AN INTRODUCTION TO MATERIALS ENGINEERING AND SCIENCE AN INTRODUCTION TO MATERIALS ENGINEERING AND SCIENCE FOR CHEMICAL AND MATERIALS ENGINEERS Brian S. Mitchell Department of Chemical Engineering, Tulane University A JOHN WILEY & SONS, INC., PUBLICATION Thisbookisprintedonacid-freepaper. Copyright2004byJohnWiley&Sons,Inc.,Hoboken,NewJersey.Allrightsreserved. PublishedsimultaneouslyinCanada. 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LibraryofCongressCataloging-in-PublicationData: Mitchell,BrianS.,1962- Anintroductiontomaterialsengineeringandscience:forchemicalandmaterialsengineers BrianS.Mitchell p.cm. Includesbibliographicalreferencesandindex. ISBN0-471-43623-2(cloth) 1.Materialsscience.I.Title. TA403.M6852003 620.1(cid:1)1—dc21 2003053451 PrintedintheUnitedStatesofAmerica. 10987654321 Tomyparents;whose Materialwasloam; Engineeringwaslabor; Sciencewaslore; Andgreatestproductwaslove. CONTENTS Preface xi Acknowledgments xv 1 The Structure of Materials 1 1.0 Introduction and Objectives 1 1.1 Structure of Metals and Alloys 28 1.2 Structure of Ceramics and Glasses 55 1.3 Structure of Polymers 76 1.4 Structure of Composites 99 1.5 Structure of Biologics 114 References 128 Problems 130 2 Thermodynamics of Condensed Phases 136 2.0 Introduction and Objectives 136 2.1 Thermodynamics of Metals and Alloys 140 2.2 Thermodynamics of Ceramics and Glasses 165 2.3 Thermodynamics of Polymers 191 2.4 Thermodynamics of Composites 200 2.5 Thermodynamics of Biologics 204 References 209 Problems 211 3 Kinetic Processes in Materials 215 3.0 Introduction and Objectives 215 3.1 Kinetic Processes in Metals and Alloys 219 3.2 Kinetic Processes in Ceramics and Glasses∗ 233 3.3 Kinetic Processes in Polymers 246 3.4 Kinetic Processes in Composites∗ 269 3.5 Kinetic Processes in Biologics∗ 277 References 280 Problems 282 4 Transport Properties of Materials 285 4.0 Introduction and Objectives 285 4.1 Momentum Transport Properties of Materials∗ 287 vii viii CONTENTS 4.2 Heat Transport Properties of Materials 316 4.3 Mass Transport Properties of Materials∗ 343 References 374 Problems 376 5 Mechanics of Materials 380 5.0 Introduction and Objectives 380 5.1 Mechanics of Metals and Alloys 381 5.2 Mechanics of Ceramics and Glasses 422 5.3 Mechanics of Polymers 448 5.4 Mechanics of Composites 472 5.5 Mechanics of Biologics 515 References 532 Problems 533 6 Electrical, Magnetic, and Optical Properties of Materials 537 6.1 Electrical Properties of Materials 538 6.2 Magnetic Properties of Materials 600 6.3 Optical Properties of Materials 644 References 677 Problems 678 7 Processing of Materials 681 7.0 Introduction 681 7.1 Processing of Metals and Alloys 681 7.2 Processing of Ceramics and Glasses 704 7.3 Processing of Polymers 754 7.4 Processing of Composites 795 7.5 Processing of Biologics 804 References 811 Problems 812 8 Case Studies in Materials Selection 814 8.0 Introduction and Objectives 814 8.1 Selection of Metals for a Compressed Air Tank 821 8.2 Selection of Ceramic Piping for Coal Slurries in a Coal Liquefaction Plant 827 8.3 Selection of Polymers for Packaging 832 8.4 Selection of a Composite for an Automotive Drive Shaft 835 8.5 Selection of Materials as Tooth Coatings 842 References 848 Problems 849 CONTENTS ix Appendix 1: Energy Values for Single Bonds 851 Appendix 2: Structure of Some Common Polymers 852 Appendix 3: Composition of Common Alloys 856 Appendix 4: Surface and Interfacial Energies 869 Appendix 5: Thermal Conductivities of Selected Materials 874 Appendix 6: Diffusivities in Selected Systems 880 Appendix 7: Mechanical Properties of Selected Materials 882 Appendix 8: Electrical Conductivity of Selected Materials 893 Appendix 9: Refractive Index of Selected Materials 900 Answers to Selected Problems 903 Index 907 ∗Sections marked with an asterisk can be omitted in an introductory course. PREFACE This textbook is intended for use in a one- or two-semester undergraduate course in materials science that is primarily populated by chemical and materials engineering students. This isnotto saythat biomedical,mechanical,electrical,or civilengineering students will not be able to utilize this text, nor that the material or its presentation is unsuitable for these students. On the contrary, the breadth and depth of the material covered here is equivalent to most “traditional” metallurgy-based approaches to the subject that students in these disciplines may be more accustomed to. In fact, the treatment of biological materials on the same level as metals, ceramics, polymers, and composites may be of particular benefit to those students in the biologically related engineering disciplines. The key difference is simply the organization of the material, which is intended to benefit primarily the chemical and materials engineer. This textbook is organized on two levels: by engineering subject area and by mate- rials class, as illustrated in the accompanying table. In terms of topic coverage, this organization is transparent: By the end of the course, the student will have covered many of the same things that would be covered utilizing a different materials science textbook. To the student, however, the organization is intended to facilitate a deeper understanding of the subject material, since it is presented in the context of courses theyhavealreadyhadorarecurrentlytaking—forexample,thermodynamics,kinetics, transport phenomena, and unit