Material Science with Corrosion

Program: Bachelor of Chemical Engineering

Semester: 1 Year 3

Module code: ENG 3001

Credits: 3

Prerequisites: Physical Chemistry, General chemistry

Exemption: None

1.0 Module description
This course is looking at structure, properties and in some cases processing of engineering materials (metals, ceramics and polymers) and their mechanical properties and the behavior in different environments.

2.0 Module objectives:

2.1 General objectives

After successful completion of the course the student should:
a) Know the structure of engineering materials
b) Relate the structure of material to its mechanical properties
c) Understand how thermal changes can bring about structural changes
d) Interpret phase diagrams for binary and ferrous alloys
e) Know how materials are behaving in different environmental conditions

2.2 Units and specific objectives

Unit 1: Bonding and structure of engineering materials

On successful completion of the course the students should:

1.1 Explain the structure and bonding in metals, ceramics and polymers.
1.2 Briefly describe ionic, covalent, metallic, hydrogen, and van der Waals bonds.
1.3 Describe the difference in atomic/molecular structure between crystalline and non-crystalline materials.
1.4 Draw unit cells for face centered cubic, body-centered cubic and hexagonal close-packed crystal structures.
1.5 Compute the densities for metals having FCC and BCC unit cell structures.

Unit 2: Mechanical properties

On successful completion of the course the students should:

2.1 Define engineering stress, engineering strain and Hooke’s law.
2.2 Interpret the engineering stress-strain diagram
2.3 Name the two most common hardness-testing techniques
2.4 Describe the mechanism of crack propagation
2.5 Name and describe the two impact fracture testing techniques
2.6 Define creep and specify the conditions under which it occurs.


Unit 3: Thermal effects

On successful completion of the course the students should:

3.1 Discuss the effect of temperature on toughness
3.2 Describe with the aid of diagram how cold work and annealing are affecting the properties of metals.

Unit 4: Phase diagrams

On successful completion of the course the students should:

4.1 Interpret the phase diagrams for binary alloys
4.2 Calculate the amount of phases present at a given temperature, using the diagram.
4.3 Calculate the phase composition at a given temperature, using the diagram.
4.4 Develop the microstructure of alloys

Unit 5: Ferrous alloys

On successful completion of the course the students should:

5.1 Interpret the phase diagrams for iron –iron carbide diagram
5.2 Briefly describe the microstructure of pearlite, bainite, martensite for steel alloys
5.3 List the uses of hypoutectoid and hyperutectoid alloys
5.4 Explain how the composition of alloy affects its mechanical properties

Unit 6: Polymers (thermoplastics, thermosetting, processing)

On successful completion of the course the students should:

6.1 Describe a typical polymer molecule in term of its structure
6.2 Draw mer structures for commodity polymers
6.3 Cite a difference in behavior and molecular structure for thermoplastic and thermosetting polymers
6.4 Explain, by the use of diagram, stress strain behavior of polymers
6.5 Describe five fabrication techniques used for plastics (extrusion, injection molding, blow molding, compression molding and reaction injection molding)

Unit 7: Corrosion

7.1 Distinguish between oxidation and reduction electrochemical reactions
7.2 Compute the cell potential for a given electrochemical cell
7.3 For each of the corrosion types describe the nature of the process, and note the proposed mechanism
7.4 List measures that are used for prevent corrosion
7.5 Discuss two degradation process that occur when polymers are exposed to solvents and different environmental conditions



3.0 Module content

Unit 1: Bonding and Structure of engineering materials

1.1 Engineering materials metals, ceramics and polymers
1.2 Types of bonding(ionic, covalent, metallic and intermolecular)
1.3 Crystalline and non-crystalline structures
1.4 Crystalline structure of metals (FCC, BCC, HCPS)
1.4.1 Correlation of Data unit cell with density
1.4.2 Crystallographic points, directions and planes
1.4.3 Imperfections in solids (point defects

Unit 2: Mechanical Properties

2.1 Testing of metals
2.1.1. Engineering stress-strain curves
2.1.2. Hardness testing (Brinnel hardness)
2.1.3. Impact fracture testing (Izod test)
2.1.4. Creep

Unit 3: Thermal Effects

3.1 Ductile to brittle transition with temperature change
3.2 Cold work and annealing
3.3 Grain size and properties

Unit 4: Phase diagrams

4.1 Equilibrium phase diagram(Al-Si)
4.2 Phase composition
4.3 Amounts of phases
4.4 Formation of microstructures

Unit 5: Ferrous alloys

5.1 Iron-iron carbide phase diagram
5.2 Hypoeutectoid alloys
5.3 Hypereutectoid alloys

Unit 6: Polymers (thermoplastics, thermosetting, processing)

6.1 thermoplastics, thermosetting polymers
6.2 structure and nomenclature
6.3 copolymers
6.4 effect of time and temperature on polymers
6.5 glass transition temperature
6.6 processing of polymers ( injection molding, reaction injection molding, blow molding, extrusion)

Unit 7: Corrosion

7.1 Electrochemical principals
7.2 Types of Corrosion of metals (Galvanic corrosion, selective leaching, hydrogen damage, pit and crevice corrosion, erosion and cavitation, intergranular corrosion) case studies
7.3 Fundamental ways of corrosion protection
7.3.1 material selection and heat treatment
7.3.2 cathodic protection
7.3.3 coating and lining
7.3.4 surface preparation
7.3.5 design considerations


4.0 Instructional/Learning Approaches

This module will be developed through lectures, lab work and assignments.


5.0 Assessment procedures

Test 20% (2 tests)
Lab 20% (3-4 labs)
Assignment 10% (Oral presentation with written report)
Exam 50%


6.0 Textbook and references

Required
1. Callister W.D. (2003) Materials Science and Engineering: An introduction, 6th Ed.,John Wiley and Sons, NY

Recommended reading

2. Callister W.D. (2003) Materials Science and Engineering: An introduction, 6th Ed., John Wiley and Sons, NY
3. Budinski K.G., Budinski M.K. (1999) Engineering materials, 6th Ed., Prentice Hall, USA
4. Lawrence H. Van Vlack (1990) Elements of Material Science and Engineering, 6th Ed., Addison-Westley Publishing Company, USA