materials in manufacturing (composites)

Most engineering materials can be classified into one of three basic categories.

1-metals
2-ceramics
3-polymers
-In addition to the three basic categories there are
v
v
4-composites : that can be defined as a nonhomogeneous mixtures of the three types

In this topic i will talk about
Composites
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)

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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 .

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One Possible Classification of Composite Materials

1-Traditional composites – composite materials that occur in nature or have been produced by civilizations for many years
-Examples: wood, concrete, asphalt
2-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

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Components in a Composite Material

Nearly all composite materials consist of two phases:
1-Primary phase - forms the matrix within which the secondary phase is imbedded
2-Secondary phase - imbedded phase sometimes referred to as a reinforcing agent, because it usually serves to strengthen the composite

* The reinforcing phase may be in the form of fibers, particles, or various other geometries

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Our Classification Scheme for Composite Materials

1-Metal Matrix Composites (MMCs) ‑ mixtures of ceramics and metals, such as cemented carbides and other cermets
2-Ceramic Matrix Composites (CMCs) ‑ Al2O3 and SiC imbedded with fibers to improve properties, especially in high temperature applications
The least common composite matrix
3-Polymer Matrix Composites (PMCs) ‑ thermosetting resins are widely used in PMCs
-Examples: epoxy and polyester with fiber reinforcement, and phenolic with powders



Typical uses of composites are monocoque structures for aerospace and automobiles, as well as more mundane products like fishing rods and bicycles. The stealth bomber was the first all-composite aircraft, but many passenger aircraft like the Airbus uses an increasing proportion of composites in its fuselage. The quite different physical properties of composites gives designers much greater freedom in shaping parts, which is why composite products often look different to conventional products. On the other hand, some products such as drive shafts, helicopter rotor blades, and propellers look identical to metal precursors owing to the basic functional needs of such components.

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All this information are from books and sites talk about mechanics
and this is just a Research

materials in manufacturing (polymers)

Most engineering materials can be classified into one of three basic categories.

1-metals
2-ceramics
3-polymers
-In addition to the three basic categories there are
v
v
4-composites : that can be defined as a nonhomogeneous mixtures of the three types

In this topic i will talk about polymers.

Polymers
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A polymer is a large molecule (macromolecule) composed of repeating structural units typically connected by covalent chemical bonds. While polymer in popular usage suggests plastic, the term actually refers to a large class of natural and synthetic
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Well-known examples of polymers include plastics and proteins. A simple example is polypropylene, whose repeating unit structure is shown at the right. However, polymers are not just limited to having predominantly carbon backbones, elements such as silicon form familiar materials such as silicones, examples being silly putty and waterproof plumbing sealant. The backbone of DNA is in fact based on a phosphodiester bond.

Natural polymer materials such as shellac and amber have been in use for centuries. Biopolymers such as proteins and nucleic acids play crucial roles in biological processes. A variety of other natural polymers exist, such as cellulose, which is the main constituent of wood and paper.

The list of synthetic polymers includes Bakelite, neoprene, nylon, PVC, polystyrene, polyacrylonitrile, PVB, silicone, and many more.

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Polymerization is the process of combining many small molecules known as monomers into a covalently bonded chain. During the polymerization process, some chemical groups may be lost from each monomer. The distinct piece of each monomer that is incorporated into the polymer is known as a repeat unit or monomer residue.
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Polymer structure

The structural properties of a polymer relate to the physical arrangement of monomer residues along the backbone of the chain. Structure has a strong influence on the other properties of a polymer. For example, a linear chain polymer may be soluble or insoluble in water depending on whether it is composed of polar monomers (such as ethylene oxide) or nonpolar monomers (such as styrene). On the other hand, two samples of natural rubber may exhibit different durability, even though their molecules comprise the same monomers. Polymer scientists have developed terminology to describe precisely both the nature of the monomers as well as their relative arrangement.

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Monomer identity

The identity of the monomers comprising the polymer is generally the first and most important attribute of a polymer. The repeat unit is the constantly repeated unit of the chain and is also characteristic of the polymer. Polymer nomenclature is generally based upon the type of monomers comprising the polymer. Polymers that contain only a single type of monomer are known as homopolymers, while polymers containing a mixture of monomers are known as copolymers. Poly(styrene), for example, is composed only of styrene monomers, and is therefore classified as a homopolymer. Ethylene-vinyl acetate, on the other hand, contains more than one variety of monomer and is thus a copolymer. Some biological polymers are composed of a variety of different but structurally related monomers, such as polynucleotides composed of nucleotide subunits.

The repeating unit of the polymer may be different from the starting monomer(s), for example in condensation polymerization. A simple example is PET polyester. The monomers are terephthalic acid (HOOC-C6H4-COOH) and ethylene glycol (HO-CH2-CH2-OH) but the repeating unit is -OC-C6H4-COO-CH2-CH2-O-, which corresponds to the combination of the two monomers with the loss of two water molecules.