operations. To the instructor, this organization means that,inprinciple,thematerialcanbepresentedeitherinthetraditionalsubject-oriented sequence(i.e.,inrows)orinamaterials-orientedsequence(i.e.,incolumns).Thelatter approach is recommended for a two-semester course, with the first two columns cov- ered in the first semester and the final three columns covered in the second semester. The instructor should immediately recognize that the vast majority of “traditional” materials science concepts are covered in the columns on metals and ceramics, and that if the course were limited to concepts on these two materials classes only, the student would receive instruction in many of the important topics covered in a “tradi- tional” course on materials. Similarly, many of the more advanced topics are found in the sections on polymers, composites, and biological materials and are appropriate for asenior-level,orevenintroductorygraduate-level,courseinmaterialswithappropriate supplementation and augmentation. This textbook is further intended to provide a unique educational experience for the student. This is accomplishedthrough the incorporationof instructional objectives, active-learning principles, design-oriented problems, and web-based information and visualization utilization. Instructional objectives are included at the beginning of each chapter to assist both the student and the instructor in determining the extent of topics and the depth of understanding required from each topic. This list should be used as a guideonly:Instructorswillrequireadditionalinformationtheydeemimportantorelim- inatetopicstheydeeminappropriate,andstudentswillfindadditionaltopiccoveragein their supplemental reading, which is encouragedthrough a list of referencesat the end xi xii PREFACE Metals& Ceramics& Alloys Glasses Polymers Composites Biologics Structure Crystal Crystal Configuration, Matrices, Biochemistry, structures, structures, Conformation, Reinforce- Tissue Point Defect Molecular ments structure defects, reactions, Weight Dislocations Theglassy state Thermo- Phase Ternary Phaseseparation, Adhesion, Cell dynamics equilibria, systems, Polymer Cohesion, Adhesion, GibbsRule Surface solutions, Spreading Cell LeverRule energy, Polymer spreading Sintering blends Kinetics Trans- Devitrification, Polymerization, Deposition, Receptors, formations, Nucleation, Degradation Infiltration Ligand Corrosion Growth binding Transport Inviscid Newtonian non-Newtonian PorousFlow, Convection, Properties systems, flow,Heat flow,Heat Heat Diffusion Heat capacity, capacity, capacity, capacity, Diffusion Diffusion Diffusion Diffusion Mechanical Stress-strain, Fatigue, Viscoelasticity, Laminates Sutures, Properties Elasticity, Fracture, Elastomers Bone, Ductility Creep Teeth Electrical, Resistivity, Dielectrics, Ionconductors, Dielectrics, Biosensors, Magnetic& Magnetism, Ferrites, Molecular Storage MRI Optical Reflectance Absorbance magnets,LCDs media Properties Processing Casting, Pressing, Extrusion, Pultrusion, Surface Rolling, CVD/CVI, Injection RTM, modification Compaction Sol-Gel molding,Blow CVD/CVI molding CaseStudies Compressed Ceramic Polymeric Composite Tooth airtank piping packaging driveshaft coatings of each chapter. Active-learning principles are exercised through the presentation of example problems in the form of Cooperative Learning Exercises. To the student, this means that they can solve problems in class and can work through specific difficulties in the presence of the instructor. Cooperative learning has been shown to increase the level of subject understanding when properly utilized.∗ No class is too large to allow students to take 5–10 minutes to solve these problems. To the instructor, the Coop- erative Learning Exercises are to be used only as a starting point, and the instructor is encouraged to supplement his or her lecture with more of these problems. Particu- larly difficult concepts or derivations are presented in the form of Example Problems that the instructor can solve in class for the students, but the student is encouraged to solve these problemsduringtheirowngroup orindividual study time.Design-oriented problems are offered, primarily in the Level III problems at the end of each chapter, ∗Smith,K.CooperativeLearningandCollegeTeaching,3(2),10–12(1993). PREFACE xiii that incorporate concepts from several chapters, that involve significant information retrieval or outside reading, or that require group activities. These problems may or may not have one “best” answer and are intended to promote a deeper level of under- standingofthesubject.Finally,thereismuchinformationonthepropertiesofmaterials available on the Internet. This fact is utilized through the inclusion of appropriate web links. There are also many excellent visualization tools available on the Internet for conceptsthataretoodifficulttocomprehendinastatic,two-dimensionalenvironment, and links are provided to assist the student in their further study on these topics. Finally,theultimate testofthesuccessofanytextbookiswhetherornotitstayson your bookshelf. It is hoped that the extent of physical and mechanical property data, along with the depth with which the subjects are presented, will serve the student well as they transition to the world of the practicing engineer or continue with their studies in pursuit of an advanced degree. BRIAN S. MITCHELL Tulane University