Manufacturing materials – IE251 Chapter 1, Slide 1

IE 251 Manufacturing materials Instructor: Dr. Mohamed Ali Eissa Saleh

Room: ………….... 2A 128/1 Phone: …………... 467-3703

Grading Midterm #1: ………. .……….....…… 15% Midterm #2: ………. ……………….. 15% Lecture assignments ……………… 10 Lab #3: ………. ………………….……20% Final Exam: . ……...………………… 40%

Manufacturing materials – IE251 Chapter 1, Slide 2

Visual Materials...

Texts

● Fundamentals of Materials Science and Engineering, by William D. Callister, Jr.; John Wiley & Sons, Inc.

References Engineering Materials 1: An introduction to their

properties and applications - M. Ashby & D.Jones Engineering Materials 2: An introduction to

microstructures, processing & design - M. R. Ashby & D. R. H. Jones

Manufacturing materials – IE251 Chapter 1, Slide 3

Introduction to the structure, processing, properties and performance of Manufacturing materials metals, polymers, glasses, ceramics and composites

Case studies covering... selection of materials component design analysis of component failures

IE 251 Manufacturing Materials

Manufacturing materials – IE251 Chapter 1, Slide 4

The course objectives for the student

To develop an understanding of the impact of modern materials on the performance of products that are encountered daily, such as bicycles, beverage containers, and sports equipment.

To develop an understanding of the classes of engineering materials (metal alloys, polymers, ceramics and composites), with an emphasis on their properties and their uses.

To understand how the materials selection process fits into the product design, development and manufacturing process used by industry today. To come to appreciate that product cost and quality play a key role in the materials selection process.

To recognize that environmental regulations (emissions), and societal pressures (energy, safety) can strongly influence the adoption of new technologies and alternate materials.

To discuss the competition of alternate materials for the same application

Manufacturing materials – IE251 Chapter 1, Slide 5

syllabus

*Chapter 1. Introduction* *Chapter 2. Atomic

Structure and Bonding* *Chapter 3. The Structure

of Crystalline Solids* *Chapter 4. Imperfections

in Solids* *Chapter 5. Diffusion* *Chapter 6. Mechanical

Properties of Metals* *Chapter 7. Dislocations

and Strengthening Mechanisms*

*Chapter 8. Failure** Chapter 9. Phase

Diagrams*

*Chapter 10. Phase Transformations in Metals*

*Chapter 11. Thermal Processing of Metal Alloys*

*Chapter 13. Structure and Properties of Ceramics*

*Chapter 14. Applications and Processing of Ceramics*

*Chapter 15. Polymer Structures*

*Chapter 16. Characteristics, Applications, and Processing of Polymers*

*Chapter 19. Electrical Properties*

Manufacturing materials – IE251 Chapter 1, Slide 6

1. Engineering materials and their propertiesKey points

Enormous range of engineering materials Types of material properties Range of properties within and among materials classes Development of new materials and their impact on

design Failure to select suitable materials can lead to

failure of engineering structures and systems Some failures can be quite spectacular

Liberty shipsComet (1st commercial jetliner)Space Shuttle Challenger

Manufacturing materials – IE251 Chapter 1, Slide 7

Manufacturing materials – IE251 Chapter 1, Slide 8

There are more than 50,000 commercially available materials with which an engineer may

choose to designTable 1.2

Metals and alloys Steel, aluminum, etc.

Polymers Polyethylene, polystyrene,

nylon, epoxies, etc. Ceramics and glasses

Alumina, silica, silicon carbide, etc.

Composite materials Fiberglass, carbon fiber

reinforced polymers, etc. Natural materials

Wood, leather, silk, bone

How to Choose?

Manufacturing materials – IE251 Chapter 1, Slide 9

The Possible Combinations of Composite Materials are Virtually Unlimited

(Fig. 1.1)

Composites

PolymersCeramics,Glasses

Metals, Alloys

Steel cord tires cermets

Filled polymers

Manufacturing materials – IE251 Chapter 1, Slide 10

The Three P’s

SuccessfulCommercial

Products

Price

Performance Producibility

Manufacturing materials – IE251 Chapter 1, Slide 11

We Make Decisions Regarding Material Selection Based on

Material Properties Economic

Mechanical

Physical and Chemical

Electrical, magnetic, optical

Manufacturing

Aesthetics

Price, availablity, recyclability, etc.

Modulus, yield strength, tensile strength, etc.

Density, reactivity (oxidation & corrosion), thermal expansion, melting temp., etc.

Resistivity, dielectric constant, optical absorption, etc.

Forming, joining, finishing, etc.

Color, touch, texture, etc.

Manufacturing materials – IE251 Chapter 1, Slide 12

Screwdriver

Aesthetics

Economic Mechanical Physical and Chemical

ElectricalMagneticoptical

Manufacturing

Manufacturing materials – IE251 Chapter 1, Slide 13

Jet Engine Fan Blades(complex Ni base alloys)

Conventional Directionally Cast

Single Crystal

High Temperature Strength (creep)

Oxidation Resistance

Manufacturing materials – IE251 Chapter 1, Slide 14

Microelectronic Devices are Complex Composite Structures