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An overview to the science of materials.
- 1. An Overview To The Science of Materials Presented by – W. Andrew Nallayan Associate Professor Department of Mechanical Engineering Dr.M.G.R. Educational & Research Institute
- 2. To be Covered… ● Objectives of Materials ● Material science & Fundamentals ● Evolution of Materials & Three Age System ● Material Classification ● Failure Analysis ● Engineering Disasters ● Plastics …The Good..Bad….and Ugly ● Career in materials
- 3. Objective – Material Science To Understand the Properties and Behavior of ▪ Metals ▪ Polymers (Plastics) ▪ Ceramics ▪ Semiconductors ▪ Composites
- 4. Material Science The central concept in Materials Science and Engineering is that the properties and behavior of every material is dependant on its microstructure, and that microstructure can be controlled by the way in which the material is made and processed. Structure – How the atoms fit together..? For crystalline materials, then this involves the size and shape of the crystals (usually called Grains)
- 5. Fundamental of Material Science Material science is the investigation of the relationship among the “components” i.e., Processing, Structure, Properties & Performance of the materials
- 6. Evolution of Materials Three Age System •1•Stone Age •2•Bronze Age •3•Iron Age
- 7. Stone Age 3.4 Million BC – 2000 BC 1.9 Million BC Olduvai Gorge, Tanzania 1.2 Million BC Olduvai George, Tanzania
- 8. Bronze Age 2000 BC – 1000 BC 1400 BC – France 1200 BC – Britain
- 9. Iron Age 1000 BC – 500 AD 900 BC – Iran 300 BC - Yorkshire
- 10. Steel Age First steel Age 500 AD – 850 AD 900 AD Oxford 1200 AD Damascus
- 11. Steel Age Second Steel Age 1876 – 1926 ➢ Great impact on Industrial Revolution ➢ Construction of Rail Roads Problem: Due to unproven structure steel production was slow and costly “Carbon content in molten iron” Solution: Henry Bessemer – 1856 – now called as Bessemer process – Effective way to introduce oxygen into molten iron – To reduce the carbon content/
- 12. Steel Age Second Steel Age 1876 – 1926 Other Revolutions 1876 – France 1906 – Portsmouth
- 13. The Development of materials over time. The materials of pre-history, on the left, all occur naturally; the challenge for the engineers of that era was one of shaping them. The development of thermo chemistry and (later) of polymer chemistry enabled man-made materials, shown in the colored zones. Three— stone, bronze and iron—were of such importance that the era of their dominance is named after them.
- 14. Materials Classification •Solid materials •Advanced Materials •Materials for the future
- 16. Advanced Materials ❖ Used in high Technology Applications •Semiconductors – Electronic Age •Bio materials
- 17. Materials for Future •Smart Materials • Piezoelectric • Shape memory • Thermo chromic • Photo chromic • Magneto Rheological •Nanoengineered Materials •Applied in – •Medical purposes •Tissue Engineering •Manufacturing & Materials •Environment •Energy Electronics
- 18. Smart Material - Piezoelectric ➢ On applying a mechanical stress to these materials it generates an electric current. ➢ Piezoelectric microphones transform changes in pressure caused by sound waves into an electrical signal.
- 19. Smart Material – Shape Memory ➢ After deformation - materials they remember their original shape - return back to its original shape when heated. ➢ Applications include shape memory “stents - tubes threaded into arteries” that expand on heating to body temperature to allow increased blood flow.
- 20. Smart Material – Thermo chromic ➢ These are the materials which change their color in response to changes in temperature. ➢ They have been used in “bathplugs that change color when the water is to hot” or “Sensing Temperature in Coffee cups”
- 21. Smart Material – Photo chromic These materials change color in response to changes in light conditions.
- 22. Smart Materials – Magneto rheological ➢It is a fluid ➢ Fluids become solid when placed in a magnetic field. ➢These can be used for buildings and bridges to suppress the damaging effects. ➢For example, high winds or earthquakes
- 23. Nanoengineered Materials – Medical Applications ● Polymeric micelle Nanoparticles - drugs to tumors ● Carbon Nanoparticles called Nanodiamonds ● For example: Protein molecules can be attached to nanodiamonds - increase bone growth around joint or dental implants. ● Chemotherapy drugs attached to nanodiamonds - tested for brain tumor treatment, and some researchers are looking to use the same to treat leukemia.
