General introduction
1. Engineering Materials and their Properties
examples of structures and devices showing how we select the right material for the job
3 A. Price and availability
2. The Price and Availability of Materials 15
what governs the prices of engineering materials, how long will supplies last, and how can we make the most of the resources that we have?
B. The elastic moduli
3. The Elastic Moduli 27
stress and strain; Hooke's Law; measuring Young's modulus; data for design
4. Bonding Between Atoms 36
the types of bonds that hold materials together; why some bonds are stiff and others floppy
5. Packing of Atoms in Solids 45
how atoms are packed in crystals - crystal structures, plane (Miller) indices, direction indices; how atoms are packed in polymers, ceramics and glasses
6. The Physical Basis of Young's Modulus 58
how the modulus is governed by bond stiffness and atomic packing; the glass transition temperature in rubbers; designing stiff materials - man-made composites
7. Case Studies of Modulus-limited Design 66
the mirror for a big telescope; a stiff beam of minimum weight; a stiff beam of minimum cost
vi Contents
C. Yield strength, tensile strength, hardness and ductility
8. The Yield Strength, Tensile Strength, Hardness and Ductility
definitions, stress-strain curves (true and nominal), testing methods, data
9. Dislocations and Yielding in Crystals
the ideal strength; dislocations (screw and edge) and how they move to give plastic flow
10. Strengthening Methods and Plasticity of Polycrystals
solid solution hardening; precipitate and dispersion strengthening; work-hardening; yield in polycrystals
11. Continuum Aspects of Plastic Flow
the shear yield strength; plastic instability; the formability of metals and polymers
12. Case Studies in Yield-limited Design
materials for springs; a pressure vessel of minimum weight; a pressure vessel of minimum cost; how metals are rolled into sheet
D. Fast fracture, toughness and fatigue
where the energy comes from for catastrophic crack growth; the condition for fast fracture; data for toughness and fracture toughness
13. Fast Fracture and Toughness
14. Micromechanisms of Fast Fracture
ductile tearing, cleavage; composites, alloys - and why structures are more likely to fail in the winter
15. Fatigue Failure
fatigue testing, Basquin's Law, Coffin-Manson Law; crack growth rates for pre-cracked materials; mechanisms of fatigue
16. Case Studies in Fast Fracture and Fatigue Failure
fast fracture of an ammonia tank; how to stop a pressure vessel blowing up; is cracked cast iron safe?
E. Creep deformation and fracture
high-temperature behaviour of materials; creep testing and creep curves; consequences of creep; creep damage and creep fracture
17. Creep and Creep Fracture
Contents vii
18. Kinetic Theory of Diffusion 1 79
Arrhenius's Law; Fick's first law derived from statistical mechanics of thermally activated atoms; how diffusion takes place in solids
19. Mechanisms of Creep, and Creep-resistant Materials 187
metals and ceramics - dislocation creep, diffusion creep; creep in polymers; designing creep-resistant materials
20. The Turbine Blade - A Case Study in Creep-limited Design 197
requirements of a turbine-blade material; nickel-based super-alloys, blade cooling; a new generation of materials? - metal-matrix composites, ceramics, cost effectiveness
F. Oxidation and corrosion
21. Oxidation of Materials
the driving force for oxidation; rates of oxidation, mechanisms of oxidation; data
22. Case Studies in Dry Oxidation
making stainless alloys; protecting turbine blades
23. Wet Corrosion of Materials
voltages as driving forces; rates of corrosion; why selective attack is especially dangerous
24. Case Studies in Wet Corrosion
how to protect an underground pipeline; materials for a light-weight factory roof; how to make motor-car exhausts last longer
G. Friction, abrasion and wear
25. Friction and Wear
surfaces in contact; how the laws of friction are explained by the asperity-contact model; coefficients of friction; lubrication; the adhesive and abrasive wear of materials
26. Case Studies in Friction and Wear
the design of a journal bearing; materials for skis and sledge runners; 'non-skid' tyres
viii Contents
Final case study
27. Materials and Energy in Car Design
the selection and economics of materials for automobiles
Appendix 1 Examples
Appendix 2 Aids and Demonstrations
Appendix 3 Symbols and Formulae
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General introduction ix
A. Metals
1. Metals 3
the generic metals and alloys; iron-based, copper-based, nickel-based,
aluminium-based and titanium-based alloys; design data
2. Metal structures 14
the range of metal structures that can be altered to get different properties: crystal and glass structure, structures of solutions and compounds, grain and phase boundaries, equilibrium shapes of grains and phases
3. Equilibrium constitution and phase diagrams 25
how mixing elements to make an alloy can change their structure; examples: the lead-tin, copper-nickel and copper-zinc alloy systems
4. Case studies in phase diagrams 34
choosing soft solders; pure silicon for microchips; making bubble-free ice
5. The driving force for structural change 46
the work done during a structural change gives the driving force for the change; examples: solidification, solid-state phase changes, precipitate coarsening, grain growth, recrystallisation; sizes of driving forces
6. Kinetics of structural change: I "diffusive transformations 57
why transformation rates peak " the opposing claims of driving force and thermal activation; why latent heat and diffusion slow transformations down
7. Kinetics of structural change: II - nucleation 68
how new phases nucleate in liquids and solids; why nucleation is helped by solid catalysts; examples: nucleation in plants, vapour trails, bubble chambers and caramel
8. Kinetics of structural change: III displacive transformations 76
how we can avoid diffusive transformations by rapid cooling; the alternative displacive (shear) transformations at the speed of sound
9. Case studies in phase transformations 89
artificial rain-making; fine-grained castings; single crystals for semiconductors; amorphous metals
10. The light alloys 100
where they score over steels; how they can be made stronger: solution, age and work hardening; thermal stability
11. Steels: I carbon steels 113
structures produced by diffusive changes; structures produced by displacive changes (martensite); why quenching and tempering can transform the strength of steels; the TTT diagram
