref. - MS&E, WDC & DGR, 9E, Sec. 1.3 AM13103 MSE, AMD, MNNITA, Prayagraj 24
 U1
Material Selection Process
1. Pick Application Desired Performance

2. Performance Determine required Properties

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

3. Properties Identify candidate Material(s)

Material: composition, structure.

4. Material’s structure Identify required Processing

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

5. Material & Processing Governs cost

Economic considerations are most overriding
Ref. - MS&E, WDC & DGR, 9E, Sec. 1.3 AM13103 MSE, AMD, MNNITA, Prayagraj 25
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Selection of Materials
• On only rare occasions does a material possess the maximum or ideal combination of
properties.
• Thus, it may be necessary to trade one characteristic for another.
• The classic example involves strength and ductility; normally, a material having a high
strength has only a limited ductility.
• The more familiar an engineer is with the various characteristics and structure–property
relationships, as well as the processing techniques of materials, the more proficient and
confident he or she will be in making judicious materials choices based on these criteria.

Ref. - MS&E, WDC & DGR, 9E, Sec. 1.3 AM13103 MSE, AMD, MNNITA, Prayagraj 26
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Classification of Materials
• Solid materials have been classified based on subatomic structure/bonding:
• Metals (Metallic bond: pool of electron, non-directional),
• Ceramics (Ionic – covalent bond: transfer of electron, non-directional ), and
• Polymers (Covalent bond: sharing of electron, directional).

• A classification scheme is based primarily on chemical makeup (bond) and atomic

structure of material.

• In addition, there are the composites that are engineered combinations of two or
more different materials.

Ref. - MS&E, WDC & DGR, 9E, Sec. 1.4 AM13103 MSE, AMD, MNNITA, Prayagraj 27
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Classification of Materials
• Metals are composed of one or more metallic elements (Fe, Al, Cu, Ti, Au, Ni).
• And also nonmetallic elements (C, N, O) in relatively small amounts.
• Atoms in metals and their alloys are arranged in a very orderly manner.
• Metals are dense, strong, ductile, high thermal and electrical conductivity, opaque to visible
light. reflective, polished metal surface is lustrous
• Ceramics are compounds between metallic and nonmetallic elements.
• They are most frequently oxides (Al2O3, SiO2), nitrides (Si3N4), and carbides (SiC), sulfides.
• The traditional ceramics are composed of clay minerals, cement, glass, and refractory
• Inert, Brittle, glassy, insulator, optically it may be transparent, translucent or opaque
• Some oxide ceramics (Fe3O4) exhibit magnetic behaviour and some superconducting
• Polymers include the familiar plastic and rubber materials.
• They are organic compounds that are chemically based on C, H, and other nonmetallic
elements (O, N, and Si).
• They have very large molecular structures, often chainlike in nature, that often have a
backbone of carbon atoms. polyethlene, nylon, polyvinyl chloride (PVC),.
• Soft, ductile, low strength, low density, thermal and electrical insulator, optically translucent
or transparent.
Ref. - MS&E, WDC & DGR, 9E, Sec. 1.4 AM13103 MSE, AMD, MNNITA, Prayagraj 28
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Comparison of Materials

Figure: Bar chart of density of various metals, ceramics, polymers, and composite materials.
Ref. - MS&E, WDC & DGR, 9E, Sec. 1.4 AM13103 MSE, AMD, MNNITA, Prayagraj 29
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Comparison of Materials

Figure: Bar chart of room temperature strength (i.e., tensile strength)

values for various metals, ceramics, polymers, and composite materials.
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Comparison of Materials

Figure: Bar chart of room temperature stiffness (i.e., elastic modulus)

values for various metals, ceramics, polymers, and composite materials.
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Comparison of Materials

Figure: Bar chart of room-temperature resistance to fracture (i.e., fracture

toughness) for various metals, ceramics, polymers, and composite materials.
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Comparison of Materials

Figure: Bar chart of room temperature electrical conductivity ranges

for metals, ceramics, polymers, and semiconducting materials.
Ref. - MS&E, WDC & DGR, 9E, Sec. 1.4 AM13103 MSE, AMD, MNNITA, Prayagraj 33
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Applications of Materials

Figure: Familiar objects made of Figure: Common objects made Figure: Several common objects
metals and metal alloys. of ceramic materials. made of polymeric materials.

