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Fundamentals of Materials Science and Engineering. An Integrated Approach. 6th Edition, International Adaptation

  • Book

  • 992 Pages
  • July 2022
  • Region: Global
  • John Wiley and Sons Ltd
  • ID: 5827820

Fundamentals of Materials Science and Engineering provides a comprehensive coverage of the three primary types of materials (metals, ceramics, and polymers) and composites. Adopting an integrated approach to the sequence of topics, the book focuses on the relationships that exist between the structural elements of materials and their properties. This presentation permits the early introduction of non-metals and supports the engineer's role in choosing materials based upon their characteristics. Using clear, concise terminology that is familiar to students, the book presents material at an appropriate level for student comprehension.

 

This International Adaptation has been thoroughly updated to use SI units. This edition enhances the coverage of failure mechanism by adding new sections on Griffith theory of brittle fracture, Goodman diagram, and fatigue crack propagation rate. It further strengthens the coverage by including new sections on peritectoid and monotectic reactions, spinodal decomposition, and various hardening processes such as surface, and vacuum and plasma hardening.  In addition, all homework problems requiring computations have been refreshed.

Table of Contents

List of Symbols xix

1. Introduction 1

Learning Objectives 2

1.1 Historical Perspective 2

1.2 Materials Science and Engineering: Need of Its Study 3

Case Study 1.1 - Cargo Ship Failures 6

1.3 Classification of Materials 7

Case Study 1.2 - Carbonated Beverage Containers 12

1.4 Advanced Materials 14

1.5 Modern Materials’ Needs 17

Summary 18

References 18

Questions and Problems 19

2. Atomic Structure and Interatomic Bonding20

Learning Objectives 21

2.1 Introduction 21

Atomic Structure 21

2.2 Fundamental Concepts 21

2.3 Electrons in Atoms 24

2.4 The Periodic Table 30

Atomic Bonding in Solids 32

2.5 Bonding Forces and Energies 32

2.6 Primary Interatomic Bonds 34

2.7 Secondary Bonding or van der Waals Bonding 41

Materials of Importance 2.1 - Water (Its Volume Expansion upon Freezing) 44

2.8 Mixed Bonding 45

2.9 Molecules 46

2.10 Bonding Type-Material Classification Correlations 46

Summary 47

Equation Summary 48

List of Symbols 48

Important Terms and Concepts 49

References 49

Questions and Problems 49

3. Structures of Metals and Ceramics 52

Learning Objectives 53

3.1 Introduction 53

Crystal Structures 54

3.2 Fundamental Concepts 54

3.3 Unit Cells 55

3.4 Metallic Crystal Structures 55

3.5 Density Computations - Metals 61

3.6 Ceramic Crystal Structures 62

3.7 Density Computations - Ceramics 69

3.8 Silicate Ceramics 70

3.9 Carbon 73

3.10 Polymorphism and Allotropy 78

3.11 Crystal Systems 78

Material of Importance 3.1 - Tin (Its Allotropic Transformation) 80

Crystallographic Points, Directions, and Planes 81

3.12 Point Coordinates 81

3.13 Crystallographic Directions 83

3.14 Crystallographic Planes 90

3.15 Linear and Planar Densities 96

3.16 Close-Packed Crystal Structures 97

Crystalline and Noncrystalline Materials 100

3.17 Single Crystals 100

3.18 Polycrystalline Materials 101

3.19 Anisotropy 101

3.20 X-Ray Diffraction: Determination of Crystal Structures 103

3.21 Noncrystalline Solids 108

Summary 110

Equation Summary 112

List of Symbols 113

Important Terms and Concepts 114

References 114

Questions and Problems 114

4. Polymer Structures 123

Learning Objectives 124

4.1 Introduction 124

4.2 Hydrocarbon Molecules 124

4.3 Polymer Molecules 127

4.4 The Chemistry of Polymer Molecules 127

4.5 Molecular Weight 131

4.6 Molecular Shape 135

4.7 Molecular Structure 137

4.8 Molecular Configurations 138

4.9 Thermoplastic and Thermosetting Polymers 141

4.10 Copolymers 142

4.11 Polymer Crystallinity 143

