CLASSIFICATION OF MATERIALS

Engineering
Materials
Metals
Ferrous
Iron
Steel
Pig iron
Cast iron
Wrought
iron
Non-
Ferrous
Copper &
Alloys
Aluminium
Zinc
Tin
Lead
Non-Metals
Rubber
Plastics
Resin
CLASSIFICATION OF MATERIALS
Engineering
Materials
Materials due to
combination
composites

Metal Reinforced
metals
Carbon reinforced rubber
Metal
ceramics
Ceramic
Polymers
Whisker reinforced
plastics
Alloys
Ferrous
Alloys
Non ferrous alloys
Properties of Materials
Mechanical
Physical
Thermal
Electrical
Chemical
Dimensional
Technological

Mechanical Properties
Elasticity (Stress strain behavior)
Strength (Tensile , Compressive , Shear )
Plasticity
Ductility
Malleability
Hardness
Toughness
Brittleness
Fatigue
Creep
Stiffness
Damping capacity
Resilience


Mechanical Properties
Strength :
- ability of material by virtue of which it can
withstands or support an external force or load
without rupture
- Measure of capacity of resistance possessed by
solid masses
- Under different conditions of loading, behavior of
metal is different (Tensile strength in tension ,
Compressive break it off by crushing , Shear
load applied tangentially to shear specimen)
Mechanical Properties
Elasticity:
- A material is said to be perfectly elastic if the whole of
stress produced by load disappears completely on the
removal of load
- Property by virtue of which a body opposes permanent
elongation
Plasticity
- Property that enables the formation of permanent
deformation in a material
- It is the reverse of elasticity
- During this there is the displacement of atoms within
metallic grains & consequently the shapes of the metallic
components changes

Mechanical Properties
Ductility
Ability of material to withstand elongation
Due to this property metals can be drawn into wires
It is due to plasticity
Is measured by percentage elongation and the percentage
reduction in area before rupture of the specimen
Indicate that atoms of materials have the capacity of slipping with
respect to one another
Malleability
Property by virtue of which a material can be flattened into sheets
without cracking
It is a compressive characteristics
Indicate that atoms of materials have the capacity of slipping with
respect to one another

Mechanical Properties
Hardness
- Property of material by virtue of which it resists indentation
, penetration , machining , wearing or scratching
Toughness
- Strength with which the material opposes rupture
- It is due to the attraction between molecules, this
attractive force resists tearing
- Area under stress strain curve shows toughness i.e the
energy which can be absorbed by the material upto the
point of rupture
- Ability of the material to resist impact

Mechanical Properties
Brittleness
Lack of ductility is called brittleness
Materials fracture without much elongation
Possesses lesser toughness
Brittle materials are strong enough but lacks in plasticity
Fatigue
Leads to fracture under conditions of repeated loading or fluctuating load
Stress at which material fails due to fatigue is called fatigue strength
Fatigue fracture is progressive. It begins from minute cracks that grow
under the action of fluctuating stress
Fatigue limit / endurance limit is defined as the maximum stress which can
be applied repeatedly without causing failure
Increases with carburizing , hardening , nitriding or cold working of the
surfaces

Mechanical Properties
Creep:
Slow plastic deformation of metal under constant stress or under
prolonged loading
Creep strength of a metal is defined as the limiting stress below
which creep is so slow that it will not result in fracture within any
finite length of time. As the temp. increases , creep strength and life
is reduced
Stiffness:
Is the resistance offered to deformation , below the elastic limit
Indicated by slope of stress strain curve
Greater the slope lesser is stiffness
Opposite of stiffness is called flexibility
Mechanical Properties
Damping capacity
Ability of a material to absorb mechanical energy
during a cycle of rapid loading and unloading
Resilience
Is the capacity of materials to absorb energy with
the elastic limit
The max. energy which can be stored in body
upto elastic limit is called proof resilience
Proof resilience per unit volume is called modulus
of resilience
Physical Properties
Lustre
Colour
Density
Melting point
Dimensions
Porosity
Specific gravity

