Académique Documents
Professionnel Documents
Culture Documents
OF
BATAAN, CITY
OF
BALANGA C-2100
Introduction
neer
ing
becomes necessary that the designer select a proper material for each
machine member. This involves the consideration of such factors as the
engineering properties of the available materials; the weight, size, and
shape of the machine member as well as the loads that it must carry; cost
Mat
erial
ductility,
toughness,
resilience,
fatigue
resistance,
shock
Page 76
Materials
play
an
important
role
in
the
construction
and
on the required
properties. Engineers will select a particular grade of
REPUBLIC OF THE PHILIPPINES
material BATAAN
based on itsPENINSULA
properties suchSTATE
as malleability
or tensile strength.
UNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
Composites
comprise
two materials,AND
suchARCHITECTURE
as a metallic mesh and a resin,
COLLEGE
OF ENGINEERING
the combination of which also depends on the properties required.
MECHANICAL ENGINEERING DEPARTMENT
merely to
fill up space or for aesthetic qualities. Members must frequently
REPUBLIC OF THE PHILIPPINES
be designed
to also PENINSULA
resist corrosion. Sometimes
temperature effects are
BATAAN
STATE UNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
more important
design
than stress
strain. So many other factors
COLLEGEinOF
ENGINEERING
ANDand
ARCHITECTURE
besides stress and strain may govern the design of parts that the designer
MECHANICAL ENGINEERING DEPARTMENT
must have the versatility that comes only with a broad background in
materials and processes.
Page 76
ENGINEERING MATERIALS
OF
BATAAN, CITY
OF
BALANGA C-2100
NON-METALLIC
COLLEGE OF METALLIC
ENGINEERING AND ARCHITECTURE
MECHANICAL ENGINEERING DEPARTMENT
PLASTICS
NON-
FERROUS
FERROUS
ALLOYS
CAST IRON
GRAY CAST
IRON
-- GRAY
CAST IRON
- WHITE CAST IRON
MALLEABLE IRON
IRON
-- MALLEABLE
DUCTILE IRON
IRON
-- DUCTILE
STEEL
- PLAIN CARBON STEEL
- ALLOY STEEL
- CASE HARDENING
STEEL
- STAINLESS STEEL
-HIGH
STRENGTH LOW
-HIGH STRENGTH
LOW
ALLOY
STEEL
WROUGHT
IRON
-- ZINC
ZINC -BASED
-BASED 'DIE
'DIE
CASTING'
ALLOYS
ALLOYS
- MAGNESIUM ALLOYS
-- BRASS
BRASS
- TIN BRONZE
-- TIN
TIN -- LEAD
LEAD ALLOYS
ALLOYS
- ALUMINUM BRONZE
- COPPER- NICKEL
ALLOYS
- ALUMINUMALLOYS
METALS
- ALUMINUM
- CADMIUM
- CHROMIUM
COBALT
-- COBALT
- COPPER
- GOLD
- LEAD
MANGANESE
- NICKEL
PLATINUM
-- PLATINUM
- SILVER
- TIN
- TITANIUM
- TUNGSTEN
- VANADIUM
- ZINC
THERMOSETTIN
THERMOSETTIN
GS
-THERMOPLASTI
CS
CS
CERAMICS
- GLASS
PORCELAIN
-- PORCELAIN
CEMENTED
-- CEMENTED
CARBIDES
COMPOSITES
- CARBON FIBRE
-- CONCRETE
CONCRETE
- GLASS REINFORCED
PLASTIC
PLASTIC
Page 76
The metals
may be further
classified as:
BATAAN
PENINSULA
STATE
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
UNIVERSITY
BALANGA C-2100
c) Ferrous
metals
and
COLLEGE
OF ENGINEERING
AND ARCHITECTURE
d) Non-ferrous metals.
The ferrous metals are those which have the iron as their main
constituent, such as cast iron, wrought iron and steel.
The non-ferrous metals are those which have a metal other than iron
as their main constituent, such as copper, aluminum, brass, tin, zinc, etc.
SELECTION OF MATERIALS FOR ENGINEERING PURPOSES
Page 76
The important properties, which determine the utility of the material, are
physical, chemical and mechanical properties.
OF
BATAAN, CITY
OF
BALANGA C-2100
mass (m)
volume (V )
Relative density ( d )=
density of thematerial
0
density of water at 4 C
2. Electrical Conductivity
Electrical conductivity is a measure of how well a material
accommodates the movement of an electric charge. It is the ratio of the
current density to the electric field strength.
3. Melting temperature of material
Page 76
4. Semiconductors
REPUBLIC OF THE PHILIPPINES
Semiconductor
materials are capable
of UNIVERSITY
having their conductors
BATAAN PENINSULA
STATE
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
properties
changed
during manufacture.
Examples of semiconductor
COLLEGE
OF ENGINEERING
AND ARCHITECTURE
materials are silicon and germanium. They are used extensively in the
MECHANICAL ENGINEERING DEPARTMENT
8. Temperature stability
Page 76
Mechanical
Properties of Metals
REPUBLIC OF THE PHILIPPINES
The BATAAN
mechanicalPENINSULA
properties of the
metals
are those which are
STATE
UNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
associated
with the
of the material
to resist mechanical forces and
COLLEGE
OF ability
ENGINEERING
AND ARCHITECTURE
load. These mechanical properties of the metal include strength,
stiffness,
elasticity,
plasticity,
ductility,
brittleness,
malleability,
commonly
used
in
engineering
practice
(in
order
of
diminishing
ductility) are mild steel, copper, aluminum, nickel, zinc, tin
REPUBLIC OF THE PHILIPPINES
and lead.
