1 1 1 1
BNQ 30503
BNQ 30503
MA
MA
TERIAL
TERIAL
ENGINE
ENGINE
ERING
ERING
TECHNOLOGY
TECHNOLOGY
CHAPTER 1:
CHAPTER 1:
SOL
SOL
ID STRUCTUR
ID STRUCTUR
E
E
By: Engr. Dr. Nasrul Fikry Che Pa By: Engr. Dr. Nasrul Fikry Che Pa
http://bit.ly/19o6LoL
Content’
Content’s s ReviewReview
•
• Chapter 1: Solid StructureChapter 1: Solid Structure
–
– What you will learn?What you will learn?
••
Crystal structures fundamental concepts, metallic crystalCrystal structures fundamental concepts, metallic crystal structures, crystallographic points, directions andstructures, crystallographic points, directions and planes, crys
planes, crystalline talline and noncrystand noncrystallinealline matematerials, poinrials, pointt defects, dislocations, importance of defects.
Content’
Content’s s ReviewReview
•
• Chapter 1: Solid StructureChapter 1: Solid Structure
–
– What you will learn?What you will learn?
••
Crystal structures fundamental concepts, metallic crystalCrystal structures fundamental concepts, metallic crystal structures, crystallographic points, directions andstructures, crystallographic points, directions and planes, crys
planes, crystalline talline and noncrystand noncrystallinealline matematerials, poinrials, pointt defects, dislocations, importance of defects.
3
3
Schematic representation of the most Schematic representation of the most
basic structural unit for quartz (all silicate basic structural unit for quartz (all silicate material). Each atom of Si surrounded by material). Each atom of Si surrounded by 4 O
4 O22 atom whose center are located atatom whose center are located at the corner of a tetrahedron. Represented the corner of a tetrahedron. Represented as
as
444−4−Sketch of a unit cell for Quartz, Sketch of a unit cell for Quartz,
composed of several interconnected composed of several interconnected
444−4− tetrahedral.tetrahedral.Introduction
4
Schematic diagram showing a large interconnected
44− tetrahedral. Observe the shape resembles quartz.Photograph of 2 single crystals of quartz.
Fundamental Concepts
• Atoms pack in periodic, 3D arrays Crystalline materials...
metals, many ceramic & some polymers
crystalline SiO2
• Examples:
• Atoms have no periodic packing Non-crystalline materials...
- complex structures - rapid cooling
- Lack systematic & regular arrangement of atoms over relatively large atomic distance
noncrystalline SiO2
" Amorphous" = Noncrystalline
Si Oxygen • occurs for:
-literally means ‘without form’
“Atoms in crystalline solid are position in orderly & repeated patterns that are in contrast to the random & disordered atomic distribution found in
Metallic Crystal Structures
• How can we stack metal atoms to minimize empty space?
2-dimensions
vs.
Imagine that these 2D layers are stacked to make 3D structures. Which one having a minimized empty spaces?
Metallic Crystal Structures
• Tend to be densely packed.
• Assumptions in dense packing:
- Typically, only one element is present, so all atomic radii are the same.
- Metallic bonding is not directional.
- Nearest neighbor distances tend to be small in order to lower bond energy.
- Electron cloud shields cores from each other
• Have the simplest crystal structures.
Next…. We will examine four such structures...
Simple Cubic Structure (SC)
• Rare due to low packing density (only Po, Polonium has this structure)
• Close-packed directions are cube edges.
• Coordination # = 6 (# nearest neighbors)
Click once on image to start animation (Courtesy P.M. Anderson)
Atomic Packing Factor (APF)
• APF for a simple cubic structure = 0.52
APF = a3 4 3
p
(0.5a) 3 1 atoms unit cell atom volume unit cell volume APF = Volume of atoms in unit cell* (Vs)Volume of unit cell (Vc) *assume hard spheres
close-packed directions
a
R=0.5a
Body Centered Cubic Structure (BCC)
• Coordination # = 8
• Atoms touch each other along cube diagonals.