A polymer molecule containing ionizable subunits is known as a polyelectrolyte. An ionomer is a subclass of polyelectrolyte with a low fraction of ionizable subunit.

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Chain linearity

The simplest form of polymer molecule is a straight chain or linear' polymer, composed of a single main chain. The flexibility of an unbranched chain polymer is characterized by its persistence length. A branched polymer molecule is composed of a main chain with one or more substituent side chains or branches. Special types of branched polymers include star polymers, comb polymers, and brush polymers. If the polymer contains a side chain that has a different composition or configuration than the main chain, the polymer is called a graft or grafted polymer. A cross-link suggests a branch point from which four or more distinct chains emanate. A polymer molecule with a high degree of crosslinking is referred to as a polymer network. Sufficiently high crosslink concentrations may lead to the formation of an infinite network, also known as a gel, in which networks of chains are of unlimited extent — essentially all chains have linked into one molecule.

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Chain length

Polymer bulk properties may be strongly dependent on the size of the polymer chain. Like any molecule, a polymer molecule's size may be described in terms of molecular weight or mass. In polymers, however, the molecular mass may be expressed in terms of degree of polymerization, essentially the number of monomer units which comprise the polymer. For synthetic polymers, the molecular weight is expressed statistically to describe the distribution of molecular weights in the sample. This is because of the fact that almost all industrial processes produce a distribution of polymer chain sizes. Examples of such statistics include the number average molecular weight and weight average molecular weight. The ratio of these two values is the polydispersity index, commonly used to express the "width" of the molecular weight distribution.

The maximum length of a polymer chain is its contour length.

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Polymer properties

Types of polymer properties can be broadly divided into several categories based upon scale. At the nano-micro scale there are properties that directly describe the chain itself, and can be thought of as polymer structure. At an intermediate mesoscopic level there are properties that describe the morphology of the polymer matrix in space. At the macroscopic level properties describe the bulk behavior of the polymer.

The bulk properties of a polymer are those most often of end-use interest. These are the properties that dictate how the polymer actually behaves on a macroscopic scale.
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Relationship between chain length and polymer properties

Polymer bulk properties are strongly dependent upon their structure and mesoscopic behavior. A number of qualitative relationships between structure and properties are known.

Increasing chain length tends to decrease chain mobility, increase strength and toughness, and increase the glass transition temperature (Tg). This is a result of the increase in chain interactions such as Van der Waals attractions and entanglements that come with increased chain length. These interactions tend to fix the individual chains more strongly in position and resist deformations and matrix breakup, both at higher stresses and higher temperatures. Chain length is related to melt viscosity roughly as 1:103.2, so that a tenfold increase in polymer chain length results in a viscosity increase of over 1000 times.

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Tensile strength

The tensile strength of a material quantifies how much stress the material will endure before failing. This is very important in applications that rely upon a polymer's physical strength or durability. For example, a rubber band with a higher tensile strength will hold a greater weight before snapping. In general tensile strength increases with polymer chain length and crosslinking of polymer chains.

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Mixing behavior

In general, polymeric mixtures are far less miscible than mixtures of small molecule materials. This effect is a result of the fact that the driving force for mixing is usually entropics, not energetics. In other words, miscible materials usually form a solution not because their interaction with each other is more favorable than their self-interaction, but because of an increase in entropy and hence free energy associated with increasing the amount of volume available to each component. This increase in entropy scales with the number of particles (or moles) being mixed. Since polymeric molecules are much larger and hence generally have much higher specific volumes than small molecules, the number of molecules involved in a polymeric mixture are far less than the number in a small molecule mixture of equal volume. The energetics of mixing, on the other hand, are comparable on a per volume basis for polymeric and small molecule mixtures. This tends to increase the free energy of mixing for polymer solutions and thus make solvation less favorable. Thus, concentrated solutions of polymers are far rarer than those of small molecules.

In dilute solution, the properties of the polymer are characterized by the interaction between the solvent and the polymer. In a good solvent, the polymer appears swollen and occupies a large volume. In this scenario, intermolecular forces between the solvent and monomer subunits dominate over intramolecular interactions. In a bad solvent or poor solvent, intramolecular forces dominate and the chain contracts. In the theta solvent, or the state of the polymer solution where the value of the second virial coefficient becomes 0, the intermolecular polymer-solvent repulsion balances exactly the intramolecular monomer-monomer attraction. Under the theta condition (also called the Flory condition), the polymer behaves like an ideal random coil.

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Polymer engineering is generally an engineering field that designs, analyses, and/or modifies polymer materials. Polymer engineering covers aspects of petrochemical industry, polymerization, structure and characterization of polymers, properties of polymers, compounding and processing of polymers and description of major polymers, structure property relations and applications.

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All this information are from books and sites talk about mechanics

and this is just a Research

materials in manufacturing (ceramics)

Most engineering materials can be classified into one of three basic categories.