- 24. Alloys Alloy is a mixture of two or more elements with a certain fixed composition in which the major component is metal Aim: ▪ To increase the Hardness and strength of the metal ▪ To prevent corrosion or Rusting ▪ To improve the appearance of the metal surface
- 25. Properties of Alloys, Composition & Uses Alloys Composition Properties Uses Bronze • 90% Copper • 10% Tin ✓ Heat & strong ✓ Does not corrode easily ✓ Has shiny Surface ✓ Statues and monuments ✓ Medal swards & artistic materials Brass • 70% Copper • 30% Zinc ✓ Harder than copper ✓ Musical instruments & Kitchen wares Steel • 99% Iron • 1% Carbon ✓ Hard & Strong ✓ Construction of buildings & bridges Stainless Steel • 74% Iron • 8% Carbon • 18% Chromium ✓ Shiny ✓ Strong ✓ Doesn’t rust ✓ Surgical Instruments Duralumin • 93% Aluminium • 3% Copper • 3% Magnesium • 1% Manganese ✓ Light ✓ Strong ✓ Body of Aero planes & Bullet trains Pewter • 96% Tin • 3% Copper • 1% Antimony ✓ Luster ✓ Shiny ✓ Strong ✓ Making of souvenirs
- 26. Requirement – Alloy Design
- 27. Failure Analysis A Systematic approach and investigation to determine the most probable causes of failure When to consider a failure…? In general, an engineering component or assembly is considered to have failed under the following three conditions when the component is – Inoperable, – Operates but doesn’t perform the intended function – Operates but safety and reliability is very poor
- 28. Failure of mechanical components Failure of a mechanical component can occur in many ways – Elastic deformation is beyond acceptable limit – Excessive and unacceptable level of plastic deformation – Complete fracture and – Loss of dimension due to variety of reasons.
- 29. Fundamental causes of failure The failure of an engineering component in actual working conditions can occur due to very large of factors related with – design – Materials – manufacturing – service conditions etc…
- 30. Need to know causes of failure – Improper design – Improper selection of materials – Defects and discontinuities in metal itself – Improper processing of materials – Poor service conditions – Poor assembling – Poor maintenance
- 31. Major Engineering Disaster ➢ Titanic Ship – 1912 ➢ St. Francis Dam Flooding – 1928 ➢ Tacoma Narrow Bridge Collapse – 1940 ➢ Bhopal Gas Tragedy - 1984 ➢ Chernobyl Disaster – 1986 ➢ Space Shuttle Columbia Disaster – 2003
- 32. Titanic Ship - 1912 ● On April 14, 1912, Passenger ship (R.M.S. Titanic) that sank in less than 3 hours after collided with the massive ice berg from Southampton (UK) to New York city. ● More than 2200 passengers and crew were aboard the Titanic - more than 1500 lost their lives
- 33. Engineering Failure - Material Several Rivets of the 3 million Rivets - recovered and tested- found – Manufactured - low quality iron which on “impact” caused them to fall apart (Breakage) Example: “Impact Resistance” (iron) – low- Charpy Impact test
- 34. Causes & Reasons ● Metallurgists Tim Foecke and Jennifer Hooper McCarty - investigated - materials - building of the Titanic - Belfast shipyard – found - steel plates toward the bow and the stern were held together - low - grade iron rivets.
- 35. Reason For the Cause ✓ Higher-grade rivets may be in short supply ✓ The better rivets couldn't be inserted in those areas using the shipyard crane-mounted hydraulic equipment. ✓ The metallurgists said - low-grade rivets - ripped - more easily during the collision causing - ship to sink more quickly that it would have if stronger rivets had been used.