--Note: All atoms are identical; the center atom is shaded differently only for ease of viewing.
ex: Cr, W, Fe (), Tantalum, Molybdenum
2 atoms/unit cell:
1 center + 8 corners x 1/8
Click once on image to start animation (Courtesy P.M. Anderson)
Atomic Packing Factor: BCC
length = 4R =
Close-packed directions: 3 a • APF for a body-centered cubic structure = 0.68
a R a 3 a a 2 APF = atoms
unit cell atom
volume 3 unit cell volume 4 3
p
( 3a/4)3 2 aFace Centered Cubic Structure (FCC)
• Coordination # = 12
• Atoms touch each other along face diagonals.
--Note: All atoms are identical; the face-centered atoms are shaded differently only for ease of viewing.
4 atoms/unit cell: 6 face x 1/2 + 8 corners x 1/8
Click once on image to start animation (Courtesy P.M. Anderson)
Atomic Packing Factor: FCC
• APF for a face-centered cubic structure = 0.74
maximum achievable APF
APF =
4
3
p
( 2a/4)3 4atoms
unit cell atom
volume a3 unit cell volume Close-packed directions: length = 4R = 2 a Unit cell contains:
6 x 1/2 + 8 x 1/8 = 4 atoms/unit cell a
A sites B B B B B B B C sites C C C A B B sites
• ABCABC... Stacking Sequence • 2D Projection • FCC Unit Cell
FCC Stacking Sequence
B B B B B B B B sites C C C A C C C A A B CHexagonal Close-Packed
Structure (HCP)
• Coordination # = 12
• ABAB... Stacking Sequence
• APF = 0.74
• 3D Projection • 2D Projection
6 atoms/unit cell
ex: Cd, Mg, Ti, Zn • c/a = 1.633 (long over short branch)
c
a
A sites B sites
A sites Bottom layer
Middle layer Top layer
Exercise:
1. If the atomic radius of aluminum (FCC) is 0.143
nm, calculate the volume of its unit cell in cubic
meters.
Theoretical Density,
where n = number of atoms/unit cell
A = atomic weight
VC = Volume of unit cell = a3 for cubic
N A = Avogadro’s number
= 6.022 x 1023 atoms/mol Density =
r
= VCN A n Ar
= Cell Unit of Volume Total Cell Unit in Atoms of Mass• Ex: Cr (BCC) A = 52.00 g/mol R = 0.125 nm n = 2 atoms/unit cell
Theoretical Density,
a = 4R/ 3 = 0.2887 nm a Rr
= a3 52.00 2 atoms unit cell mol g unit cell volume atoms mol 6.022x1023r
theoreticalr
actual = 7.18 g/cm3 = 7.19 g/cm3Exercise:
20
Exercise:
1) Zirconium has an HCP crystal structure and a density of 6.51 g/cm3.
– (a) What is the volume of its unit cell in cubic meters?
– (b) If the c/a ratio is 1.593, compute the values of c and a.
VC N A n A =
Exercise
2. Below are listed the atomic weight, density, and atomic radius for three hypothetical alloys. For each determine whether its crystal structure is FCC, BCC, or simple cubic and then justify your
determination. A simple cubic unit cell is shown in Figure 3.24.
Alloy Atomic Weight (g/mol) Density (g/cm3) Atomic Radius (nm) A 77.4 8.22 0.125
B 107.6 13.42 0.133 C 127.3 9.23 0.142
Fig. 3.24: Hard sphere unit cell representation of the simple cubic crystal structure.
Exercise
3. Rhenium has an HCP crystal structure, an atomic
radius of 0.137 nm, and a c/a ratio of 1.615.
Densities of Material Classes
r
metals >r
ceramics >r
polymersWhy? r ( g / c m ) 3 Graphite/ Ceramics/ Semicond Metals/ Alloys Composites/ fibers Polymers 1 2 20 30
Based on data in Table B1, Callister *GFRE, CFRE, & AFRE are Glass, Carbon, & Aramid Fiber-Reinforced Epoxy composites (values based on 60% volume fraction of aligned fibers
in an epoxy matrix). 10 3 4 5 0.3 0.4 0.5 Magnesium Aluminum Steels Titanium Cu,Ni Tin, Zinc Silver, Mo Tantalum Gold, W Platinum Graphite Silicon Glass -soda Concrete Si nitride Diamond Al oxide Zirconia HDPE, PS PP, LDPE PC PTFE PET PVC Silicone Wood AFRE* CFRE* GFRE* Glass fibers Carbon fibers Aramid fibers Metals have... • close-packing (metallic bonding)
• often large atomic masses
Ceramics have...