4.12 Polymer Crystals 147

Summary 149

Equation Summary 150

List of Symbols 151

Important Terms and Concepts 151

References 151

Questions and Problems 152

5. Composites 155

Learning Objectives 156

5.1 Introduction 156

Particle-Reinforced Composites 158

5.2 Large-Particle Composites 159

5.3 Dispersion-Strengthened Composites 162

Fiber-Reinforced Composites 163

5.4 Influence of Fiber Length 163

5.5 Influence of Fiber Orientation and Concentration 164

5.6 The Fiber Phase 173

5.7 The Matrix Phase 174

5.8 Polymer-Matrix Composites 175

5.9 Metal-Matrix Composites 180

5.10 Ceramic-Matrix Composites 182

5.11 Carbon-Carbon Composites 183

5.12 Hybrid Composites 184

5.13 Processing of Fiber-Reinforced Composites 184

Structural Composites 188

5.14 Laminar Composites 188

5.15 Sandwich Panels 190

Case Study 5.1 - Use of Composites in the Boeing 787 Dreamliner 192

5.16 Nanocomposites 193

Summary 195

Equation Summary 198

List of Symbols 199

Important Terms and Concepts 199

References 199

Questions and Problems 200

6. Imperfections in Solids 204

Learning Objectives 205

6.1 Introduction 205

Point Defects 206

6.2 Point Defects in Metals 206

6.3 Point Defects in Ceramics 207

6.4 Impurities in Solids 210

6.5 Point Defects in Polymers 215

6.6 Specification of Composition 215

Miscellaneous Imperfections 219

6.7 Dislocations - Linear Defects 219

6.8 Interfacial Defects 222

Materials of Importance 6.1 - Catalysts (and Surface Defects) 225

6.9 Bulk or Volume Defects 226

6.10 Atomic Vibrations 226

Microscopic Examination 227

6.11 Basic Concepts of Microscopy 227

6.12 Microscopic Techniques 228

6.13 Grain-Size Determination 232

Summary 235

Equation Summary 237

List of Symbols 237

Important Terms and Concepts 238

References 238

Questions and Problems 238

7. Diffusion 243

Learning Objectives 244

7.1 Introduction 244

7.2 Diffusion Mechanisms 245

7.3 Fick’s First Law 246

7.4 Fick’s Second Law - Nonsteady-State Diffusion 248

7.5 Factors that Influence Diffusion 252

7.6 Diffusion in Semiconducting Materials 258

Materials of Importance 7.1 - Aluminum for Integrated Circuit Interconnects 261

7.7 Other Diffusion Paths 262

7.8 Diffusion in Ionic and Polymeric Materials 262

Summary 264

Equation Summary 266

List of Symbols 266

Important Terms and Concepts 266

References 267

Questions and Problems 267

8. Mechanical Properties 272

Learning Objectives 273

8.1 Introduction 273

8.2 Concepts of Stress and Strain 274

Elastic Deformation 278

8.3 Stress-Strain Behavior 278

8.4 Anelasticity 281

8.5 Elastic Properties of Materials 282

Mechanical Behavior - Metals 284

8.6 Tensile Properties 285

8.7 True Stress and Strain 292

8.8 Elastic Recovery after Plastic Deformation 295

8.9 Compressive, Shear, and Torsional Deformations 295

Mechanical Behavior - Ceramics 296

8.10 Flexural Strength 296

8.11 Elastic Behavior 297

8.12 Influence of Porosity on the Mechanical Properties of Ceramics 297

Mechanical Behavior - Polymers 299

8.13 Stress-Strain Behavior 299

8.14 Macroscopic Deformation 301

8.15 Viscoelastic Deformation 302

Hardness and Other Mechanical Property Considerations 306

8.16 Hardness 306

8.17 Hardness of Ceramic Materials 307

8.18 Tear Strength and Hardness of Polymers 312

8.19 Hardness at Elevated Temperature 313

Property Variability and Design/Safety Factors 313

8.20 Variability of Material Properties 313

8.21 Design/Safety Factors 315

Summary 319

Equation Summary 322

List of Symbols 323

Important Terms and Concepts 324

References 324

Questions and Problems 324

9. Dislocation, Deformation, and Strengthening Mechanisms 333

Learning Objectives 334

9.1 Introduction 334

Deformation Mechanisms for Metals 334

9.2 Historical 335

9.3 Basic Concepts of Dislocations 335

9.4 Characteristics of Dislocations 337

9.5 Slip Systems 338

9.6 Slip in Single Crystals 340

9.7 Plastic Deformation of Polycrystalline Metals 343

