Essentials of Materials Science & Engineering - SI Version

625 Pages·2009·98.033 MB·English

by  Donald R. Askeland, Pradeep P. Fulay

This page intentionally left blank
Essentials
of Materials
Science
and
Engineering
Second Edition, SI
Donald R. Askeland
University of Missouri—Rolla, Emeritus
Pradeep P. Fulay
University of Pittsburgh
SI Edition prepared by
D. K. Bhattacharya
Solid State Physics Laboratories
New Delhi
· · · · · · · ·
Australia Brazil Japan Korea Mexico Singapore Spain UnitedKingdom UnitedStates
EssentialsofMaterialsScienceand 82010CengageLearning
Engineering,SecondEdition,SI
DonaldR.AskelandandPradeepP.Fulay ALLRIGHTSRESERVED.Nopartofthisworkcoveredbythecopyrightherein
SIEditionpreparedbyD.K.Bhattacharya maybereproduced,transmitted,stored,orusedinanyformorbyanymeans—
graphic,electronic,ormechanical,includingbutnotlimitedtophotocopying,
Director,GlobalEngineeringProgram: recording,scanning,digitizing,taping,Webdistribution,informationnetworks,
ChrisCarson informationstorageandretrievalsystems,orinanyothermanner—exceptas
SeniorDevelopmentalEditor:HildaGowans maybepermittedbythelicensetermsherein.
DevelopmentEditor:SwatiMeherishi
MarketingSpecialist:LaurenBetsos Forproductinformationandtechnologyassistance,contactusat
ContentProjectManager:AbigailGreshik CengageLearningCustomer&SalesSupport,1-800-354-9706
ProductionService:Pre-PressPMG,RPK Forpermissiontousematerialfromthistextorproduct,submitallrequests
EditorialServices,Inc. onlineatwww.cengage.com/permissions
CopyEditor:PatDaly Furtherpermissionsquestionscanbeemailedto
[email protected]
Proofreader:MarthaMcMaster
Indexer:ShellyGerger-Knechtl
Compositor:Pre-PressPMG LibraryofCongressControlNumber:2008942016
SeniorArtDirector:MichelleKunkler ISBN-13:978-0-495-43850-2
InternalDesign:RPKEditorialServices ISBN-10:0-495-43850-2
CoverDesign:AndrewAdams
CoverImage:8LorelynMedina/iStockphoto; CengageLearning
8IvanDinev/iStockphoto;8Jankaliciak/ 200FirstStamfordPlace,Suite400
Dreamstime Stamford,CT06902
SeniorFirstPrintBuyer:DougWilke USA
CengageLearningisaleadingproviderofcustomizedlearningsolutionswith
officelocationsaroundtheglobe,includingSingapore,theUnitedKingdom,
Australia,Mexico,Brazil,andJapan.Locateyourlocalofficeat:
international.cengage.com/region
CengageLearningproductsarerepresentedinCanadabyNelsonEducationLtd.