• less dense packing • often lighter elements
Polymers have...
• low packing density (often amorphous)
• lighter elements (C,H,O)
Composites have...
• intermediate values
Crystals as Building Blocks
• Some engineering applications require single crystals:
• Properties of crystalline materials often related to crystal structure.
-- Ex: Quartz fractures more easily along some crystal planes than others.
-- diamond single
crystals for abrasives -- turbine blades
(Courtesy Martin Deakins, GE Superabrasives,
Worthington, OH. Used with permission.)
Polycrystals
• Most engineering materials are polycrystals.
• Each "grain" is a single crystal. • If grains are randomly oriented,
overall component properties are not directional. • Grain sizes typically range from 1 nm to 2 cm
(i.e., from a few to millions of atomic layers).
Adapted from Fig. K, color inset pages of Callister 5e.
(Fig. K is courtesy of Paul E. Danielson, Teledyne Wah Chang Albany)
1 mm
Isotropic Anisotropic
Single crystal vs Polycrystals
• Single Crystals
-Properties vary with direction: anisotropic. -Example: the modulus
of elasticity (E) in BCC iron:
Data from Table 3.3, Callister & Rethwisch 8e. (Source of data is R.W. Hertzberg, Deformation and Fracture Mechanics of Engineering Materials, 3rd ed., John Wiley and Sons, 1989.)
• Polycrystals
-Properties may/may not vary with direction.
-If grains are randomly oriented: isotropic.
(Epoly iron = 210 GPa)
-If grains are textured, anisotropic.
200 mm Adapted from Fig.4.14(b), Callister &
Rethwisch 8e.
(Fig. 4.14(b) is courtesy of L.C. Smith and C. Brady, the National Bureau of Standards, Washington, DC [now the National Institute of Standards and
Technology,
Gaithersburg, MD].)
E (diagonal) = 273 GPa
Polymorphism
• Two or more distinct crystal structures for the same material (allotropy/polymorphism) titanium
,
-Ti carbon diamond, graphite BCC FCC BCC 1538ºC 1394ºC 912ºC -Fe liquid iron system -Fe -FeCrystal Systems
Fig. 3.4, Callister & Rethwisch 8e.
7 crystal systems
14 Bravais crystal lattices
Unit cell: smallest repetitive volume which contains
the complete lattice pattern of a crystal.
Three edge lengths a, b, and c and three interaxial angles α, β, and γ are the lattice constants
4. Below is a unit cell for a hypothetical metal.
(a) To which crystal system does this unit cell belong?
(b) What would this crystal structure be called?
(c)
Calculate the density of the material, given that its atomic weight is 141 g/mol.Point Coordinates
•Point coordinates for unit cell center are
a/2, b/2, c/2 ½ ½ ½
•Point coordinates for unit cell corner are 111 z x y a b c 000 111
The manner in which the q, r and s
coordinates at point P within the unit cell are determined. The q coordinate
(which is a fraction) corresponds to the distance qa along the x axis, where a is the unit cell edge length. The respective r and s coordinates for the y and z axes are determined similarly.
Exercise
5. List the point coordinates for all atoms that
are associated with the FCC unit cell.
Crystallographic Directions
1. Vector repositioned (if necessary) to pass through origin.
2. Read off projections in terms of unit cell dimensions a, b, and c 3. Adjust to smallest integer values
4. Enclose in square brackets, no commas
[uvw]
ex: 1, 0, ½ => 2, 0, 1 => [201] -1, 1, 1
families of directions <uvw> (crystallographically equivalent [spacing btw atoms is the same] e.g in cubic system)
z
x
Algorithm
where overbar represents a negative index
[111] =>
Linear Density
Linear Density of Atoms
LD =ex: linear density of Al in [110] direction
a = 0.405 nm
a
[110]
Unit length of direction vector
No. of atoms centered on direction vector
# atoms length 1 3.5 nm a 2 2 LD
=
=
-Exercise
6. What are the indices for the directions
indicated by the two vectors in the sketch
below?
