MODERN ENGINEERING MATERIALS AND

THEIR APPLICATIONS
ABSTRACT:
ABSTRACT Advanced Composite Materials Advance
Engineering Materials and their manufacturing is going
to play a predominant role in industrial revolution of
21st century .Materials can be broadly classified as
Polymer, Metal and Ceramics, as they find wide array of
application, starting from automotive, electronic ,
biomedical, pharmaceutical , construction, aerospace
sector to defense ,technical textiles and sports. This
paper reviews the analysis of , the advancement in
manufacturing process , properties of carbon fibers and
along with their high end application ..
INTRODUCTION :
INTRODUCTION Materials science is an interdisciplinary
field involving the properties of matter and its
applications to various areas of science and
engineering. This scientific field investigates the
relationship between the structure of materials at
atomic or molecular scales and their macroscopic
properties Materials science also deals with
fundamental properties and characteristics of materials
It is also an important part of forensic engineering and
failure analysis In materials science, rather than
haphazardly looking for and discovering materials and
exploiting their properties, the aim is instead to
understand materials so that new materials with the
desired properties can be created . The basis of
materials science involves relating the desired
properties and relative performance of a material in a
certain application to the structure of the atoms. The
major determinants of the structure of a material and
thus of its properties are its constituent chemical

elements and the way in which it has been processed

into its final form. These characteristics, taken together
and related through the laws of thermodynamics
govern a materials microstructure, and thus its
properties.
Classes of materials :
Classes of materials Ionic crystals Covalent crystals
Metals Semiconductors Polymers Composite materials
Vitreous materials Plastics
Materials in industry :
Materials in industry Radical materials advances can
drive the creation of new products or even new
industries, but stable industries also employ materials
scientists to make incremental improvements and
troubleshoot issues with currently used materials.
Industrial applications of materials science include
materials design, cost-benefit tradeoffs in industrial
production of materials, processing techniques
( casting, rolling, welding, ion implantation , crystal
growth, thin-film deposition, sintering, glassblowing,
etc.), and analytical techniques (characterization
techniques such as electron microscopy, x-ray
diffraction, calorimetry , nuclear microscopy (HEFIB),
Rutherford backscattering, neutron diffraction, smallangle X-ray scattering (SAXS), etc . Besides material
characterization, the material scientist/engineer also
deals with the extraction of materials and their
conversion into useful forms. Thus ingot casting,
foundry techniques, blast furnace extraction, and
electrolytic extraction are all part of the required
knowledge of a metallurgist/engineer. Often the
presence, absence or variation of minute quantities of
secondary elements and compounds in a bulk material
will have a great impact on the final properties of the
materials produced, for instance, steels are classified

based on 1/10th and 1/100 weight percentages of the

carbon and other alloying elements they contain. Thus,
the extraction and purification techniques employed in
the extraction of iron in the blast furnace will have an
impact of the quality of steel that may be produced.
Materials in industry :
Materials in industry The overlap between physics and
materials science has led to the offshoot field of
materials physics, which is concerned with the physical
properties of materials. The study of metal alloys is a
significant part of materials science. Of all the metallic
alloys in use today, the alloys of iron ( steel, stainless
steel, cast iron, tool steel, alloy steels) make up the
largest proportion both by quantity and commercial
value. Iron alloyed with various proportions of carbon
gives low, mid and high carbon steels. For the steels,
the hardness and tensile strength of the steel is directly
related to the amount of carbon present, with
increasing carbon levels also leading to lower ductility
and toughness. The addition of silicon and
graphitization will produce cast irons (although some
cast irons are made precisely with no graphitization).
The addition of chromium, nickel and molybdenum to
carbon steels (more than 10%) gives us stainless
steels. Other significant metallic alloys are those of
aluminium , titanium, copper and magnesium. Copper
alloys have been known for a long time (since the
Bronze Age), while the alloys of the other three metals
have been relatively recently developed. Due to the
chemical reactivity of these metals, the electrolytic
extraction processes required were only developed
relatively recently. The alloys of aluminium , titanium
and magnesium are also known and valued for their
high strength-to-weight ratios and, in the case of
magnesium, their ability to provide electromagnetic
shielding. These materials are ideal for situations where