9.8 Deformation by Twinning 345

Mechanisms of Strengthening in Metals 346

9.9 Strengthening by Grain Size Reduction 346

9.10 Solid-Solution Strengthening 348

9.11 Strain Hardening 349

Recovery, Recrystallization, and Grain Growth 352

9.12 Recovery 352

9.13 Recrystallization 353

9.14 Grain Growth 357

Deformation Mechanisms for Ceramic Materials 359

9.15 Crystalline Ceramics 359

9.16 Noncrystalline Ceramics 359

Mechanisms of Deformation and for Strengthening of Polymers 360

9.17 Deformation of Semicrystalline Polymers 360

9.18 Factors that Influence the Mechanical Properties of Semicrystalline Polymers 362

Materials of Importance 9.1 - Shrink-Wrap Polymer Films 365

9.19 Deformation of Elastomers 366

Summary 368

Equation Summary 371

List of Symbols 371

Important Terms and Concepts 371

References 372

Questions and Problems 372

10. Failure 378

Learning Objectives 379

10.1 Introduction 379

Fracture 380

10.2 Fundamentals of Fracture 380

10.3 Ductile Fracture 380

10.4 Brittle Fracture 382

10.5 Principles of Fracture Mechanics 384

10.6 Griffith Theory of Brittle Fracture 394

10.7 Brittle Fracture of Ceramics 395

10.8 Fracture of Polymers 399

10.9 Fracture Toughness Testing 401

Fatigue 405

10.10 Cyclic Stresses 406

10.11 The S-N Curve 407

10.12 Fatigue in Polymeric Materials 412

10.13 Crack Initiation and Propagation 413

10.14 Factors that Affect Fatigue Life 415

10.15 Thermal and Corrosion Fatigue 417

10.16 Goodman Diagram 418

10.17 Fatigue Crack Propagation Rate 420

Creep 423

10.18 Mechanical Behavior Dependent on Time 423

10.19 Stress and Temperature Effects 424

10.20 Data Extrapolation Methods 427

10.21 High-Temperature Material 428

10.22 Creep in Ceramic and Polymeric Materials 429

Summary 429

Equation Summary 432

List of Symbols 433

Important Terms and Concepts 434

References 434

Questions and Problems 434

11. Phase Diagrams 441

Learning Objectives 442

11.1 Introduction 442

Definitions and Basic Concepts 442

11.2 Solubility Limit 443

11.3 Phases 444

11.4 Microstructure 444

11.5 Phase Equilibria 444

11.6 One-Component (or Unary) Phase Diagrams 445

Binary Phase Diagrams 446

11.7 Binary Isomorphous Systems 447

11.8 Interpretation of Phase Diagrams 449

11.9 Development of Microstructure in Isomorphous Alloys 453

11.10 Mechanical Properties of Isomorphous Alloys 456

11.11 Binary Eutectic Systems 456

11.12 Development of Microstructure in Eutectic Alloys 462

Materials of Importance 11.1 - Lead-Free Solders 463

11.13 Equilibrium Diagrams Having Intermediate Phases or Compounds 469

11.14 Eutectoid and Peritectic Reactions 472

11.15 Peritectoid and Monotectic Reactions 473

11.16 Congruent Phase Transformations 475

11.17 Ceramic Phase Diagrams 476

11.18 Ternary Phase Diagrams 479

11.19 The Gibbs Phase Rule 480

The Iron-Carbon System 482

11.20 The Iron-Iron Carbide (Fe-Fe 3 C) Phase Diagram 482

11.21 Development of Microstructure in Iron- Carbon Alloys 485

11.22 The Influence of Other Alloying Elements 492

11.23 Spinodal Decomposition 493

Summary 496

Equation Summary 498

List of Symbols 499

Important Terms and Concepts 499

References 500

Questions and Problems 500

12. Phase Transformations 507

Learning Objectives 508

12.1 Introduction 508

Phase Transformations in Metals 508

12.2 Basic Concepts 509

12.3 The Thermodynamics and Kinetics of Phase Transformations 509

12.4 Metastable Versus Equilibrium States 520

Microstructural and Property Changes in Iron-Carbon Alloys 521

12.5 Isothermal Transformation Diagrams 521

12.6 Continuous-Cooling Transformation Diagrams 531

12.7 Mechanical Behavior of Iron-Carbon Alloys 534

12.8 Tempered Martensite 539

12.9 Review of Phase Transformations and Mechanical Properties for Iron-Carbon Alloys 541

Materials of Importance 12.1 - Shape- Memory Alloys 544

Precipitation Hardening 547

12.10 Heat Treatments 547

12.11 Mechanism of Hardening 549

12.12 Martempering and Austempering 551

