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Description of topics
3rd Jan
6.30pm /
2 hours
Constitution Of Alloys Solid Solutions, Substitutional and Interstitial Solid Solutions, Phase Diagrams - types,
Isomorphous, Eutectoid, Eutectic, Peritectic, and Peritectoid Reactions
2 hours
Iron Iron Carbide Equilibrium Diagram, Classification Of Steel and Cast Iron, Microstructure,
Properties and Applications.
2 hours
2 hours
Isothermal Transformation Diagrams Cooling Curves Superimposed On I.T. Diagram, CCR - Hardenability, Jominy
End Quench Test Austempering, Martempering
2 hours
Case Hardening - Carburising, Nitriding, Cyaniding, Carbonitriding, Flame and Induction Hardening
2 hours
3 hours
Testing Of Materials Under Tension, Compression and Shear Loads Hardness Tests (Brinell, Vickers
And Rockwell), Impact Test - Izod And Charpy, Fatigue and Creep Tests, Fracture Toughness Tests.
2 hours
Effect Of Alloying Elements On Steel (Mn, Si, Cr, Mo, V, Ti & W) - Stainless And Tool Steels HSLA - Maraging
Steels Cast Irons - Grey, White Malleable, Spheroidal Graphite, Alloy Cast Irons
2 hours
Copper and Copper Alloys - Brass, Bronze And Cupronickel Aluminum and Al-Cu Alloy Precipitation Hardening
Bearing Alloys.
10
2 hours
Polymers Types Of Polymer, Commodity and Engineering Polymers Properties and Applications Of PE, PP, PS,
PVC, PMMA, PET, PC, PA, ABS, PI, PAI, PPO, PPS, PEEK, PTFE Polymers
2 hours
Urea and Phenol Formaldehydes Engineering Ceramics Introduction To Fibre Reinforced Plastics.
S.No
Unit
1
I
II
III
IV
V
11
Remarks
Text Books
Sydney H.Avner Introduction to Physical
Metallurgy McGraw Hill Book Company, 2007
Kenneth G.Budinski and Michael K.Budinski
Engineering Materials Prentice-Hall of India
Private Limited, 4th Indian Reprint 2002.
O.P. Khanna , A text book of Materials Science
and Metallurgy, Khanna Publishers, 2003
Dieter G. E., Mechanical Metallurgy, Mc Graw
Hill Book Company, 1988.
Jayakumar, Engineering Materials and
Metallurgy
Materials
Properties of materials
Material Science
- as science dealing the relationships that exist
between the structures and properties of materials,
which are useful in practice of engineers profession
Classification of Materials
Metals
Ceramics
Polymers
Alloys
Properties of materials
All solid engineering materials are
characterized for their properties.
All important properties can be grouped into
six categories: Mechanical, Electrical, Thermal,
Magnetic, Optical, and Deteriorative.
Based on several criteria on which the final
decision is based on.
A need to trade off between number of
factors
Alloys
Alloy is a substance that has metallic properties and
is composed of two or more chemical elements, of
which at least one is a metal
Major proportion of the metal is called as base
metal and
Minor proportion of the metal or element is
alloying element.
Classification of Alloys
Alloys can be according to classified by
Based on the no of components
Based on the no of equilibrium or phases
Based on the structures
Phase
A phase can be defined as a homogeneous
portion of a system that has uniform physical
and chemical characteristics with a given
chemical composition and structure.
i.e. it is a physically distinct from other phases,
chemically homogeneous and mechanically
separable portion of a system.
Pure Metal
In nature 100% pure metal is impossible to get,
hence only 99.99% of pure metal can exist with
0.01% of impurities.
In the equilibrium conditions, all the metals
exhibit a definite melting or freezing point
This condition implies extremely slow heating
and cooling (i.e for any change is to occur
sufficient time must be allowed)
The cooling cure for the pure metal will be a
horizontal line at the melting or freezing point
Homogeneous
Mixture
Intermediate
alloy phase
Any combination of
solid phases
Solid Solution
Substitutional
Interstitial
Intermetallic Interstitial
Electron
Solid Solution
A solid solution is formed when two metals are completely
soluble in liquid state and also completely soluble in solid
state.
