Engineering Materials Essentials

Cheatsheet Content

1. Cements Definition: A binder, a substance used for construction that sets, hardens, and adheres to other materials to bind them together. Types: Ordinary Portland Cement (OPC): Most common, general construction. Rapid Hardening Cement: Faster strength gain, less curing time. Sulphate Resisting Cement: Resists sulphate attack in soil/water. Low Heat Cement: For mass concrete structures to reduce thermal cracking. Portland Pozzolana Cement (PPC): Improved durability, reduced permeability. Properties: Fineness, consistency, setting time, compressive strength, soundness. Uses: Concrete, mortar, plaster, grout. 2. M-Sand (Manufactured Sand) Definition: Crushed aggregates produced from hard granite stone, often used as a substitute for natural river sand. Properties: Cubical shape, angular, rough texture, consistent grading. Advantages: Environmentally friendly, consistent quality, better workability in concrete, reduced impurities. Uses: Concrete, mortar, plaster. 3. Concrete 3.1. Plain Cement Concrete (PCC) Definition: Mixture of cement, aggregates (sand & gravel), and water. Cures to form a hard, stone-like material. Properties: High compressive strength, low tensile strength. Uses: Foundations, flooring, pathways, mass concrete works. 3.2. Reinforced Cement Concrete (RCC) Definition: PCC combined with steel reinforcement bars (rebar) to resist tensile forces. Properties: High compressive and tensile strength, ductile. Uses: Beams, columns, slabs, bridges, high-rise buildings. 3.3. Fibre-Reinforced Concrete (FRC) Definition: Concrete containing discrete, discontinuous fibers (steel, glass, synthetic) to improve tensile strength, ductility, and crack resistance. Steel Fibre-Reinforced Concrete (SFRC): Improved impact resistance, fatigue strength. Uses: Industrial floors, pavements. Glass Fibre-Reinforced Concrete (GFRC): Lightweight, good tensile strength, often used for architectural panels. 3.4. Lightweight Concrete Definition: Concrete with a density significantly lower than normal concrete, achieved by using lightweight aggregates (e.g., pumice, expanded clay) or incorporating air voids. Properties: Reduced dead load, good thermal insulation. Uses: Non-load-bearing walls, insulation, precast panels. 3.5. High Performance Concrete (HPC) Definition: Concrete meeting special combinations of performance and uniformity requirements that cannot be met by conventional concrete. Typically characterized by high strength, high workability, and enhanced durability. Properties: High strength ($>$ 60 MPa), low permeability, excellent durability. Uses: High-rise buildings, bridges, aggressive environments. 3.6. Polymer Concrete Definition: Concrete where polymeric binders completely replace cement hydrate as the binder. Properties: High strength, rapid curing, excellent chemical resistance, low permeability. Uses: Repair materials, overlays, chemical storage tanks. 4. Ceramics and Refractories 4.1. Ceramics Definition: Inorganic, non-metallic materials processed at high temperatures. Types: Traditional (bricks, tiles), Advanced (alumina, zirconia). Properties: High hardness, high melting point, chemically resistant, brittle, good electrical insulators. Uses: Tiles, sanitaryware, electrical insulators, cutting tools, biomedical implants. 4.2. Refractories Definition: Ceramic materials designed to withstand very high temperatures without softening or deforming, while also resisting thermal shock, chemical attack, and abrasion. Types: Fireclay, alumina, silica, magnesia. Properties: High refractoriness, thermal stability, chemical inertness. Uses: Furnaces, kilns, incinerators, linings for high-temperature vessels. 5. Bitumen and Asphaltic Materials Bitumen: A black, sticky, viscous mixture of hydrocarbons, obtained as a residue from petroleum distillation. Asphalt (Asphalt Concrete): A mixture of asphalt cement (bitumen) and mineral aggregates. Properties: Viscoelastic, waterproof, good adhesive properties. Uses: Road paving, roofing, waterproofing. 6. Timbers Definition: Wood prepared for use in construction or carpentry. Types: Softwoods: From coniferous trees (e.g., pine, spruce). Faster growing, less dense. Hardwoods: From deciduous trees (e.g., oak, maple). Slower growing, denser, more durable. Properties: Good strength-to-weight ratio, renewable, aesthetic, anisotropic (properties vary with grain direction). Uses: Structural framing, flooring, furniture, joinery. 7. Glass and Plastics 7.1. Glass Definition: An amorphous solid, typically transparent, produced by cooling molten materials (mainly silica) rapidly. Types: Soda-lime glass (windows), Borosilicate glass (heat resistant), Tempered glass (safety). Properties: Transparent, brittle, chemically resistant, good electrical insulator. Uses: Windows, architectural facades, optical fibers, laboratory equipment. 