MODULE- 3

ENGINEERING MATERIALS
INTRODUCTION

• Nowadays we use many types of materials, fashioned in many different ways to

satisfy our requirements for various purposes like housing, furniture, defense and
many more.
• There are various materials available and the choice of a particular material
for a specific application depends on the set of properties possessed by the
material
• Engineering materials are defined as solid substances, which are manufactured
and used for various engineering applications.

Common engineering materials that fall within the scope of material science and engineering
maybe classified into one of the following seven groups:
1. Metals (ferrous and non-ferrous) and alloys
2. Ceramics
3. Polymeric (plastic) materials
4. Composites

1. Metals (ferrous and non-ferrous) and alloys:

All the elements are broadly divided into metals and non-metals according to their
properties. Metals are element substances which readily give up electrons to form metallic bonds
and conduct electricity.
Some of the important basic properties of metals are:
• Metals are usually good electrical and thermal conductors,
• At ordinary temperature metals are usually solid,
• To some extent metals are malleable and ductile,
• The freshly cut surfaces of metals are lustrous,
• When struck metal produce typical sound and  Most of the metals form alloys.

When two or more pure metals are melted together to forma new metal whose properties are quite
different from those of original metals, it is called an alloy.
Metallic materials possess specific properties like plasticity and strength. Few favorable
characteristics of metallic materials are hardness, resistance to corrosion, good thermal and
electrical conductivity, malleability, stiffness, the property of magnetism, etc. Metals may be
magnetic, non-magnetic in nature.

I. FERROUS METALS:
Iron is the principal constituent of these ferrous metals. Ferrous alloys contain significant
amount of non-ferrous metals. Ferrous alloys are extremely important for engineering purposes. On
the basis of the percentage of carbon and their alloying elements present, these can be classified in
to following groups:
CLASSIFICATION OF FERROUS METALS
Ferrous
metal

Wrought
Pig iron Cast iron Steel
iron

Grey cast Low carbon

iron steel

White cast Medium iron

carbon steel

Malleable High carbon cast

iron steel

Ductile cast iron Alloy steels

Tool steel

Stainless steel
1) CAST IRON :
Cast iron is obtained by re-melting pig iron in cupola furnace by making certain changes to its
composition while in molten state.
Composition 90-92% iron, 2-4.5% carbon, 1-3% silicon and small amounts of sulphur, manganese
and phosphorous
Properties Low ductility, low melting point, good fluidity, castability, excellent machinability,
resistance to deformation.
Applications hardware-hinges, columns, fences, piping etc

a) Grey cast iron:

Most widely used type of cast irons. Its fractioned surface looks or appears grey due to presence
of graphite flakes.
Composition 2.5%-4% carbon, 1.3-2.3% silicon and small amount of sulpur,
phosphorous, manganese in small amount.
Properties High fluidity, very high compressive strength, excellent castability, wear resistant, more
brittle.

Applications Manufacturing of piston rings, cylinder and blocks, machine frames, flywheel.

b) White cast iron:

White cast iron is produced by chilling (rapid cooling) selecting areas of a casting in a mould, this
prevents graphite carbon from precipitating it out.
Composition 8-3.6% carbon, 0.5-2% silicon along with small amount of S, Ph, Mn
Properties Very hard and brittle, highly wear resistance, high compressive strength, machinability is
poor.
Applications Used for making pump liners, mill liners, extrusion nozzles, car wheels, crushers, clay
mixing.

c) Malleable cast iron:

It is produced by annealing-heat treated process in order to transform iron carbide present in white
cast iron to graphite.
Composition 2-3% carbon, 0.6-1.3% silicon, sulphur, manganese, phosphorous in small
amount
Properties Ductile, shock resistance and easily machined, highly malleable
Applications Manufacturing of automotive components such as crankshaft, transmission gears

4) STEELS:
Steel is an alloy of iron and carbon. Carbon content less than 2%, in addition various alloying
element like sulphur, phosphorous, manganese, nickel, chromium, copper etc. a) Low carbon steel:
It is also called as mild steel

Composition Iron+ 0.16-0.18% carbon, 0.4% silicon, small amount of s, ph, mn

Properties Good machinability, formability, more malleable, more ductile
Applications Manufacturing of gears, screws, nails, rivets, nuts, pins, shaft, some machine parts
 b) Medium carbon steel:

Composition Iron+ 0.25-0.59% carbon

Properties wear resistance, stronger less than low carbon steel
Applications making forging, manufacturing of automotive and machine
components, bolts, crankshaft, axels etc.

c) High carbon steel:

Composition iron+ carbon content in the range of 0.6-1%.