Physical Properties
Lustre :
Ability of a metal to reflect light when finely polished
It is also known as brightness of a surface
Colour :
Many metals have specific colours that distinguish them
from others( brass and gold are yellow , silver is white ,
copper is reddish brown , aluminium is white , tin is silvery
white , grey cast iron is greyish black
Density
Mass per unit volume of substance
Metals having more weight per unit volume are said to be
of higher density

Physical Properties
Melting point :
Is that temp. at which a solid material is changed into liquid
Used in safety devices like fuse plug , fuse wire etc.
Dimensions
Implies its size and shape
Porosity
If it has pores within it
Pores can absorb lubricant as in a sintered self lubricating bearing
True porosity= total pore vol./total vol.
Specific gravity :
Ratio of mass or weight of a solid or liquid to the mass or weight of
an equal volume of water



Thermal Properties
Heat capacity
Thermal expansion
Thermal conductivity
Thermal stresses and strains
Thermal shock resistance
Thermal Properties
Heat capacity :
Is a property that is indicative of a materials ability to absorb heat from the
external surroundings
Amount of energy required to produce a unit temperature rise
Thermal expensions:
When thermal energy is added to a material , a change in its dimensions
occurs , this property is known as coefficient of thermal expansion
Thermal conductivity :
Property by virtue of which the flow of heat takes place from one end to
another is called thermal conductivity
As the no. of kilocalories of heat that would flow per second through specimen
having cross section of 1 sq. mm and 1 m length , when temp. gradient is 1
degree C .
Thermal stresses and strains :
Stresses induced in a body due to change in temp either raised or lowered
Corresponding strains due to temp. stresses are called temp. strains
If the body is allowed to expand or contract freely , no thermal stresses will
set up in the body
Thermal Properties
Thermal shock resistance :
Conditions of a body when it is subjected to sudden and
severe changes in temperature caused either by a change
in external environment or by internal heat generation
Ability of a body to withstand such temperature changes
without failure is called thermal shock resistance.
A ductile material will withstand severe thermal shock
much better than brittle materials of comparable strength
and thermal properties because excessive thermal stresses
developed can be dissipated as a result of plastic
deformation whereas in brittle materials , the stress at a
point of stress concentration is usually the governing
stress tending towards failure
Electrical Properties
Resistivity :
it is the property of the material of which the
conductor is made
Property of a material due to which it resists
the flow of electricity through it
Electrical conductivity :
It is the reciprocal of the resistivity
Used to specify the electrical character of a
material
Chemical Properties
Composition :
The elemental or chemical component that make up a
material
Microstructure :
Structure of polished and etched materials as revealed by
microscope magnification greater than ten diameters
Studies indicate grain size , phases present , inclusion etc.
Crystal structure :
Ordered , repeating arrangement of atoms or molecules in
a material
Corrosion :
Gradual chemical or electrochemical attack on the metal
by its surroundings
Metal is converted into oxide , salt etc.

Dimensional Properties

Roughness :
Finely spaced surface irregularities , height , width , and direction of
which establish a definite surface pattern
Waviness :
A wavelike variation from a perfect surface
Generally much wider in spacing and higher in amplitude than surface
roughness
Lay :
Direction of a predominating surface pattern , usually after a machine
operation
Camber:
Deviation from edge straightness ; usually max. deviation of an edge
from a straight line of given length
Out of flat :
Deviation of a surface from a flat plane
Surface finish:
Microscopic & macroscopic characteristics that describe a surface
Technological Properties
Castability:
The ease with which it is casted into different shapes and sizes from its liquid
state .
Machineability :
The ease with which it can be easily machined
Evaluated on basis :long tool life at a given cutting speed , lower power
consumption per unit volume of metal removed , max. metal removal per tool
resharpening , high quality of surface finish , good and uniform dimensional
accuracy , easily disposable chips
Weldability :
Capacity of being welded into reliable permanent joints having specified
properties
Ease of welding depends upon melting temperature , thermal conductivity ,
thermal expansion and the surface condition of the work
Forgeability:
Metal s tolerance or relative ability to deform before cracks appear in the
metal
Degree of forgeability of a metal depends upon the crystallographic structure ,
metallurgical factors (purity , phases present , grain size , melting point , yield
strength , strain rate and die friction


