Fundamentals of Materials Engineering - A Basic Guide

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Fundamentals of Materials Engineering - A Basic Guide is a helpful textbook for readers learning the basics of materials science. This book covers important topics and fundamental concepts of materials engineering including crystal structure, imperfections, mechanical properties of materials, polymers, powder metallurgy, corrosion and composites. The authors have explained the concepts in an effective way and by using simple language for the benefit of a broad range of readers. This book is also beneficial to the students in engineering courses at B.Sc, M.Sc, and M.Tech. levels. Cover Title Copyright End User License Agreement Contents Preface CONSENT FOR PUBLICATION CONFLICT OF INTEREST ACKNOWLEDGEMENTS Foreword Introduction to Materials Engineering 1. WHAT IS MATERIALS SCIENCE AND ENGINEERING? 2. WHAT EXACTLY MATERIAL ENGINEERS DO? 3. CLASSIFICATION OF MATERIALS 3.1. What are Metals? 3.2. What are Ceramics? 3.3. What are Composites? 4. LEARNING OBJECTIVES CONCLUSION REFERENCES The Structure Of Materials 1. INTRODUCTION 2. ATOMIC BONDING 3. PRIMARY BONDING 3.1. Ionic Bonding 3.2. Covalent Bonding 3.3. Metallic Bonding 4. SECONDARY BONDING 4.1. Hydrogen Bonding 4.2. Van Der Waals Bonding 5. STRUCTURE OF METALS 6. LATTICE, LATTICE POINTS, MOTIF 7. UNIT CELLS 8. CRYSTAL STRUCTURES OF METALS 8.1. Simple Cubic Structure 8.2. Face Centered Cubic (FCC) Structure 8.3. Body-Centered Cubic (BCC) Structure 8.4. Hexagonal Close Packing (HCP) Crystal Structure 8.5. Radius Ratio and Co-Ordination Number 9. IMPORTANCE OF THE RADIUS RATIO RULE 10. DENSITY COMPUTATION 10.1. Volume Density (ρv) 10.2. Planar Atomic Density (ρp) 11. CRYSTAL SYSTEMS 12. CHARACTERISTICS OF THE UNIT CELL CONCLUSION QUESTIONS NUMERICALS REFERENCES Imperfections or Defects in Crystals 1. INTRODUCTION 2. TYPES OF DEFECTS 3. POINT DEFECTS 3.1. Vacancy Defect 3.2. Interstitial Defect 3.2.1. Self-Interstitial Defects 3.2.2. Impurity Interstitial Defects 3.3. Substitutional Defects 4. LINE DEFECTS 4.1. Edge Dislocation 4.2. Screw Dislocation 5. SURFACE DEFECTS 5.1. Grain Boundary Defect 5.2. Twin Boundary Defect 5.3. Staking Fault Defect 6. VOLUME DEFECTS 7. STRENGTHENING OF MATERIALS 7.1. Strain Hardening 7.2. Grain Boundary Strengthening 7.3. Solid Solution Strengthening 7.3.1. Substitutional Solid Solution Strengthening 7.3.2. Interstitial Solid Solution Strengthening 7.4. Precipitation Hardening 7.5. Dispersion Strengthening CONCLUSION QUESTIONS REFERENCES Mechanical Properties of Materials 1. INTRODUCTION 2. TENSILE TEST 3. ENGINEERING STRESS-STRAIN CURVES 4. TRUE STRESS-STRAIN CURVES 5. EVALUATION OF PROPERTIES 5.1. Proportional Limit or Stress 5.2. Elastic Limit or Stress 5.3. Ultimate Tensile Stress 5.4. Breaking or Fracture