MME101 Introduction to Metallurgy and Materials Engineering Asst. Prof. Dr. Ayşe KALEMTAŞ Bursa Technical University, Metallurgical and Materials Engineering Department

Office Hours: Tuesday, 16:00-17:00 [email protected], [email protected]

Asst. Prof. Dr. Ayşe KALEMTAŞ

References 1) ―Materials Science and Engineering: An Introduction‖, William D. Callister

2) Malzeme Bilimi ve Mühendisliği, Nobel Yayınları, Çevirenler: Cuma Bindal, Kenan Genel, Mehmet Demirkol, Recep Artır, Mustafa Bakkal, S. Ahmet Parasız, 8. Basımdan Çeviri, 2015 3) ―Essentials of Materials For Science And Engineering‖, Donald R. Askeland, Pradeep P. Phule 4) ―Introduction to Material Science for Engineering‖, James F. Shackelford 5) ―Introduction to Materials Science and Engineering‖, Douglas

Elliot P.

Asst. Prof. Dr. Ayşe KALEMTAŞ

GRADING

1. Mid Term Exam: 25 % 2. Mid Term Exam: 25 %

FINAL EXAM : 50 %

Asst. Prof. Dr. Ayşe KALEMTAŞ

Materials drive our society  Stone Age  Bronze Age  Iron Age Now?  Silicon Age?  Polymer Age?

Asst. Prof. Dr. Ayşe KALEMTAŞ

Materials drive our society Ages of ―Man‖ we survive based on the materials we control:  The Stone Age (>10,000 BC) –naturally occurring materials •Special rocks, skins, wood, ceramics and glasses, naturalpolymers and composites  The Bronze Age (4000 BC-1000 BC) • Casting and forging  The Iron Age (1000 BC-1620 AD) • High Temperature furnaces; cast iron technology (1620's) established the dominance of metals inengineering  Steel Age (1859 and up) • High strength alloys  Non-Ferrous and Polymer Age (light (1940's) and special alloys) • Aluminum, Titanium and Nickel (super-alloys) – aerospace • Silicon – Information • Plastics and Composites –food preservation, housing, aerospace and higher speeds  Exotic Materials Age? • Nano-Material and bio-materials – they are coming and then… Asst. Prof. Dr. Ayşe KALEMTAŞ

 Important to understand capabilities and limitations of materials  Design better components, parts, devices, etc. • how do you make something stronger or lighter? • how do elements come together to form alloys? • why do some materials have vastly different properties than others?  It is interesting and helps to make you a more informed person

Asst. Prof. Dr. Ayşe KALEMTAŞ

Introduction to Metallurgy and Materials Engineering

Materials are probably more deep seated in our culture than most of us realize. Transportation, housing, clothing, communication, recreation, and food production— virtually every segment of our everyday lives is influenced to one degree or another by materials. Historically, the development and advancement of societies have been intimately tied to the members’ ability to produce and manipulate materials to fill their needs. In fact, early civilizations have been designated by the level of their materials development (Stone Age, Bronze Age, Iron Age).

Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Perspective

Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Perspective The materials of prehistory (before 10,000 BC, the Stone Age) were ceramics and glasses, natural polymers, and composites. Weapons—always the peak of technology—were made of wood and flint; buildings and bridges of stone and wood. Naturally occurring gold and silver were available locally and, through their rarity, assumed great influence as currency, but their role in technology was small. The development of rudimentary thermo-chemistry allowed the extraction of, first, copper and bronze, then iron (the Bronze Age, 4000–1000 BC and the Iron Age, 1000 BC–1620 AD), stimulating enormous advances in technology. Cast iron technology (1620s) established the dominance of metals in engineering; since then the evolution of steels (1850 onward), light alloys (1940s), and special alloys has consolidated their position. By the 1950s, ―engineering materials‖ meant ―metals‖. Engineers were given courses in metallurgy; other materials were barely mentioned. Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Perspective There had, of course, been developments in the other classes of material. Improved cements, refractories, and glasses; and rubber, Bakelite, and polyethylene among polymers; but their share of the total materials market was small. Since 1950 all that has changed. The rate of development of new metallic alloys is now slow; demand for steel and cast iron has in some countries actually fallen.

