Student Guide Book

Subject: Physical Metallurgy 1

(MMS 210802)

Prof. Dr. Ir. Bondan T. Sofyan, M.Si.

Department of Metallurgy and Materials Engineering

Faculty of Engineering

University of Indonesia
2010
Preface

Physical Metallurgy 1 is the basic knowledge in the stream of Metallurgy and Materials
Engineering. It covers the microscopic phenomenon and mechanism which control behaviour of
materials. It lays foundation for further subjects related to manufacturing and processing,
because it studies the relationship between structure, processing, properties and performance of
materials.

This guidebook is intended to provide guidelines for students taking this subject. By reading this
guidebook, it is expected that students understand the learning objectives and should be able to
prepare themselves prior to each topic. It is also to guide students in working in group so that
they may make the most of the group exercises. Any comments, critics, correction to this
guidebook is thankfully accepted.

Depok, September 2010

Lecturer,

Dr. Ir. Bondan T. Sofyan, M.Si.

NIP. 19690421 199202 2001
Table of Content

Endorsement Page
Preface
Table of Content
Chapter 1. General Information 1
Chapter 2. Learning Objectives 4
Chapter 3. Outlines of Subject 5
Chapter 4: Teaching Methods and Learning Activities 7
Chapter 5: Exercises and Assignments 9
Chapter 6. Assessment 15
References 18
General Information
Chapter

1
1. Subject : Physical Metallurgy
2. Subject Code : MMS 210802
3. Semester : 3
4. Credit : 3 SKS
5. Year : 2010/2011
6. Type of Subject : Basic Competence Subject (Mata Kuliah Dasar Keahlian)
7. Prerequisite : Mineralogy and Crystallography
8. Relationship between this subject and other subjects in Metallurgy and Materials Engineering

Student Guide Book Physical Metallurgy 1

 Figure 2. Relationship of this subject with other subjects in Dept. of Metallurgy and Materials
Engineering

9. Lecturer : Prof. Dr. Ir. Bondan T. Sofyan, M.Si.

2nd Floor, Dept. Metallurgy and Materials Engineering,
Phone: 786 3510, bondan@metal.ui.ac.id

10. Description of the subject

As a materials engineer, you must have understanding on the structure, the processing /fabrication and
degradation of materials which overall determine the performance of the material during application.
This is illustrated in Figure 3.

ore/feedstock

processing

atoms,
molecules, components
microstructure materials fabrication devices
electrons,
crystals structures

protection against
degradation

recycling

Figure 3. Scope of metallurgy and materials engineering

Student Guide Book Physical Metallurgy 2

Physical Metallurgy covers the basic of structure of solid materials, including the crystal structure,
defects, and how they are determined by many factors, such as: processing routes, type of materials,
alloying, etc. The structure of materials will also determine how a material can be utilized and how it
reacts to loading and other external factors. So in fact, Physical Metallurgy covers the interrelationship
between microstructure materials fabrication, as shown in Figure 3.

Learning activities will be conducted through various method, which consists of: interactive lecture,
question-based learning, discussion, demonstration and unguided structured assignments. Assessment will
be made continuously through a set of exercises, group discussion, mid semester exam and final exam.

This guide book will help students prepare for learning activities throughout the semester for this subject.
Preparation may include reading, preparation of worksheet and practice. Achievement of students will
entirely be due to their activities and preparation. Construction of knowledge will be made through
exercises, and questions available in this book. Students are expected to do the exercises, and they may
move to further stage as they ready for that. Overall, students are expected to be active learners by
acquiring knowledge through thinking and exercising. Students may also use this guidebook to self-assess
their achievement.

Student Guide Book Physical Metallurgy 3

Learning Objectives
Chapter

2
2.1. Terminal Learning Objectives

Upon completion of this subject students are expected to be able to design structures of materials in order
to obtain particular characteristics of materials.