METALS
Are composed of elements which readily give up electrons to provide a
metallic bond and electrical conductivity
Metals possesses following properties :
- Lusture
- Low specific heat
- Hardness
- Plastic deformation
- Good thermal &electrical conductivity
- Strength
- Malleability
- Ductility
- Stiffness
- Rigidity
- Machinability
- Formability
- Weldability
- Castability
- Dimensional stability
NON METALS
Non - Metals possesses following properties :
- No Lusture
- Good thermal & electrical conductivity
- High Strength which is maintainable at high temp.
- Malleability
- Generally brittle
- Resistance to oxidation and corrosion

Alloys (Ferrous & Non Ferrous)

Combination of two or more metals
Alloy steels are obtained by adding some
elements as nickel, chromium, cobalt, vanadium
tungsten, silicon etc. to the carbon steel to get
the desire properties.
Prepared for a specific purpose to meet the
particular requirement of an application
Possesses properties quite different from those
of their constituents metals



Ferrous Metals and Their Alloys
Ferrous Metals are those in which
-Chief constituent is iron , although other
constituent like carbon , manganese ,
phosphorous, and sulphur etc., also exist in
varying proportions
- Iron , steel and their alloys fall under this
category
- Their widespread use is due to
: iron containing compounds exist in abundant
quantities

Ferrous Metals and Their Alloys
- Metallic iron and steel alloys may be produced
using relatively economical techniques
- Ferrous metals are extremely versatile
Principal Disadvantage :
- Susceptibility to corrosion

NON FERROUS METALS :
- Those which do not contain iron
FERROUS METALS
NAME ALLOY OF IRON
AND.
PROPERTIES USES
Mild steel
(acero
templado)
Up to 0,6% of
Carbon (C)
Tough (tenaz)
It rusts easily.
Common in
workshops.
Carbon steel
(acero al
carbono)
Up to 1,6% C Tough (tenaz =
resistente a los
golpes)
Cutting tools
Stainless
steel
Nickel and chromium Resistant to rust.
Tough.
Home, buildings,
knives
Cast iron
(fundicin)
Up to 6% of C Strong but brittle
(quebradizo)
Engines
NON FERROUS METALS
NAME COLOUR PROPERTIES USES
ALUMINIUM Whitish grey Light, soft, ductile,
malleable, easy to
work
COPPER
(cobre)
Redish brown corrosion resistant,
ductile, malleable
SILVER
(plata)
Whitish grey Ductil, malleable,
resists corrosion
LEAD
(plomo)
Bluish grey Heavy, ductile,
malleable.
TIN
(estao)
Bluish grey Soft, it does not
rust
CLASSIFICATION OF FERROUS MATERIALS
FERROUS
- CAST IRON
Grey iron, White iron , Malleable iron , Nodular
iron , Alloy iron , Mottled iron
- STEEL
i) Carbon steel Low , Medium, High Carbon
ii) Alloy steel Stainless , Heat resisting , Spring
steel , Silicon steel , Tool steel

FORMS OF IRON (AFTER EXTACTION FROM ORE )
Iron
Pig iron
Cast iron
white cast iron
grey cast iron
Malleable cast iron
Nodular cast iron
Alloy cast iron
Molted cast iron
Wrought iron

PIG IRON
Obtained by the chemical reduction of iron
ore in the blast furnace ( process of reduction
of iron is called smelting)
Amount of carbon varies from 3 to 4 %
Brittle and can not worked with hammer
Pig iron contains varying quantities of other
elements as carbon, sulphur , phosphorous ,
silicon etc.
WROUGHT IRON
A highly refined iron with uniformly distributed quantity of slag is
incorporated without subsequent fusion
Chemical analysis shows 99% of iron
Ductile , malleable , tough and has an ultimate tensile strength of
about 150 N/ sq.mm
It can not be melted , but at a white heat , it becomes soft enough
to take any shape under hammer
Able to withstand sudden and excessive shock loads without
permanent deformation
Can neither be hardened nor tempered like steel
Produced by puddling process or aston /byers process
Applications are : bolts and nuts , chains , plates , cranehooks , pipe
and fittings , plates , sheets , bars , boiler tubes etc.
Cast Iron
Refined form of pig iron. Pig iron is melted and
refined in cupola furnace
Expands slightly on solidification
Does not rust easily
Used for making sharp castings of machine
parts and other equipments
Grey Cast Iron
Grey Cast Iron
- Obtained by allowing the molten metal to cool and
solidify slowly
- Contains 2.5 to 3.75 % of carbon
- Greater part of carbon is in the form of flakes
- Microstructure of grey cast iron depends upon rate of
cooling
i) Rapid cooling graphite embedded in pearlitic matrix
ii) Intermediate cooling graphite in ferritic and
pearlitic matrix
iii) Slow cooling graphite embedded in ferrite matrix
Grey Cast Iron
Properties of grey cast iron
- Brittle & may be broken if hammer is used
- Ultimate tensile strength varies from 120
300 N/sq. mm
- Hardness varies from 150 240 B.H.N
- Melting point is low
- Easily machinable
- The graphite present acts as a lubricant