1-metals
2-ceramics
3-polymers
-In addition to the three basic categories there are
v
v
4-composites : that can be defined as a nonhomogeneous mixtures of the three types

In this topic i will talk about ceramics

ceramics
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In the most simple of terms, ceramics can be defined as inorganic, nonmetallic materials. They are typically crystalline in nature (have an ordered structure) and are compounds formed between metallic and nonmetallic elements such as aluminum and oxygen (alumina, Al₂O₃), calcium and oxygen (calcia, CaO), and silicon and nitrogen (silicon nitride, Si₃N₄).

In broader terms ceramics also include glass (which has a non-crystalline or amorphous random structure), enamel (a type of glassy coating), glass-ceramics (a glass containing ceramic crystals), and inorganic cement-type materials (cement, plaster and lime). However, as ceramic technology has developed over time, the definition has expanded to include a much wider range of other compositions used in a variety of applications.

Types of ceramic products

For convenience ceramic products are usually divided into four sectors, and these are shown below with some examples:

1 - Structural, including bricks, pipes, floor and roof tiles
2 - Refractories, such as kiln linings, gas fire radiants, steel and glass making crucibles
3 - Whitewares, including tableware, wall tiles, pottery products, and sanitary ware
4 - Technical, is also known as Engineering, Advanced, Special, and in Japan, Fine Ceramics. Such items include tiles used in the Space Shuttle program, gas burner nozzles, ballistic protection, nuclear fuel uranium oxide pellets, bio-medical implants, jet engine turbine blades, and missile nose cones. Frequently the raw materials do not include clays.

Classification of technical ceramics

Technical ceramics can also be classified into three distinct material categories:

* Oxides: Alumina, zirconia
* Non-oxides: Carbides, borides, nitrides, silicides
* Composites: Particulate reinforced, combinations of oxides and non-oxides.

Each one of these classes can develop unique material properties.

The two main categories of ceramics are traditional and advanced. Traditional ceramics include objects made of clay and cements that have been hardened by heating at high temperatures. Traditional ceramics are used in dishes, crockery, flowerpots, and roof and wall tiles. Advanced ceramics include carbides, such as silicon carbide, SiC; oxides, such as aluminum oxide, Al₂O₃; nitrides, such as silicon nitride, Si₃N₄; and many other materials, including the mixed oxide ceramics that can act as superconductors. Advanced ceramics require modern processing techniques, and the development of these techniques has led to advances in medicine and engineering.

Glass is sometimes considered a type of ceramic. However, glasses and ceramics differ in that ceramics have a crystalline structure while glasses contain impurities that prevent crystallization. The structure of glasses is amorphous, like that of liquids. Ceramics tend to have high, well-defined melting points, while glasses tend to soften over a range of temperatures before becoming liquids. In addition, most ceramics are opaque to visible light, and glasses tend to be translucent. Glass ceramics have a structure that consists of many tiny crystalline regions within a noncrystalline matrix. This structure gives them some properties of ceramics and some of glasses. In general, glass ceramics expand less when heated than most glasses, making them useful in windows, for wood stoves, or as radiant glass-ceramic cooktop surfaces.

Manufacture of Traditional Ceramics

Traditional ceramics are made from natural materials such as clay that have been hardened by heating at high temperatures (driving out water and allowing strong chemical bonds to form between the flakes of clay). In fact, the word "ceramic" comes from the Greek keramos, whose original meaning was "burnt earth." When artists make ceramic works of art, they first mold clay, often mixed with other raw materials, into the desired shape. Special ovens called kilns are used to "fire" (heat) the shaped object until it hardens.

Clay consists of a large number of very tiny flat plates, stacked together but separated by thin layers of water. The water allows the plates to cling together, but also acts as a lubricant, allowing the plates to slide past one another. As a result, clay is easily molded into shapes. High temperatures drive out water and allow bonds to form between plates, holding them in place and promoting the formation of a hard solid. Binders such as bone ash are sometimes added to the clay to promote strong bond formation, which makes the ceramic resistant to breakage. The common clay used to make flowerpots and roof tiles is usually red-orange because of the presence of iron oxides. White ceramics are made from rarer (and thus more expensive) white clays, primarily kaolin.

The oldest known ceramics made by humans are figurines found in the former Czechoslovakia that are thought to date from around 27,000 B.C.E. It was determined that the figurines were made by mixing clay with bone, animal fat, earth, and bone ash (the ash that results when animal bones are heated to a high temperature), molding the mixture into a desired shape, and heating it in a domed pit. The manufacture of functional objects such as pots, dishes, and storage vessels, was developed in ancient Greece and Egypt during the period 9000 to 6000 B.C.E.