The polymer and composite industries, on the other hand, are growing rapidly, and projections of the growth of production of new highperformance ceramics suggests continued expansion here also.

Alloy :

Metallic material consisting of a base metal and one or more alloying elements partially or completely dissolving in the base metal. Alloys are frequently denoted by symbols of their components, the symbol of the base metal being usually underlined, as, e.g., Cu–Zn alloy for brasses. Brass : Cu alloy where zinc is the main alloying element. Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Use of Materials • Throughout the history of man, countries that produced metals of

exceptional quality became wealthy lands.

For example, Britain learned to produce high-quality steel that enabled it to conquer 1/5 of the world. • A country was often invaded because of the metal ores that were known to exist there.

For example, Rome invaded Britain for its Tin mines.

• Kings spent fortunes trying to find the secret of the Philosopher’s stone where Lead could be turned into Gold with the transmutation agent being able to right bodily imperfections, cure all illnesses and confer long life. For a long time, mercury (Hg) was thought to be this agent. Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Use of Materials STONE AGE

Flint knife

Metals are the oldest elements known and in the past, the AGES are named after metals… I. Copper II. Bronze Flint arrowhead

III. Iron Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Use of Materials The development of civilisation has relied heavily on the discovery of metals. Prehistoric man used metals to build tools and weapons and as our knowledge of metallurgy has developed, metals have played an essential role in the advancement of agriculture, transport and arts and craft – forging the path to today’s modern society. The first seven metals which mankind identified and used in the past are:

 GOLD  COPPER  SILVER  LEAD

 TIN  IRON

(6000 BC) (4200 BC) (4000 BC) (3500 BC)

(1750 BC) (1500 BC)

 MERCURY (750 BC)

 Jewelery  Weapons  Ornaments, Jewelery  Container, Pipes

 Bronze, Adding to Cu  Weapons

METALS of ANTIQUITY

 Weapons  Tombsdissolve Ag and Au

Why not the other metals give names to the AGES!!! Until the end of the 17th century only 12 metals are known; Arsenic (As), Antimony (Sb), Zinc (Zn), Bismuth (Bi) [13-14th] and Platinum (Pt), 16th

http://www.makin-metals.com/about/history-of-metals-infographic/

Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Use of Materials SO, what is the answer for GOLD not being a NAME for an AGE? It was not used as a

WEAPON

WHY NOT USE as a WEAPON? For the first question, gold was still valuable and rare, no one would think of using a golden material for daily use. Also gold is a very soft metal, and thus cannot be used for hard tasks as it will bend and break easily. Gold was used commonly before copper or iron, yet wasn't ever a vital part of its time periods way of life. Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Use of Materials

MESOLITHIC 10,000-4,500 BC Hunting and gathering communities moved across land near the British Isles forming stone tools and ―microliths‖ – small trimmed blades mounted in different combinations to make a variety of tools.

4,500-2,300 BC

6000 BC Gold Stone Age man learned to fashion gold into jewellery. The popularity of gold is largely due to its scarcity, value and mankind’s fascination with the metal.

Widespread use of polished stones and flint axes. http://www.makin-metals.com/about/history-of-metals-infographic/

Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Use of Materials Copper 4200 BC Silver 4000 BC

The use of copper in antiquity is of more significance than gold as the first tools, implements and weapons were made from copper.

Silver had always been very widely used throughout history as a basis for monetary systems and played central roles in the currencies of the Roman and Chinese Empires.