Properties posses’ high hardness and wear resistance, very brittle

Applications used for making hammer, dies, screws, hacksaw blades, springs

5) Alloy steel:
Steel which have other element than carbon to provide specific characteristics are known as alloy
steels.
Composition alloying elements are Ni, Cr, Mo, Mg, Si, Vn, etc

Mild Steels (Low carbon steel):

The percentage of carbon in these materials range from 0.15% to 0.25%. These are
moderately strong and have good weldability. The production cost of these materials is also low.
Applications- Deep drawing parts, chain, wire, pipe etc.

Medium Carbon Steels:

These contains carbon between 0.3% to 0.6%. The strength of these materials is high but
their weldability is comparatively less. Applications- Rolls, screws, axels, crank shafts etc.
High Carbon Steels:
These contain carbon varying from 0.65% to 1.5%. These materials get hard and tough by
heat treatment and their weldability is poor. Applications- Rolling mills, rope wire, screw driver
hammers etc.

Plain carbon steel:

The steel formed in which carbon content is up to 1.5%, silica up to 0.5%, and manganese up to
1.5% along with traces of other elements is called plain carbon steel.
In general the types of cast iron are (a) grey cast iron and (b) white cast iron
Cast Irons:
The carbon content in these substances varies between 2% to 4%. The cost of production of these
substances is quite low and these are used as ferrous casting alloys. In general the types of cast iron
are (i) grey cast iron and (ii) white cast iron (i) Grey cast iron:
- Carbon here is mainly in the form of graphite. It contains 1.5 to 4.3% carbon and 0.3 to 5%
silicon. This type of cast iron is inexpensive and has high compressive strength.
Applications: To make IC engine cylinder blocks, pump housings, valve bodies, fly wheels,
machine tool base, etc.
(ii) White cast iron:
- In these cast irons carbon is present in the form of iron carbide is called as cementite which is hard
and brittle. It contains 2.5% carbon, 0.8 to 1.2% silicon. These cast irons are difficult to machine
and abrasion resistant.
Applications: Outer surface of car wheel, Rolls for crushing grains etc.

II. NON-FERROUS METALS:

These substances are composed of metals other than iron. However, thesemay contain iron in small
proportion. Out of several non-ferrous metals only seven are available insufficient quantity
reasonably at low cost and used as common engineering metals. These are aluminium, tin, copper,
nickle, zinc and magnesium.
CLASSIFICATION OF NON - FERROUS METALS

Non-
Ferrous
Metals
Copper & its Aluminium Lead & Nickel &
& its its
alloys its alloys alloys aloys

Brass

Bronze

Non- Ferrous Metals are engineering materials that do not contain iron.
The various reasons non ferrous materials are preferred
• Good strength to weight ratio
• Good resistance to corrosion
• Light weight
• High electrical and thermal conductivity
 DIFFERENCE BETWEEN FERROUS AND NON FERROUS METALS:

FERROUS METALS NONFERROUS METALS

Ferrous metals contains iron Nonferrous metals do not contain iron
Magnetic Nonmagnetic
Little resistance to corrosion More resistance to corrosion
High tensile strength Low tensile strength
Lower melting point Higher melting point

Aluminium:
This is the white metal produced from Alumina. In its pure state it is weak and soft but addition of
small amounts of Cu, Mn, Si and Magnesium makes it hard and strong.
Properties: - Good corrosion resistant, light weight, good thermal and electric conductor etc.
Applications: - Pistons, connecting rods power transmission lines, cooking utensils, aerospace and
marine applications, etc.
Aluminium is silverish white non ferrous metal extracted from bauxite mineral.

