Basic Mechanical Engineering

Classification of Materials

Materials are broadly classified into: (1) Metals; (2) Non-metals; (3) Ceramics; (4) Composites.

(1) Metals: They have thermal and electrical conductivity. They generally have higher strength
compared to non-metals. Metals can be processed in a variety of ways to get the required
shapes and sizes of Parts.
 Iron is the major element in Ferrous metals and alloys. Due to magnetic properties, ferrous
metals are used in many industrial applications.
 Non-ferrous metals do not have iron. They are light in weight compared to ferrous metals.
Aluminium and Copper are widely used in thermal and electrical fields.

(2) Polymers: They are broadly classified into Thermoplastics and Thermo-setting plastics..
 Thermoplastics can be recycled several times. They have linearly linked Polymers.
 Thermosets are cross-linked polymers. Thermosetting plastics cannot be recycled.
Due to light-weight and insulating properties, they are preferred in Auto & electrical fields.

(3) Ceramics: Ceramics are compounds that include cements, bricks and Refractories.
They possess high compressive strength and can withstand high temperatures.
Powder metallurgy method is used for the manufacture of ceramic Parts.
Ceramics are used in Construction industry and high-temperature applications (Furnaces).

(4) Composites: These materials are composed of basically two types of components.
Matrix is the base for a Composite Part and the Reinforcement is the component that adds
strength to the Part.
Metal, Ceramic or Plastic fibres and particles are used for Reinforcement.
Composites are used in Aircraft building, Sports and medical applications.

Unit 1 Materials
16
Basic Mechanical Engineering

____________________________________________________________________________
Ferrous Metals Vs Non- Ferrous Metals

[Link]. Ferrous Metals Non- Ferrous Metals

1 Contain Iron as the main constituent They Do not contain Iron

2 They can be easily magnetised They cannot be magnetised

3 They have Higher strength & density They have Lower strength & density

4 They have Higher Melting point They have Lower Melting point

5 They are affected by Rust & Corrosion They are Corrosion-resistant

6 They are Less malleable They are More malleable

7 They are used in Heavy structures They are used in Lighter structures

8 Examples: Steel, Cast Iron Examples: Aluminium, Copper

______________________________________________________________________

 Cast iron is used in casting products such as pump body, turbine casting.
 Cast iron is also used in making statues, Holy lamps, and Machine tools.
 Steel is employed in fabricated structures - Boilers and Bridges.
 Steel is used in Automobile Body panels and Machine parts.

 Aluminium is used to fabricate Aeroplane Body panel and Pistons.

Unit 1 Materials
16
Basic Mechanical Engineering

______________________________________________________________________
Composition of Ferrous Alloys

1. Mild Steel:
Iron - 98% Carbon - 0.25% Silicon - 0.25%
Copper - 0.25% Manganese - 1% Others - 0.25%

2. Cast Iron:
Iron - 95% Carbon - 3% Silicon - 1%
Manganese - 0.5% Others - 0.5%

3. Stainless Steel:
Iron - 74% Carbon - 0.5% Nickel - 8.5%
Chromium - 15% Others - 2%

4. Wrought Iron:
Iron - 97% Carbon - 0.1% Silicon - 0.2%
Manganese - 0.2% Slag - 2.5%

____________________________________________________________________________

Unit 1 Materials
16
Basic Mechanical Engineering

Ceramics

Ceramics are inorganic compounds composed of oxides, nitrides and carbides.

Examples: Glass, Bricks, Firebricks, Tiles, Porcelain, and Cement.

Ceramics generally have (i) high mechanical strength; (ii) hardness and (ii) fracture toughness.

They can withstand higher temperatures (Refractoriness), and possess wear resistance and
corrosion resistance.

They are insulators (non-conductors) of both heat and electricity.

1. Glasses: They are non-metallic, inorganic compounds made of silicates.

Glassware is used in domestic, hospitality and industrial applications.

Hardened Temper glass is widely used in Smart phones and Automobiles.

2. Glass ceramics: They are NOT glasses. They are clear, transparent ceramics.

They are used in kitchenware, insulators and telescopic mirrors.

3. Refractories: Firebricks employed in blast and electric furnaces for melting the metals.

Bricks and tiles find applications in construction industry - houses and buildings.

4. Abrasives & Tools: Ceramics can be used in Metal Grinding operations in the form of

abrasives (Silicon carbide (SiC), Aluminium oxide (Al2O3) and Diamond).