In other words, when homogeneous mixtures of two or more
kinds of atoms (of metals) occur in the solid state, they are
known as solid solutions.
Solvent (The more abundant atomic form) + Solute (the less
abundant atomic form)
For example
sterling silver (92.5 percent silver and the remainder copper) is a
solid solution of silver and copper
Brass is a solid solution of copper (64 percent) and zinc (36
percent).
In this case copper atoms are solvent atoms whereas zinc atoms are
solute atoms.
Intermetallic Compounds
Intermetallic compounds are generally formed when
one metal (for example magnesium) has chemical
properties which are strongly metallic and the
other metal (for example antimony, tin or bismuth)
has chemical properties which are only weakly
metallic.
Examples of intermetallic compounds are Mg2Sn,
Mg2Pb, Mg3Sb2.
These intermetallic compounds have higher melting
point than either of the parent metal.
This higher melting point indicates the high strength
of the chemical bond in intermetallic compounds.
Intersitial
It is formed between transition elements
Transition element are half filled with the
outer most d subshell
Like B, C, N, Fe, Ti, W etc.
Properties are high hardness and toughness
Phase Diagrams
Component
either pure metal and/or compounds of which an alloy is composed.
The components of a system may be elements, ions or compounds.
They refer to the independent chemical species that comprise the system.
System
it can either refer to a specific body of material under consideration or it may relate to the
series of possible alloys consisting of the same components but without regard to alloy
composition.
Solid solution
it consists of atoms of at least two different types where solute atoms occupy either
substitutional or interstitial positions in the solvent lattice and the crystal structure of the
solvent is maintained.
Solubility limit
for almost all alloy systems, at a specific temperature, a maximum of solute atoms can dissolve
in solvent phase to form a solid solution.
The limit is known as solubility limit.
In general, solubility limit changes with temperature.
If solute available is more than the solubility limit that may lead to formation of different
phase, either a solid solution or compound.
Where,
P no of phases (solid, liquid, Gaseous etc)
C No of components in the alloy
F Degrees of freedom refers to the number of
independent variables (e.g.: pressure, temperature) that
can be varied individually to effect changes in a system.
Polymorphism
is a physical phenomenon where a material may
have more than one crystal structure.
A material that shows polymorphism exists in
more than one type of space lattice in the solid
state.
If the change in structure is reversible, then the
polymorphic change is known as allotropy.
The prevailing crystal structure depends on both
the temperature and the external pressure.
Solubility
Unlimited Solid Solubility: Solute and solvent are
mutually soluble at all concentrations, e.g., Cu-Ni
system Meets the requirements of the HumeRothery Rules,result is a single phase alloy
Limited or Partial Solid Solubility: There is a limit
to how much of the solute can dissolve in the
solvent before saturation is reached, e.g., Pb-Sn
and most other systems. Does not meet the
requirements of the Hume-Rothery Rules. Results
in a multi-phase alloy
Experimental Methods
The data for the construction of equilibrium
diagrams are determined experimentally by a
variety of methods, the most common
methods are:
Metallographic Methods
X-ray Diffraction Technique
Thermal Analysis
Allotropic change
Order Disorder
The Eutectoid reaction
The Peritectoid reaction
Type - I
Extent solid solubility for a system of two metallic
components can be predicted based on HumeRuthery conditions, summarized in the following:
Crystal structure of each element of solid solution
must be the same.
Size of atoms of each two elements must not differ by
more than 15%.
Elements should not form compounds with each
other i.e. there should be no appreciable difference in
the electro-negativities of the two elements.
Elements should have the same valence.
Type I
Micro-structures
28
74
Type II
Type - III
Type IV
Example
Invariant Reactions
Iron-Carbon System
Typical metal (e.g. Cu)
T
Iron
T(oC)
Liquid
Liquid
1538
Tm
Ferrite (BCC)
1394
Austenite (FCC)
Solid
912
Ferrite (BCC)
E
2.14
L + Fe3C
4.30
F
G
M
O
0.76
0.022
Cementite Fe3C
C
6.70
Eutectoid cooling
Hypoeutectoid Alloys
Cooling below eutectoid
composition.
c: homogeneous g solid.
d: a + g coexistence. a-phase
nucleate at the grain boundaries
(Why?).
e -> f:
- crossing eutectoid isotherm will
cause all remaining g-phase into
eutectoid structure.