Stress 5.5. Yield Stress 5.6. Proof Stress 5.7. Toughness 5.8. Resilience 5.9. Stiffness 5.10. Ductility 5.11. Malleability 6. TYPES OF ENGINEERING STRESS-STRAIN CURVES FOR DIFFERENT TYPES OF MATERIALS 6.1. Ductile Materials without Yield Point 6.2. Ductile Materials with a Yield Point 6.3. Brittle Materials 6.4. Polymeric Materials 7. COMPRESSION TEST 8. FRACTURE 9. CREEP 10. CASTABILITY 11. HARDNESS 11.1. Mohs Hardness Test 11.2. Brinell Hardness Test 11.3. Rockwell Hardness Test 11.4. Vickers Microhardness Test CONCLUSION QUESTIONS REFERENCES Polymers 1. INTRODUCTION 2. PROPERTIES OF A POLYMER 3. CLASSIFICATION OF POLYMERS 3.1. Based on The Source [3] 3.1.1. Natural Polymers 3.1.2. Synthetic Polymers 3.2. Based on Structure 3.2.1. Linear polymers 3.2.2. Branched Polymers 3.2.3. Cross-linked Polymers 3.2.4. Graft Polymers 3.3. Based on Tacticity 3.3.1. Atactic Polymers 3.3.2. Syndiotactic Polymers 3.3.3. Isotactic Polymers 3.4. Based on Properties 3.4.1. Thermoplastic Polymers 3.4.2. Thermosetting Polymers 3.5. Based on Monomeric Units 3.5.1. Homopolymers 3.5.2. Copolymers 4. TYPES OF POLYMERIZATION 4.1. Addition Polymerization 4.2. Condensation Polymerization 5. DIFFERENCES BETWEEN ADDITION AND CONDENSATION POLYMERIZATION 6. FREE RADICAL MECHANISM DURING ADDITION POLYMERIZATION [3] 7. IONIC POLYMERIZATION 7.1. Anionic Polymerization [18] 7.1.1. Initiation 7.1.2. Propagation 7.1.3. Termination 7.2. Cationic Polymerization 8. SYNTHESIS OF SOME INDUSTRIALLY IMPORTANT POLYMERS 9. POLYETHYLENE 9.1. Low-density Polyethylene 9.2. High-density Polyethylene 9.3. Properties of Polyethylene 9.4. Applications of Polyethylene 10. POLYVINYL CHLORIDE (PVC) 10.1. Properties of Polyvinyl Chloride 10.2. Applications of Polyvinyl Chloride 11. POLYPROPYLENE 11.1. Properties of Polypropylene 11.2. Applications of Polypropylene 12. POLYSTYRENE 12.1. Properties of Polystyrene 12.2. Applications of Polystyrene 13. POLYAMIDES [3] 13.1. Nylon-6,6 13.1.1. Properties 13.1.2. Applications 13.2. Nylon-6,10 13.2.1. Properties and Applications 13.3. Nylon-6 13.3.1. Properties 13.3.2. Applications 14. BAKELITE [3] 14.1. Properties 14.2. Applications 15. PROCESSING OF POLYMERS 15.1. Injection Molding 15.2. Blow Molding 15.3. Compression Molding 15.4. Film Insert Molding 15.5. Gas Assist Molding 15.6. Rotational Molding 15.7. Structural Foam Molding CONCLUSION QUESTIONS REFERENCES Powder Metallurgy 1. INTRODUCTION 2. POWDER METALLURGY PROCESS 2.1. Manufacturing of Metal Powder 2.1.1. Atomization 2.1.2. Reduction of Metals 2.1.3. Electrolysis Process 2.1.4. Carbonyl Process 2.1.5. Granulation Process 2.1.6. Mechanical Alloying 2.1.7. Production of Fine Metals by Machining 3. BLENDING OF POWDERS 4. COMPACTING THE POWDERS IN A MOLD OR DIE 5. SINTERING 5.1. Sintering in The Powder Metallurgy Process 5.2. Sinter Hardening 5.3. Liquid