12.13 Surface Hardening (Case-Hardening Process) 552

12.14 Vacuum and Plasma Hardening 554

Crystallization, Melting, and Glass Transition Phenomena in Polymers 554

12.15 Crystallization 555

12.16 Melting 556

12.17 The Glass Transition 556

12.18 Melting and Glass Transition Temperatures 556

12.19 Factors that Influence Melting and Glass Transition Temperatures 557

Summary 560

Equation Summary 562

List of Symbols 563

Important Terms and Concepts 563

References 563

Questions and Problems 564

13. Electrical Properties of Materials 571

Learning Objectives 572

13.1 Introduction 572

Electrical Conduction 573

13.2 Ohm’s Law 573

13.3 Electrical Conductivity 573

13.4 Electronic and Ionic Conduction 574

13.5 Energy Band Structures in Solids 574

13.6 Conduction in Terms of Band and Atomic Bonding Models 577

13.7 Electron Mobility 579

13.8 Electrical Resistivity of Metals 580

13.9 Electrical Characteristics of Commercial Alloys 583

Semiconductivity 583

13.10 Intrinsic Semiconduction 583

13.11 Extrinsic Semiconduction 586

13.12 The Temperature Dependence of Carrier Concentration 589

13.13 Factors that Affect Carrier Mobility 591

13.14 The Hall Effect 595

13.15 Semiconductor Devices 597

Electrical Conduction in Ionic Ceramics and in Polymers 603

13.16 Conduction in Ionic Materials 603

13.17 Electrical Properties of Polymers 604

Dielectric Behavior 605

13.18 Capacitance 605

13.19 Field Vectors and Polarization 607

13.20 Types of Polarization 610

13.21 Frequency Dependence of the Dielectric Constant 611

13.22 Dielectric Strength 612

13.23 Dielectric Materials 612

Other Electrical Characteristics of Materials 613

13.24 Ferroelectricity 613

13.25 Piezoelectricity 614

Materials of Importance 13.1 - Piezoelectric Ceramic Ink-Jet Printer Heads 615

13.26 Electrostriction 616

Summary 617

Equation Summary 619

List of Symbols 620

Important Terms and Concepts 621

References 621

Questions and Problems 622

14. Types and Applications of Materials628

Learning Objectives 629

14.1 Introduction 629

Types of Metal Alloys 629

14.2 Ferrous Alloys 629

14.3 Nonferrous Alloys 642

Materials of Importance 14.1 - Metal Alloys Used for Euro Coins 652

Types of Ceramics 653

14.4 Glasses 654

14.5 Glass-Ceramics 654

14.6 Clay Products 656

14.7 Refractories 656

14.8 Abrasives 659

14.9 Cements 661

14.10 Ceramic Biomaterials 662

14.11 Carbons 663

14.12 Advanced Ceramics 666

Types of Polymers 668

14.13 Plastics 668

Materials of Importance 14.2 - Phenolic Billiard Balls 670

14.14 Elastomers 671

14.15 Fibers 673

14.16 Miscellaneous Applications 673

14.17 Polymeric Biomaterials 675

14.18 Advanced Polymeric Materials 677

Summary 680

Important Terms and Concepts 683

References 683

Questions and Problems 683

15. Processing of Engineering Materials686

Learning Objectives 687

15.1 Introduction 687

Fabrication of Metals 687

15.2 Forming Operations 688

15.3 Casting 689

15.4 Miscellaneous Techniques 691

15.5 3D Printing (Additive Manufacturing) 692

Thermal Processing of Metals 696

15.6 Annealing Processes 697

15.7 Heat Treatment of Steels 699

Fabrication of Ceramic Materials 711

15.8 Fabrication and Processing of Glasses and Glass-Ceramics 711

15.9 Fabrication and Processing of Clay Products 716

15.10 Powder Pressing 721

15.11 Tape Casting 723

15.12 3D Printing of Ceramic Materials 723

Synthesis and Fabrication of Polymers 725

15.13 Polymerization 725

15.14 Polymer Additives 728

15.15 Forming Techniques for Plastics 729

15.16 Fabrication of Elastomers 732

15.17 Fabrication of Fibers and Films 732

15.18 3D Printing of Polymers 733

Summary 736

Important Terms and Concepts 739

References 739

Questions and Problems 740

16. Corrosion and Degradation 743

Learning Objectives 744

16.1 Introduction 744

Corrosion of Metals 745

16.2 Electrochemical Considerations 745

16.3 Corrosion Kinetics 751

16.4 Prediction of Corrosion Rates 753

16.5 Passivity 759