Grey Cast Iron
Applications
Machine tool structure
Gas / water pipes
Cylinder blocks & heads for I.C .Engines
Frames for electric motors
Ingot moulds
Sanitary wares
Piston rings etc.

Grey Cast Iron
Mechanical properties :
- High compressive strength
- Low tensile strength
- High rigidity
Casting properties:
- High fluidity and ability to make castings
- Relative low melting temperature
Machinability :
- Easily machined to give good finish
Special properties :
- Self damping does not vibrate
- Self lubricating
- Good anti friction properties

Grey Cast Iron
White Cast Iron
White Cast Iron
Contains carbon in the form of cementite
Obtained by rapid cooling
Due to absent of graphite , metal has white
colour
Contains 1.75% to 2.3 % carbon
White Cast Iron
Properties of white cast iron
Very Hard and brittle
Wear resistant and less ductile
Hardness varies from 400 600 B.H.N
Can not be machined

White Cast Iron
Applications
Used for manufacturing wrought iron
For manufacturing those parts which require a
hard and abrasion resistant material
For producing malleable cast iron
Malleable cast iron
Obtained from white cast iron by special
annealing process
Contains 2 3.6% carbon
Micro structure of malleable cast iron contains
graphite in pearlitic matrix
Graphite present in the form of small rounded
nodules
Malleable cast iron
Properties
Less brittle
Tensile strength of malleable cast iron is 180
N/ sq. mm
Good wear resistant and vibration damping
capacity
Malleable cast iron
Applications
Automobile parts
Sewing machine parts
Bicycle parts
Agriculture equipments
Electrical line hardware etc. etc.
Malleable cast iron
Nodular Cast Iron
Also known as spheroidal cast iron because
the graphite is precipitated not in the form of
flakes but in the form of spheroids
High grade cast iron
Also called ductile cast iron
Nodular Cast Iron
Properties
Good casting properties as high fluidity and low
melting point
Produces better machined surfaces
Tensile strength is 330 N / sq. mm
High strength and toughness
Good resistance to wear
Higher machineability than grey cast iron
Weldable
Modulus of elasticity is high
Nodular Cast Iron
Applications
Paper industry machinery
I.C Engines
Power transmission equipment
Farm implements and tractors
Earth moving machinery
Valves and fittings
Pumps and fittings
Construction machinery
Nodular Cast Iron

Alloy Cast Iron
Have better corrosion resistant properties ,
better machinability and more strength
Elements which provide more strength to the
pearlitic and ferritic matrix e.g. vanadium ,
chromium , nickel , copper etc. are added.
Are developed to provide more suitability for
special purpose
Mottled Cast Iron
Mixture of white cast iron and grey cast iron in
which carbon is present in the form of graphite
% of carbon is 1.75%
Properties
Hard , brittle and hardly effected by corrosion
Very good fluidity
Less tendency to rust
Applications
Pipes and manholes

STEEL
Alloy of iron and iron carbide in which the maximum
percentage of carbon is 1.5 %.
Difference between cast iron and steel is the % of
carbon present.
% of carbon in steel is intermediate between that of
cast iron and that of wrought iron
In steel carbon present is completely in the combined
form. Higher the % of carbon , harder and tougher is
the steel (max. limit 1.5%)
These steel are called plain carbon steels because they
owe their properties due to the % of carbon present in
them
Classification of Steels
Carbon Steel
- mild
- medium
- high carbon

