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Transcript of BBM 10103 material technology
7/24/2019 BBM 10103 material technology
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#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
CHAPTER 1:
INTRODUCTION
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Introduction to material science and
engineering • Materials science and engineering is an multidisciplinary field
concerned with inventing new materials and improve previously
known materials by developing a deeper understanding of the
microstructure-composition-synthesis-processing relation ship.
• Material Science:-
The emphasis is on underlying relationship between the synthesis and
processing. Structure and properties of material.
• Material Engineering:-
The focus is on how to translate or transform materials to useful device
or structure.
#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
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The modern materials scientist plays three major roles in the
development of technology
1) Material Selection
In order to produce working machines from engineering design, each
part of the machine must fill a number of criteria, for example high
strength, high ductility, good electrical properties, low weight, orlow cost. The materials scientist responsible for recommending
materials to best fit these criteria
2) Materials research
The materials scientist determines the strength, wear resistance, and
other properties of materials as well as studying the microscopic,
electronic and atomic structures that give rise to these properties.
This enable both proper use of materials by engineers as well as the
possibility of designing new materials to fulfill specific needs
#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
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• Materials development
By applying the knowledge gained by studying the structure of
materials, the materials scientist can design materials with
specific properties by varying composition and processing.
Such work often results in materials which can be used in
applications that would have been impossible before.
#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
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Generic Product development flow
diagram
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Function
Material Shape
Process
Material selection and process cannot be separated from the shape and the
function of the product, two way interaction.
Function dictates the choice of
material and shape.
Process interacts withshape.
Process is influenced bymaterial
Shape restricts the
choice of material
and process.
#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
Factors that influences the material
selection process
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Mater ials Properties
Mechanical Physical Chemical Optical
Material Properties
Properties are the way the material responds to the environmentand external forces.
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Mechanical Properties
Deformation and fracture as a response to applied
mechanical forces
•
Strength•Hardness
•Ductility
•Stiffness
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Physical Properties (Thermal)
Affected by heat fluxes and temperature changes
•Thermal Capacity – Heat storage capacity of a
material
•Thermal Conductivity
–
Capacity of a material totransport heat
•Thermal Expansion – How a material expands or
contracts if the temperature is raised or lowered
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Physical Properties (Electrical)
Material response to electromagnetic fields
•Electrical Conductivity – Insulators, dielectrics,
semiconductors, semimetals, conductors,superconductors
•Thermoelectric – Electrical stimuli provoke thermo
responses; thermo stimuli provoke electrical responses
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Chemical Properties
Response and impact of environment on material
structures
•
Oxidation and Reduction –
Occur in corrosion andcombustion
•Toxicity – The damaging effect a material has on other
materials
• Flammability –
The ability of a material to ignite and
combust
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Example
Material
Properties
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Engineering Materials Classification
Composi tes
#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
Materials
Metals Plast ics Ceramics
Glass
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Materials
Metals Plastics
Steel
Stainless steel
Die & tool steel
Cast iron
Ferrous Non-ferrous
Aluminum
Copper
Zinc
Titanium
Tungsten
Thermoplast ics
Acrylic
Nylon
ABS
Polyethylene
Polycarbonate
PVC
Thermosets
Phenolic
Polymide
Epoxies
Polyester
Elastomers
Rubber
Polyurethane
Silicone
#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
Materials Classification Con’t
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Materials
Metals PlasticsCeramics
Glass
Carbides
Nitrides
Graphite
Diamond
Glasses
Glass ceramics
Composi tes
Reinforced
plastics
Metal-Matrix
Ceramic-Matrix
Laminates
#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
Materials Classification Con’t
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Major characteristics of metallic materials are crystalline,conductivity to heat and electricity and relatively high strength& toughness.
Classification: systematic arrangement or division of materials into
group on the basis of some common characteristicGenerally classified as ferrous and nonferrous
• Ferrous materials-iron as the base metal,
range from plain carbon (>98% Fe) to high alloy steel
(<50% alloying elements)
• Nonferrous materials consist of the rest of the metalsand alloys
Eg. Aluminum, magnesium, titanium & their alloys
Classifications & Specifications of MetallicMaterials
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Within each group of alloy, classification can be madeaccording
(a) chemical composition, e.g. carbon content or alloyscontent in steels;
(b) finished method, e.g. hot rolled or cold rolled;
(c) product form, e.g. bar, plate, sheet, tubing, structuralshape;
(d) method of production, e.g. cast, wrought alloys.
#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
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In most eng. application, selection of metallic is usually based on thefollowing considerations:
1) Product shape: a) sheet, strip, plate, (b) bar, rod, wire, (c)tubes, (d) forging (e) casting
2) Mechanical properties-tensile, fatigue, hardness, creep,impact
test3) Physical & chemical properties-specific gravity, thermal &
electrical conductivity, thermal expansion
4) Metallurgical consideration-anisotrophy of properties,
hardenability of steel, grain size & consistency of properties5) Processing castability-castability, formability, machinability
6) Sales appeal-color, luster
7) Cost & availability
#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
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• Polymer –
low density, good thermal & electrical insulation,high resistance to most chemicals and ability to take colours
and opacities.