- a-phase that formed prior to
eutectoid isotherm are called
proeutectoid ferrite.
C 0.022
Fraction of pearlite = W p o
0.76 0.022
Fraction of proeutectoid a =
Wa '
0.76 Co
0.76 0.022
Hypereutectoid Alloys
Cooling above the eutectoid
composition
Compositions and wt% can be found
similarly as hypoeutectoid cooling.
Instead of proeutectoid a,
proeutectoid cementite appears.
Example problem
For 0.35 wt% C, at T just below
eutectoid isotherm,
determine:
a) Fractions of total ferrite and
cementite phases.
b) Fractions of proeutectoid
ferrite and pearlite.
c) Fraction of eutectoid ferrite.
Heat Treatment
Annealing
Normalizing
Hardening
Tempering
Iron Carbon
TTT
TTT Diagram
800
723
Eutectoid temperature
Austenite
Coarse
Pearlite
600
Pearlite + Bainite
500
400
300
Not an isothermal
transformation
200
100
Fine
Bainite
Ms
Austenite
Mf
Martensite
0.1
102
10
t (s)
103
104
105
800
723
Eutectoid temperature
Austenite
Pearlite
600
a + Fe3C
500
Pearlite + Bainite
400
Bainite
300
200
100
Ms
Mf
Martensite
0.1
102
10
t (s)
103
104
105
800
723
Austenite
Eutectoid temperature
600
Pearlite
500
Original TTT lines
400
300
Cooling curves
Constant rate
200
100
Ms
Mf
Martensite
0.1
T2
T1
102
10
t (s)
103
104
105
800
723
M = Martensite 600
P = Pearlite
T
500
400
300
200
Coarse P
100
M
0.1
Fine P
M +P
102
10
t (s)
103
104
105
Pearlite
[1]
[1]
g a + Fe3C
Bainite
[1]
[1]
Bainite formed at 348oC
Martensite
g ( FCC )
0.8 %C
Quench
a ' ( BCT )
0.8 %C
Possible positions of
Carbon atoms
Only a fraction of
the sites occupied
FCC
Austenite
Tetragonal
Martensite
In Pure Fe after
the Matensitic transformation
c=a
Refer Fig.9.11 in textbook
Martensite
The martensitic transformation occurs without composition change
Hardness (Rc)
60
Harness of Martensite as a
function of Carbon content
40
20
% Carbon
0.2
0.4
0.6
Coarse pearlite
16
710
Fine pearlite
30
990
Bainite
45
1470
Martensite
65
55
1990
Constituent
Tempering
a ' ( BCT )
Martensite
Temper
Cementite
MARTEMPERING
Martempering
500
Pearlite + Bainite
400
Bainite
300
Austempering
AUSTEMPERING
Ms
200
Mf
100
Martensite
0.1
10
102
t (s)
103
104
105
Advantages of Austempering:
(1) Less distortion and cracking than martempering,
(2) No need for final tempering (less time
consuming and more energy efficient)
(3) Improvement of toughness (impact resistance is
higher than the conventional quench and
tempering)
(4) Improved ductility
ALLOY STEELS
Various elements like Cr, Mn, Ni, W, Mo etc are added to plain carbon
steels to create alloy steels
The alloys elements move the nose of the TTT diagram to the right
this implies that a slower cooling rate can be employed to obtain
martensite increased HARDENABILITY
Substitutional
Element Added
Compound (new crystal structure)
Alloying elements
Case Hardening
Carburizing
Carburizing
Depth of Hardening:
There is no technical limit to the depth of hardening with carburizing
techniques, but it is not common to carburize to depths in excess of 0.050 in.
Carburizing Time:
4 to 10 hours
Carburizing Temperature:
1750 oF (above the upper critical temperature-Austenite area)
Quenching:
All of the carburizing processes (pack, gas, liquid) require quenching from the
carburizing temperature or a lower temperature or reheating and quenching.
Parts are then tempered to the desired hardness.
Pack Carburizing
In this process, the part that is to be carburized is packed
in a steel container so that it is completely surrounded by
granules of charcoal.
The charcoal is treated with an activating chemical such as
Barium Carbonate (BaCO3) that promotes the formation
of Carbon Dioxide (CO2).