high strength-to-weight ratios are more important than

bulk cost, such as in the aerospace industry and certain
automotive engineering applications.
Materials in industry:
Materials in industry Other than metals, polymers and
ceramics are also an important part of materials
science. Polymers are the raw materials (the resins)
used to make what we commonly call plastics. Plastics
are really the final product, created after one or more
polymers or additives have been added to a resin
during processing, which is then shaped into a final
form. Polymers which have been around, and which are
in current widespread use, include polyethylene ,
polypropylene, PVC, polystyrene, nylons, polyesters,
acrylics, polyurethanes, and polycarbonates. Plastics
are generally classified as "commodity", "specialty" and
"engineering" plastics. PVC (polyvinyl-chloride) is
widely used, inexpensive, and annual production
quantities are large. It lends itself to an incredible array
of applications, from artificial leather to electrical
insulation and cabling, packaging and containers. Its
fabrication and processing are simple and wellestablished. The versatility of PVC is due to the wide
range of plasticisers and other additives that it accepts.
The term "additives" in polymer science refers to the
chemicals and compounds added to the polymer base
to modify its material properties .
Materials in industry:
Materials in industry Polycarbonate would be normally
considered an engineering plastic (other examples
include PEEK, ABS). Engineering plastics are valued for
their superior strengths and other special material
properties. They are usually not used for disposable
applications, unlike commodity plastics. Specialty
plastics are materials with unique characteristics, such

as ultra-high strength, electrical conductivity, electrofluorescence, high thermal stability, etc. The dividing
line between the various types of plastics is not based
on material but rather on their properties and
applications. For instance, polyethylene (PE) is a cheap,
low friction polymer commonly used to make
disposable shopping bags and trash bags, and is
considered a commodity plastic, whereas MediumDensity Polyethylene MDPE is used for underground gas
and water pipes, and another variety called Ultra-high
Molecular Weight Polyethylene UHMWPE is an
engineering plastic which is used extensively as the
glide rails for industrial equipment and the low-friction
socket in implanted hip joints.
Materials in industry:
Materials in industry Another application of material
science in industry is the making of composite
materials. Composite materials are structured materials
composed of two or more macroscopic phases.
Applications range from structural elements such as
steel-reinforced concrete, to the thermally insulative
tiles which play a key and integral role in NASA's Space
Shuttle thermal protection system which is used to
protect the surface of the shuttle from the heat of reentry into the Earth's atmosphere. One example is
Reinforced Carbon-Carbon (RCC), The light gray
material which withstands reentry temperatures up to
1510 C (2750 F) and protects the Space Shuttle's
wing leading edges and nose cap.
Materials in industry:
Materials in industry Other examples can be seen in the
"plastic" casings of television sets, cell-phones and so
on. These plastic casings are usually a composite
material made up of a thermoplastic matrix such as
acrylonitrile -butadiene-styrene(ABS ) in which calcium

carbonate chalk , talc, glass fibres or carbon fibres have

been added for added strength, bulk, or electro-static
dispersion. These additions may be referred to as
reinforcing fibres , or dispersants, depending on their
purpose.
Material Selection* :
Material Selection* Failures arising from hasty material
selection are not uncommon in any other industry . In
an application that demands high-impact resistance, a
high-impact material must be specified. If the material
is to be used outdoors for a long period, an Ultraviolet
resistant (UV) material must be specified. For proper
material selection, careful planning, a thorough
understanding of materials , and reasonable prototype
testing are required.
The Need for Material Selection :
The Need for Material Selection During the last decades
many new materials and material types have been
developed. At present of the order of 100 000
engineering materials exist. In addition many materials
have successively obtained improved properties. This
has been possible due to the development of the
materials but also due to the appearance of new
production methods. As a consequence of this rapid
development many material types can be used for a
given component. This also applies to situations where
one previously only employed one material for example
cast iron in cylinder heads where cast aluminium alloys
are also used now. Another example is body panels in
cars where low carbon mild sheet steel is still the
dominating material but many other materials like high
strength sheet steels, aluminium alloys, sheet moulding
compounds (SMC), thermoplastics, thermoplastic
elastomers and expanded plastics are used. In fact it is
quite a common case that many entirely different

