Materials for Engineering
Applications (CH2210)
Prof. Shantha Egodage
Department of Chemical and Process Engineering
University of Moratuwa
Material Selection : Considerations
• Properties (Mechanical, Physical, Chemical, Manufacturing)
• Cost
• Availability
• Service in life
• Appearance
Materials
Classification of Engineering Materials
Metals Non-Metals
Ferrous Non-Ferrous Polymers Ceramics Composites
(contains Iron) (contains no Iron)
Refractories Fiber-
Elastomers
Wrought Iron Aluminum
(NR, SBR, PU, Glass reinforced
Cast Iron Copper Cement epoxy
EPDM
Pig Iron Nickel
Concrete composites
Carbon Steel Tin Thermosets
Alloy Steel Lead Abrasives Cermet
(P/F, Polyesters, (<20%metal)
Tool and die Zinc Bakelite, Epoxy
Graphite
steel Refractory metals Resins) Advanced Materials
Stainless steel Titanium
Nanoengineered Materials
Super alloys Thermoplastics Smart materials
(Acrylics, PE, PVC) Biomaterials
Metals
Element substances which readily give up electrons to form metallic bonds and
conduct electricity.
Important properties
Good electrical and thermal conductors
Solid at ordinary temperature
Malleable to some extent and ductile
Lustrous when freshly cut or polished
Produce typical sound when struck
Form alloys
Hard and Stiff
Metals may be magnetic, non-magnetic
in nature.
Metallic Materials
Pure Metal
Single metallic element
Metal ore: Composed of one or more metallic elements, and often also
nonmetallic elements (C, N, O) in relatively small amounts.
No use in engineering applications
Alloy Two or more pure metals are
melted together to form a new
metal of homogeneous mixture
Engineering Applications
Wrought iron (high corrosion resistance)
Steam and water pipes, Engine bolts and Railway Couplings
Cast Iron
Fly wheels, Railway tracks, Columns, Machine frames
Carbon Steel (Low, Medium, High)
Boiler plates, Bolts, Nuts, Keys,
Structural sections like beams, channels
Shafts, Gears, Connecting rods
Screws, Chisels, Ball bearings and Springs
Alloy Steels (Stainless steels, nickel)
Kitchen equipment, Shaving blades, Springs
Piston rods, axel
Engineering Applications
Aluminium
Metallurgical Applications (deoxidizer for steel and iron manufacturing)
Electrical cables, motors, rotors, Aircraft and automotive components
Packaging (foils and cans), roofing, windows, doors, solar panels in construction industry
Copper
Tubes in refrigerators, air conditioners
Electrical tubes, cables, knobs
Nickel
Catalysts for chemical reactions
Medical equipment, Vessels for heating and cooling
Tin
Storing food and beverages
Brass and Bronze
Door and window frames
Ceramic Materials
Inorganic nonmetallic materials containing metallic and non-metallic elements
High melting temperatures
Hard, Brittle, Strong, Stiff, Chemically Inert, Abrasion Resistant
Insulative to the passage of heat and electricity due to absence of conductive
Electrons
Classification based on composition
Oxides (Al2O3, SiO2, Nitrides (Si3N4), Carbides (SiC) Sulfides, Fluorides
Classification based on their application
Glasses, Clay products, Refractories, Abrasives, Cements, Advanced ceramics
Graphite, Diamond
Advanced Ceramics: Conductive/ Automotive/ Bio/ Nuclear/
Wear resistant/ Optical ceramics
Applications:
Oil free bearings in Food Processing Equipment
Furnace/kiln furniture
Substrates for electronic devices
Polymers: Long chain molecules, built from repeating chains of
smaller chemical units
Classification by Source of Availability
Natural Polymers:
Found in plants and animals. (proteins, starch, cellulose, rubber)
Biodegradable polymers called biopolymers.
Semi-synthetic Polymers:
Derived from naturally occurring polymers and undergo further
chemical modification. (cellulose nitrate, cellulose acetate)
Synthetic Polymers:
Man-made polymers (plastics: nylon-6, 6, polyesters, rubbers: nitrile
rubber, butyl rubber)
Classification of Polymers based on the Structure of the
Monomer Chain
Linear Polymers
containing long and straight chains (PVC)
Branched-chain Polymers
When linear chains of a polymer form branches (Low-density polythene)
Cross-linked Polymers
Composed of bifunctional and trifunctional monomers.
Have a stronger covalent bond in comparison to other linear polymers
(Bakelite, melamine)
Classification based on Molecular Forces
Elastomers
Rubber-like solids, weak interaction forces (Natural/Synthetic rubbers)
Fibres
Strong, tough, high tensile strength, strong forces of interaction (nylon 6,6)
Thermoplastics
Reversible phase upon cooling and heating; solid at room temp, liquid at High temp.
(PP, PVC, PE, PET)
Thermosetting polymers
Irreversible in phase by heating and cooling
Degrade /Decompose upon heating (phenolics, epoxies, polyesters)
The Best Engineering Application of Rubber
Rubber Products and
Components
Rail pads
Bushes and bearings
Flooring
Tubing
Dock fenders
Seals and gaskets
Bellows and Diaphragms
Cable covers
Microcellular packing
Plastic Products and Components
Bearings, Bushes
Gear wheels
Insulation panels
Door/Window frames
Nuts and bolts
Roofing, Flooring
Heat seal guides
Piston rings
Pump components
Pressure plates
Vessel liners
Safety glass & guards
Valve bodies
Water pipes and
plumbing accessories
Classification of Materials Based on Structure
Crystalline
One or Many Crystals; In each crystal, atoms show a long-range periodic arrangement
Single Crystals
Crystalline material made up of only one crystal
Polycrystalline
Crystalline materials with many crystals or grains
Amorphous
Arrangement of the material’s atoms does not have a long-range order
Classification of Materials Based on Function