Composition Bauxite is a hydrated aluminium oxide. Mineral bauxite is primarily a mixture of

Al2O3, 3H2O, fe2O3, and SiO2
Properties light weight, easily machinable, highly reflective to heat and light, good conductor heat
and electricity, high ductility and malleability, good corrosive resistance.
Applications electrical applications, such as overhead cables, electrical wires, windings of motor,
generator, manufacturing of parts in aircraft, spacecraft, marine
applications.

➢ Magnalium:
- This is an aluminium alloy with 2 to 10 % magnesium. It also contains 1.75% Cu.
Properties: - Good damping properties, light weight, high thermal conductivity, low specific weight,
non toxic, etc.
Applications: - Due to its light weight and good strength it is used for aircraft and automobile
components.
 Copper alloys:
Copper is one of the most widely used non-ferrous metals in industry.
The following two important copper alloys are widely used in practice:

Brass (Cu-Zn alloy): It is fundamentally a binary alloy with Zn up to 50%. As Zn percentage

increases, ductility increases up to ~37% of Zn beyond which the ductility falls. Lead or tin imparts
other properties to brass. Lead gives good machining quality and tin imparts strength.
Brass is highly corrosion resistant, easily machine able and therefore a good bearing material.
Brass:

Composition alloy of copper and zinc the amount of zinc varying from 5-45%
Properties High strength than copper, good thermal and electrical conductivity. higher
machinability
Applications manufacture of nuts, bolts, taps, condenser and heat exchanger tubes

Bronze (Cu-Sn alloy): This is mainly a copper-tin alloy where tin may vary between 5 to 25
percentages. It provides hardness but tin content also oxidizes resulting in brittleness. Deoxidizers
such as Zn may be added. Gun metal is one such alloy where 2% Zn is added as deoxidizing agent
and typical compositions are 88% Cu, 10% Sn, 2% Zn. This is suitable for working in cold state. It
was originally made for casting guns but used now for boiler fittings, bushes, glands and other such
uses.
Properties: - It is soft, malleable and ductile and is a good conductor of heat and electricity.
Applications: - Electrical wires, circuits, plumbing fittings, refrigeration, air conditioning, water
supply systems, cookware, doorknobs etc.
b) Bronze:

Composition 88% copper, small amount of tin (not more than 11%).
Properties High strengths than brasses, higher hardness and better corrosion resistance, easily
machinable.

Applications bronze can be rolled into wires, rods and sheets due to good ductility and
malleability, condenser tubes, valve parts

2) LEAD AND ITS ALLOYS:

Lead is a soft, silvery white (or) greyish non-ferrous metal.
Properties It is a malleable, ductile, corrosion resistance and heaviest among all
common metals, poor conductor of electricity and poisons in nature.

Applications used for solder, electrical fuses and boiler plugs. It is also used as electrode in lead
acid batteries.
 3) NICKEL AND ITS ALLOY:
Nickel and its alloy are nonferrous metals with high strength and toughness, excellent corrosion
resistance and superior elevated temperature.
Applications: used in aerospace, power generation, petrochemical industries.

4) ZINC

Composition Zinc is a heavy, bluish white metal which can be extracted from zinc
sulphide
Properties air conductor of electricity, has relatively low melting and boiling point, resistant to
corrosion
Applications Usually used for coating steel to make galvanised items
5) TIN

Composition It is a silvery-white metal obtained from an oxide called tin stone by refining in a
reverberatory furnace
Properties Soft, malleable and ductile, corrosion resistant from water but is not resistant for acids
and alkalies, low melting point (232ºC)
Applications : It is coated for storing food and water, Used in perforated lanters, candle shields and
mirror frames, Used as roofing material due to its light weight and
corrosion resistance.