• But unreinforced bulk polymer are mechanically weaker,
lower elastic moduli & high thermal expansion coefficients.
• Improvement Reinforced variety of fibrous materials
Composites (PMC).
#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
Classifications & Specifications of Polymers
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• Advantages : ease of manufacturing & versatility.
Can manufacture into complicated shapes in one stepwith little need for further processing or surface
treatment.
Versatility : ability to produce accurate component, with
excellent surface finish and attractive color, at low costand high speed
• Application: automotive, electrical & electronic products,
household appliance, toys, container, packaging, textiles
• Basic manufacturing processes for polymer parts are
extrusion, molding, casting and forming of sheet.
#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
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• Thermoset & thermoplastic
Differ in the degree of their inter-molecular bonding Thermoplastic-litle cross bonding between polymer,
soften when heated & harden when cooled
Thermoset-strong intermolecular bonding which
prevents fully cured materials from softening when
heated
• Rubber are similar to plastic in structure and the difference
is largely based on the degree of extensibility or stretching.
#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
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• Ceramics – inorganic compounds of one or more metals with a
nonmetallic element. Eg Al2O3, SiC, Si2 N3.
o Crystal structure of ceramic are complex
They accommodate more than one element of widelydifferent atomic size.
o The interatomic forces generally alternate between ionic &covalent which leave few free electrons
usually heat & electrical insulators.o Strong ionic & covalent bonds give high hardness, stiffness
& stability (thermal & hostile env.).
#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
Classifications & Specifications of Ceramic
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• Structure:
(1) Amorphous or glass-short range order, (2) crystalline(long range order) & (3) crystalline material bonded byglassy matrix.
• Clasiification:
Whitewares, glass, refractories, structural clay products& enamels.
• Characteristics:
Hard & brittleness,
low mechanical & thermal shock
High melting points
Thermal conductivities between metal & polymer
#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
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Design consideration for ceramics
• Britle, low mechanical & thermal shock-need special
consideration
• Ratio between tensile strength, modulus of rupture &compressive strength ~ 1:2:10. In design, load ceramic parts incompression & avoid tensile loading
• Sensitive to stress concentration Avoid stress raiser during design.
• Dimensional change take place during drying and firing, should be consider
• Large flat surface can cause wrapping• Large changes in thickness of product can lead to nonuniform
drying and cracking.
• Dimensional tolerances should be generous to avoid machining
#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
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#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
Classifications & Specifications of Composites
• Can be any type of mixture: polymer+metal, polymer+glass,metal+ceramic, ceramic+ceramic
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#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
Characteristics of Composites
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Design consideration for composites• Consider special characteristics and properties of
composites (why do you prefer them in the product?)• Composites combine the properties of different
materials and generate new properties• For example glass fibers are strong but brittle;
polymers are much tougher. A glass fiber reinforcedpolymer is both tough and strong.
• For conventional materials, the designer may consult ahandbook or manual to obtain a certain property
(strength, hardness, thermal conductivity- etc.)• For composite materials, the designer has to consult
“performance charts” or “carpet plots” representing aparticular property of a given composite system
#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
Application of Most Commonly Used Materials
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Ken Youssefi SJSU, ME dept. 28
Component Material
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Application of Most Commonly Used Materials
Application of Most Commonly Used Material
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Ken Youssefi SJSU, ME dept. 29
Application of Most Commonly Used Material
Component Material
#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
Application of Most Commonly Used Materials
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Ken Youssefi SJSU, ME dept. 30
Application of Most Commonly Used Materials
Component Material
#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
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Application of composite materials in
Boeing 757-200
#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
Source: Courtesy of Boeing Commercial Airplane Company
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#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
Example :Research impacts products (Nokia)
Power management
Battery life, charging,thermal durability
MaterialsStructural, functional,
optical, decorative
Cameras and optics
ElectronicsSemiconductors,
microelectromechanical
componentsAlgorithms
Signal processing, image and
sound processing
ProximityWLAN, Ultra Wideband,
RFID, Bluetooth
Voice & Video codecsImproved quality
Software and
ApplicationsPlatforms, middleware,
architectures
GSM/WCDMAStrong IPR portfolio
User experience
Ergonomy, usability, userinterfaces, user behavior,
security
MechanicsStructures, user interface,
mechanisms
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33 © 2005 Nokia YN10.10.2006
Materials research in products
Nokia 5140
• Integrated soft-hard
cover
Nokia N90
• Materials for
transformable
mechanics
• High strength &
accuracy, low friction
Nokia 7280
• laser patterned
decoration• half-mirror window
• thin rotator plate
#Mr. Muhammad Azri Bin Othman#BBM 10103# Pemilihan Bahan# SEM1 SESI 2013/2014#
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Multi-disciplinary research needed
Need research in multi-disciplinary areas• Materials technology• Novel manufacturing
technologies• Examples:
• Flexible/Printed
electronics• Nanotechnology
Drivers for futurecommunication devices • Enhanced user experience,
new features/functions,design look & feel
• Small, compact, easy touse, easy to carry/wear
• Integration of electronics
and mechanics forfunctionality andproduction