An important advance was the development of white porcelain. Porcelain is a hard, tough ceramic that is less brittle than the ceramics that preceded it. Its strength allows it to be fashioned into beautiful vessels with walls so thin they can even be translucent. It is made from kaolin mixed with china stone, and the mixture is heated to a very high temperature (1,300°C, or 2,372°F). Porcelain was developed in China around C.E. 600 during the T'ang dynasty and was perfected during the Ming dynasty, famous for its blue and white porcelain. The porcelain process was introduced to the Arab world in the ninth century; later Arabs brought porcelain to Spain, from where the process spread throughout Europe.

Bone china has a composition similar to that of porcelain, but at least 50 percent of the material is finely powdered bone ash. Like porcelain, bone china is strong and can be formed into dishes with very thin, translucent walls. Stoneware is a dense, hard, gray or tan ceramic that is less expensive than bone china and porcelain, but it is not as strong. As a result, stoneware dishes are usually thicker and heavier than bone china or porcelain dishes.

Manufacture of Advanced Ceramics

The preparation of an advanced ceramic material usually begins with a finely divided powder that is mixed with an organic binder to help the powder consolidate, so that it can be molded into the desired shape. Before it is fired, the ceramic body is called "green." The green body is first heated at a low temperature in order to decompose or oxidize the binder. It is then heated to a high temperature until it is "sintered," or hardened, into a dense, strong ceramic. At this time, individual particles of the original powder fuse together as chemical bonds form between them. During sintering the ceramic may shrink by as much as 10 to 40 percent. Because shrinkage is not uniform, additional machining of the ceramic may be required in order to obtain a precise shape.

Sol-gel technology allows better mixing of the ceramic components at the molecular level, and hence yields more homogeneous ceramics, because the ions are mixed while in solution. In the sol-gel process, a solution of an organometallic compound is hydrolyzed to produce a "sol," a colloidal suspension of a solid in a liquid. Typically the solution is a metal alkoxide such as tetramethoxysilane in an alcohol solvent. The sol forms when the individual formula units polymerize (link together to form chains and networks). The sol can then be spread into a thin film, precipitated into tiny uniform spheres called microspheres, or further processed to form a gel inside a mold that will yield a final ceramic object in the desired shape. The many crosslinks between the formula units result in a ceramic that is less brittle than typical ceramics.

Although the sol-gel process is very expensive, it has many advantages, including low temperature requirements; the ceramist's ability to control porosity and to form films, spheres, and other structures that are difficult to form in molds; and the attainment of specialized ceramic compositions and high product purity.

Porous ceramics are made by the sol-gel process. These ceramics have spongelike structures, with many porelike lacunae, or openings, that can make up from 25 to 70 percent of the volume. The pore size can be large, or as small as 50 nanometers (2 × 10⁻⁶ inches) in diameter. Because of the large number of pores, porous ceramics have enormous surface areas (up to 500 square meters, or 5,382 square feet, per gram of ceramic), and so can make excellent catalysts. For example, zirconium oxide is a ceramic oxygen sensor that monitors the air-to-fuel ratio in the exhaust systems of automobiles.

Aerogels are solid foams prepared by removing the liquid from the gel during a sol-gel process at high temperatures and low pressures. Because aerogels are good insulators, have very low densities, and do not melt at high temperatures, they are attractive for use in spacecraft.

Structure and Properties

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The properties of ceramic materials, like all materials, are dictated by the types of atoms present, the types of bonding between the atoms, and the way the atoms are packed together. The type of bonding and structure helps determine what type of properties a material will have.

Ceramics usually have a combination of stronger bonds called ionic (occurs between a metal and nonmetal and involves the attraction of opposite charges when electrons are transferred from the metal to the nonmetal); and covalent (occurs between two nonmetals and involves sharing of atoms). The strength of an ionic bond depends on the size of the charge on each ion and on the radius of each ion.

The greater the number of electrons being shared, is the greater the force of attraction, or the stronger the covalent bond.

These types of bonds result in high elastic modulus and hardness, high melting points, low thermal expansion, and good chemical resistance. On the other hand, ceramics are also hard and often brittle (unless the material is toughened by reinforcements or other means), which leads to fracture.

In general, metals have weaker bonds than ceramics, which allows the electrons to move freely between atoms. Think of a box containing marbles surrounded by water. The marbles can be pushed anywhere within the box and the water will follow them, always surrounding the marbles. This type of bond results in the property called ductility, where the metal can be easily bent without breaking, allowing it to be drawn into wire. The free movement of electrons also explains why metals tend to be conductors of electricity and heat.

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All this information are from books and sites talk about mechanics

and this is just a Research

materials in manufacturing (Metals)

Most engineering materials can be classified into one of three basic categories.

1-metals
2-ceramics
3-polymers
-In addition to the three basic categories there are
v
v
4-composites : that can be defined as a nonhomogeneous mixtures of the three types

in this topic I will talk about metals.

Metals

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Metals account for about two thirds of all the elements and about 24% of the mass of the planet. Metals have useful properties including strength, ductility, high melting points, thermal and electrical conductivity, and toughness. From the periodic table, it can be seen that a large number of the elements are classified as being a metal. A few of the common metals and their typical uses are presented below.