DIFFERENCE BETWEEN FERROUS AND NON FERROUS METALS:

FERROUS METALS NONFERROUS METALS

Ferrous metals contains iron Nonferrous metals do not contain iron
Magnetic Nonmagnetic
Little resistance to corrosion More resistance to corrosion
High tensile strength Low tensile strength
Lower melting point Higher melting point

SILICA
It is also called silicon dioxide, compound of the two most abundant elements in Earth's crust, silicon
and oxygen
Crystalline silica is a common mineral found in the earth's crust. Materials like sand, stone, concrete,
and mortar contain crystalline silica.
Silica is a chemical compound also known as silicon dioxide or silox. The chemical formula for
silicon is SiO2.
Silica may be found in many forms of nature.
For example, flint, quartz, and opalIt is also used to make products such as glass, pottery, ceramics,
bricks, and artificial stone.
Applications of Silica:
Silica has many industrial applications in abrasives and polishes; in glass manufacturing, fillers and
extenders, silica brick manufacturing as a catalyst; in specialty coatings, cleaners ceramics, electronics
optics, and refractories; in ferro-silicon manufacturing and rubber.
It is usually used to manufacture glass, ceramics and abrasives. Flooring, mortars, cement, roofing
shingles, asphalt, and other industrial materials all use silica to improve durability and structural
integrity.
As silica is resistant to weather, wear and corrosion, it is often used as a caulk or sealant.

CERAMICS

The word "ceramic" is derived from the Greek word keramikos meaning pottery.

“Ceramics can be defined as inorganic, non-metallic materials that are typically produced using clay
and other minerals from the earth or chemically processed powders.”

Ceramics may be crystalline in nature and are compounds of metallic and non-metallic elements such
as aluminum and oxygen (alumina), silicone and nitrogen (silicon nitride) and silicon and carbon
(silicon carbide).
Properties of ceramics

High hardness
Hi gh melting point
Good Thermal insulator
Highly electricity resistance
Low mass density
Generally, chemically inert
Brittle in nature
Zero ductility
Low tensile strength

Applications of ceramics

They are used in space industry because of their low weight

They are used as cutting tools

They are used as refractory materials

They are used as thermal insulator

They are used as electrical insulator

GLASS:

“Glass may also be defined as a hard, brittle, transparent or translucent material mainly
compound of silica, combined with varying proportions of oxides of sodium, potassium,
calcium, magnesia, iron and other minerals.

The term "glass" as ordinarily used refers to material which is made by the fusion of mixture
of silica, basic oxides and a few other compounds that react either with silica or with the basic
oxides.

Properties of Glass

1. Glass is an amorphous solid that is its constituent particles are not arranged in any regular fashion.
2. Glass is brittle that is it can easily crack by applying little external force.

3. Glass may be transparent or translucent depending upon the compounds used in its manufacturing.

GRAPHITE :

Graphite is a distinct material as it displays the properties of both a metal and a non-metal.
Although graphite is flexible, it is not elastic and has high electrical and thermal conductivity.
It is also chemically inert and highly refractory.
Properties of Graphite

• A greyish black, opaque substance.

• Lighter than diamond, smooth and slippery to touch.

• A good conductor of electricity( Due to the presence of free electrons) and good conductor of

heat.

USES:
Diamond’s crystal structure is isometric, which means the carbon atoms are bonded in essentially the
same way in all directions.  
• The special combination of chemical composition, crystal structure, and formation process gives
diamonds the qualities that make them extraordinary.
Properties

Besides the hardness, diamond provides an impressive combination of chemical, physical and mechanical
properties:
 Hardness

 Low coefficient of friction

 High thermal conducti vity

 High electrical resistivity

 Low thermal expansion coefficient

 High strength

Broad optical transparency from ultraviolet to infrared

 Resistant to chemical corrosion

 Biologically compatible

APPLICATIONS :

.  Wear components

 Cutting tools

 Thermal management ( in e.g. substrates, heat spreaders and heat sinks)

 Semiconductor devices

 Optical components

 Other high performance applications

POLYMERS

The word polymer comes from the Greek poly -, which means "many", and the mer, which
means "parts".

A polymer is a large molecule made up of chains or rings of linked repeating subunits, which are called
monomers.