Ref. - MS&E, WDC & DGR, 9E, Sec. 1.4 AM13103 MSE, AMD, MNNITA, Prayagraj 34
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Aluminium (Metal) Plastic (Polymer)

Point to Ponder
• Why tetra pack is not used for
packaging carbonated drinks?
• Why glass bottles are discontinued?
• If you have to choose one which one
will you choose and why?
Glass (Ceramic)
Ref. - MS&E, WDC & DGR, 9E, Sec. 1.4 AM13103 MSE, AMD, MNNITA, Prayagraj 35
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Advanced Materials
• Materials utilized in high-technology applications are termed advanced materials.
• High technology, mean a device or product that operates or functions using relatively
intricate and sophisticated principles.
• It includes
• Electronic equipment (camcorders, CD/DVD players),
• Computers,
• Fiber-optic systems,
• Spacecraft,
• Aircraft, and
• Military rocketry.
• These advanced materials are typically traditional materials whose properties have been
enhanced and also newly developed, high-performance materials.
• Advanced materials include polymers, composites, FGM, semiconductors, biomaterials,
and materials of the future (i.e., nano-engineered materials and smart materials).

Ref. - MS&E, WDC & DGR, 9E, Sec. 1.5 AM13103 MSE, AMD, MNNITA, Prayagraj 37
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Polymeric Materials
• Naturally occurring polymers—those derived from plants and animals includes
• Wood,
• Rubber,
• Cotton,
• Wool,
• Leather, and
• Silk.
• Other natural polymers, such as
• Proteins,
• Enzymes,
• Starches, and
• Cellulose.
• These are important in biological and physiological processes in plants and animals.

Ref. - MS&E, WDC & DGR, 9E, Sec. 14.1 AM13103 MSE, AMD, MNNITA, Prayagraj 38
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Polymeric Materials
• Today, most used plastics, rubbers, and fiber materials are synthetic polymers.
• The commercial use of synthetic polymers begins only around 100 years ago (modern/new).
• Since the conclusion of World War II, the field of materials has been virtually revolutionized
by the advent of synthetic polymers.
• Most polymers are organic and are hydrocarbons, composed of Hydrogen and Carbon.
• The synthetic polymers can be produced inexpensively, and their properties may be
managed to the degree that many are superior to their natural counterparts.
• The physical characteristics of a polymer depend not only on its molecular weight
and shape, but also on differences in the structure of the molecular chains.
• Modern polymer synthesis techniques permit considerable control over various structural
possibilities (linear, branched, cross-linked, and network, in addition to various isomeric
configurations).
• In some applications, metal and wood parts have been replaced by plastics, which have
satisfactory properties and can be produced at a lower cost.

Ref. - MS&E, WDC & DGR, 9E, Sec. 14.1, 14.2,

14.7, AM13103 MSE, AMD, MNNITA, Prayagraj 39
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Polymeric Materials
• The response of a polymer to mechanical forces at elevated temperatures is related
to its dominant molecular structure.

• One classification scheme for these materials is according to behavior with rising
temperature viz. Thermoplastics and thermosets.

• Thermoplastics soften when heated (and eventually liquefy) and harden when
cooled (recyclable).
• Thermosetting polymers become permanently hard during their formation and do
not soften upon heating (non-recyclable).

Ref. - MS&E, WDC & DGR, 9E, Sec. 14.9 AM13103 MSE, AMD, MNNITA, Prayagraj 40
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Polymeric Materials
• Commodity plastics – large volume ca. $0.50 / lb = INR 90/kg
Ex. Polyethylene
Polypropylene
Polystyrene etc.

• Engineering Resins – small volume > $1.00 / lb = INR 180/kg

Ex. Polycarbonate
Nylon
Polysulfone etc.