Alloy Steel
- Stainless
- Heat Resisting
- Spring
- Silicon
- Tool
Mild carbon steel
Amount of carbon varies from 0.01% - 0.03%
Low carbon steel
If amount of carbon steel varies from 0.05% -
0.15%, then it is known as Dead Mild Steel
Mild carbon steel
Properties
Soft , ductile , malleable
Good forming properties
Easily forged and welded
Mild steel can be magnetised permanently
It cannot easily hardened and tempered
It has bright fibrous structure
Tougher and more elastic than wrought iron
Melting point is 1400 degree C
Ultimate compressive strength varies from 8- 12 ton / sq.
cm
Tensile strengh is better than cast iron and wrought iron
Mild carbon steel
Applications
Steels having % C < 0.1% - used for wires
Steels having % C 0.1% - 0.15% - for boiler
plates
Steels having % C 0.15% - 0.25% - for crank
axle
Steels having % C 0.25% - 0.30% - for gears ,
valves connecting rods and railway axles




Medium carbon steel
Carbon varies from 0.30% - 0.55%
Properties
Stronger than mild steel
Greater tensile strength and more hardness
than mild steel
Easily work-able
Can be rolled and forged
Medium carbon steel
Applications
Steels having % C 0.35% - 0.45% - for rails ,
springs , brake levers
Steels having % C 0.45% - 0.55% - for riffle
barrels , gun parts and gear wheels
Used for forging like turbine, bucket , pinion
nuts and bolts etc.


HIGH CARBON STEEL
Carbon % varies from 0.55% - 1.5%
Can be heat treated to improve the properties
Properties
High carbon steel can be easily hardened and
tempered
Can be magnetised permanently
Granular structure
Can not easily forged and welded
Less impact resistance
HIGH CARBON STEEL
Applications
Used for wood working tools , metal cutting tools ,
punches , dies, small drills , reamers etc.
Steels having % C 0.55% - 0.65% - for die blocks
Steels having % C 0.65% - 0.75% - for hammers ,
general tools
Steels having % C 0.75% - 0.85% - for chisels
Steels having % C 0.85% - 1.0% - for drills , taps , keys
etc.
Steels having % C 1.0% - 1.5% - for razor , dies and
knives

Alloy steels
Obtained by adding some elements as nickel ,
chromium , cobalt , vanadium , tungsten , silicon etc. to
the carbon steel to get the desired properties i.e
- To improve tensile strength , elastic limit & ductility
- To provide free cutting properties (lead is added to
steel)
- To improve wear and corrosion resistant
- To improve machinability and weldability
- To refine the grain structure of steel

ALLOYING ELEMENTS ADDED TO STEEL

CARBON : Increases hardness , tensile strength , machine ability , melting point
CHROMIUM : increases the hardening properties of steel significantly along with
improving its corrosion resistance
NICKEL : improves corrosion resistance of steel ,if added in larger quantity it leads to
greater strength and toughness , lessens distortion in quenching
MOLYBDENUM : is used to increase harden ability , toughness , hot hardness and creep
strength of steel , enhancing corrosion resistance , abrasion resisting particles
MANGANESE : increases harden ability of steel if added in increased quantity , lowers
both ductility and weld ability
VANADIUM : improves toughness and wear resistance of steel, resist tempering
TIN : is used to make steel sheet corrosion resistant by forming a silvery white protective
coating over it
COBALT : increases red hardness by hardening ferrite
TUNGSTEN : if added in large quantity improves hot strength and hot hardness , resist
heat , promotes fine grain
SILICON : improves the oxidation resistance of steel , acts as a deoxidiser , strengthen low
alloy steels
Copper : increase resistance to atmospheric corrosion , acts as a strengthening agent
BORON : increases harden ability
ALUMINIUM : produces fine austenite grain size , promoting nitriding