Exercise
7. For tetragonal crystals, cite the indices of
directions that are equivalent to each of the
following directions:
(a) [001]
(b) [110]
(c) [010]
HCP Crystallographic Directions
1. Vector repositioned (if necessary) to pass through origin.
2. Read off projections in terms of unit cell dimensions a1, a2, a3, and c 3. Adjust to smallest integer values
4. Enclose in square brackets, no commas [uvtw]
[1120]
ex: ½, ½, -1, 0 =>
dashed red lines indicate
projections onto a1 and a2 axes a1
a2 a3 -a3 2 a2 2 a1 z Algorithm
Adapted from Fig. 3.8(a), Callister & Rethwisch 8e.
-a3
a1 a2
HCP Crystallographic Directions
•
Hexagonal Crystals
– 4 parameter Miller-Bravais lattice coordinates are
related to the direction indices (i.e., u'v 'w ') as follows.
=
=
=
' w w t v u ) v u ( + -) ' u ' v 2 ( 3 1 -) ' v ' u 2 ( 3 1-=
] uvtw [ ] ' w ' v ' u [
Fig. 3.8(a), Callister & Rethwisch 8e.
-a3
a1 a2
Exercise
8. Determine indices for the directions shown in
the following hexagonal unit cells:
Crystallographic Planes
Crystallographic Planes
Adapted from Fig
Adapted from Fig. 3.10,. 3.10, Callister & Rethwisch 8e. Callister & Rethwisch 8e.
Crystallographic Planes
Crystallographic Planes
•
•
Miller Indices: Reciproc
Miller Indices:
Reciprocals of
als of the (thr
the (three) a
ee) axial
xial
inter
intercepts for a plane, cl
cepts for a plane, cleared of fractions & common
eared of fractions & common
multiples.
multiples. All par
All parallel pl
allel planes ha
anes have
ve same Miller
same Miller indices.
indices.
•
•
Algorithm
Algorithm
1.
1. Read Read off ioff intenterceprcepts of ts of plane plane with awith axes xes inin terms of
terms of aa,, bb,, cc
2. Take reciprocals of intercepts 2. Take reciprocals of intercepts 3.
3. ReduReduce to smallece to smallest intst integer vaeger valueslues 4.
4. EncloEnclose in se in parenparenthesestheses, no, no commas i.e.,
Crystallographic Planes
Crystallographic Planes
z z x x y y a a bb c c 4.4. Miller Miller Indices Indices (1(110)10)
example example aa bb cc zz x x y y a a bb c c 4.
4. Miller Miller Indices Indices (100)(100) 1. Intercepts 1. Intercepts 1 1 11 2. Reciprocals 2. Reciprocals 1/1 1/1 1/1 1/1 1/1/ 1 1 1 1 00 3. Reduction 3. Reduction 1 1 1 1 00 1. Intercepts 1. Intercepts 1/21/2 2. Reciprocals 2. Reciprocals 1/½ 1/½ 1/1/ 1/1/ 2 2 0 0 00 3. Reduction 3. Reduction 2 2 0 0 00 example example aa bb cc
Crystallographic Planes
z x y a b c 4. Miller Indices (634) example 1. Intercepts 1/2 1 3/4 a b c 2. Reciprocals 1/½ 1/1 1/¾ 2 1 4/3 3. Reduction 6 3 4 (001) (010), Family of Planes {hkl} (100), (010), (001), Ex: {100} = (100),9. Determine the Miller indices for the planes shown in the
following unit cell:
10. Cite the indices of the direction that results from the
intersection of each of the following pair of planes
within a cubic crystal: (a) (100) and (010) planes, (b)
(111) and (111) planes, and (c) (101) and (001) planes.
Crystallographic Planes (HCP)
•
In hexagonal unit cells the same idea is used
example a1 a2 a3 c 4. Miller-Bravais Indices (1011) 1. Intercepts 1 -1 1 2. Reciprocals 1 1/ 1 0 -1 -1 1 1 3. Reduction 1 0 -1 1 a2 a3 a1 z
Adapted from Fig. 3.8(b), Callister & Rethwisch 8e.
a1 = h a3 = i = -(h+k) a2 = k z = l
Planar Density
•
Used to examine the atomic packing of crystallographic
planes
•
E.g: Iron foil can be used as a catalyst. The atomic
packing of the exposed planes is important.
a) Draw (100) crystallographic planes for Fe assuming that the structure is BCC.