Ref. - MS&E, WDC & DGR, 9E, Sec. 14.9 AM13103 MSE, AMD, MNNITA, Prayagraj 41
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Polymeric Materials

Billiard balls made of phenol-

Top: Electrical connection positioned within a
formaldehyde (Bakelite)
section of as-received polymer shrink-tubing.
A polyethylene produce Center, Bottom: Application of heat to the
bag containing some fruit. tubing caused its diameter to shrink. In this
constricted form, the polymer tubing
stabilizes the connection and provides
electrical insulation. (Photograph courtesy of
Insulation Products Corporation.)
Ref. - MS&E, WDC & DGR, 9E, Chap. 15 AM13103 MSE, AMD, MNNITA, Prayagraj 42
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Composite Materials
• Composite is composed of two or more different materials (metals, ceramics, and
polymers).
• The design goal of a composite is to achieve a combination of properties that is not
displayed by any single material and also to incorporate the best characteristics of
each of the component materials.
• Some naturally occurring materials are composites (wood and bone).
• The most common and familiar composites is fiberglass (GFRP), in which small glass
fibers (relatively strong and stiff, but also brittle) are embedded within a polymeric
(epoxy or polyester) material (flexible). Helmet, Sheets
• Another technologically important material is the carbon fiber–reinforced polymer
(CFRP) composite—carbon fibers that are embedded within a polymer.
• CFRP composites are used in some aircraft and aerospace applications, as well as in
high-tech sporting equipment (e.g., bicycles, golf clubs, tennis rackets,
skis/snowboards) and recently in automobile bumpers.

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Composite Materials

One relatively complex composite structure is the modern ski. This illustration, a cross
section of a high performance snow ski, shows the various components. The function
of each component is noted, as well as the material used in its construction.
Ref. - MS&E, WDC & DGR, 9E, Chap. 16 AM13103 MSE, AMD, MNNITA, Prayagraj 44
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Composite Materials
A can of Double Core tennis
balls and an individual ball.
Each ball retains its original
pressure and bounces twice
as long as a conventional
one because the inner core
has a nanocomposite
barrier coating that
consists of a matrix of butyl
rubber, within which is
embedded thin platelets of
vermiculite. These particles
inhibit the permeation of
air molecules through the
walls of the ball.
(Photograph courtesy of
Figure 16.20 Locations of the various material Wilson Sporting Goods
types used in the Boeing 787 Dreamliner. Company.)
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Functionally Graded Materials

• Functionally Graded Material (FGM) belongs to a class of advanced material
characterized by variation in properties.
• The overall properties of FGM are unique and different from any of the individual
material that forms it.
• FGMs occur in nature as bone, teeth, etc.
• Nature designed this materials to meet expected service requirements.
• FGM eliminates the sharp interfaces existing in composite material where failure
(de-lamination) is initiated and replaces this sharp interface with a gradient
interface which produces smooth transition from one material to the next.
• One unique characteristics of FGM is the ability to tailor a material for specific
application.
Ref. -
https://pdfs.semanticscholar.org/0fef/378e55d75da
31e7f148e1487277307f0deed.pdf?_ga=2.24482424.
393070079.1596760119-198651655.1594895706 AM13103 MSE, AMD, MNNITA, Prayagraj 46
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Functionally Graded Materials

• Functionally graded materials can be divided into two broad groups namely..
• Thin FGM and
• Bulk FGM
• Thin FGM are relatively thin sections or thin surface coating.
• Bulk FGM are volume of materials which require more labour intensive processes.
• Thin section or surface coating FGM are produced by Physical or Chemical Vapour
Deposition (PVD/CVD), Plasma Spraying, Self-propagating High temperature
Synthesis (SHS), etc.
• Bulk FGM is produced using Powder Metallurgy, Centrifugal Casting, Solid Freeform
Technology, etc.