High speed steel
Heat resistant steel having properties like high
hardness , good wear resistant and high
compressive strength
Very hard at high temperatures
Resistant to wear , distortion and deformation
To provide red hardness elements like Co ,W ,
V are added in the steel
Classification of H.S.S
18:4:1 HSS
Contains 18% tungsten , 4% chromium , 1%
vanadium with 0.75% carbon
Used for making tools of lathe machine , planers ,
shapers and milling cutters
Cobalt High Speed Steel
Cobalt is added in carbon steel from 5-8 % to
increase hot hardness and wear resistant
Also known as super high speed steel
Classification of H.S.S
Vanadium high speed steel
Contains more than 1% vanadium and 0.7% carbon
Very good abrasive resistant
Improves strength , toughness and hardness
Used for manufacturing springs and chasis etc.
Molybdenum high speed steel
Contains 6% molybdenum , 6% tungsten , 4%
chromium and 2% vanadium
Very good toughness and cutting ability
Retains hardness at red hot



Stainless steel
Known as corrosion resistant steel
Chromium is the essential element of steel
Does not allow stains to be formed
Non magnetic
Have good strength , toughness , heat
resistance and corrosion resistance
Used for making surgical instruments , ball
bearings , door handles etc.
Classification of stainless steel
Austenitic Stainless Steel
Contains 15 -20% Cr , 7-10% Ni and 0.15% C
18 /8 STEEL is widely used(18% Cr and 8% Ni)
Molybdenum is added to increased corrosion resistant
Titanium and niobium is added to stabilize the carbon
Non magnetic
Can not be hardened by heat treatment
Used for making utensils , sinks , dental and surgical
instruments.
Classification of stainless steel
Martensitic stainless steel
Also called plain chromium stainless steel
Contains 10 14% Cr with no other alloying
element
Magnetic , tough and can be worked in cold state
Can be hardened by heat treatment
Resistant to water
Used for making blades , cutlery and surgical
instruments

Classification of stainless steel
Ferritic Stainless Steel
Contains Cr 14 to 18% or 23 to 30 % .
Donot contain any other elements
Cannot hardened by heat treatment
Can be forged , rolled and machined
Have more corrosion resistance
Used for making chemical equipments

Classification of stainless steel
Spring steels
Possess good strength , toughness and resilence.
Capable of storing energy
Spring steel of composition C 0.6 TO 0.7%, Si 0.2 To
0.55% , Mn 0.65 TO 1.0% is used for laminated spring
for locomotive
Spring steel of composition C 0.6 TO 0.7%, Si 0.5 To
0.8% , Mn 0.6% and Cr 1.0 to 1.5% used for car
springs & air craft engine
Spring steel of composition C 0.6 To 0.7%, Si 0.7 To
0.9% , Mn 0.4 To 0.8% used for making leaf springs
and helical springs
Quenched and tempered to provide desired hardness

Classification of stainless steel
Silicon steel
% of silicon varies from 0.8 to 4.8%
Used in electrical machines because they have
very low hysterisis loss
Contains 1.25% to 2.5 % Si and 0.5 to 0.65 %
carbon and 0.6 to 0.9% Mn
Silicon increases the magnetic permeability
Silicon increases the electrical properties of steel
More ductile than plain carbon steel
Classification of stainless steel
Heat resisting steel
Suitable for working at high temperature
Contains chromium , nickel and tungsten gives
heat resisting steel
Steel containing 23 to 30 % Cr with C < 0.35%
used for service at temp. 800 degree C 1150
degree C
Used for making furnace parts
NON FERROUS METALS
ALUMINIUM : Most commercially used engg. materials. It is
soft , ductile and not very strong.
Main properties are :
1. Light weight
2. High electrical and thermal conductivity
3. Good formability, workability and castability
4. Resistance to corrosion
5. Non toxic, non sparking, non magnetic
6. Excellent casting properties
7. Has FCC Structure
8. Melting point : 659 degree C and boiling point: 2057 degree C
APPLICATIONS : Automobile, bodies, electrical cables,
rivets, aluminium foils, furniture etc.
NON FERROUS METALS
COPPER : Most commercially used engg. materials. It has
high electrical, thermal conductivity, good strength with high
ductility and corrosion resistance. Copper is the backbone of
electrical industry.
Main properties are :
1. Good strength and high ductility
2. High electrical and thermal conductivity
3. Copper is heavier than iron
4. Resistance to corrosion
5. Red heated and cooled slowly, it becomes brittle
6. In pure state copper can not be cast
7. Copper forms important alloy like bronze and gun metal
APPLICATIONS : electric cables, wires, condenser tubes,
electroplating, winding wires etc.
NON FERROUS METALS
BRASS : Alloy of copper and zinc. Addition of zinc to copper in
varying proportion can improve machine ability, hardness,
ductility and corrosion resistance.
Main properties are :
1. Good mechanical properties
2. Resistance to corrosion
3. Easily soldered
4. Easily fabricated
5. Can be electroplated
Types of brass
IronBrass (37% zinc & 60% copper & 3% Fe)
Properties :
1. Easily castable
2. High tensile strength
3. Highly resistant to corrosion
4. Hard and strong
Uses:
In place of mild steel
Tin Brass (37% zinc & 60% copper & 3% Fe)
Properties :
1. High strength
2. Good resistant to corrosion
3. Good Hard and strong
Uses: in Marine industry






