Aircraft Structural Materials

AE 332

Chapter 1
Introduction

Dr. Abdallah Almomani

[email protected]

Chapter 1 - 1
Introduction
• What is Materials Science & Engineering?
Ø Materials science
– Investigate relationships between
internal structures and properties of
materials
– Design/develop new materials
Ø Materials engineering
– Create products from existing materials
– Develop materials processing techniques

Chapter 1 - 2
Historical Perspective
Beginning of the Material Science –

Ø People began to make tools from stone –

Start of the Stone Age about two million years
ago.
• Natural materials: stone, wood, clay, skins,
etc.
• The Stone Age ended about 5000 years
ago with introduction of Bronze.

Chapter 1 - 3
Historical Perspective
Ø Bronze is an alloy (copper + tin (chemical
element with the symbol Sn and atomic
number 50 ) + other elements).
• Bronze: can be hammered or cast into a
variety of shapes, can be made harder by
alloying, corrode only slowly after a surface
oxide film forms.
Ø The Iron Age began about 3000 years ago
and continues today.
• Use of iron and steel, a stronger and
cheaper material changed drastically daily
life of a common person. Chapter 1 - 4
Historical Perspective
Ø Age of Advanced materials: throughout the
Iron Age many new types of materials have
been introduced (ceramic, semiconductors,
polymers, composites…).

Why we study Material science and

engineering?
To understand the relationship among structure,
properties, processing, and performance of
materials. Intelligent design of new materials.

Chapter 1 - 5
Why is it Important for Engineers
to Understand Materials?

• Products/devices/components that engineers

design are all made of materials

• To select appropriate materials and processing

techniques for specific applications engineers must
– Have knowledge of material properties and
– Understand the structure-property relationships

Chapter 1 - 6
Structure, Processing, & Properties
• Properties depend on structure
ex: hardness vs structure of steel

(d)
600
Hardness (BHN)

30 μm
500 (c)
Data obtained from Figs. 10.31(a) and
400 (b) 10.32 with 4 wt% C composition, and from
(a) Fig. 11.15, Callister & Rethwisch 9e.
Micrographs adapted from (a) Fig. 10.19;
4 μm
300 (b) Fig. 9.30; (c) Fig. 10.33; and (d) Fig.
10.21, Callister & Rethwisch 9e. (Figures
30 μm 10.19, 10.21, & 10.33 copyright 1971 by United
200 30 μm States Steel Corporation. Figure 9.30 courtesy
of Republic Steel Corporation.)

100
0.01 0.1 1 10 100 1000
Cooling Rate (ºC/s)
• Processing can change structure
ex: structure vs cooling rate of steel
Chapter 1 - 7
Material Property Types
• Mechanical
• Electrical
• Thermal
• Magnetic
• Optical
• Deteriorative

Chapter 1 - 8
Mechanical Properties

Effect of carbon content on the hardness of a common steel:

Chapter 1 - 9
ELECTRICAL
• Electrical Resistivity of Copper:
6 Fig. 18.8, Callister & Rethwisch 9e.
N i
at % [Adapted from: J.O. Linde, Ann Physik 5, 219

5 3.3 2 (1932); and C.A. Wert and R.M. Thomson,

Physics of Solids, 2nd edition, McGraw-Hill
+
Cu Ni
Company, New York, 1970.]
Resistivity, ρ

t%
(10-8 Ohm-m)

4 1 6 a N i
+2 . at%
u 1 2
3
C
u + 1.
m e dC
defo
r
t % Ni
2 1 .12 a
+
Cu
1 e ” Cu
r
“P u
0
-200 -100 0 T (°C)
• Adding “impurity” atoms to Cu increases resistivity.
• Deforming Cu increases resistivity.
• Increasing T of Cu increases resistivity.
Chapter 1 - 10
THERMAL
• Space Shuttle Tiles: • Thermal Conductivity
-- Silica fiber insulation of Copper:
offers low heat conduction. -- It decreases when
Chapter-opening you add zinc!
photograph, Chapter 17,
Callister & Rethwisch 3e.
400

Thermal Conductivity
(Courtesy of Lockheed
Missiles and Space
Company, Inc.)
300

(W/m-K)
200

100
0
0 10 20 30 40
Composition (wt% Zinc)
Fig. 19.4W, Callister 6e. Fig. 19.4, Callister & Rethwisch 9e.
(Courtesy of Lockheed [Adapted from Metals Handbook: Properties
Aerospace Ceramics and Selection: Nonferrous alloys and Pure
Systems, Sunnyvale, CA) Metals, Vol. 2, 9th ed., H. Baker, (Managing
(Note: "W" denotes fig. is on Editor), ASM International, 1979, p. 315.]
CD-ROM.)

100 μm Chapter 1 - 11
OPTICAL
• Transmittance:
-- Aluminum oxide may be transparent, translucent, or
opaque depending on the material’s structure (i.e.,
single crystal vs. polycrystal, and degree of porosity).
polycrystal: polycrystal:
single crystal no porosity some porosity

Fig. 1.2, Callister &

Rethwisch 9e.
(Specimen preparation,
P.A. Lessing)

Chapter 1 - 12
DETERIORATIVE
• Stress & Saltwater... • Heat treatment: slows
-- causes cracks! crack speed in salt water!