Ref. -
https://pdfs.semanticscholar.org/0fef/378e55d75da
31e7f148e1487277307f0deed.pdf?_ga=2.24482424.
393070079.1596760119-198651655.1594895706 AM13103 MSE, AMD, MNNITA, Prayagraj 47
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Functionally Graded Materials

• Some of the applications of functionally graded materials are highlighted below:
• Aerospace
• Functionally graded materials can withstand very high thermal gradient, this makes
them suitable for structure and space plane body, rocket engine component etc.
• FGM are promising and can be used in wider areas of aerospace.
• Medicine
• Living tissues like bones and teeth are characterized as FGM from nature, for their
replacement, a compatible material is needed that will serve the purpose.
• The ideal candidate for this application is functionally graded material.
• FGM has wide range of application in dental and orthopedic applications for teeth
and bone replacement.
Ref. -
https://pdfs.semanticscholar.org/0fef/378e55d75da
31e7f148e1487277307f0deed.pdf?_ga=2.24482424.
393070079.1596760119-198651655.1594895706 AM13103 MSE, AMD, MNNITA, Prayagraj 48
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Functionally Graded Materials

• Defense
• Most important characteristics of FGM is the ability to inhibit crack propagation.
• This makes it useful in defense application, as a penetration resistant materials used for
armour plates and bullet-proof vests.
• Energy
• FGM are used in energy conversion devices and also provide thermal barrier and are used
as protective coating on turbine blades in gas turbine engine.
• Optoelectronics
• FGM also finds its application in optoelectronics as graded refractive index materials and in
audio-video discs magnetic storage media.
• Application as cutting tool insert coating, automobile engine components, nuclear reactor
components, turbine blade, heat exchanger, tribology, sensors, fire retardant doors, etc.
Ref. -
https://pdfs.semanticscholar.org/0fef/378e55d75da
31e7f148e1487277307f0deed.pdf?_ga=2.24482424.
393070079.1596760119-198651655.1594895706 AM13103 MSE, AMD, MNNITA, Prayagraj 49
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Nano--materials
Nano
• Nanomaterials are new material class that has fascinating properties and
tremendous technological promise.
• They may be metals, ceramics, polymers, or composites.
• They are not distinguished on the basis of their chemistry but rather their size.
• Nano denotes the dimensions of entities on the order of a nanometer (10-9 m).
• Nanomaterials - Less than 100 nm (equivalent to diameter of approx. 500 atoms).
• Two approaches Top-down and Bottom-up
• Top-down is the general procedure scientists used to understand the chemistry and
physics of materials by studying large and complex structures and then investigate
the fundamental building blocks of these structures that are smaller and simpler.
• Bottom-up is approach/ability to arrange atoms, carefully provides opportunities to
develop mechanical, electrical, magnetic, and other properties that are not
otherwise possible.
Ref. - MS&E, WDC & DGR, 9E, Sec. 1.5 AM13103 MSE, AMD, MNNITA, Prayagraj 50
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Nano--materials
Nano
• Small nanoparticles have exceedingly large surface area–to–volume ratios, which can
lead to high chemical reactivities.
• Some of the physical and chemical characteristics exhibited by matter may experience
dramatic changes as particle size approaches atomic dimensions.
• For example,
• Some solids become liquids,
• Materials that are opaque in the macroscopic domain may become transparent on the nanoscale;
• Chemically stable materials become combustible, and
• Electrical insulators become conductors.
• Furthermore, properties may depend on size in the nanoscale domain.
• Because of these unique and unusual properties, nanomaterials are finding niches
in electronic, biomedical, sporting, energy production, and other industrial
applications.
Ref. - MS&E, WDC & DGR, 9E, Sec. 1.5 AM13103 MSE, AMD, MNNITA, Prayagraj 51
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Nano--materials
Nano

• Although the safety of nanomaterials is relatively unexplored, there are concerns

that they may be absorbed into the body through the skin, lungs, and digestive
tract at relatively high rates.

• If present in sufficient concentrations, will pose health risks—such as damage to

DNA or promotion of lung cancer.

• Whenever a new material is developed, its potential for harmful and toxicological
interactions with humans and animals must be considered.