NON FERROUS METALS
BRONZE: Alloy of copper and zinc
Main properties are :
1. High wear resistant
2. Good Resistance to corrosion
3. Produces very good casting
4. Good machine ability properties
Alloys of Bronze are:
1. Gun metal
2. Aluminium bronze
3. Phosphor bronze

Gun Metal
Gun Metal ( 80% Cu & 2% Zn & Cu + Sn 10 %)
Properties :
1. Powerful deoxidant
2. Resistant to corrosion
3. Good machineability
Uses:
for less expensive sand casting , gear wheels manufacturing, pump castings
Aluminium Bronze (Cu 88% & Al 8% & Fe 3% and Sn 0.5%)
Properties :
1. High strength
2. Good resistant to corrosion
3. Non magnetic and easy to cast
Uses: for making gears, condensers, cams, stamping and marine works






Gun Metal
Phosphor Bronze( 93.8% Cu & Sn 6 % & P 0.2%)
Properties :
1. Improves soundness
2. Improves cleanliness of castings
3. Good strength, ductility and resistant to sea water
Uses:
for making springs, wire brushes, gears, pins and marine works






Ceramic materials
Are any inorganic , non-metallic solids processed or used at
high temperatures
Consist of oxides , nitrides , carbides , silicates or borides of
various metals
Properties :
- Brittleness
- Rock like appearance
- Resistance to high temperatures
- Hardness
- Abrasiveness
- Insulation
- Corrosion resistance
- Opaque to light
- High temperature strength
Organic materials
Polymeric materials composed of carbon
compounds
Solids composed of long molecular chains
Properties :
- Light weight
- Combustible
- Soft
- Ductile
- Poor conductors of heat and electricity
- Poor resistance to temperature etc.
Polymers
Includes plastic and rubber materials (may be natural/
synthetic)
Monomer is a small molecule which on polymerization
converts into large molecules called polymers.
Most of them are organic compounds that are
chemically based on carbon , hydrogen and other non
metallic elements
Materials typically have low densities and may be
extremely flexible
Have very large molecular structure
Polymerization : process of linking together of monomers
Degree of polymerization = molecular wt of polymer
/molecular wt of monomer