10-8 “as-is”

crack speed (m/s)

“held at
160°C for 1 hr
before testing”
Alloy 7178 tested in
10-10
saturated aqueous NaCl
solution at 23°C

increasing load
Fig. 17.21, Callister & Rethwisch 9e.
(from Marine Corrosion, Causes, and Prevention,
John Wiley and Sons, Inc., 1975.) Adapted from Fig. 11.20(b), R.W. Hertzberg, "Deformation and
Fracture Mechanics of Engineering Materials" (4th ed.), p. 505, John
Wiley and Sons, 1996. (Original source: Markus O. Speidel, Brown
Boveri Co.)

Chapter 1 - 13
Types of Materials
• Metals:
– Strong, ductile
– High thermal & electrical conductivity
– Opaque, reflective.

• Ceramics: ionic bonding (refractory) – compounds of metallic

& non-metallic elements (oxides, carbides, nitrides, sulfides)
– Brittle, glassy, elastic
– Non-conducting (insulators)
– Used in high temperature applications
• Polymers/plastics: Covalent bonding à sharing of electrons
– Soft, ductile, low strength, low density
– Thermal & electrical insulators
– Optically translucent or transparent.
• Composites: Two (or more) individual materials

Chapter 1 - 14
Types of Materials: Metals
• Metals are composed of one or more metallic
elements (such as iron, aluminum, copper, titanium,
gold, and nickel), and often also nonmetallic elements.
• Atoms in metals and their alloys are arranged in a very
orderly manner. ( metals are relatively dense)
• Metals are relatively stiff and strong yet are ductile
(i.e., capable of large amounts of deformation without
fracture), and are resistant to fracture.
• Have large numbers of nonlocalized electrons.
extremely good conductors of electricity and heat
and are not transparent to visible light.

Chapter 1 - 15
Types of Materials: Metals

Chapter 1 - 16
Types of Materials: Ceramics
• Ceramics are compounds between metallic and
nonmetallic elements; they are most frequently oxides,
nitrides, and carbides.
– Examples: aluminum oxide (or alumina,Al2O3), silicon dioxide (or silica,
SiO2),silicon carbide (SiC), silicon nitride (Si3N4), and, in addition, what some
refer to as the traditional ceramics—those composed of clay minerals (i.e.,
porcelain), as well as cement, and glass.

• Ceramic materials are relatively stiff and strong.

• Typically, very hard, extremely brittle (lack ductility),
and are highly susceptible to fracture.
• Typically, insulative to the passage of heat and
electricity.
• More resistant to high temperatures and harsh
environments than metals and polymers
Chapter 1 - 17
Types of Materials: Ceramics

Chapter 1 - 18
Types of Materials: Ceramics

Chapter 1 - 19
Types of Materials: Ceramics

Chapter 1 - 20
Types of Materials: Ceramics

Chapter 1 - 21
Types of Materials: Polymers
• Polymers include the familiar plastic and
rubber materials. Many of them are organic
• compounds that are chemically based on
carbon, hydrogen, and other nonmetallic
elements (O,N, and Si).
• Examples: polyethylene (PE), nylon, poly(vinyl
chloride) (PVC), polycarbonate (PC), polystyrene
(PS), and silicone rubber.
• Have low densities, not as stiff nor as
strong as these other material types

Chapter 1 - 22
Types of Materials: Composite
• A composite is composed of two (or more) individual
materials, which come from, metals, ceramics, and
polymers.
• The design goal of a composite is to achieve a
combination of properties that is not displayed
by any single material, and also to incorporate
the best characteristics of each of the component
materials.
• Fiberglass, Carbon fiber reinforced polymer(
“CFRP”) .
• Wood and bone are naturally-occurring materials
Chapter 1 - 23
The Materials Selection Process

1. Pick Application Determine required Properties

Properties: mechanical, electrical, thermal,
magnetic, optical, deteriorative.

2. Properties Identify candidate Material(s)

Material: structure, composition.
3. Material Identify required Processing
Processing: change structure and overall shape
ex: casting, sintering, vapor deposition, doping
forming, joining, annealing.

4. Other factors Cost, Availability , Working conditions..

Chapter 1 - 24
The Materials Selection Process

Chapter 1 - 25
Example – Hip Implant
• With age or certain illnesses joints deteriorate.
Particularly those with large loads (such as hip).

Adapted from Fig. 22.25, Callister 7e.

Chapter 1 - 26
Example – Hip Implant

• Requirements
– mechanical
strength (many
cycles)
– good lubricity
– biocompatibility

Adapted from Fig. 22.24, Callister 7e.

Chapter 1 - 27
Example – Hip Implant

Adapted from Fig. 22.26, Callister 7e.

Chapter 1 - 28
Hip Implant
• Key problems to overcome
– fixation agent to hold Ball
acetabular cup
– cup lubrication material
– femoral stem – fixing agent
Acetabular
– must avoid any debris in cup Cup and Liner

Femoral
Stem
Adapted from chapter-opening photograph,
Chapter 22, Callister 7e. (Photograph
courtesy of Zimmer, Inc., Warsaw, IN, USA.)

Chapter 1 - 29
SUMMARY
Course Goals:
• Use the right material for the job.

• Understand the relation between properties,

structure, and processing.

• Recognize new design opportunities offered

by materials selection.

Chapter 1 - 30