Lead 3500 BC

Bronze Age 2300-700 BC The bronze age began when metallurgists discovered mixing two metals together created a stronger substance than either of the individual metals. http://www.makin-metals.com/about/history-of-metals-infographic/

It is believed that lead smelting began at least 9000 years ago, and the oldest known artifact of lead is a statuette found at the temple of Osiris on the site of Abydos dated circa 3800 BC. The wheel is central Europe.

used

in

Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Use of Materials IRON smelted 1500 BC

The discovery of smelting around 3000 BC led to the start of the Iron Age around 1200 BC and the prominent use of iron for tools and weapons.

Tin 1750 BC First smelted in combination with copper around 3500 BC to produce bronze. The oldest artifacts date from around 2000 BC.

The Hattites discovered iron around 1500 BC giving them a distinct advantage in war.

Mercury 750 BC

Known to ancient Chinese and Indians before 2000 BC, and found in Egyptian tombs dating from 1500 BC

http://www.makin-metals.com/about/history-of-metals-infographic/

Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Use of Materials

Nickel 1751 After iron, nickel is believed to be the second most plentiful element in the Earth and is used in the production of corrosion resistant alloys.

Uranium 1789 Uranium oxide has been used to colour glass and ceramics from as early as A.D. 79. Its applications today are almost exclusively in the production of nuclear fuels and weapons. http://www.makin-metals.com/about/history-of-metals-infographic/

Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Use of Materials Uranium 1789 Titanium 1791

Uranium oxide has been used to colour glass and ceramics from as early as A.D. 79. Its applications today are almost exclusively in the production of nuclear fuels and weapons.

Although discovered in the 18th century, it was not until the 1940’s that titanium was used in structures due to impurities.

Chromium 1797 Mainly used as an additional alloy in steels. Improves corrosive resistance and essential in the production of stainless steel.

http://www.makin-metals.com/about/history-of-metals-infographic/

Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Use of Materials

Aluminium 1827 It is the most common metal in the Earth’s crust and at around a third of the weight of steel, aluminium is one of the lightest of the all metals. http://www.makin-metals.com/about/history-of-metals-infographic/

Silicon 1823 Around 26% of the Earth’s crust contains silicon however it is never found in its pure form as it is naturally occurs as either an oxide or a sillicate.

Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Use of Materials Aluminium 1827 It is the most common metal in the Earth’s crust and at around a third of the weight of steel, aluminium is one of the lightest of the all metals.

Silicon 1823 Around 26% of the Earth’s crust contains silicon however it is never found in its pure form as it is naturally occurs as either an oxide or a sillicate.

http://www.makin-metals.com/about/history-of-metals-infographic/

Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Use of Materials

Polonium 1898

Radium 1898

Both polonium and radium are radioactive and very rarely occur in nature. Both these metals were discovered by Marie and Pierre Curie in 1898.

http://www.makin-metals.com/about/history-of-metals-infographic/

Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Use of Materials History of Metals Timeline There are currently 86 known metals but before the 19th century only 24 had been discovered and, of these 24 metals, 12 were discovered in the 18th century. The Metals of Antiquity, were the metals upon which civilisation was based. (1) Gold (ca) 6000BC - Stone Age man learned to fashion gold into jewellery. The popularity of gold is largely due to its scarcity, value and mankind’s fascination with the metal. (2) Copper, (ca) 4200BC - The use of copper in antiquity is of more significance than gold as the first tools, implements and weapons were made from copper.

(3) Silver,(ca) 4000BC - Silver had been widely used throughout time as a basis for monetary systems and played central roles in the currencies of the Roman and Chinese Empires. (4) Lead, (ca) 3500BC - It is believed that lead smelting began at least 9,000 years ago, and the oldest known artifact of lead is a statuette found at the temple of Osiris on the site of Abydos dated circa 3800 BC. http://www.makin-metals.com/about/history-of-metals-infographic/

Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Use of Materials History of Metals Timeline

(5) Tin, (ca) 1750BC - First smelted in combination with copper around 3500 BC to produce bronze. The oldest artifacts date from around 2000 BC. (6) Iron,smelted, (ca) 1500BC - The discovery of smelting around 3000 BC led to the start of the Iron Age around 1200 BC and the prominent use of iron for tools and weapons. (7) Mercury, (ca) 750BC - Known to ancient Chinese and Indians before 2000 BC, and found in Egyptian tombs dating from 1500 BC.