PLASTICS
PROPERTIES :
Light in weight
Low thermal conductivity
Good electrical properties
Resistant to inorganic chemicals
Good vibration damping capacity
Excellent fabrication properties
Good resistant to acid, base, salt and moisture
USES:
Electrical insulation, flooring, sheets, pipes, paints, wall
tiles etc.
CLASSIFICATION OF PLASTICS
Thermoplastic Materials : plastics , finished
products of which can be re melted to
manufacture fresh products.
linear polymer without any cross linkage in its
structure. As a result secondary bond between
individual chains breaks on heating and the
polymers become plastic . On cooling , it again
become hard and rigid as secondary bonds are
reformed.
Soft, brittle, less heat resistant, not suitable for
high temp. applications, recycled and used for
toys , combs, plastic bags etc.
CLASSIFICATION OF PLASTICS
Thermosetting Materials : have Three
dimensional network of primary bonds with
covalent cross links predominating between
chains. Upon heating these bonds retain their
strength.
Hard, strong, more heat resistant, more brittle,
suitable for high temp. applications, can not be
recycled, and used for automobile parts, electrical
switches
Composite Material
A materials system composed of two or
more physically distinct phases whose
combination produces aggregate properties
that are different from those of its
constituents
Examples:
Cemented carbides (WC with Co binder)
Plastic molding compounds containing fillers
Rubber mixed with carbon black
Wood (a natural composite as distinguished
from a synthesized composite)
Why Composites are Important
Composites can be very strong and stiff, yet very light in
weight, so ratios of strength-to-weight and
stiffness-to-weight are several times greater than steel
or aluminum
Fatigue properties are generally better than for
common engineering metals
Toughness is often greater too
Composites can be designed that do not corrode like
steel
Possible to achieve combinations of properties not
attainable with metals, ceramics, or polymers alone
Classification of Composite Materials
Traditional composites composite materials
that occur in nature or have been produced by
civilizations for many years
Examples: wood, concrete, asphalt
Synthetic composites - modern material
systems normally associated with the
manufacturing industries, in which the
components are first produced separately and
then combined in a controlled way to achieve
the desired structure, properties, and part
geometry
Classification
2. Reinforcing Phase (Secondary)
Polymer Matrix Composites (PMCs)
A polymer primary phase in which a
secondary phase is imbedded as fibers,
particles, or flakes
Commercially, PMCs are more important
than MMCs or CMCs
Examples: most plastic molding
compounds, rubber reinforced with carbon
black, and fiber-reinforced polymers (FRPs)
FRPs are most closely identified with the
term composite
Ceramic Matrix Composites (CMCs)
A ceramic primary phase imbedded with a secondary phase,
which usually consists of fibers
Attractive properties of ceramics: high stiffness, hardness, hot
hardness, and compressive strength; and relatively low density
Weaknesses of ceramics: low toughness and bulk tensile
strength, susceptibility to thermal cracking
CMCs represent an attempt to retain the desirable properties of
ceramics while compensating for their weaknesses
Metal Matrix Composites (MMCs)
A metal matrix reinforced by a second
phase
Reinforcing phases:
Particles of ceramic (these MMCs are
commonly called cermets)
Fibers of various materials: other metals,
ceramics, carbon, and boron
CERAMICS
Made from burning clay materials
Non metallic inorganic , amorphous solids and
are mostly metallic oxides
High wear resistance , withstand high temp., high
compressive strength, high modulus of elasticity,
good impact energy, poor thermal conductivity,
hard, brittle, high resistant to chemicals
Uses : fire bricks, biomedical field, grinding
wheels, used for making various composites
Classification of ceramics : clay, glass and cement

Shape Memory Alloys

Materials that after having deformed revert back to
their original shape, when temp. is changed. Below a
critical transition temp., they can deform plastically to
their memorized shape. (Cu-Zn, Ni-Ti )
Piezoelectric materials
Which expands and contract in response to an applied
electric field or voltage. When an electric current is
passed through a piezoelectric material it experiences a
significant increase in size (upto 4% change in vol.)
Electrorheological / Magnetorehcological materials
Shows dramatically change in viscosity upon the
application of electric or magnetic field

PHOTOCHROMIC MATERIALS
Change reversibly colour with changes in light
intensity. Usually they are colourless in dark
place and when sunlight or ultraviolet radiation
is applied molecular structure of the material
changes and it exhibit colour.
Uses : paints , inks etc.
THERMOCHROMIC MATERIALS :
Change reversibly colour with changes in temp.
Usually are semi conductor compounds
Uses : paints, inks etc.
Conductors :
Carry electric currents from place to place
without dissipating a lot of power
Obeys ohms law and have very low resistant
INSULATORS :
Materials which refuse to carry an electric
current
SEMICONDUCTORS:
Have electrical properties that are
intermediate between electrical conductors
and insulators

SELECTION OF ENGINEERING MATERIALS
Four selection factors :
Service requirement mechanical properties,
chemical properties, processing requirements,
dimensional requirements, magnetic properties,
electrical properties
Availabilty ready available, getting after placing
order, available suppliers
Economics or costs cost of raw material,
quantity required
Business issues recycling , health hazards,
waste disposal