Polymers usually have high melting and boiling points. Because the molecules consist of many
monomers, polymers tend to have high molecular masses.
Types of Polymers:

1. Thermoplastic Polymer 2.

Thermosetting Polymer
Shape Memory Alloys:
• Shape memory alloys are those materials, even after being deformed, have the ability to
remember and return to their original shape and size, upon appropriate heat treatment.
• Deformation is normally carried out at relatively low temperature, whereas, shape memory
effect happens due to heating.

• Among materials that are capable of recovering significant amounts of deformation, the
best known are Nickel-Titanium (NITINOL) alloys; and some Copper based alloys (Cu-
Zn-Al and Cu-Al-Ni).
A group of metallic materials that can return to some previously defined shape or size when subjected to
the appropriate thermal procedure.
 That is, shape memory alloys can be plastically deformed at some relatively low temperature
and, upon exposure to so me higher temperature, will return to their original shape.

Uses of Shape Memory Alloys

Medical Applications
 NiTinol SMA is [Link] can be used in the body without an adverse [Link]
is used as stent

 SMAs are used in Detistry for orthodontic braces which straighten the teeth

 Surgical Tools used in key hole surgery are made from SMA

Domestic applications
• SMAs can be used as actuators which exert a force associated with the shape change
• [Link] which are incorporated into green house windows to open or close them selves at a
given temperature

• SMAs are used in cut out switches for kettles, security door locks, fire protection devices
Manufacturing applications

• SMA tubes are used as couplings for connecting two tubes

COMPOSITE MATERIALS:
 In the present rapidly developing industrial era there is a need for the materials with specific
requirement of properties and it is impossible for any single material to fulfill all the required
properties, so the research and development of newer materials begun and the result is the composite
material.

Composites can be defined in many ways, for simple understanding we can define it as a
material which consists of two or more materials with significantly different properties in a
microscopic [Link] base material is called as matrix and constituent which is mixed to matrix is
called reinforcement material. In some composites along with these matrix and reinforcement, fillers
are also used in addition.

MATRIX

COMPOSITE
MATERIAL
REINFORCEMENT
MATERIAL

Figure: Composites
Composites play a most important role in many industrial applications. This is an evergreen
field for researchers to research on new composite materials which will satisfy the need of various
applications like structural, medical, house hold, industrial, construction, automobile, aerospace,
marine, electrical, electronics and many more.

Composites are heterogeneous in microscopic level, but they are statically homogeneous at
macroscopic level. Sometimes the properties obtained from composites formed may not be obtained
from its constituents and sometimes we may not call only addition or mixing of two or more materials
as composites as it must need to satisfy some conditions like,

• The mixture or addition of two or more materials should results in change of properties.
• The content of the reinforcement material should be more than 10% by volume.
Classifications of Composite Materials:

Composite
materials

Based on Based on
Fiber Matrix

Particulate Fiber Laminate Metal Ceramic Polymer

Figure - Classification of composites

Classification of composites based on reinforcement
1. Particulate reinforced composite.
2. Fiber reinforced composite.
3. Laminated reinforced composite.
Particulate reinforced composite:

Figure -Particulate reinforced composite

Particulate composites are formed by immersing particles of different shapes like sphere, rod, bead,
flake and some other shapes in matrix materials such as alloys, polymers and ceramics. They are
usually isotropic due to random addition of particles. These composites have many advantageous like
good strength, excellent working temperature, high resistance to oxidation, etc. General examples for
these particulate composites include polymer composites reinforced with different fillers such as finely
powdered glass, alumina particulates in rubber, silicon carbide particles in aluminum, polymers with
fine rubber particles and concrete made up of cement, crushed stones and sand.
Fiber Reinforced composites:
 Short fiber Long fiber
Figure - Short & Long fiber

Fiber composites consist of matrix reinforced by long and short fibers. Long fibers are
generally continuous and short fibers are discontinuous fibers. There are lot of things to be taken care
of when we manufacturing a fiber reinforced composite, which includes the dimension, position,
quantity, properties and bonding of the fibers and matrix. Fibers are generally anisotropic these fibers
may be unidirectional, cross woven or random. Generally long fibers are used most due to their load
carrying capacity is very low at the ends compared to the other. So as the rods are long, the ends are
less, and load carrying capacity is high. Examples of matrix materials include epoxy resins, metals like
copper, aluminum, steel and ceramics like calcium- alumino silicate. And examples of fiber reinforced
composites include glass fiber reinforced in epoxy, carbon fibers in polyester and banana fiber in
polymers.