Foryourcourseandlearningsolutions,visitwww.cengage.com/engineering
Purchaseanyofourproductsatyourlocalcollegestoreoratourpreferredonline
storewww.ichapters.com
Printed in Canada
1 2 3 4 5 6 7 8 12 11 10 09
To Mary Sue and Tyler
—DonaldR.Askeland
To Suyash, Aarohee, and Jyotsna
—PradeepP.Fulay
This page intentionally left blank
Contents
Preface xv
About the Authors xix
Chapter 1 Introduction to Materials Science and Engineering 1
Introduction 1
1-1 What is Materials Science and Engineering? 2
1-2 Classification of Materials 5
1-3 Functional Classificationof Materials 9
1-4 Classification of Materials Based onStructure 11
1-5 Environmental and Other Effects 12
1-6 Materials Design and Selection 14
SUMMARY 17 9 GLOSSARY 18 9 PROBLEMS 19
Chapter 2 Atomic Structure 21
Introduction 21
2-1 The Structure of Materials: Technological Relevance 22
2-2 The Structure of the Atom 23
2-3 The ElectronicStructure of the Atom 28
2-4 The Periodic Table 30
2-5 Atomic Bonding 32
2-6 Binding Energy and Interatomic Spacing 40
SUMMARY 44 9 GLOSSARY 45 9 PROBLEMS 48
Chapter 3 Atomic and Ionic Arrangements 51
Introduction 51
3-1 Short-Range Order versus Long-Range Order 52
3-2 Amorphous Materials: Principles and Technological Applications 54
3-3 Lattice, Unit Cells, Basis, and Crystal Structures 55
vii
viii CONTENTS
3-4 Allotropic or Polymorphic Transformations 63
3-5 Points, Directions, and Planes in theUnit Cell 64
3-6 Interstitial Sites 74
3-7 Crystal Structures of IonicMaterials 76
3-8 Covalent Structures 79
3-9 Diffraction Techniques for Crystal Structure Analysis 80
SUMMARY 82 9 GLOSSARY 83 9 PROBLEMS 86
Chapter 4 Imperfections in the Atomic and Ionic Arrangements 90
Introduction 90
4-1 Point Defects 91
4-2 Other Point Defects 97
4-3 Dislocations 98
4-4 Significance of Dislocations 105
4-5 Schmid’s Law 105
4-6 Influence of Crystal Structure 108
4-7 Surface Defects 109
4-8 Importance of Defects 114
SUMMARY 116 9 GLOSSARY 117 9 PROBLEMS 119
Chapter 5 Atom and Ion Movements in Materials 122
Introduction 122
5-1 Applications of Diffusion 123
5-2 Stability of Atoms and Ions 125
5-3 Mechanisms for Diffusion 127
5-4 Activation Energyfor Diffusion 129
5-5 Rate of Diffusion(Fick’s First Law) 130
5-6 Factors Affecting Diffusion 133
5-7 Permeability of Polymers 141
5-8 Composition Profile (Fick’s Second Law) 142
5-9 Diffusion and Materials Processing 146
SUMMARY 147 9 GLOSSARY 148 9 PROBLEMS 149
Chapter 6 Mechanical Properties: Fundamentals and Tensile, Hardness, and
Impact Testing 153
Introduction 153
6-1 Technological Significance 154
CONTENTS ix
6-2 Terminology for MechanicalProperties 155
6-3 The Tensile Test: Useof the Stress-Strain Diagram 159
6-4 Properties Obtained from theTensile Test 163
6-5 True Stress and True Strain 169
6-6 The Bend Test for Brittle Materials 171
6-7 Hardness of Materials 174
6-8 Strain Rate Effects and Impact Behavior 176
6-9 Properties Obtained from theImpact Test 177
SUMMARY 180 9 GLOSSARY 181 9 PROBLEMS 183
Chapter 7 Fracture Mechanics, Fatigue, and Creep Behavior 187
Introduction 187
7-1 Fracture Mechanics 188
7-2 The Importance of Fracture Mechanics 191
7-3 Microstructural Features of Fracture in Metallic Materials 194
7-4 Microstructural Features of Fracture in Ceramics, Glasses,and
Composites 198
7-5 Weibull Statistics for Failure Strength Analysis 200
7-6 Fatigue 206
7-7 Results of theFatigueTest 209
7-8 Application of FatigueTesting 212