Ref. - MS&E, WDC & DGR, 9E, Sec. 1.5 AM13103 MSE, AMD, MNNITA, Prayagraj 52
 Carbon Nano
Nano--materials

Prinzbach et al. (2000)

C720 and C540

Zope et al. (2008)

Okwundu, O.S.; Aniekwe, E.U.; Nwanno C.E.; UNLIMITED

POTENTIALS OF CARBON: DIFFERENT STRUCTURES AND USES
(A REVIEW), Metall. Mater. Eng. Vol 24 (3) 2018 p. 145-171 AM13103 MSE, AMD, MNNITA, Prayagraj 53
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Carbon Nano
Nano--materials

Figure 13.7 The structure Figure 13.8 The structure of single- Figure 13.9 The structure of a
of a C60 fullerene molecule walled carbon nanotube (schematic). graphene layer (schematic).
(schematic).

Ref. - MS&E, WDC & DGR, 9E, Chap. 13 AM13103 MSE, AMD, MNNITA, Prayagraj 54
 Applications of Carbon Nano-
Nano-materials

Okwundu, O.S.; Aniekwe, E.U.; Nwanno C.E.; UNLIMITED

POTENTIALS OF CARBON: DIFFERENT STRUCTURES AND USES
(A REVIEW), Metall. Mater. Eng. Vol 24 (3) 2018 p. 145-171 AM13103 MSE, AMD, MNNITA, Prayagraj 55
 Biomaterials
• Uses of Biomaterials
• Mainly, biomaterials are employed in components implanted into the human body
to replace diseased or damaged body parts.

Source: https://www.ele.uri.edu/courses/
AM13103 MSE, AMD, MNNITA, Prayagraj 56
bme462/handouts/Intro_Biomaterials.pdf
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Biomaterials
• These materials must be nontoxic.
• They must be compatible with body tissues (must not cause adverse biological
reactions).
• Types of Biomaterials based on biocompatiblity
• Bioinert (stainless steel, titanium, alumina, partially stabilized zirconia, and ultra high molecular
weight polyethylene).
• Bioactive (hydroxyapatite, tri-calcium phosphate).
• Bioresorbable (tricalcium phosphate, and polylactic–polyglycolic acid copolymers).

Ref. - MS&E, WDC & DGR, 9E, Sec. 1.5, & Web AM13103 MSE, AMD, MNNITA, Prayagraj 57
 Biomaterials
• All types of the materials—metals, ceramics, polymers, and composites may be
used as biomaterials.

Source: https://www.ele.uri.edu/courses/
AM13103 MSE, AMD, MNNITA, Prayagraj 58
bme462/handouts/Intro_Biomaterials.pdf
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Biomaterials

Drug Skin/Cartilage
Delivery Ocular
Devices Polymers Implants

Orthopedic Bone
screws/Fixation Replacements
Synthetic
Metals Ceramics
Bio--materials
Bio
Dental Dental
Implants Implants

Implantable Semiconductor Biosensors

Microelectrodes Materials

Ref. - AM13103 MSE, AMD, MNNITA, Prayagraj 59

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Biomaterials
• Example: Hip Implant
• With age or certain illnesses joints deteriorate. Particularly those with large
loads (such as hip).

Adapted from Fig. 22.25, Callister 7e. AM13103 MSE, AMD, MNNITA, Prayagraj 60
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Biomaterials

• Requirements
• mechanical strength (many cycles)
• good lubricity
• biocompatibility

Adapted from Fig. 22.24, Callister 7e. AM13103 MSE, AMD, MNNITA, Prayagraj 61
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Biomaterials

Adapted from Fig. 22.26, Callister 7e. AM13103 MSE, AMD, MNNITA, Prayagraj 62
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Biomaterials
• Hip Implant
• Key challenges to overcome Ball

• fixation agent to hold acetabular cup

• cup lubrication material
• femoral stem – fixing agent
Acetabular
• must avoid any debris in cup Cup and Liner

Femoral
Stem

Adapted from chapter-opening photograph, Chapter 22,

Callister 7e. (Photograph courtesy of Zimmer, Inc., Warsaw,
IN, USA.) AM13103 MSE, AMD, MNNITA, Prayagraj 63
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Smart/Intelligent Materials
• Smart Systems

Sensor Processor Actuator

• Temperature, • Shape,
• Electric fields, and/or • Position,
• Natural frequency, or
• Magnetic fields. • Mechanical characteristics.
• Smart material perform all the three tasks
• These materials are able to sense changes in their environment and then respond to
these changes in predetermined manners.
• Smart (or intelligent) materials are a group of new and state-of-the-art materials
developed that will have a significant influence on many of our technologies.