Common Metallic Materials

• Iron/Steel - Steel alloys are used for strength critical applications
• Aluminum - Aluminum and its alloys are used because they are easy to form, readily available, inexpensive, and recyclable.
• Copper - Copper and copper alloys have a number of properties that make them useful, including high electrical and thermal conductivity, high ductility, and good corrosion resistance.
• Titanium - Titanium alloys are used for strength in higher temperature (~1000° F) application, when component weight is a concern, or when good corrosion resistance is required
• Nickel - Nickel alloys are used for still higher temperatures (~1500-2000° F) applications or when good corrosion resistance is required.
• Refractory materials are used for the highest temperature (> 2000° F) applications.

The key feature that distinguishes metals from non-metals is their bonding. Metallic materials have free electrons that are free to move easily from one atom to the next. The existence of these free electrons has a number of profound consequences for the properties of metallic materials. For example, metallic materials tend to be good electrical conductors because the free electrons can move around within the metal so freely
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Physical properties
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Gallium crystals
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Metals in general have superior electric and thermal conductivity, high luster and density, and the ability to be deformed under stress without cleaving. While there are several metals that have low density, hardness, and melting points, these (the alkali and alkaline earth metals) are extremely reactive, and are rarely encountered in their elemental, metallic form Density

The majority of metals have higher densities than the majority of nonmetals. Nonetheless, there is wide variation in the densities of metals; lithium is the least dense solid element and osmium is the densest.
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Malleability
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The nondirectional nature of metallic bonding is thought to be the primary reason for the malleability of metal. Planes of atoms in a metal are able to slide across one another under stress, accounting for the ability of a crystal to deform without shattering.
Hot metal work from a blacksmith.

When the planes of an ionic bond are slid past one another, the resultant change in location shifts ions of the same charge into close proximity, resulting in the cleavage of the crystal. Covalently bonded crystals can only be deformed by breaking the bonds between atoms, thereby resulting in fragmentation of the crystal.
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Conductivity
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The electrical and thermal conductivity of metals originate from the fact that in the metallic bond, the outer electrons of the metal atoms form a gas of nearly free electrons, moving as an electron gas in a background of positive charge formed by the ion cores. Good mathematical predictions for electrical conductivity, as well as the electrons' contribution to the heat capacity and heat conductivity of metals can be calculated from the free electron model, which does not take the detailed structure of the ion lattice into account.
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Electric charge
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When considering the exact band structure and binding energy of a metal, it is necessary to take into account the positive potential caused by the specific arrangement of the ion cores - which is periodic in crystals. The most important consequence of the periodic potential is the formation of a small band gap at the boundary of the brillouin zone. Mathematically, the potential of the ion cores is treated in the nearly-free electron model

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we can classify metals to

1-ferrous metals : ferrous metals are based on iron
2-Nonferrous metals
-ferrous metals includes steel and cast iron

steel
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Steels can be classified by a variety of different systems depending on:

• The composition, such as carbon, low-alloy or stainless steel.
• The manufacturing methods, such as open hearth, basic oxygen process, or electric furnace methods.
• The finishing method, such as hot rolling or cold rolling
• The product form, such as bar plate, sheet, strip, tubing or structural shape
• The deoxidation practice, such as killed, semi-killed, capped or rimmed steel
• The microstructure, such as ferritic, pearlitic and martensitic
• The required strength level, as specified in ASTM standards
• The heat treatment, such as annealing, quenching and tempering, and thermomechanical processing
• Quality descriptors, such as forging quality and commercial quality.

Carbon Steels

The American Iron and Steel Institute (AISI) defines carbon steel as follows:

Steel is considered to be carbon steel when no minimum content is specified or required for chromium, cobalt, columbium [niobium], molybdenum, nickel, titanium, tungsten, vanadium or zirconium, or any other element to be added to obtain a desired alloying effect; when the specified minimum for copper does not exceed 0.40 per cent; or when the maximum content specified for any of the following elements does not exceed the percentages noted: manganese 1.65, silicon 0.60, copper 0.60.

Carbon steel can be classified, according to various deoxidation practices, as rimmed, capped, semi-killed, or killed steel. Deoxidation practice and the steelmaking process will have an effect on the properties of the steel. However, variations in carbon have the greatest effect on mechanical properties, with increasing carbon content leading to increased hardness and strength. As such, carbon steels are generally categorized according to their carbon content. Generally speaking, carbon steels contain up to 2% total alloying elements and can be subdivided into low-carbon steels, medium-carbon steels, high-carbon steels, and ultrahigh-carbon steels; each of these designations is discussed below.

As a group, carbon steels are by far the most frequently used steels. More than 85% of the steel produced and shipped in the United States is carbon steel.