- 36. Engineering Failure - Design Water tight Compartments: Sections with intervening water tight partitions into which the interior of the large ship is usually divided for safety ➢ 16 water tight compartment that kept the boat a float - were not individually sealed - rather connected near ceiling - this enabled water to spill - one compartment to another - sink the ship
- 37. Bhopal Gas Tragedy - 1984 Disaster -World worst Industrial Catastrophes – December 2-3, 1984 – Union carbide India limited (UCIL) Pesticide plant in Bhopal, Madhya Pradesh, India. ● Problem – Leak of Methyl Isocyanate Gas & other chemicals ● Immediate death – 2,259 ● Later Madhya Pradesh government confirmed 3,787 deaths related to gas release
- 38. Bhopal Gas Tragedy - UCIL ● Union Carbide India Limited started in 1969 ● Manufacturers of – Phosgene Monomethlyamine Methyl Isocyanate & Pesticides of carbaryl (also known as Sevin)
- 39. Leakage of Gas - UCIL ● Entry of Water into the Tank E610 containing 40 tons of Methyl Isocyanate at 5 Psi ● Resulting in Exothermic Reaction - increased the pressure from 5 Psi - 40 Psi - Methyl Isocyanate - leak into the atmosphere ● Atmosphere – weak wind – weak Turbulence – cause slow dilution of Gas which spreaded widely
- 40. Cause - Bhopal Disaster
- 41. Factors – Gas Leak ● Storing Methyl Isocyanate in large tanks & filling beyond the recommended levels ● Flare tower & several vent gas scrubbers – out of service for 5 month before the disaster ● Failure of several saftey system & available saftey system – switched off to save money ● Methyl Isocyanate tank refrigeration was kept at 20 degree Celsius instead of 4.5 degree celsius as directed by the manual ● Only 1 back up system was present instead of 4 back up system which has been used by an USA plant
- 42. Plant View – After Deadly Disaster
- 43. Space Shuttle Columbia Disaster - 2003 ● 28th mission of NASA ● Rocket + space shuttle ● Rocket – Liquid Fuel (Liquid Oxidizer Tank) – insulated with foam – to maintain low temperature (liquid fuel) ● Insulation - Internally & Externally
- 44. Part - Lead to Disaster
- 45. Cause ● Space Shuttle Wings - Subjected - more heat ● Protection - Reinforced Carbon Panel
- 46. Plastics & RIC Material consisting of any of a wide range of synthetic or semi-synthetic organic compounds that are malleable and so can be molded into solid objects RIC – Resin Identification Code: The “ASTM International Resin Identification Coding System” - abbreviated as the RIC, is a set of symbols appearing on plastic products - identify the plastic resin out of which the product is made Developed originally by the Society of the Plastics Industry (Now the Plastics Industry Association) – 1988 - administered by ASTM International since 2008
- 47. Seven Classification of Plastics (RIC) & Uses
- 48. You ought to know!! ▪ Did you Know there are7 types of plastics? ▪ Did you know that each plastic type is assigned a number? ▪ Did you know that only some varieties of plastics are recyclable?
- 49. Plastic Type - 1: PETE Polyethylene Terephthalate This variety of plastic is widely used in disposable water bottles. It is safe to use as long as it is disposed of within a short period of time. This is because it often attracts bacteria. This plastic type is recyclable.
- 50. Plastic Type - 2: HDPE High-density Polyethylene - The plastic used in milk jugs, juice bottles and detergent bottles. Products made of this plastic are opaque in color. This plastic type is recyclable. HDPE
- 51. Plastic Type - 3: PVC Polyvinyl Chloride - This plastic type is durable and used to manufacture pipes, food wraps and bottles that store various types of oil. This plastic type is not recyclable.
- 52. Plastic Type - 4: LDPE Low-density polyethylene - LDPE is safe for human use but not exactly recyclable. It is used to manufacture grocery bags and a variety of bottles.
- 53. Plastic Type - 5: PP Polypropylene - Medicine bottles, straws and a variety of cups are made of polypropylene. It is safe and recyclable.
- 54. Plastic Type - 6: PS Polystyrene - Disposable cups, plates and containers are made of polystyrene. This type of plastic is considered to feature toxic chemicals and shouldn't be used too often. This type of plastic is not recyclable.
- 55. Plastic Type - 7: PETE BPA, Polycarbonate - Difficult to recycle, this plastic type is unpredictable. It is used in a variety of items, from DVDs and iPods to sports and medical equipment. There is no guarantee about the safety aspect of this plastic type.
- 56. YOU could HELP – Laying Roads a) collecting waste plastics, including plastic carry bags, cups, soft and hard foams and laminated plastics; b) cleaning it by washing; c) shredding it to a uniform size; d) melting the waste plastics at temperature of 165 degree Celsius and blending it with hot aggregates and bitumen and using this mixture to lay the road.
- 58. When did plastics become so popular? Post-war boom in plastics production
- 60. What is Plastic Made of ?
- 61. What’s Made of Plastic?