Phase Sintering 5.3.1. Transient Liquid Phase Sintering 5.3.2. Permanent Liquid Phase Sintering [41] 6. APPLICATIONS OF POWDER METALLURGY 6.1. The Automotive Sector 6.2. Aerospace Applications 6.3. Oil and Gas Industry 6.4. Healthcare Sector 6.5. Filters 6.6. Cutting Tools and Dies 6.7. Magnets 6.8. Turbine Disk Super Alloy 6.9. Injection Molded 3C Products 6.10. Sintered Soft Magnetic Materials 7. ADVANTAGES AND DISADVANTAGES OF POWDER METALLURGY [48] 7.1. Advantages 7.2. Disadvantages CONCLUSION QUESTIONS REFERENCES Corrosion 1. INTRODUCTION 2. CAUSES OF CORROSION 3. WHAT IS CORROSION? 4. OUTCOME OF CORROSION 5. ECONOMIC LOSS 6. HEALTH EFFECTS 7. TECHNOLOGICAL EFFECTS 8. CULTURAL EFFECTS 9. SAFETY EFFECTS 10. EFFECT OF CORROSION ON METALS 11. CONDITIONS NECESSARY FOR CORROSION 10.1. Corrosion Cell 12. TYPES OF CORROSION 12.1. Dry Corrosion 12.1.1. Oxidation Corrosion 12.1.2. Liquid Metal Corrosion 12.1.3. Corrosion by other Gases 12.2. Wet Corrosion 13. DIFFERENCES BETWEEN DRY AND WET CORROSION 14. TYPES OF WET OR ELECTROCHEMICAL CORROSION 14.1. Differential Metal Corrosion (Galvanic Corrosion) 14.2. Differential Aeration Corrosion (Concentration Cell Corrosion) 14.3. Waterline Corrosion 14.4. Crevice Corrosion 14.5. Pitting Corrosion 15. OTHER TYPES OF CORROSION 14.1. Stress Corrosion Cracking 15.2. Intergranular Corrosion 15.3. Microbiological Corrosion 15.4. Soil Corrosion 15.5. Erosion Corrosion 16. FACTORS INFLUENCING THE RATE OF CORROSION 16.1. Primary Factors 16.2. Secondary Factors 17. METHODS TO CONTROL CORROSION 17.1. Application of Protective Coatings 18. POLARIZE OR SHIFT THE POTENTIAL OF THE METAL 19. MATERIALS SELECTION 20. CORROSION INHIBITORS 21. ELECTROPLATING 21.1. Plating Bath 21.2. Electroless Plating 21.2.1. Applications of Electroless Plating CONCLUSION QUESTIONS REFERENCES Composites 1. INTRODUCTION 2. CLASSIFICATION OF COMPOSITES 2.1. Based on Matrix Constituent 2.1.1. Organic Matrix or Polymer Matrix Composites 2.1.2. Metal Matrix Composites 2.1.3. Ceramic Matrix Composites 2.2. Based on Reinforcement Form 2.2.1. Laminar Composites 2.2.2. Particulate Composites 2.2.3. Fiber-reinforced Composites 3. APPLICATIONS OF FIBER-REINFORCED COMPOSITES 3.1. Manufacturing Processes 3.1.1. Spray Lay–up Process 3.1.2. Wet Lay-up Process 3.1.3. Vacuum Bagging 3.1.4. Filament Winding 4. ADVANTAGES AND DISADVANTAGES OF COMPOSITES MATERIALS 4.1. Advantages [4] 4.2. Disadvantages of Composites 4.3. Nanocomposites 5. WHY NANOCOMPOSITES EXHIBIT BETTER PROPERTIES THAN THEIR BULK COMPOSITES? 5.1. Classification of Nanocomposites 5.1.1. Ceramic Based Nanocomposites 5.1.2. Metallic Based Nanocomposites 5.1.3. Polymer-Based Nanocomposites 6. RECENT ADVANCES IN COMPOSITES [11] 6.1. Ceromers 6.2. Smart Composites 6.3. Ormocer 6.4. Giomers CONCLUSION QUESTIONS REFERENCES Subject Index Back Cover