16.6 Environmental Effects 760

16.7 Forms of Corrosion 761

16.8 Corrosion Environments 768

16.9 Corrosion Prevention 769

16.10 Oxidation 771

Corrosion of Ceramic Materials 775

Degradation of Polymers 775

16.11 Swelling and Dissolution 775

16.12 Bond Rupture 777

16.13 Weathering 779

Summary 779

Equation Summary 781

List of Symbols 782

Important Terms and Concepts 783

References 783

Questions and Problems 783

17. Thermal Properties 787

Learning Objectives 788

17.1 Introduction 788

17.2 Heat Capacity 788

17.3 Thermal Expansion 792

Materials of Importance 17.1 - Invar and Other Low-Expansion Alloys 794

17.4 Thermal Conductivity 795

17.5 Thermal Stresses 798

Summary 800

Equation Summary 801

List of Symbols 802

Important Terms and Concepts 802

References 802

Questions and Problems 802

18. Magnetic Properties 805

Learning Objectives 806

18.1 Introduction 806

18.2 Basic Concepts 806

18.3 Diamagnetism and Paramagnetism 810

18.4 Ferromagnetism 812

18.5 Antiferromagnetism and Ferrimagnetism 813

18.6 The Influence of Temperature on Magnetic Behavior 817

18.7 Domains and Hysteresis 818

18.8 Magnetic Anisotropy 821

18.9 Soft Magnetic Materials 823

Materials of Importance 18.1 - An Iron-Silicon Alloy That Is Used in Transformer Cores 823

18.10 Hard Magnetic Materials 825

18.11 Magnetic Storage 828

18.12 Superconductivity 831

Summary 834

Equation Summary 836

List of Symbols 836

Important Terms and Concepts 837

References 837

Questions and Problems 837

19. Optical Properties 840

Learning Objectives 841

19.1 Introduction 841

Basic Concepts 841

19.2 Electromagnetic Radiation 841

19.3 Light Interactions with Solids 843

19.4 Atomic and Electronic Interactions 844

Optical Properties of Metals 845

Optical Properties of Nonmetals 846

19.5 Refraction 846

19.6 Reflection 848

19.7 Absorption 849

19.8 Transmission 852

19.9 Color 852

19.10 Opacity and Translucency in Insulators 854

Applications of Optical Phenomena 855

19.11 Luminescence 855

19.12 Photoconductivity 855

Materials of Importance 19.1 - Light-Emitting Diodes 856

19.13 Lasers 858

19.14 Optical Fibers in Communications 862

Summary 864

Equation Summary 866

List of Symbols 867

Important Terms and Concepts 867

References 867

Questions and Problems 868

20. Economic, Environmental, and Societal Issues in Materials Science and Engineering 870

Learning Objectives 871

20.1 Introduction 871

Economic Considerations 871

20.2 Component Design 872

20.3 Materials 872

20.4 Manufacturing Techniques 873

Environmental and Societal Considerations 873

20.5 Recycling Issues in Materials Science and Engineering 876

Materials of Importance 20.1 - Biodegradable and Biorenewable Polymers/Plastics 880

Summary 882

References 883

Questions and Problems 883

Appendix A The International System of Units (SI) A-1

A.1: The SI Base Units A-1

A.2: Some SI Derived Units A-2

A.3: SI Multiple and Submultiple Prefixes A-2

A.4: Unit Abbreviations A-3

A.5: Unit Conversion Factors A-3

Appendix B Properties of Selected Engineering Materials A-5

B.1: Density A-5

B.2: Modulus of Elasticity A-9

B.3: Poisson’s Ratio A-12

B.4: Strength and Ductility A-14

B.5: Plane Strain Fracture Toughness A-19

B.6: Linear Coefficient of Thermal Expansion A-20

B.7: Thermal Conductivity A-24

B.8: Specific Heat A-27

B.9: Electrical Resistivity A-30

B.10: Metal Alloy Compositions A-33

Appendix C Costs and Relative Costs for Selected Engineering Materials A-35

Appendix D Repeat Unit Structures for Common Polymers A-40

Appendix E Glass Transition and Melting Temperatures for Common Polymeric Materials A-45

Appendix F Characteristics of Selected Elements A-46

Appendix G Values of Selected Physical Constants A-47

Appendix H Periodic Table of the ElementsA-48

Glossary G-1

Answers to Selected Problems (available online)

Index I-1

Authors

William D. Callister, Jr. University of Utah. David G. Rethwisch University of Iowa.