Laminated Reinforced composite:

Figure - Laminated composite

Laminar composites may also called as platelet composites these are formed by two or more
successive thin layers having different grain or fiber orientation held together by matrix binder. And
laminated composites are more or less isotropic composite sheet that is weaker in any direction than it
would be if the fibers were all placed in one direction. These have two of their measurements much
bigger than the third. Examples include car bumper made of glass and epoxy laminates, plywood and
some golf clubs use graphite and aramide fiber laminates. And also some metal laminates also used in
pressure cookers, heating vessels, etc.
Classification based to type of matrix materials used:

1. Metal Matrix Composites (MMC).

2. Ceramic Matrix Composites (CMC).
3. Polymer Matrix Composites (PMC).

Metal Matrix Composites:

As the name only specifies metal matrix composites commonly called as MMCs uses metal as a
matrix material. Matrix materials such as aluminum, magnesium, titanium, iron, tungsten and nickel
are commonly used. And typical fibers used are carbon, silicon carbide and alumina. MMCs are better
at higher temperatures than PMCs. They are mainly reinforced with metals and metal oxides to
enhance thermal and mechanical properties to meet the needs of design. And to enhance the properties
like strength and elastic stiffness, and control properties like thermal and electrical conductivity by
adding silicon carbide fillers.

MMCs generally consist of bulky metals like steel and aluminum to increase their properties
and advantages such as high specific strength and modulus by adding low density metal oxides like
alumina and titanium dioxide. And graphite is used as reinforcing material to lower coefficients of
thermal expansion. The applications of MMCs are in space vehicles, military, transportation, etc.

Ceramic matrix Composites:

Ceramic matrix composites as their name only say they use ceramic as matrix material. They
are even called as CMCs. Ceramic composites are very hard in structures as they commonly reinforced
by the materials like carbon and silicon carbide, cause of which they are brittle and have high service
temperature. CMCs fracture toughness is very high because of reinforcement materials like silicon
carbide. Ceramic composites are strong but they lack in ductility. CMCs are used in aerospace engine
parts and outer protective shields due to their high strength and temperature resistance capacity.

3. Polymer Matrix Composites:

Polymer matrix composites also known as PMCs are most commonly used and advanced
composite materials which consists of polymer like polyester, epoxy, urethane reinforced by fibers like
glass fiber, carbon fiber, armide, boron fibers. Due to less cost, excellent strength to weight ratio and
easy manufacturing techniques make PMCs find most important applications in many industries like
aerospace structures, automobile parts, structural applications and many more. Now a day's polymer
composites replaced many conventional materials and metals.
 There are two basic categories of polymer matrices:

i) Thermo sets.
ii) Thermoplastics.

Roughly 95% of the composite market uses thermosetting plastics.

1. Thermosets
The materials which are once set or manufactured then cannot be molded back are called as
thermo sets. The most commonly available thermo set resins are epoxy, polyester and polyvinyl Ester.
They have a large grade of chemicals and verity of physical and mechanical properties. Thermosetting
polymers are formed by chemical cross linking of the liquid resins to get into a hard tuff solid. Thermo
sets are usually strong, and are very brittle when compared to thermo plastics. In general Thermo sets
are thermally stable, dimensionally stable, they have good rigidity, light weight, and they are thermally
and electrically insulating, and have high resistance to creep, they are deformed under load.

2. Thermoplastics
The materials which can be remolded even after setting or manufacturing just by applying heat
are called as thermoplastics. Thermo plastics are not cross linked like thermosetting materials. Inbuilt
characters of the monomers and their excellent molecular weight
is responsible to get their strength and stiffness. The generally available thermoplastics are
polyethylene, polystyrene, polyamides, nylon and polypropylene.