Ref. - MS&E, WDC & DGR, 9E, Sec. 1.5 AM13103 MSE, AMD, MNNITA, Prayagraj 64
 Smart /Intelligent Materials

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Smart/Intelligent Materials
• Smart Materials
• Shape-memory alloys: are metals that, after having been deformed, revert to their
original shape when temperature is changed.
• Piezoelectric ceramics: expand and contract in response to an applied electric field
(or voltage); conversely, they also generate an electric field when their dimensions
are altered.
• Magnetostrictive materials: the behavior of is analogous to that of the
piezoelectrics, except that they are responsive to magnetic fields.
• Electrorheological and magnetorheological fluids: are liquids that experience
dramatic changes in viscosity upon the application of electric and magnetic fields,
respectively.

Ref. - MS&E, WDC & DGR, 9E, Sec. 1.5 AM13103 MSE, AMD, MNNITA, Prayagraj 66
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Smart/Intelligent Materials
• Shape-Memory Alloys (An Example)
• A materials, after being deformed, has the ability to return to its predeformed size
and shape upon being heat treatment.
• Nickel–Titanium alloys (Nitinol) and Copper-base alloys (Cu–Zn–Al and Cu–Al–Ni).
• A shape-memory alloy is polymorphic (two crystal structures), and the shape-
memory effect involves phase transformations between them.
• One phase (termed an austenite phase, BCC) that exists at elevated temperatures.
• Upon cooling, the austenite transforms spontaneously into a martensite phase.

Ref. - MS&E, WDC & DGR, 9E, Chap. 10. AM13103 MSE, AMD, MNNITA, Prayagraj 67
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Smart/Intelligent Materials

Figure 10.37 Diagram illustrating

the shape-memory effect. The
insets are schematic
representations of the crystal
structure at the four stages. Ms
and Mf denote temperatures at
which the martensitic
transformation begins and ends,
respectively. Likewise for the
austenite transformation, As and
Af represent the respective
beginning and end transformation
temperatures.

Ref. - MS&E, WDC & DGR, 9E, Chap. 10 AM13103 MSE, AMD, MNNITA, Prayagraj 68
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Miles to go…
• In spite of the tremendous progress that has been made in the discipline of
Materials Science and Engineering within the past few years, technological
challenges remain, including the development of even more sophisticated and
specialized materials, as well as consideration of the environmental impact of
materials production.
• Some comment is appropriate relative to these issues…..
• Nuclear energy.
• Energy are involved in transportation and weight reduction.
• Solar power into electrical energy.
• Hydrogen fuel cell.
• Various materials for Pollution Control Techniques.
• Nonrenewable resources of materials.

Ref. - MS&E, WDC & DGR, 9E, Sec. 1.6 AM13103 MSE, AMD, MNNITA, Prayagraj 69
 U1
Self--help Problem
Self
Current state-of-the-art (material, properties, processing, cost and LCA, corrosion),
and future directions in development of material for any one of the following:
• Nano-composite,
• Semiconductor materials,
• Superconductor materials,
• Nano-material,
• Biomaterial,
• Smart-materials,
• Space materials,
• Defense materials,
• Liquid Crystal Display materials,
• Fibre-optics materials,
• Energy materials,
• Solar cell materials,
• Nuclear materials,
• Sports equipment materials,
• Chemical plant materials,
• Cell phone materials,
• Microprocessor materials etc.
Ref. - AM13103 MSE, AMD, MNNITA, Prayagraj 70
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References
• Ref. MS&E, WDC & DGR, 9E
• MATERIALS SCIENCE and ENGINEERING, 9th Edition, William D. Callister, Jr. and David G. Rethwisch,
Wiley Binder Version ISBN: 978-1-118-47770-0.
• https://pdfs.semanticscholar.org/0fef/378e55d75da31e7f148e1487277307f0deed.p
df?_ga=2.24482424.393070079.1596760119-198651655.1594895706

Ref. - AM13103 MSE, AMD, MNNITA, Prayagraj 71