2.2. Supportive Learning Objectives

1. Students are expected to understand how dislocations form and move in crystalline materials.
2. If the students are given a particular crystal structure (FCC, BCC or CPH) of materials they can
examine slip system for dislocation on the structure and how it affects mechanical properties of the
materials.
3. Students are able to distinguish fatigue and static fractures in term of dislocation movement and
fracture appearance.
4. If students are given a fatigue fracture surface, they can analyze the initial crack and predict the type
of loading that may cause it.
5. Students can differentiate movement of dislocations at low and high temperature, which may lead to
creep mechanism.
6. Students are expected to be able to illustrate 6 (six) mechanisms to hinder dislocation movements in
order to increase strength of materials.
7. If the students are given various microstructures of materials, they may predict the difference of
mechanical properties of each material.
8. If students are given information on processing routes of materials, they may predict the mechanical
properties of the materials.
9. If low-strength materials are given to the student, they may design a set of process to increase the
strength of the materials.

Student Guide Book Physical Metallurgy 4

Outline of Subject
Chapter

3
Supportive Topic Sub-topic Reference
Learning
Objective
1, 2 1. Review on crystal 1.1. Review on crystal structures [1] Chap.3
structure
2. Crystal Defects 2.1. Introduction [1] Chap. 4
2.2. Point Defects (0-dimension) [2]
2.3. Line Defects (Dislocations) (1- [4]
dimension): [6]
2.3.1. Edge Dislocations
2.3.2. Screw Dislocations
2.3.3. Burgers Vector
2.3.4. Movement of Dislocations
2.3.5. Energy of Dislocation
2.3.6. Dislocations in FCC, BCC and HCP
structures
2.3.7. Effects of dislocations in properties
of materials
2.4. Planar Defects (2-dimension)
3, 4 3. Fatigue and 3.1. Introduction [1] Chap. 8
Fracture of Materials 3.2. Fatigue stress [5]
3.3. Fatigue failure
3.4. Fatigue test
5 4. Creep of Materials 4.1.Creep and high temperature failure [1] Chap. 8
4.2.Creep testing [2]
4.3.Stress rupture life time behaviour [5]
4.4.Factors affecting creep
4.5.Creep mechanisms
4.6.Materials for high creep resistance
6,7,8,9 5. Strengthening 5.1.Introduction [1] Chap.7
Mechanism 5.2.Strain (Work) hardening [2]
5.3.Grain boundary strengthening [3]
5.4.Solid Solution strengthening [4]
5.5.Precipitation (two-phase) Strengthening [5]
5.6.Steel Alloys Strengthening
5.7.Composite Strengthening

Student Guide Book Physical Metallurgy 5

Texbooks and Reference Books:
[1] Callister, W.D, Materials Science and Engineering: An Introduction, 7 th ed., Wiley., 2006
[2] Abbaschian, R and Reed-Hill, R.E, Physical Metallurgy Principles, 4th ed, Brooks Cole, 2008.
[3] Smallman, R.E and Bishop, R.L, Modern Physical Metallurgy and Materials Engineering, 6th
ed., Butterworth Heinemann, 1999.
[4] Philips, R, Crystals, Defects and Microstructures, Modeling Across Scale, Cambridge Univ. Press,
2001.
[5] Mangonon, P. L, The Principles of Materials Selection for Engineering Design, Prentice-Hall, 1998
[6] Hull, D and Bacon, D,J, Introduction to Dislocations, 4th ed., Pergamon, 2001