7.2. Plastics (Polymers) Definition: Synthetic or semi-synthetic organic compounds that are malleable and can be molded into various shapes. Types: Thermoplastics: Can be repeatedly melted and reshaped (e.g., PVC, PE, PP, PET). Thermosets: Undergo irreversible chemical change upon heating, cannot be reshaped (e.g., epoxy, polyester). Properties: Lightweight, corrosion-resistant, good electrical insulators, varied strength and flexibility. Uses: Pipes, insulation, packaging, coatings, structural components. 8. Structural Steel and Other Metals 8.1. Structural Steel Definition: An alloy of iron and carbon (typically $0.05\% - 0.25\%$ carbon) with other alloying elements, designed for structural applications. Properties: High strength, high ductility, tough, recyclable, good weldability. Uses: Beams, columns, trusses, frames in buildings and bridges. 8.2. Other Metals Aluminum: Lightweight, corrosion-resistant, good electrical conductor. Uses: Window frames, aircraft, electrical cables. Copper: Excellent electrical and thermal conductivity, corrosion-resistant. Uses: Electrical wiring, plumbing. Stainless Steel: High corrosion resistance (due to chromium content). Uses: Architectural cladding, medical instruments. 9. Paints and Varnishes 9.1. Paints Definition: A liquid mixture, usually of a pigment and a liquid vehicle, that forms a thin protective and decorative coating when spread on a surface. Components: Pigment (color), Binder (film formation), Solvent (viscosity), Additives (performance). Uses: Protection against corrosion, weathering, aesthetics. 9.2. Varnishes Definition: A clear, transparent protective finish or film. It has no pigment. Components: Resin, solvent, drying oil. Uses: Enhancing natural wood grain, protection, clear finish. 10. Acoustical Materials and Geo-textiles 10.1. Acoustical Materials Definition: Materials designed to absorb, diffuse, or block sound waves to control noise levels and improve sound quality. Types: Porous absorbers (mineral wool, foam), Resonators (perforated panels), Barriers (dense materials). Properties: Sound absorption coefficient, noise reduction coefficient (NRC). Uses: Auditoriums, recording studios, offices, industrial noise control. 10.2. Geo-textiles Definition: Permeable fabrics made of synthetic fibers (polypropylene, polyester) used in geotechnical engineering applications. Functions: Separation (prevent mixing of layers), Filtration (allow water flow but retain soil particles), Reinforcement (improve soil strength), Drainage, Protection. Uses: Roads, railways, embankments, retaining walls, erosion control. 11. Rubber and Asbestos 11.1. Rubber Definition: An elastic hydrocarbon polymer, obtained from various plants (natural rubber) or synthesized (synthetic rubber). Properties: Elasticity, flexibility, waterproofing, good electrical insulation, high friction. Uses: Seals, gaskets, tires, hoses, conveyor belts. 11.2. Asbestos (Historical/Hazardous) Definition: A group of six naturally occurring fibrous silicate minerals. Historically used for its heat resistance and insulating properties. Properties: High tensile strength, heat resistance, chemical inertness, good insulation. Hazard: Carcinogenic, now largely banned. Past Uses: Insulation, fireproofing, roofing, brake linings. 12. Laminates and Adhesives 12.1. Laminates Definition: Materials constructed by uniting two or more layers of material together to create a new material with improved strength, stability, appearance, or other properties. Types: Plywood, high-pressure laminates (HPL), laminated glass. Properties: Enhanced strength, dimensional stability, aesthetic appeal, durability. Uses: Furniture, flooring, countertops, safety glass. 12.2. Adhesives Definition: A substance, typically liquid or semi-liquid, that adheres or bonds items together. Types: Epoxies, polyurethanes, acrylics, cement-based. Properties: Bonding strength, flexibility, chemical resistance, setting time. Uses: Joining materials, sealing, coating, structural bonding. 13. Graphene, Carbon Composites, and Other Advanced Materials 13.1. Graphene Definition: A single layer of carbon atoms arranged in a two-dimensional hexagonal lattice. Properties: Extremely strong ($~200 \times$ stronger than steel), lightweight, excellent electrical and thermal conductivity, transparent. Uses (Emerging): Electronics, sensors, batteries, composites, filtration. 13.2. Carbon Composites Definition: Materials made from carbon fibers embedded in a polymer matrix (e.g., epoxy resin). Types: Carbon Fiber Reinforced Polymer (CFRP). Properties: Very high strength-to-weight ratio, stiffness, fatigue resistance, corrosion resistance. Uses: Aerospace, automotive, sporting goods, high-performance structural components. 13.3. Other Engineering Materials Shape Memory Alloys (SMAs): Alloys that can "remember" their original shape and return to it upon heating (e.g., Nitinol). Uses: Biomedical, actuators. Piezoelectric Materials: Generate an electric charge in response to mechanical stress, and vice versa. Uses: Sensors, actuators, energy harvesting. Nanomaterials: Materials with at least one dimension in the nanoscale ($1-100$ nm), exhibiting unique properties. Uses: Coatings, catalysts, electronics.