This gas in turn reacts with the excess carbon in the
charcoal to produce carbon monoxide, CO.
Carbon Monoxide reacts with the low-carbon steel
surface to form atomic carbon which diffuses into the
steel.
Carbon Monoxide supplies the carbon gradient that is
necessary for diffusion.
Quenching Process:
It is difficult to quench the part immediately, as the sealed
pack has to be opened and the part must be removed from
the pack.
One technique that is used often is to slow cool the entire
pack and subsequently harden and temper the part after it is
removed from the sealed pack.
Depth of Hardening:
There is no technical limit to the depth of hardening with
carburizing techniques, but it is not common to carburize to
depths in excess of 0.050 in.
Carburizing Time:
4 to 10 hours
Gas Carburizing
Can be done with any carbonaceous gas, such as
methane, ethane, propane, or natural gas.
Most carburizing gases are flammable and controls
are needed to keep carburizing gas at 1700 oF from
contacting air(oxygen).
The advantage of this process over pack carburizing is
an improved ability to quench from the carburizing
temperature.
Conveyor hearth furnaces make quenching in a
controlled atmosphere possible.
Liquid Carburizing
Can be performed in internally or externally heated
molten salt pots.
Carburizing salt contains cyanide compounds such as
sodium cyanide (NaCN). Cycle times for liquid cyaniding
is much shorter (1 to 4 hours) than gas and pack
carburizing processes.
Disadvantage is the disposal of salt. ( environmental
problems)and cost (safe disposal is very expensive).
Nitriding
In this process, nitrogen is diffused into the surface of the steel being treated.
The reaction of nitrogen with the steel causes the formation of very hard iron and alloy
nitrogen compounds.
The resulting nitride case is harder than tool steels or carburized steels.
The advantage of this process is that hardness is achieved without the oil, water or air
quench.
Nitriding temperature is below the lower critical temperature of the steel and it is set
between 925 oF and 1050oF.
At the nitriding temperature the ammonia dissociates into Nitrogen and Hydrogen.
Carbonitriding
This process involves with the diffusion of both carbon and nitrogen into the steel surface.
The process is performed in a gas atmosphere furnace using a carburizing gas such as
propane or methane mixed with several percent (by volume) of ammonia.
Methane or paropane serve as the source of carbon, the ammonia serves as the source of
nitrogen.
Quenching is done in a gas which is not as severe as water quench. As a result of les severe
quench, there is less distortion on the material to be treated.
A typical carbonitriding system is shown in the following slide. Case hardnesses of HRC 60 to
65 are achieved at the surface.( Not as high as nitrided surfaces.)
One of the advantages of this process is that it can be applied to plain carbon steels which
give significant case depths.
Cyaniding
The source of the diffusing element in this method is a molten cyanide salt such
as sodium cyanide.
Advantage of this method is the short time it requires to complete the diffusion,
otherwise it should be avoided because of high distortion.
Induction Hardening
Every electrical conductor carrying a current has a magnetic field surrounding the
conductor.
Since the core wire is a dead-end circuit, the induced current cannot flow anyplace,
so the net effect is heating of the wire.
The induced current in the core conductor alternates at frequencies from 60 cycles
per second (60 Hz) to millions of Herz.
The resistance to current flow causes very rapid haeting of the core material.
Heating occurs from the outside inward. Indusction hardening process includes
water quench after the haeting process.
The big advantage of this system is its speed and ability to confine haeting on small
parts.
Flame hardening
Flame hardening is the process of selective hardening with a combustible gas flame as
the source of heat for austenitizing. (The material should have at least 0.40 % Carbon
content to allow hardening.)
The heating media can be oxygen acetylene, propane, or any other combination of fuel
gases that will allow reasonable heating rates.
This procedure is applied to the gear teeth, shear blades, cams, ways on the lathes, etc.
For best results the hardness depth is 3/16 inch.There are three methods:
(1) SPOT Flame Hardening: Flame is directed to the spot that needs to be heated and
hardened.
(2) SPIN Flame Hardening: The workpiece is rotated while in contavct with the flame
(3) PROGRESSIVE Flame Hardening: The torch and the quenching medium move across
the surface of the workpiece.