Planar Density of (100) Iron
• Solution: At T < 912ºC iron has the BCC structure.
(100) Radius of iron R = 0.1241 nm R 3 3 4 a = 2D repeat unit = Planar Density = a2 1 atoms 2D repeat unit = nm2 atoms 12.1 m2 atoms = 1.2 x 1019 1 2 R 3 3 4 area 2D repeat unit
11. (a) Derive planar density expressions for FCC (100) and (111) planes in terms of the atomic radius R.
(b) Compute the planar density values for these same two planes for nickel when R = 0.125 nm.
Summary from part 1
• Atoms may assemble into crystalline or amorphous structures.
• We can predict the density of a material, provided we know the atomic weight, atomic radius, and crystal geometry (e.g., FCC, BCC, HCP).
• Common metallic crystal structures are FCC, BCC, and HCP. Coordination number and atomic packing factor are the same for both FCC and HCP crystal structures.
• Crystallographic points, directions and planes are specified in terms of indexing schemes.
Crystallographic directions and planes are related to atomic linear densities and planar densities.
Summary from part 1 (Cont.)
• Some materials can have more than one crystal structure. This is referred to as polymorphism (or allotropy).
• Materials can be single crystals or polycrystalline.
Material properties generally vary with single crystal orientation (i.e., they are anisotropic), but are generally non-directional (i.e., they are isotropic) in polycrystals with randomly oriented grains.
• Solidification- result of casting of molten material
– 2 steps
• Nuclei form
• Nuclei grow to form crystals – grain structure
• Start with a molten material – all liquid
Imperfections in Solids
• Crystals grow until they meet each other
grain structure crystals growing
nuclei
Polycrystalline Materials
• Grain Boundaries
• regions between crystals
• transition from lattice of one region to that of
the other
• slightly disordered
• low density in grain boundaries
– high mobility
– high diffusivity
– high chemical reactivity
• Grains can be - equiaxed (roughly same size in all directions) - columnar (elongated grains)
Solidification
Columnar in area with less undercooling Shell of equiaxed grains due to rapid cooling (greater T) near wall
Grain Refiner - added to make smaller, more uniform, equiaxed grains.
heat flow
~ 8 cm
heat flow
Types of Imperfections
• Vacancy atoms
• Interstitial atoms
• Substitutional atoms
Point defects
• Dislocations
Line defects
Point Defects in Metals
• Vacancies:
-vacant atomic sites in a structure.
• Self-Interstitials:
-"extra" atoms positioned between atomic sites.
Vacancy
distortion of planesself-interstitial
distortion of planesEquilibrium Concentration:
Point Defects
Boltzmann's constant (1.38 x 10-23 J/atom-K) (8.62 x 10-5 eV/atom-K)N
vN
=
exp
-
Q
vkT
No. of vacancies Total No. of atomic sites Activation energy TemperatureEach lattice site is a potential
vacancy site
Estimating Vacancy Concentration
• Find the equil. # of vacancies in 1 m3 of Cu at 1000
C.• Given:
ACu = 63.5 g/mol
r
= 8.4 g/cm3Qv = 0.9 eV/atom N A = 6.02 x 1023 atoms/mol
For 1 m3, N = N A A Cu
r
x x 1 m3= 8.0 x 1028 sites= 2.7 x 10
-4 8.62 x 10-5 eV/atom-K 0.9 eV/atom 1273 K
N
vN
=
exp
-
Q
vkT
• Answer: Nv = (2.7 x 10-4)(8.0 x 1028) sites = 2.2 x 1025 vacanciesExercise (Tutorial)
1.
Calculate the fraction of atom sites that are vacant for lead at its melting temperature of 327°C (600 K).Assume an energy for vacancy formation of 0.55 eV/atom.