7-9 Creep, Stress Rupture,and Stress Corrosion 215
7-10 Evaluation of Creep Behavior 217
SUMMARY 220 9 GLOSSARY 220 9 PROBLEMS 222
Chapter 8 Strain Hardening and Annealing 225
Introduction 225
8-1 Relationship of Cold Working to the Stress-Strain Curve 226
8-2 Strain-HardeningMechanisms 231
8-3 Properties versus Percent Cold Work 232
8-4 Microstructure, Texture Strengthening, and Residual Stresses 235
8-5 Characteristics of Cold Working 239
8-6 The Three Stagesof Annealing 241
8-7 Control of Annealing 244
8-8 Annealing and Materials Processing 246
8-9 Hot Working 248
SUMMARY 250 9 GLOSSARY 250 9 PROBLEMS 252
x CONTENTS
Chapter 9 Principles and Applications of Solidification 257
Introduction 257
9-1 Technological Significance 258
9-2 Nucleation 259
9-3 Growth Mechanisms 264
9-4 Cooling Curves 269
9-5 Cast Structure 271
9-6 Solidification Defects 272
9-7 Casting Processes for Manufacturing Components 274
9-8 Continuous Casting, Ingot Casting, and Single Crystal Growth 276
9-9 Solidification of Polymers and Inorganic Glasses 278
9-10 Joining of MetallicMaterials 279
9-11 Bulk Metallic Glasses(BMG) 280
SUMMARY 282 9 GLOSSARY 283 9 PROBLEMS 286
Chapter 10 Solid Solutions and Phase Equilibrium 291
Introduction 291
10-1 Phases and the Phase Diagram 292
10-2 Solubility and Solid Solutions 296
10-3 Conditions for Unlimited Solid Solubility 299
10-4 Solid-Solution Strengthening 301
10-5 Isomorphous Phase Diagrams 303
10-6 Relationship BetweenPropertiesand the Phase Diagram 312
10-7 Solidification of aSolid-Solution Alloy 314
SUMMARY 317 9 GLOSSARY 318 9 PROBLEMS 319
Chapter 11 Dispersion Strengthening and Eutectic Phase Diagrams 324
Introduction 324
11-1 Principles and Examples of Dispersion Strengthening 325
11-2 Intermetallic Compounds 326
11-3 Phase Diagrams ContainingThree-Phase Reactions 328
11-4 The Eutectic Phase Diagram 331
11-5 Strength of Eutectic Alloys 341
11-6 Eutectics and Materials Processing 347
11-7 Nonequilibrium Freezing in the Eutectic System 349
SUMMARY 350 9 GLOSSARY 350 9 PROBLEMS 352
CONTENTS xi
Chapter 12 Dispersion Strengthening by Phase Transformations and
Heat Treatment 357
Introduction 357
12-1 Nucleation and Growth in Solid-State Reactions 358
12-2 Alloys Strengthened by ExceedingtheSolubility Limit 362
12-3 Age or Precipitation Hardening 364
12-4 Applications of Age-Hardened Alloys 364
12-5 Microstructural Evolution in Age or Precipitation Hardening 365
12-6 Effects of AgingTemperature and Time 367
12-7 Requirements for Age Hardening 369
12-8 Use of Age-Hardenable Alloys at High Temperatures 369
12-9 The Eutectoid Reaction 370
12-10 Controlling theEutectoid Reaction 375
12-11 The Martensitic Reactionand Tempering 380
SUMMARY 384 9 GLOSSARY 385 9 PROBLEMS 387
Chapter 13 Heat Treatment of Steels and Cast Irons 391
Introduction 391
13-1 Designations and Classification of Steels 392
13-2 Simple Heat Treatments 396
13-3 Isothermal Heat Treatments 398
13-4 Quench and TemperHeat Treatments 401
13-5 Effect of Alloying Elements 406
13-6 Application of Hardenability 409
13-7 Specialty Steels 412
13-8 Surface Treatments 415
13-9 Weldability of Steel 417
13-10 Stainless Steels 418
13-11 Cast Irons 422
SUMMARY 428 9 GLOSSARY 428 9 PROBLEMS 431
Chapter 14 Nonferrous Alloys 436
Introduction 436
14-1 Aluminum Alloys 438
14-2 Magnesium and Beryllium Alloys 444
14-3 Copper Alloys 447
14-4 Nickel and Cobalt Alloys 451