Low-carbon steels contain up to 0.30% C. The largest category of this class of steel is flat-rolled products (sheet or strip), usually in the cold-rolled and annealed condition. The carbon content for these high-formability steels is very low, less than 0.10% C, with up to 0.4% Mn. Typical uses are in automobile body panels, tin plate, and wire products.

For rolled steel structural plates and sections, the carbon content may be increased to approximately 0.30%, with higher manganese content up to 1.5%. These materials may be used for stampings, forgings, seamless tubes, and boiler plate.

Medium-carbon steels are similar to low-carbon steels except that the carbon ranges from 0.30 to 0.60% and the manganese from 0.60 to 1.65%. Increasing the carbon content to approximately 0.5% with an accompanying increase in manganese allows medium carbon steels to be used in the quenched and tempered condition. The uses of medium carbon-manganese steels include shafts, axles, gears, crankshafts, couplings and forgings. Steels in the 0.40 to 0.60% C range are also used for rails, railway wheels and rail axles.

High-carbon steels contain from 0.60 to 1.00% C with manganese contents ranging from 0.30 to 0.90%. High-carbon steels are used for spring materials and high-strength wires.

Ultrahigh-carbon steels are experimental alloys containing 1.25 to 2.0% C. These steels are thermomechanically processed to produce microstructures that consist of ultrafine, equiaxed grains of spherical, discontinuous proeutectoid carbide particles.

High-Strength Low-Alloy Steels

High-strength low-alloy (HSLA) steels, or microalloyed steels, are designed to provide better mechanical properties and/or greater resistance to atmospheric corrosion than conventional carbon steels in the normal sense because they are designed to meet specific mechanical properties rather than a chemical composition.

The HSLA steels have low carbon contents (0.05-0.25% C) in order to produce adequate formability and weldability, and they have manganese contents up to 2.0%. Small quantities of chromium, nickel, molybdenum, copper, nitrogen, vanadium, niobium, titanium and zirconium are used in various combinations.

HSLA Classification:

• Weathering steels, designated to exhibit superior atmospheric corrosion resistance
• Control-rolled steels, hot rolled according to a predetermined rolling schedule, designed to develop a highly deformed austenite structure that will transform to a very fine equiaxed ferrite structure on cooling
• Pearlite-reduced steels, strengthened by very fine-grain ferrite and precipitation hardening but with low carbon content and therefore little or no pearlite in the microstructure
• Microalloyed steels, with very small additions of such elements as niobium, vanadium, and/or titanium for refinement of grain size and/or precipitation hardening
• Acicular ferrite steel, very low carbon steels with sufficient hardenability to transform on cooling to a very fine high-strength acicular ferrite structure rather than the usual polygonal ferrite structure
• Dual-phase steels, processed to a micro-structure of ferrite containing small uniformly distributed regions of high-carbon martensite, resulting in a product with low yield strength and a high rate of work hardening, thus providing a high-strength steel of superior formability.

The various types of HSLA steels may also have small additions of calcium, rare earth elements, or zirconium for sulfide inclusion shape control.

Low-alloy Steels

Low-alloy steels constitute a category of ferrous materials that exhibit mechanical properties superior to plain carbon steels as the result of additions of alloying elements such as nickel, chromium, and molybdenum. Total alloy content can range from 2.07% up to levels just below that of stainless steels, which contain a minimum of 10% Cr.

For many low-alloy steels, the primary function of the alloying elements is to increase hardenability in order to optimize mechanical properties and toughness after heat treatment. In some cases, however, alloy additions are used to reduce environmental degradation under certain specified service conditions.

As with steels in general, low-alloy steels can be classified according to:

• Chemical composition, such as nickel steels, nickel-chromium steels, molybdenum steels, chromium-molybdenum steels
• Heat treatment, such as quenched and tempered, normalized and tempered, annealed.

Because of the wide variety of chemical compositions possible and the fact that some steels are used in more than one heat-treated, condition, some overlap exists among the alloy steel classifications. In this article, four major groups of alloy steels are addressed: (1) low-carbon quenched and tempered (QT) steels, (2) medium-carbon ultrahigh-strength steels, (3) bearing steels, and (4) heat-resistant chromium-molybdenum steels.

Low-carbon quenched and tempered steels combine high yield strength (from 350 to 1035 MPa) and high tensile strength with good notch toughness, ductility, corrosion resistance, or weldability. The various steels have different combinations of these characteristics based on their intended applications. However, a few steels, such as HY-80 and HY-100, are covered by military specifications. The steels listed are used primarily as plate. Some of these steels, as well as other, similar steels, are produced as forgings or castings.

Medium-carbon ultrahigh-strength steels are structural steels with yield strengths that can exceed 1380 MPa. Many of these steels are covered by SAE/AISI designations or are proprietary compositions. Product forms include billet, bar, rod, forgings, sheet, tubing, and welding wire.

Bearing steels used for ball and roller bearing applications are comprised of low carbon (0.10 to 0.20% C) case-hardened steels and high carbon (-1.0% C) through-hardened steels. Many of these steels are covered by SAE/AISI designations.