Student Guide Book Physical Metallurgy 6

 Teaching Methods and
Chapter

4
Learning Activities

Week/Date Subtopic Supportive Learning Methods Media/

Learning Orientation Exercise Feedback Module
Objective (O) (L) (U)
1/ 1. Review on crystal 1 Interactive Individual Group WB,I/
2 Sep 10 structure Lecture exercise, exercise Module 1
2.1. Introduction Group
2.2. Point Defects (0-d) discussion
2.3. Line Defects , Self
(Dislocations) (1-d) study
2.4. Planar Defects (2-d)
2/ IDUL FITRI BREAK 2 Interactive Group WB,I /
9 Sep 10 Lecture exercise, Module 2
Self study
3/ 2.3.1. Edge Dislocations 2 Interactive Group Journal WB,I /
16 Sep 10 2.3.2. Screw Dislocations Lecture exercise, review, Module 2
2.3.3. Burgers Vector Group Presentation
2.3.4. Movement of discussion
Dislocations , Self
2.3.5. Energy of Dislocation study

4/ 2.3.6. Dislocations in FCC, 2 SCELE SCELE SCELE SCELE/

23 Sep 10 BCC and HCP Module 2
structures
2.3.7. Effects of dislocations
in properties of
materials
5/ 3.1. Introduction 3, 4 Interactive Group WB,I /
30 Sep 10 3.2. Fatigue stress Lecture, exercise, Module 3
3.3. Fatigue failure Group
3.4. Fatigue test discussion
, Case
study
6/ 3.5. Case study in fatigue 5 Interactive SCELE SCELE WB,I /
7 Oct 10 Lecture, Module 4
SCELE

Student Guide Book Physical Metallurgy 7

 7/ 4.1. Creep and high temperature 5 Group Study Study case, WB,I /
14 Oct 10 failure discussion, case, SCELE Module 4
4.2. Creep testing SCELE SCELE
4.3. Stress rupture life time
behaviour
4.4. Factors affecting creep
4.5. Creep mechanisms
4.6. Materials for high creep
resistance
8/ Review 5 Lecture, SCELE SCELE WB, I/
21 Oct 10 SCELE Module 4
9/ Midsemester Exam
28 Oct 10
10/ 5.1. Introduction 6, 7 Interactive Self SCELE WB, I/
4 Nov 10 5.2. Strain (Work) hardening Lecture, study, Module 5
Midsemester exam SCELE Virtual
lab,
SCELE
11/ Guest lecture by Dr. H. Enwiden Interactive I
11 Nov 10 Rachmantio, founding father of students Lecture
DTMM view on
the real
materials
world
12/ 5.3. Grain boundary 7,8 Interactive Self WB,I /
18 Nov 10 strengthening Lecture study, Module 5
5.4. Solid Solution Virtual
strengthening lab

13/ 5.5. Precipitation (two-phase) 7,8 Interactive Self Group WB,I /

25 Nov 10 Strengthening Lecture study, exercise Module 5
Group
Exercise
14/ 5.6. SteelAlloys Strengthening 9 Interactive Self study WB,I /
2 Dec 10 Lecture Module 5
15/ 5.7. Composite Strengthening 9 Interactive Self study WB,I /
10 Dec 10 Review Lecture Module 5
16 Final exam period, see the
17 Exam schedule in SIAK NG

Student Guide Book Physical Metallurgy 8

 Exercises and Assignments
Chapter
Subtopic Assignment

5
Week Group Assignment Individual
Assignment
1/ 1. Review on crystal structure Assignment 1, due
2 Sep 10 2.1. Introduction date: 2 Sept 10 in class
2.2. Point Defects (0-d)
2.3. Line Defects (Dislocations) (1-d)
2.4. Planar Defects (2-d)
2/ IDUL FITRI BREAK
9 Sep 10
3/ 2.3.1. Edge Dislocations Journal review, due Reading: Ref. [2]
16 Sep 10 2.3.2. Screw Dislocations date: 30 Sep10 in (Reed-Hill) Chapt. 4
2.3.3. Burgers Vector class. and 5.
2.3.4. Movement of Dislocations
2.3.5. Energy of Dislocation