12. Steels: II alloy steels 125
adding other elements gives hardenability (ease of martensite formation), solution strengthening, precipitation strengthening, corrosion resistance, and austenitic (f.c.c.) steels
13. Case studies in steels 133
metallurgical detective work after a boiler explosion; welding steels together safely; the case of the broken hammer
14. Production, forming and joining of metals 143
processing routes for metals; casting; plastic working; control of grain size; machining; joining; surface engineering
B. Ceramics and glasses
15. Ceramics and glasses 161
the generic ceramics and glasses: glasses, vitreous ceramics, hightechnology ceramics, cements and concretes, natural ceramics (rocks and ice), ceramic composites; design data
16. Structure of ceramics 167
crystalline ceramics; glassy ceramics; ceramic alloys; ceramic microstructures: pure, vitreous and composite
17. The mechanical properties of ceramics 177
high stiffness and hardness; poor toughness and thermal shock resistance; the excellent creep resistance of refractory ceramics
vi Contents
18. The statistics of brittle fracture and case study 185
how the distribution of flaw sizes gives a dispersion of strength: the Weibull distribution; why the strength falls with time (static fatigue); case study: the design of pressure windows
19. Production, forming and joining of ceramics 194
processing routes for ceramics; making and pressing powders to shape; working glasses; making high-technology ceramics; joining ceramics; applications of high-performance ceramics
20. Special topic: cements and concretes 207
historical background; cement chemistry; setting and hardening of cement; strength of cement and concrete; high-strength cements
C. Polymers and composites
21. Polymers 219
the generic polymers: thermoplastics, thermosets, elastomers, natural polymers; design data
22. The structure of polymers 228
giant molecules and their architecture; molecular packing: amorphous or crystalline?
23. Mechanical behaviour of polymers 238
how the modulus and strength depend on temperature and time
24. Production, forming and joining of polymers 254
making giant molecules by polymerisation; polymer 'alloys'; forming and joining polymers
25. Composites: fibrous, particulate and foamed 263
how adding fibres or particles to polymers can improve their stiffness, strength and toughness; why foams are good for absorbing energy
26. Special topic: wood 277
one of nature's most successful composite materials
D. Designing with metals, ceramics, polymers and composites
27. Design with materials 289
the design-limiting properties of metals, ceramics, polymers and composites; design methodology
Contents vii
28. Case studies in design 296
1. Designing with metals: conveyor drums for an iron ore terminal 296
2. Designing with ceramics: ice forces on offshore structures 303
3. Designing with polymers: a plastic wheel 308
4. Designing with composites: materials for violin bodies 312
Appendix 1 Teaching yourself phase diagrams 320
Appendix 2 Symbols and formulae 370
Index
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Mirror
Widely adopted around the world, this is a core materials science and mechanical engineering text. Engineering Materials 1 gives a broad introduction to the properties of materials used in engineering applications. With each chapter corresponding to one lecture, it provides a complete introductory course in engineering materials for students with no previous background in the subject. Ashby & Jones have an established, successful track record in developing understanding of the properties of materials and how they perform in reality.* One of the best-selling materials properties texts; well known, well established and well liked* New student friendly format, with enhanced pedagogy including many more case studies, worked examples, student questions, full instructors manual and online tutorial material for adopting tutors* World-renowned author team"
Mirror 2
Materials are evolving faster today than at any time in history. As a consequence the engineer must be more aware of materials and their potential than ever before. In comparing the properties of competing materials with precision involves an understanding of the basic properties of materials, how they are controlled by processing, formed, joined and finished and of the chain of reasoning that leads to a successful choice. This book will provide the reader with this understanding.
Materials are grouped into four classes: Metals, Ceramics, Polymers and Composites, and each are examined in turn. The chapters are arranged in groups, with a group of chapters to describe each of the four classes of materials. Each group first of all introduces the major families of materials that go to make up each materials class. The main microstructural features of the class are then outlined and the reader is shown how to process or treat them to get the structures (properties) that are wanted. Each group of chapters is illustrated by Case Studies designed to help the reader understand the basic material.
This book has been written as a second level course for engineering students. It provides a concise introduction to the microstructures and processing of materials and shows how these are related to the properties required in engineering design.
TABLE OF CONTENTS
General Introduction
Metals: Metals
Metal Structures
Equilibrium Constitution and Phase Diagrams
Case Studies in Phase Diagrams
The Driving Force for Structural Change
Kinetics of Structural Change: I – Diffusive Transformations
Kinetics of Structural Change: II – Nucleation
Kinetics of Structural Change: III – Displacive Transformations
Case Studies in Phase Transformations
The Light Alloys
Steels: I – Carbon Steels
Steels: II – Alloy Steels
Case Studies in Steels
Production, Forming and Joining of Metals
Ceramics and Glasses: Ceramics and Glasses
Structure of Ceramics
The Mechanical Properties of Ceramics
The Statistics of Brittle Fracture and Case Study
Production, Forming and Joining of Ceramics
Special Topic: Cements and Concretes
Polymers and Composites: Polymers
The Structure of Polymers
Mechanical Behaviour of Polymers
Production, Forming and Joining of Polymers
Composites: Fibrous, Particulate and Foamed
Special Topic: Wood
Designing with Metals, Ceramics, Polymers and Composites: Design with Materials
Case Studies in Design.Appendix 1 – Teaching Yourself Phase Diagrams
Appendix 2 – Symbols and Formulae
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