Chromium-molybdenum heat-resistant steels contain 0.5 to 9% Cr and 0.5 to 1.0% Mo. The carbon content is usually below 0.2%. The chromium provides improved oxidation and corrosion resistance, and the molybdenum increases strength at elevated temperatures. They are generally supplied in the normalized and tempered, quenched and tempered or annealed condition. Chromium-molybdenum steels are widely used in the oil and gas industries and in fossil fuel and nuclear power plants.

Classification of Stainless Steels

Stainless steels are iron-based alloys containing at least 10.5% Cr. Few stainless steels contain more than 30% Cr or less than 50% Fe. They achieve their stainless characteristics through the formation of an invisible and adherent chromium-rich oxide surface film. This oxide forms itself in the presence of oxygen.

Other elements added to improve characteristics include nickel, molybdenum, copper, titanium, aluminum, silicon, niobium, nitrogen, sulfur, and selenium. Carbon is normally present in amounts ranging from less than 0.03% to over 1.0% in certain martensitic grades.

The selection of stainless steels may be based on corrosion resistance, fabrication characteristics, availability, mechanical properties in specific temperature ranges and product cost. However, corrosion resistance and mechanical properties are usually the most important factors in selecting a grade for a given application.

Stainless steels are commonly divided into five groups: martensitic stainless steels, ferritic stainless steels, austenitic stainless steels, duplex (ferritic-austenitic) stainless steels, and precipitation-hardening stainless steels.

The development of precipitation-hardenable stainless steels was spearheaded by the successful production of Stainless W by U.S. Steel in 1945. The problem of obtaining raw materials has been a real one, particularly in regard to nickel during 1950s when civil wars raged in Africa and Asia, prime sources of nickel, and Cold War politics played a role because Eastern-bloc nations were also prime sources of the element. This led to the development of a series of alloys (AISI 200 type) in which manganese and nitrogen are partially substituted for nickel. These stainless steels are still produced today.

Over the years, stainless steels have become firmly established as materials for cooking utensils, fasteners, cutlery, flatware, decorative architectural hardware, and equipment for use in chemical plants, dairy and food-processing plants, health and sanitation applications, petroleum and petrochemical plants, textile plants, and the pharmaceutical and transportation industries. Some of these applications involve exposure to either elevated or cryogenic temperatures; austenitic stainless steels are well suited to either type of service.

Modifications in composition are sometimes made to facilitate production. For instance, basic compositions are altered to make it easier to produce stainless steel tubing and casting. Similar modifications are made for the manufacture of stainless steel welding electrodes; here combinations of electrode coating and wire composition are used to produce desired compositions deposited weld metal.

Martensitic stainless steels are essentially alloys of chromium and carbon that possess a distorted body-centered cubic (bcc) crystal structure (martensitic) in the hardened condition. They are ferromagnetic, hardenable by heat treatments, and are generally resistant to corrosion only to relatively mild environments. Chromium content is generally in the range of 10.5 to 18%, and carbon content may exceed 1.2%. The chromium and carbon contents are balanced to ensure a martensitic structure after hardening.

General corrosion is often much less serious than localized forms such as stress corrosion cracking, crevice corrosion in tight spaces or under deposits, pitting attack, and intergranular attack in sensitized material such as weld heat-affected zones (HAZ). Such localized corrosion can cause unexpected and sometimes catastrophic failure while most of the structure remains unaffected, and therefore must be considered carefully in the design and selection of the proper grade of stainless steel.

Corrosive attack can also be increased dramatically by seemingly minor impurities in the medium that may be difficult to anticipate but that can have major effects, even when present in only part-per-million concentrations; by heat transfer through the steel to or from the corrosive medium; by contact trimmed only on the ends.

Stainless steels are available in the form of plate, sheet, strip, foil, bar, wire, semi-finished products, pipes, tubes, and tubing.

Sheet

Sheet is a flat-rolled product in coils or cut lengths at least 610 mm wide and less than 4.76 mm thick. Stainless steel sheet is produced in nearly all types except the free machining and certain martensitic grades. Sheet from the conventional grades is almost exclusively produced on continuous mills. Hand mill production is usually confined to alloys that cannot be produced economically on continuous mills, such as certain high-temperature alloys.

The steel is cast in ingots, and the ingots are rolled on a slabbing mill or a blooming mill into slabs or sheet bars. The slabs or sheet bars are then conditioned prior to being hot rolled on a finishing mill. Alternatively, the steel may be continuous cast directly into slabs that are ready for hot rolling on a finishing mill. The current trend worldwide is toward greater production from continuous cast slabs.

Sheet produced from slabs on continuous rolling mills is coiled directly off the mill. After they are descaled, these hot bands are cold rolled to the required thickness and coils off the cold mill are either annealed and descaled or bright annealed. Belt grinding to remove surface defects is frequently required at hot bands or at an intermediate stage of processing. Full coils or lengths cut from coils may then be lightly cold rolled on either dull or bright rolls to produce the required finish. Sheet may be shipped in coils, or cut sheets may be produced by shearing lengths from a coil and flattening them by roller leveling or stretcher leveling.