4/ 2.3.6. Dislocations in FCC, BCC and HCP Assignment 2, due

23 Sep 10 structures date: 30 Sep 10 in
2.3.7. Effects of dislocations in properties of class.
materials
5/ 3.1. Introduction Case study, due Reading: Ref. [2]
30 Sep 10 3.2. Fatigue stress date:7 Oct 10 in class (Reed-Hill) Chapt. 19.
3.3. Fatigue failure
3.4. Fatigue test
6/ 3.5. Case study in fatigue
7 Oct 10
7/ 4.1. Creep and high temperature failure Assignment 3, due
14 Oct 10 4.2. Creep testing date: 14 Oct 10 in
4.3. Stress rupture life time behaviour class
4.4. Factors affecting creep
4.5. Creep mechanisms
4.6. Materials for high creep resistance
8/ Review
21 Oct 10
9/ Midsemester Exam Assignment 4: due
28 Oct 10 date: 4 Nov 10 in class
10/ 5.8. Introduction Assignment 5, due
4 Nov 10 5.9. Strain (Work) hardening date: 11 Nov 10 in
Midsemester exam class
11/ Guest lecture by Dr. H. Rachmantio, founding
11 Nov 10 father of DTMM
12/ 5.10. Grain boundary strengthening Assignment 6, due
18 Nov 10 5.11. Solid Solution strengthening date: 2 Dec 10 in
class + 1 group
Presentation
13/ 5.12. Precipitation (two-phase) Strengthening
25 Nov 10 5.13. SteelAlloys Strengthening
5.14. Composite Strengthening

Student Guide Book Physical Metallurgy 9

 14/ Presentation
2 Dec 10
15/ Review
10 Dec 10
16 Final exam period, see the Exam schedule in SIAK
NG
17

Assignment 1: Review on Crystal Structure

1. Face Centered Cubic

a. Draw the hard sphere model of FCC.
b. Calculate the atomic packing factor (APF).
c. Draw the plane (111), (100) and (101) in FCC structure.
d. Calculate the planar density of plane (111), (100) and (101)
e. Calculate the linear density of direction [111], [100], [101]
f. Which is the densest plane and direction in FCC?

2. Body Centered Cubic

a. Draw the hard sphere model of BCC.
b. Calculate the atomic packing factor (APF).
c. Draw the plane (100) and (110) in BCC structure.
d. Calculate the planar density of plane (100) and (110)
e. Calculate the linear density of direction [100], [110]
f. Which is the densest plane and direction in BCC?

3. Close Packed Hexagonal

a. Draw the hard sphere model of CPH.
b. Calculate the atomic packing factor (APF).
c. Draw the plane (10 1 0) and (0001) in CPH structure.
d. Calculate the planar density of plane (10 1 0) and (0001)
e. Calculate the linear density of direction [10 1 0], [11 2 0] and [01 1 1 ]
f. Which is the densest plane and direction in CPH?

Understanding on the densest plane and direction in crystal structure is essential in understanding
dislocations and their movement.

Assignment 2: Partial Dislocations and Cross-Slip

In an FCC metal, a screw dislocation approaches an obstacle and is momentarily stuck. After the stress is
increased, the screw dislocation can bypass the obstacle by cross slipping:

If the same screw dislocation were initially dissociated into two partials:

Student Guide Book Physical Metallurgy 10

Can cross slip happen in this scenario? Why or why not? Discuss in your group and report your group
results of discussion.

Assignment 2: Perfect Dislocation and Its Movement

Make a Thompson's tetrahedron from a piece of cardboard. Thompson's tetrahedron is a tetrahedron
consists of 4 different (111) type planes in a FCC crystal. Draw ALL vectors of dislocation on each
plane of the tetrahedron, containing [110] and 1/6 [121] directions. This construction will help you in
understanding the perfect dislocations in FCC system.

Assignment 3: Stress Rupture Lifetime

Using the LarsonMiller data for S-590 iron shown in the figure above, predict the time to rupture for a
component that is subjected to a stress of 140 MPa(20,000 psi) at 800C (1073 K).