2
. Calculate the activation energy for vacancy formation in aluminum, given that the equilibrium number of vacancies at 500
C (773 K) is 7.55
1023 m-3. The atomic weight and density (at 500
C) for aluminum are,Imperfections in Metals
Two outcomes if impurity (B) added to host (A):
• Solid solution of B in A (i.e., random dist. of point defects)
• Solid solution of B in A plus particles of a new phase (usually for a larger amount of B)
OR
Substitutional solid soln. (e.g., Cu in Ni)
Interstitial solid soln. (e.g., C in Fe)
Second phase particle -- different composition -- often different structure.
Impurities in Solids
•
Specification of composition
weight percent x 100 2 1 1 1 m m m C = m1 = mass of component 1 100 x 2 1 1 ' 1 m m m n n n C =nm1 = number of moles of component 1 ,
atom percent
Derive an equation that relate C’1 & C1 ?
Ans: C’1 = [(C1 A2)/ [(C1 A2) + (C2 A1) ] ] x 100
nm1 = ()
Additional Equation 64 ′ = + x 100 2′ = + x 100
Conversion of weight percent to atom percent (for two-element alloy)
= + x 100 2 = + x 100
Conversion of atom percent to weight percent (for two-element alloy)
2 = 100 ′ 2′ = 100
& 2 = weight percent
& 2 = Atomic weight
′
2′ = Atom percents
65 Additional Equation "= + X 103 2"= + X 103
Conversion of weight percent to Mass per unit volume (for 2 element alloy)
" , = Concentration (kg/3) ρ, ρ2 = density in (g/3 ) ρ= + ρ = + +
Computation of density (for two-Element metal alloy)
= + = +
Computation of atomic weight (for a two-element metal alloy)
Line / Linear Defects
• are line defects,
• slip between crystal planes result when dislocations move, • produce permanent (plastic) deformation.
Dislocations:
Schematic of Zinc (HCP):
• before deformation • after tensile elongation
Imperfections in Solids
•
Linear Defects (Dislocations)
Are one-dimensional defects around which atoms are misaligned • Edge dislocation:
extra half-plane of atoms inserted in a crystal structure b perpendicular () to dislocation line
• Screw dislocation:
spiral planar ramp resulting from shear deformation b parallel () to dislocation line
Imperfections in Solids
•
Edge Dislocation
• Dislocation motion requires the successive bumping of a half plane of atoms (from left to right here).
• Bonds across the slipping planes are broken and remade in succession.
Imperfections in Solids
Burgers vector b Dislocation line b (a) (b)Screw Dislocation
Imperfections in Solids
Edge Screw Mixed
Imperfections in Solids
•
Dislocations are visible in electron micrographs
TEM micrograph of a titanium alloy in which the dark lines are
dislocations. 51,450x.
TEM micrograph of dislocations in austenitic stainless steel
Dislocations & Crystal Structures
• Structure: close-packed planes & directions
are preferred.
view onto two close-packed planes.
close-packed plane (bottom) close-packed plane (top)
close-packed directions • Specimens that were tensile tested. Mg (HCP) Al (FCC) tensile direction
Significance of Dislocations
1.
It provide a mechanism for plastic deformation.
2.
It provide ductility in metals.
3.
We control the mechanical properties of a metal or
alloy by interfering with the movement of
dislocations.
•
Strain hardening
•
Solid solution strengthening
•
Grain size strengthening
4.
It influence the electronic and optical properties of
materials.
Interfacial Defects in Solid (Area)
-
Grain Boundaries
• Boundary separating two small grains or crystals having different orientations.
• Atoms are bonded less regularly along the grain boundary, result in boundary energy (similar to surface energy).
• High angle boundaries have higher energy.
• Grain boundaries are
chemically reactive compared to grains because of the
boundary energy.
• Impurity atom often segregate along grain boundaries
Interfacial Defects in Solids
•
Phase Boundaries
– Exist in multiple phase materials.
– The different phases exist on each side of the boundary and it have its own relative physical and/or chemical characteristics.
– Important in determining
the mechanical characteristic of multiphase metal alloys.
500x Ni
Cu Solder
Interface IMC
Optical micrograph of intermetallic layer between Nickel-gold surface finish and lead free solder.
•
Twin boundary (plane)
– Essentially a reflection of atom positions across the twin plane. (mirror-image)
•
Stacking faults
– For FCC metals an error in ABCABC packing sequence
– Ex: ABCABABC