Strip

Strip is a flat-rolled product, in coils or cut lengths, less than 610 mm wide and 0.13 to 4.76 mm thick. Cold finished material 0.13 mm thick and less than 610 mm wide fits the definitions of both strip and foil and may be referred to by either term.

Cold-rolled stainless steel strip is manufactured from hot-rolled, annealed, and pickled strip (or from slit sheet) by rolling between polished rolls. Depending on the desired thickness, various numbers of cold rolling passes through the mill are required for effecting the necessary reduction and securing the desired surface characteristics and mechanical properties.

Hot-rolled stainless steel strip is a semi-finished product obtained by hot-rolling slabs or billets and is produced for conversion to finished strip by cold rolling.

Heat Treatment. Strip of all types of stainless steel is usually either annealed or annealed and skin passed, depending on requirements. When severe forming, bending, and drawing operations are involved, it is recommended that such requirements be indicated so that the producer will have all the information necessary to ensure that he supplies the proper type and condition. When stretcher strains are objectionable in ferritic stainless steels such as type 430, they can be minimized by specifying a No 2 finish. Cold-rolled strip in types 410, 414, 416, 420, 431, 440A, 440B, and 440C can be produced in the hardened and tempered condition.

Experience in the use of stainless steels indicates that many factors can affect their corrosion resistance. Some of the more prominent factors are:

• Chemical composition of the corrosive medium including impurities
• Physical state of the medium-liquid, gaseous, solid, or combinations thereof
• Temperature
• Temperature variations
• Aeration of the medium
• Oxygen content of the medium
• Bacteria content of the medium
• Ionization of the medium
• Repeated formation and collapse of bubbles in the medium
• Relative motion of the medium with respect to the steel
• Chemical composition of the metal
• Nature and distribution of microstruc-tural constituents etc.

Surface Finish. Other characteristics in the stainless steel selection checklist are vital for some specialized applications but of little concern for many applications. Among these characteristics, surface finish is important more often than any other except corrosion resistance. Stainless steels are sometimes selected because they are available in a variety of attractive finishes. Surface finish selection may be made on the basis of appearance, frictional characteristics, or sanitation.

Plate

Plate is a flat-rolled or forged product more than 250 mm (10 in.) in width and at least 4.76 mm (0.1875 in.) in thickness. Exceptions include highly alloyed ferritic stainless steels, some of the martensitic stainless steels, and a few of the free-machining grades. Plate is usually produced by hot rolling from slabs that have been directly cast or rolled from ingots and that usually have been conditioned to improve plat surface. Some plate may be produced by direct rolling from ingot.

For strip, edge condition is often more important than it usually is for sheet. Strip can be furnished with various edge specifications:

• Mill edge (as produced, condition unspecified)
• No.1 edge (edge rolled, rounded, or square)
• No.3 edge (as slit)
• No.5 edge (square edge produced by rolling or filing after slitting)

Foil

Foil is a flat-rolled product, in coil form, up to 0.13 mm thick and less than 610 mm wide. Foil is produced in slit widths with edge conditions corresponding to No.3 and No.5 edge conditions for strip. Foil is made from types 201, 202, 301, 302, 304, 304L, 305, 316, 316L, 321, 347, 430, and 442, as well as from certain proprietary alloys.

The finishes, tolerances, and mechanical properties of foil differ from those of strip because of limitations associated with the way in which foil is manufactured. Nomenclature for finishes, and for width and thickness tolerances, vary among producers.

Mechanical Properties. In general, mechanical properties of foil vary with thickness. Tensile strength is increased somewhat, and ductility is lowered, by a decrease in thickness.

Bar

Bar is a product supplied in straight lengths; it is either hot or cold finished and is available in various shapes, sizes, and surface finishes. This category includes small shapes whose dimensions do not exceed 75 mm and, second, hot-rolled flat stock at least 3.2 mm thick and up to 250 mm wide.

Hot-finished bar is commonly produced by hot rolling, forging, or pressing ingots to blooms or billets of intermediate size, which are subsequently hot rolled, forged, or extruded to final dimensions

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cast iron

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Is an alloy of iron and carbon(2% to 4%) used in casting. silicon is also present in the alloy fin amounts from (0.5% to 3%) .we will not talk abput cast iron more than this

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Nonferrous metals

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Nonferrous metals include the other metalic elements and their alloys. in almost all cases, the alloys are more important commercially than the pure metals. the nonferrous metals include the pure metals and alloys of aluminum, copper, gold, magnesium, nickel, silver, tin, titanium, zinc, and other metals.

Among the more difficult metals to process are nickel and titanium.

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All this information are from books and sites talk about mechanics

and this is just a Research