Assignment 4: Strain hardening

Two previously undeformed specimens of the same metal are to be plastically deformed by reducing their
cross-sectional areas. One has a circular cross section, and the other is rectangular; during deformation the
circular cross section is to remain circular, and the rectangular is to remain as such. Their original and
deformed dimensions are as follows:
Circular (diameter, mm) Rectangular (mm)
Original dimensions 15.2 125 x 175
Deformed dimensions 11.4 75 x 200
Which of these specimens will be the hardest after plastic deformation, and why?

Assignment 5: Virtual Lab

Open:
http://www.aluminium.matter.org.uk/content/html/eng/default.asp?CATID=64 &PAGEID=997788167
Do the virtual experiment there to prove that Hall-Petch equation does work!

Assignment 6: Precipitation strengthening

Student Guide Book Physical Metallurgy 11

An as-cast Al-6Si-2Cu-0.1Mg-12Zn-0.6Fe-0.2Mn alloy (wt. %) was solution treated at 525 oC for 1 h ,
quenched and aged at 200 oC up to peak hardness. The hardness of the alloy increased from 65 BHN to 95
BHN as shown by the age-hardening curve in Fig. 1. The microstructures at as-cast and as-peak aged, as
well as micro-compositional analysis of each phase, are shown in Fig. 2 (a) and (b), respectively.
Describe:
a. Why the hardness of the alloy increased?
b. Describe the strengthening mechanisms that contribute to the increase in hardness of the alloy.

Fig.1. Age hardening curve at 200 oC for the alloy

1 1
3

3
2 4

2
x

Fig.2 (a) As-cast microstructure (65 BHN), (b) peak-aged microstructure (95 BHN)
Komposisi (% berat) Indikasi Fasa
No. Warna
Al Si Cu Fe Mn Zn Terbentuk
As-cast : 1 1,40 98,60 - - - - Abu-abu tua Kristal silicon
2 51,41 18,52 - 24,17 5,89 - Abu-abu muda Al-Fe-Mn-Si
3 47,30 - 52,70 - - - Putih CuAl2
4 85,88 - - - - 14,12 Abu-abu Matriks kaya Al

Komposisi (% berat) Indikasi Fasa

No. Warna
Al Si Cu Fe Mn Zn yang Terbentuk
Peak aged :
1 3,10 96,90 - - - - Abu-abu tua Kristal silicon
2 63,83 4,38 0,18 23,94 2,10 5,58 Abu-abu muda Al-Fe-Mn-Si
3 80,27 2,27 0,31 - - 17,15 Abu-abu Matriks kaya Al

Student Guide Book Physical Metallurgy 12

 x 73,53 3,12 3,79 - - 19,56 Putih -

Student Guide Book Physical Metallurgy 13

Case study: Fatigue
Using the chart of fracture surface appearance, identify the type of load, nominal stress and stress
concentration level for the two shaft examples given.

Student Guide Book Physical Metallurgy 14

Journal Review:
A recent research article is provided
Your assignment is to read the article carefully, and think critically about what you have read.
You will then prepare a short review of the article, in about 3 pages.
About the first third of your review should be a synopsis of the paper, inclusive of methods and
main results. The remainder of the review should offer a critique of the paper, and present some
creative thoughts for future questions to be addressed.

Student Guide Book Physical Metallurgy 15

Assessment and Code of Conduct
Chapter

6
6.1. Instrument
1. Group assignments
2. Individual assignments
3. Journal review
4. Case study (short report of case study)
5. Midsemester exam (written test, restricted response essay, extended response essay)
6. Final exam (written test, restricted response essay, extended response essay)

1.2. Assessment

No Component Weight
1. Group and individual assignments 10 %
2. Journal review 15 %
3. Case study 15 %
4. Mid semester exam 30 %
5. Final exam 30 %
Total 100 %

6.3. Grading

85 80-84.9 75-79.9 70-74.9 65-69.9 60-64.9 55-59.9 50-54.9 40 49.9 0-40

A A- B+ B B- C+ C C- D E

6.4. Code of Conduct

o No cheating. Cheating will be sanctioned with E mark.
o No sandals
o No smoking
o Attendance is required min 75 %. Why? Knowledge can be transferred through handout, but
values cant be! So, please come and we may share good values in life.