materials can be used to a given part. As a

consequence material selection becomes quite a
complex task
Materials selection is both critical and complex
as..:
Materials selection is both critical and complex
as.. ! Many new materials ! Many new material
types ! New manufacturing methods ! Properties of
existing materials improved ! Increased use of
advanced materials ! Entirely new design
configurations feasible ! Increased competition
between materials
Properties Involved in Pre-Selection of Material
Types :
Properties Involved in Pre-Selection of Material Types
Lowest and highest use temperature - ageing - Physical
and chemical degradation Environmental resistance Corrosion resistance - UV-resistance - Toxicity Physical
properties - Electrical and thermal conductivity Density -Coefficient of thermal expansion Mechanical
requirements Tensile strength -Elongation -Toughness
Key considerations are: :
Key considerations are: Thermal Properties Exposure to
Chemicals Environmental Considerations Mechanical
Properties such as.. Tensile strength and Modulus
Impact strength Compressive strength Fatigue
endurance Creep Stress-relaxation
Material Selection process :
Material Selection process The material selection
should not be solely based on cost. A systematic
approach to material selection process is necessary in
order to select the best material for any application.
The proper material selection technique involves

carefully defining the application requirement in terms

of mechanical, thermal, environmental, electrical and
chemical properties. In many instances, it makes sense
to design a thinner wall part taking advantage of the
stiffness-to-weight ratio offered by higher-priced, fast
cycling engineering materials . Many companies
including material suppliers have developed software to
assist in material selection simply by selecting
application requirement in the order of importance.
Material selection process starts with carefully defining
the requirements and narrowing down the choices by
the process of elimination. Designer must identify
application requirements including mechanical,
thermal, environmental and chemical. All special needs
such as outdoor UV exposure, light transmission,
fatigue, creep, stress relaxation, and regulatory
requirements must be considered. Processing
techniques and assembly methods play a key role in
selecting appropriate material and should be given
consideration.
Material Selection process :
Material Selection process Many plastics materials are
susceptible to chemical attack and therefore behavior
of plastics material in chemical environment is one of
the most important considerations in selecting
material. No single property defines materials ability to
perform in a given chemical environment and factors
such as external or molded-in stresses, length of
exposure, temperature, chemical concentration etc.
should be carefully scrutinized. Some of the common
pitfalls in material selection process are relying on
published material property data, misinterpretation of
data sheets and blindly accepting material suppliers
recommendations. Material property data sheets should
only be used for screening various types and grades of
materials and not for ultimate selection or engineering

design. As discussed earlier, the reported data is

generally derived from short term tests and single point
measurements under laboratory condition using
standard test bars. The published values are generally
higher and do not correlate well with actual use
conditions. Such data does not take into account the
effect of time, temperature, environment and
chemicals.
Figure shows a typical failure arising from
improper material selection. :
Figure shows a typical failure arising from improper
material selection.
APPLICATIONS:
APPLICATIONS Si3N4 ceramic bearing parts
APPLICATIONS:
APPLICATIONS Textile Reinforced Materials - materials in
the form of ceramic or concrete are reinforced with a
primarily woven or non-woven textile structure to
impose high strength with comparatively more
flexibility to withstand vibrations and sudden jerks . A
cloth of woven carbon fiber filaments is commonly used
for reinforcement in composite materials .
APPLICATIONS:
APPLICATIONS Household items made of various kinds
of plastic. Polymer properties, synthesis, and
characterization, for a specialized understanding of how
polymers behave, how they are made, and how they
are characterized; exciting applications of polymers
include liquid crystal displays (LCDs, the displays found
in most cell-phones, cameras, and iPods), novel
photovoltaic devices based on semiconductor polymers
(which, unlike the traditional silicon solar panels, are
flexible and cheap to manufacture, albeit with lower

efficiency), and membranes for room-temperature fuel

cells (as proton exchange membranes) and filtration
systems in the environmental and biomedical fields
PowerPoint Presentation:
The most advanced passenger aircraft ever Boeing
787Dreamlinerquiter , enviormental and passenger
friendly, achieved through ground breaking abilities of
carbon fibers. The entire wing structure of A350 is
made up of carbon fiber
comparison:
Material Tensile Strength ( GPa ) Tensile..Modulus
( GPa ) Density (g/ccm) Specific Strength (GPa)
Standard Grade Carbon Fiber 3.5 230.0 1.75 2.00 High
Tensile Steel 1.3 210.0 7.87 0.17comparison
Future prospects:
Future prospects The superior properties of carbon fiber
to steel and other metals meant that the aerospace
industry was an obvious market for composite
materials, the use of lighter materials in aircraft
construction allows for fuel savings or a greater
payload, Carbon fibers are used extensively in both
military and civil aircraft structures. As the technology
of producing composites advanced, other fibers were
developed to supply this market .

WHAT IS AN ADVANCED MATERIAL?