- 62. How many plastic beverage bottles get used every year in the US? Q: Chris Jordan
- 63. Chris We use 50 billion plastic beverage bottles every year in the US DETAI L 50,000,000,000
- 64. Chris Jordan
- 65. ChrisJordan 100 billion plastic bags get used each year in the US. ACUTAL SIZE 100,000,000,000 This is an artist’s visualization of what gets used in just five seconds
- 66. “But I Recycle…” What percentage of plastic gets recycled in the U.S.?
- 67. Approximately 10% recycled… So where does the rest go? CIWMB White Paper
- 69. Plastic recycling in China
- 70. (California Integrated Waste Management Board, “Plastics White Paper” 2003) Municipal Waste 50% Recycled 5% Durable Goods 20% Unaccounted for 25% Where our plastic waste goes
- 72. LA Beaches After The Rain Ballona Creek Algalita Santa Monica Beach
- 73. Great Pacific “Garbage Patch”
- 74. NORTH PACIFIC GYRE •A massive current system that circulates plastic trash •Twice the size of the continental US •Plastic trash accumulates, but doesn’t biodegrade
- 75. Captain Charles Moore and The Algalita Marine Research Foundation
- 76. 5 Gyres where plastic accumulates
- 83. All of this (more than a half-pound of plastic) was removed from the stomach of an albatross, a large sea bird
- 84. Seattle, WA - Gray Whale Necropsy - April 19, 2010 20 plastic bags
- 88. Stomach contents of a lantern fish: plastic particles (2-30 cm size deep sea fish) 2008 Lantern Fish study
- 89. Plastic in your sushi? 17 pieces of plastic in the stomach of a fish caught in the middle of the Pacific.
- 90. Plastics Leach toxic chemicals ●Bisphenol A (BPA) ● Plastic hardener ● Used in DVDs, canned food lining, baby bottles, water bottles ● Chemical found in 93% of Americans over the age of 6 ●Phthalates ● Plastic softener ● Found in toys, food packaging, shower curtains, nail polish, hair spray and shampoo, baby teething rings These Chemicals are ‘hormone mimickers’ that affect the Endocrine System.
- 91. Plastic Bath A study of 20 teens across America detected 16 chemicals from 4 chemical families including plastic (phthalates) in their blood and urine. Look up your products at SKIN DEEP www.cosmeticsdatabase.com
- 93. SUPPORT LEGISLATION TO BAN DISPOSABLE PLASTICS BAGS, BOTTLES, AND STYROFOAM
- 94. BRING YOUR OWN • • • • • • WATER BOTTLE (stainless steel) BAG CUP TUPPERWARE SILVERWEAR REUSE A GLASS JAR
- 95. BIOPLASTICS Plant based, biodegradable plastic We can change the material design of plastic
- 96. REFUSE, REDUCE, REUSE… then RECYCLE THINK TWICE •Do you really need a bag for your bag of chips? •Ask the waiter to wrap in foil instead of styrofoam •Ask for “no straw” •Don’t buy things with excess packaging •Buy the can instead of the plastic bottle •Shop at the local farmer’s markets •Bring your own salsa/jam jar to parties. Its free!
- 97. Encourage “Extended Producer Responsibility” (EPR) ● Companies that make and package products are held responsible for the end life of these products - collection and disposal. ● EPR Motivates producers to reduce the waste they produce, and make products more recyclable. • Adopted by Germany in 1991 • Packaging waste reduced by 14% in first four years • Recycling rose to 75%!
- 98. Spread the Word…with a SMILE Share what you’ve learned • Lead by example • Ask your friends and family to join you • Speak to city council • Write letters to government officials • Get your school involved • And come to the Plastics Are Forever Youth summit in 2011!
- 99. Career in Materials Materials science and engineering graduates are employed in a range of sectors, including: • Aerospace • Armed forces and Defense • Automotive • Manufacturing • Nuclear industry • Oil and gas • Pharmaceuticals • Telecommunications
- 100. Career in Materials - Qualifications Apart from a degree in materials engineering, technology or science, a number of other engineering and science-based subjects are acceptable for entry to this profession, including: ● Applied chemistry ● Applied physics ● Ceramics and glass ● Chemical engineering ● Chemistry ● Mechanical engineering ● Metallurgy ● Minerals/mining engineering ● Geology ● Physics ● Polymer science/technology ● Structural engineering.
- 101. THANK YOU