Student Guide Book Physical Metallurgy 16

Matrix for Mid semester exam

Cognitive Instrument Number of Weight

Domain 1 question/problem
C2 Restricted response essay (Interpret 2-3 45 %
(comprehension) information on a graph and details of
phenomenon)
C3 (application) Restricted response essay (Apply a 1-2 20%
concept on real case in manufacturing)
C4 (analysis) Extended response essay (Analysis of a 1-2 35%
case)

Total 4-7 100%

6.6. Matrix for Final Exam

Cognitive Instrument Number of Weight

Domain question/prob
lem
C3 (application) Restricted response essay (Apply a 2-3 30 %
concept on real case in manufacturing)
C4 (analysis) Restricted response essay (Analysis of 1-2 45 %
a case)
C6 (evaluation) Extended response essay (Evaluation 1 25%
of a given set of data and
condition that possesses
the best properties)

Total 46 100%

6.7. Examples of questions for mid semester and final exams.

Restricted response essay

C2 (Comprehension)
1. Briefly explain the differences between recovery and recrystallization processes.
2. What is the driving force for recrystallization?
3. Is it possible for an undeformed specimen to be recrystallized? Explain why.

C3 (Application)
1. When making hardness measurements, what will be the effect of making an indentation very close to
a preexisting indentation?
2. Why a tool steel containing 0.9 % C, 0.5 % Cr, 0.1 % V and 0.5 % W (wt. %) is suitable as wear-
resistant material?

1
Bloom Taxonomy

Student Guide Book Physical Metallurgy 17

Extended response essay
C4 (Analysis)

A stainless steel propeller shaft on a large yacht

failed after two years in service. The loading
conditions were rotating bending. The shaft is
made of high nitrogen austenitic stainless steel,
and the fracture surface is as shown, which is
typical of a fatigue failure. On the fractography,
show where the crack initiation, crack propagation
and the final failure area.
Picture taken from:
http://www.fract.ses.soton.ac.uk/

C6 (Evaluation)
a b

Figure 1 above are TEM micrographs of Al-

4Cu-0.3Mg (wt. %) aged at 200 oC for different duration.
a. Based on the size and distribution of the precipitates, compare the hardness of the alloy in Figure 1 (a)
and 1 (b). Give reason for your answer.
b. Predict the stage of ageing of the two samples (a) and (b) and evaluate their mechanical properties
c. Which condition will you choose if the materials to be used as fuselage of aircraft. Give scientific
reason for your answer.

Student Guide Book Physical Metallurgy 18

Figure 1.
Structure of
curriculum
of Dept.
Metallurgy
and

References

Textbooks and References

[1] Callister, W.D, Materials Science and Engineering: An Introduction, 7 th ed., Wiley., 2006
[2] Abbaschian, R and Reed-Hill, R.E, Physical Metallurgy Principles, 4th ed, Brooks Cole, 2008.
[3] Smallman, R.E and Bishop, R.L, Modern Physical Metallurgy and Materials Engineering, 6th
ed., Butterworth Heinemann, 1999.
[4] Philips, R, Crystals, Defects and Microstructures, Modeling Across Scale, Cambridge Univ. Press,
2001.
[5] Mangonon, P. L, The Principles of Materials Selection for Engineering Design, Prentice-Hall, 1998
[6] Hull, D and Bacon, D,J, Introduction to Dislocations, 4th ed., Pergamon, 2001

Related Journals
[7] Acta Materialia, Elsevier
[8] Materials Transaction, American Society of Materials
[9] Journal of Materials Science, Springer

Student Guide Book Physical Metallurgy 19