The Impact of Materials on Progress

Revolution in Transportation

Road Transport in the 18th and a major part of 19th century was mainly horse carriages. By 1890 we had Copper, Bronze, Iron, Steel , Aluminum and Rubber in addition to Wood. This paved the way for series of inventions leading to a paradigm shift in the road transport from horse carriages to motorized vehiclesKarl Benz in Germany came up with a viable motor vehicle called ‘Velo’ in 1894 Ford Motors made the first assembly line for mass production of commercial vehiclesThe Ford T-model was the first successful and affordable commercial vehicleMaterials had a very important role to play in this transformation from Velo or T to modern cars (see the next slide)

We have come of ages, developed new materials and technologies based on them

The application of these materials has led to the modern day cars

Automobile and Materials

From Cast iron blocks to more compact, lighter and powerful engine blocks – Material development has made it all possibleEngine components are traditionally made from ferrous alloys. Emphasis on weight reduction for higher fuel efficiency has increased usage of aluminum for cylinder blocks, cylinder heads, and other engine components. Some engine covers and intake manifolds are made of magnesium. Titanium is also used in high-speed engines connecting rods to reduce reciprocating mass. Materials like synthetic rubber, variety of polymers, foams have provided new dimension and aesthetic look to automotive interiors

Automobile and MaterialsEngine and Interior

Invention of Aeroplane From Wright Brothers’ invention in 1902 To today’s AircraftMaterials played a very important role in this case alsoUse of advanced materials - Stronger, lighter and better aerodynamic design, greater speed.Boeing 777, for example, used 75% aluminum whereas half of the materials used in the advanced version 787 is fiber reinforced composite.

Total materials used by weight

Boeing 787Boeing 777 (Source: Boeing)

As the aircraft design improved, the load on the engine and hence, it’s operating temperature also increased.Need of materials that can sustain such harsh conditions.The advent of High-temperature materials (Ni base super alloys) has made it possible. (www.cmse.ed.ac.uk/AdvMat45/SuperEng.pdf)

Impact of Materials

Waterways – Transport and SafetyRMS Titanic, a classic example

On it’s maiden voyage from Southampton, UK to New York city, RMS titanic sank in the North Atlantic on April 15, 1912 on colliding with an icebergAn analysis done on the hull steel years later provided the materials aspects of this tragedy.The hull of the ship was made of riveted steel platesThe quality and the composition of the steel is crucial for the required properties and performance.

Hull made of Riveted steel plates

Rivet joint

Poor Steel quality, high S and P and low Mn:S ratioA metallurgical analysis done on the hull steel revealed a Mn:S ratio of 6.8:1 which was too low compared to a quality steel like ASTM A36 (Mn:S 15:1)Low Mn:S ratio cannot remove the sulfur from steelAs a result sulphides form. The brittle sulfides reduces the impact propertiesAt lower temperature metals and alloys loose their ductility and becomes brittle – Ductile to Brittle Transition Temperature (DBTT) is the deciding factor

Metallurgical aspects of failure

Formation of brittle sulphide inclusions due to Low Mn:S ratioHigh Ductile to brittle transition temperature (DBTT) –The steel became very brittle at low temperatureImpact property testing of the titanic steel exhibited brittle behavior.Brittle fracture on collision with ice berg in the chilling water temperature (-2 C at the time of collision).Breakage of ship and sinking

Failure analysis

Modern cruise: As or more Luxurious as Titanic Use of advanced materials such as fiber reinforced composite (FRP), laminated composites, high-strength steels, non-ferrous alloys Better safety due to improved design and materials used therein combined with advanced navigation system

The modern cruise ship

The Electronics Revolution

Before invention of the Si chip Electro-mechanical computers were developedHarvard MarkI Electro-mechanical computer, 1940 – 5 tons, 8 x 51 feet and 500 miles of wireIBM Computer,1959, 33 feet longInvention of a metallurgical process, Zone refining, that can produce high purity Si led to the development of semiconductor chips.Development of smaller and smaller Si chips helped miniaturization that led to today’s computers

Silicon – the heart of every electronic component

Communication and Entertainment

Smaller and smaller microchips have brought the whole world on our palm top

The advent of new electronic, optical and optoelectronic materials has given new dimension to entertainment

Katherine Felkins et al. The Royal Mail Ship Titanic: Did a Metallurgical Failure Cause a Night to Remember? JOM 50 (1) (1998) 12-18Zygmont, Jeffrey Microchip: An Idea, Its Genesis, and The Revolution It Created (Cambridge, MA: Perseus, 2003).http://www.computersciencelab.com/ComputerHistory/HistoryPt3.htm

Further reading

Key words: Role of Materials; Impact on progress; Transportation and Electronic revolution