Applications of composite materials:

1. Aerospace:
➢ Polymer composites are having 5 to 10 times higher specific strength than the aluminium
alloys hence it is widely used in aircrafts.
➢ Skeleton of the aircraft is built by using aluminium based MMC
➢ The important parts like rudder, elevators, ailerons etc. are made of PMC  The salient
features of the composites used in aerospace applications are:
• High strength to weight ratio.
• High stiffness to weight ratio.
• Excellent fatigue performance.
• Corrosion resistance.
• Flexibility in design.
 2. Automobile:
➢ Steel and cast iron used in olden days are completely replaced by composites to reduce
the weight and increase the fuel efficiency and speed.
➢ Aluminium based MMC’s are used in engine blocks, piston, connecting rod, body of
vehicle.
➢ Fiber Reinforced Polymers(FRP) are widely used in Steering wheel, front and rear
bumpers, doors, interiors etc.

Piezoelectric Materials

Working Principle
• Generates electrical charge when mechanical stress is applied
• Also produces mechanical deformation when voltage is applied
Applications
• Sensors and actuators
• Ultrasonic transducers
• Vibration control

Magneto-Rheological (MR) Fluids

Working Principle
• Viscosity changes when exposed to a magnetic field
Applications
• Automotive suspension systems
• Shock absorbers
• Prosthetic devices
Shape Memory Alloys (SMA)

Working Principle
• Remembers original shape
 • Returns to original shape when heated
Applications
• Medical stents
• Actuators
• Robotic components

Advantages of Smart Materials

• Automatic response
• Improved system efficiency
• Compact and lightweight

Disadvantages of Smart Materials

• High cost
• Limited operating range
• Complex control systems

Applications of Smart Materials

• Aerospace structures
• Biomedical devices
• Smart sensors and actuators
• Vibration and noise control

• Ferrous metals contain iron; non-ferrous metals do not

• Composite materials consist of matrix and reinforcement
• Smart materials respond to environmental stimuli
• Piezoelectric materials convert mechanical energy to electrical energy
• MR fluids change viscosity with magnetic field
• Shape memory alloys return to original shape on heating

Shape Memory Alloys:

• Shape memory alloys are those materials, even after being deformed, have the
ability to remember and return to their original shape and size, upon appropriate
heat treatment.
• Deformation is normally carried out at relatively low temperature, whereas, shape
memory effect happens due to heating.
 • Among materials that are capable of recovering significant amounts of
deformation, the best known are Nickel-Titanium (NITINOL) alloys; and some
Copper based alloys (Cu-Zn-Al and Cu-Al-Ni).
A group of metallic materials that can return to some previously defined shape or size when
subjected to the appropriate thermal procedure.
That is, shape memory alloys can be plastically deformed at some relatively low temperature
and, upon exposure to some higher temperature, will return to their original shape.

Uses of Shape Memory Alloys

Medical Applications
• NiTinol SMA is [Link] can be used in the body without an adverse [Link]
is used as stent
• SMAs are used in Detistry for orthodontic braces which straighten the teeth
• Surgical Tools used in key hole surgery are made from SMA

Domestic applications
• SMAs can be used as actuators which exert a force associated with the shape change
• [Link] which are incorporated into green house windows to open or close them
selves at a given temperature
 • SMAs are used in cut out switches for kettles, security door locks, fire protection
devices
Manufacturing applications

• SMA tubes are used as couplings for connecting two tubes

Theory Question Bank

1. Define Engineering Material. Briefly explain classifications of Ferrous and Non ferrous
metals(JAN/FEB 2023)
2. Define Welding. With a neat sketch explain the working of Electric arc welding
(JAN/FEB 2023)
3. Define the following terms
i. Ceramic [Link] [Link] [Link] Memory alloys (JAN/FEB
2023)
4. Define soldering. With a neat sketch explain the working of gas welding and name
different types of flames used in oxy acetylene welding (JAN/FEB 2023)
5. Describe the three types of carbon steels with applications
6. List the differences between Soldering, Brazing and Welding
7. Recite the classification of metals