Cutting tools are also produced from SiC and Al2O3.

5. Cement: It is the most widely used ceramic material in the building construction.

When mixed with water, cement hardens and forms a strong compound.

It can be made to take any desired or required shape (Plasticity) in the Wet form.

6. Advanced Ceramics: Medical field uses ceramics for tooth-filling and ear implants.

Electrical devices such as capacitor use ceramics for insulation.

Sensors and semi-conductors are made of ceramic materials.

____________________________________________________________________________

Unit 1 Materials
16
Basic Mechanical Engineering

Different Types of Ceramics

Properties of Ceramics

_____________________________________________________________________________________

Unit 1 Materials
16
Basic Mechanical Engineering

Composite Materials

Composite materials are made by combining two or more materials that have different
properties.

Composite material has the properties that are different from the individual components

Main constituents of Composite Materials

1. Matrix: It is the continuous phase in the Composite. It is the medium in which the second
phase (Reinforcement) is embedded.

 The main function of the Matrix is to hold and protect the fibres embedded in it.
 It provides good impact strength and good surface finish.

Types of Matrix: (1) Polymer matrix (2) Metal matrix (3) Ceramic matrix.

2. Reinforcement: It is the discontinuous phase that gives strength to the structure.

 The main function of the Reinforcement (Fibre) is to improve the strength of the
Composite.
 It transfers the strength to the matrix.

Types of Reinforcements: (1) Continuous fibres (2) Short fibres (3) Particulates.

Polymer Matrix Composites such as Fibre boats and Tennis racquets have reduced weight
and increased strength.

This is achieved by reinforcing ceramic fibres (Reinforcements) in thermosetting

Unit 1 Materials
16
Basic Mechanical Engineering

Fiber glass reinforced composites can be produced by reinforcing plastics with glass
fibres.

______________________________________________________________________

The solid particulates of carbides are dispersed in ceramic or polymer liquid matrix.

______________________________________________________________________

Advantages:

Light weight and Lower price are the main advantages of Composites.

Composites are corrosion-resistant and wear-resistant.

Composites have reduced weight and increased strength.

Applications:

1. Polymer Matrix Composites are used to make Fibre boats and Tennis racquets

2. Automobile tyres - Carbon articles (Reinforcements) are dispersed in Rubber matrix

3. Cutting tools such as Cermets are produced with Ceramics and Metals.

4. Aeroplane interior parts are produced using Fibre Reinforced Polymer Composites.
______________________________________________________________________

Unit 1 Materials
16
Basic Mechanical Engineering

Smart Materials

1. Piezo-electric Materials

These materials produce electricity when mechanical stress or pressure is applied on them.

Lead Zirconium Titanate(PZT) is a Piezo-electric material that is sandwiched between two metal
plates as shoewn in Fig.1. As pressure is applied over the PZT crystal, electricity is produced.

Fig.1 - Piezo-electric Effect

Applications: Used in Airbag sensors in automobiles, Alarm systems and Inkjet printers.

2. Shape Memory Alloys (SMA)

These materials can return to a predefined shape when heated above a certain temperature.

They are extensively used in Medical, Robotic and Aeronautical actuator / sensor applications.

Nickel-Titanium (Nitinol) is a popular SMA which has Transformation temperature = 500º C.

Applications: Stents and guide-wires in Surgery.

Fig. Shape Memory Alloy - Principle

Unit 1 Materials
16
Basic Mechanical Engineering

3. Hydrogels:

Hydrogels can absorb and release water, changing their volume in response to environmental
conditions.

They are used in drug delivery systems, wound dressings, and tissue engineering.

Fig.3 - Hydrogel - Drug Delivery Application

4. Thermo-chromic Materials:

They change color in response to temperature changes due to reversible chemical or physical
changes in the material structure.

They are used in temperature indicators and color-changing coatings.

Applications: Used in temperature indicators, novelty items like color-changing mugs, and in
coatings to show temperature changes.

5. Magneto-strictive Materials:

These materials change shape or size in response to a magnetic field due to the alignment of
magnetic domains within the material.

These materials are employed in sensors, actuators, and sonar devices.

Unit 1 Materials
16
Basic Mechanical Engineering

6. Self-Healing Materials:

They can repair themselves after damage through embedded healing agents that activate upon
damage.

They are used in coatings, composites, and structural materials to enhance longevity and
reduce maintenance needs.

____________________________________________________________________________

Unit 1 Materials
16