1735 1751 1774 1781 1782 1783 1789 1789

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Cobalt Nickel Manganese Molybdenum Tellurium Tungsten Uranium Zirconium

1791 1794 1797 1797 1801 1802 1803 1807

http://www.makin-metals.com/about/history-of-metals-infographic/

-

Titanium Yttrium Berylium Chromium Niobium Tantalum Iridium, Palladium, Rhodium Potassium, Sodium Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Use of Materials 1808 - Boron, Barium, Calcium, Magnesium, Strontium 1814 - Cerium 1817 - Lithium, Cadmium, Selenium 1823 - Silicon 1827 - Aluminium 1828 - Thorium 1830 - Vanadium 1839 - Lanthanum 1843 - Erbium, Terbium 1844 - Ruthenium 1860 - Cesium, Rubidium 1861 - Thallium 1863 - Indium 1875 - Gallium 1878-1885 - Holmium, Thulium, Scandium, Samarium, Gadalinium, Praseodynium, Neodynium, Dysprosium

1886 - Germanium 1898 - Polonium, Radium 1899 - Actinium 1901 - Europium 1907 - Lutetium 1917 - Protactinium 1923 - Hafnium 1924 - Rhenium 1937 - Technetium 1939 - Francium 1945 - Promethium 1940-61 - Transuranium elements – (Neptunium, Plutonium, Curium, Americum, Berkelium, Californium, Einsteinium, Fermium, Mendelevium, Nobelium, Lawrencium)

http://www.makin-metals.com/about/history-of-metals-infographic/

Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Perspective  Stone Age: 2.5 million years ago  Pottery Age: 4000 B.C.E  Copper Age: 4000 B.C.E – 3000 B.C.E.  Bronze Age: 2000 B.C.E – 1000 B.C.E.  Foundation of metallurgy- Alloys of

copper and tin  Iron Age: 1000 B.C.E – 1B.C.E.  Plastics Age: late 20th Century to current time  Semiconductor Age: late 20th Century to current time Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Perspective Stone → Bronze → Iron → Advanced materials

• Beginning of the Material Science - People began to make tools from stone – Start of the Stone Age about two million years ago. Natural materials: stone, wood, clay, skins, etc. The Stone Age ended about 5000 introduction of Bronze in the Far East.

years

ago

with

• Bronze is an alloy (a metal made up of more than one element), copper + < 25% of tin + other elements. Bronze: can be hammered or cast into a variety of shapes, can be made harder by alloying, corrode only slowly after a surface oxide film forms. Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Perspective Bronze Age

3000-800 BC transition from stone to bronze for tools and arts N. Afghanistan, 2200-1800 B.C.

Bronze: Cu + Sn Tm 950°C

Turkey, 3000-2000 B.C. Asst. Prof. Dr. Ayşe KALEMTAŞ

A Materials Timeline

The scale is nonlinear, with big steps at the bottom, small ones at the top. An asterisk (*) indicates the date at which an element was first identified. Labels without asterisks note the time at which the material became of practical importance. Asst. Prof. Dr. Ayşe KALEMTAŞ

Historical Perspective • The Iron Age began about 3000 years ago and continues today. Use of iron and steel, a stronger and cheaper material changed drastically daily life of a common person. • Age of Advanced materials: throughout the Iron Age many new types of materials have been introduced (ceramic, semiconductors, polymers, composites, nanomaterials…). Understanding of the relationship among structure, properties, processing, and performance of materials. Intelligent design of new materials. Asst. Prof. Dr. Ayşe KALEMTAŞ

QUESTIONS

Asst. Prof. Dr. Ayşe KALEMTAŞ