There are many different definitions of
advanced materials and they have become so
commonly used that most tend to assume that
advanced materials are just materials. For a
physical scientist considers that advanced
materials could just as easily have been
Polymers, for these are some of the most
versatile advanced materials in use today and
often are confused as plastics by many people.
WHAT IS AN ADVANCED MATERIAL?
Some scholars define advanced materials as
those that involve knowledge (and creation of
materials) at the molecular and/or atomic scale
for the purpose of advancing technology and
improving the human experience. These might be
materials such as tiny carbon nanotubes that are
being used in new types of X-ray tubes that are
more efficient and safer than those now in use at
airports and in doctors offices. These are also
new coatings and methods of manufacturing of
Teflon, which is an example of a polymer material

made with chemical processing methods that

causes much less pollution and is
environmentally friendly. Other possibilities
include materials used in new diagnostic
methods such as those for medical biopsies.
WHAT IS AN ADVANCED MATERIAL?
Advanced materials research involves
discoveries of fundamental principles of
Chemistry, Mathematics and Physics that can be
applied to control the molecular-level properties
of new materials, and then fashioning materials
and/or nanostructures for real-life applications. It
involves knowing the conditions under which a
material will be used and identifying candidate
materials for this purpose.
There is always a real need for better materials
and/or nanostructures - the issue is how much
better and at what cost. An applied scientist,
with a particular application in mind, will scour
lists of known materials and/or nanostructures
looking for one that meets his or her needs. If
existing materials are unsuitable, the applied
and basic scientist must work together to
develop new materials and/or nanostructures.
This synergism between what is available and
what needs to be developed reflects the
important and complementary roles of the basic
and applied sciences in Materials Science.
Neither one takes precedence over the other.
Rather, they work hand-in-hand to fulfill our evergrowing need for new materials.
Materials that are utilized in high-technology
application

 High-tech, a device or product that operates

or functions using relatively intricate and
sophisticated principles
Electronic equipment, computers, fiber optic
systems, spacecraft, aircraft, and military
rocketry.
They might be of all material types whose
properties have been enhanced or newly
developed
Materials of the Future
A. SMART MATERIALS
A group of new and state of the art
materials now being developed that will
have a significant influence on many
technologies.
Smart implies the ability to sense
charges in environments and then
respond to the changes in predetermined
manners-traits that are also found in
living organisms.
Component of smart materials (or system):
Some type of sensor (detect an input
signal)
An actuator (perform a responsive
and adaptive function)
Four types of materials used for actuator:
1.Shape memory alloys; metals, after
having been deformed, revert back to
their original shapes when
temperature is changed.
2.Piezoelectric ceramics; expand and
contract in response to an applied
electric fields (or voltage);
conversely, they also generate an
electric field when their dimension
are altered.

3.Magnetostrictive; like piezoelectric

but in magnetic fields
4.Electro-rheological & magnetorheological fluids are liquids that
experience dramatic changes in
viscosity upon the application of
electric or magnetic fields.
Example of Smart materials: piezoelectric
inserted to blade of helicopter to sensor noise
computer feedback to generate noise-canceling
antinoise.
B. NANOTECHNOLOGY
To understand the chemistry and physics of
materials by studying large and complex
structures to investigate the fundamental
building blocks of these structures that are
smaller and simpler. Top-down sciences
By SPM (scanning probe microscopes) permits to
observe the individual atoms and molecules, and
it has become possible to manipulate and move
atoms and molecules to form new structures,
thus, design new materials that are built from
simple atomic level constituents (i.e. materials
by design)
It enables to carefully arrange atoms to develop
mechanical, electrical, magnetic, and other
properties. Bottom-up sciences called
nanotechnology.
Nano = 10-9, nanotechnology < 100 nm
equivalent 500 atom diameters
Modern Materials Needs
The development of more sophisticated and
specialized materials, as well as
consideration of the environmental impact of
material production.

 Nuclear energy: many problem remain in

materials, from fuel to containment
structures to facilities to the disposal of
radioactive waste.
Transportation: facing low operating
temperature engine etc.
Fuel cell energy: facing low operating
temperature for high energy output.
Manufacturing process: facing toxic as a
product of the process
Non renewable materials such as polymer,
some of metals, oil will be depleted for:
The discovery of additional reserves,
The development of new materials
having comparable properties with less
adverse environmental impact, and/or
Increased recycling effort and the
development of new recycling technology