BATAAN
OF
BATAAN, CITY
OF
BALANGA C-2100
resistMshock
AIN CAMPUS
and, impact
PROVINCEloads.
OF BATAAN
It is, measured
CITY OF BALANGA
by the
C-2100
amount of energy
COLLEGE OF ENGINEERING AND ARCHITECTURE
absorbed per unit volume within elastic limit. This property is essential
MECHANICAL ENGINEERING DEPARTMENT
Metals
are usually inclined
REPUBLIC OF THE PHILIPPINES
to
electron
loss, reacting
with PENINSULA
oxygen in the STATE
air to UNIVERSITY
form oxides over various
BATAAN
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
timescales
(iron OF
rusts
over years, AND
while
potassium burns in seconds).
COLLEGE
ENGINEERING
ARCHITECTURE
Examples:
appearance
and
good
conductivity
for
many
decades
Page 76
2. Toxicity.
It is the degree to which something is able to produce illness
REPUBLIC OF THE PHILIPPINES
or damage
to an exposed
organism.STATE
BATAAN
PENINSULA
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
UNIVERSITY
BALANGA C-2100
Stability.
Tendency
of
a material to
Page 76
OF
BATAAN, CITY
OF
BALANGA C-2100
COLLEGE
OF ENGINEERING
AND ARCHITECTURE
The
term 'ferrous'
comes from
a Latin word ferrum, meaning
MECHANICAL
ENGINEERING
'containing iron'.
Hence, ferrous
metals are DEPARTMENT
all those metals that contain
iron. Ferrous metals may contain small amounts of other elements such
as carbon or nickel, in a specific proportion that are added to achieve the
desired properties. All the ferrous metals are generally magnetic and
have high tensile strength. Now that you know what ferrous metals are,
let us have a look at a ferrous metals list.
Most commonly used ferrous metals are Mild Steel, High Speed
Steel, Stainless Steel, High Tensile Steel and Cast Iron.
1. Cast Iron
The cast iron is obtained by re-melting pig iron with coke and
limestone in a furnace known as cupola. It is primarily an alloy of iron
and carbon. The carbon contents in cast iron vary from 1.7 per cent to
4.5 per cent. It also contains small amounts of silicon, manganese,
phosphorous and sulphur. The carbon in a cast iron is present in either of
the following two forms:
a) Free carbon or graphite, and
b) Combined carbon or cementite.
Since the cast iron is a brittle material, therefore, it cannot be used
in those parts of machines which are subjected to shocks. The properties
of cast iron which make it a valuable material for engineering purposes
Page 76
are its low cost, good casting characteristics, high compressive strength,
wear resistance and excellent machinability. The compressive strength of
cast iron is much greater than the tensile strength. Following are the
values of ultimate strength of cast iron:
Chapter 1: Engineering Materials
Page 76
Compressive
strength = 400
to 1000 UNIVERSITY
MPa
BATAAN
PENINSULA
STATE
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
Shear strength
= 120 MPa
COLLEGE
OF ENGINEERING
AND ARCHITECTURE
Page 76
OF
BATAAN, CITY
OF
BALANGA C-2100
against metal chills or by regulating analysis. The chills are used when
a hard, wear resisting surface is desired for such products as for car
wheels, rolls for crushing grains and jaw crusher plates.
c. Chilled
cast iron. It is a white cast iron produced by quick cooling
REPUBLIC OF THE PHILIPPINES
of molten
iron. The
quick cooling STATE
is generally
called chilling and the
BATAAN
PENINSULA
UNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
castCOLLEGE
iron so produced
is called chilled
cast iron. All castings are chilled
OF ENGINEERING
AND ARCHITECTURE
at their outer skin by contact of the molten iron with the cool sand in
MECHANICAL ENGINEERING DEPARTMENT
and
sometimes
chilled
becomes
accidently
to
for castings
requiring shock and impact resistance along with good
REPUBLIC OF THE PHILIPPINES
machinability,
as hydraulic STATE
cylinders, UNIVERSITY
cylinder heads, rolls for
BATAANsuch
PENINSULA
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
rolling
mill andOF
centrifugally
castAND
products.
COLLEGE
ENGINEERING
ARCHITECTURE
2. Sulphur. It makes the cast iron hard and brittle. Since too much
sulphur gives unsound casting, therefore, it should be kept well
below 0.1% for most foundry purposes.
3. Manganese.
It makes the cast iron white and hard. It is often kept
REPUBLIC OF THE PHILIPPINES
below
0.75%.PENINSULA
It helps to exert
a controlling
influence over the
BATAAN
STATE
UNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
harmful
effect
of sulphur.
COLLEGE
OF ENGINEERING
AND ARCHITECTURE
4. Phosphorus. It aids fusibility and fluidity in cast iron, but induces
MECHANICAL ENGINEERING DEPARTMENT
3. Wrought Iron
It is the purest iron which contains at least 99.5% iron but may
contain up to 99.9% iron. The typical composition of a wrought iron is
Carbon = 0.020%, Silicon = 0.120%, Sulphur = 0.018%, Phosphorus =
0.020%, Slag = 0.070%, and the remaining is iron.
The wrought iron is produced from pig iron by remelting it in the
puddling furnace of reverberatory type. The molten metal free from
impurities is removed from the furnace as a pasty mass of iron and slag.
The balls of this pasty mass, each about 45 to 65 kg are formed.
These balls are then mechanically worked both to squeeze out the
slag and to form it into some commercial shape.
The wrought iron is a tough, malleable and ductile material. It
cannot stand sudden and excessive shocks. Its ultimate tensile strength
Page 76
is 250 MPa to 500 MPa and the ultimate compressive strength is 300
MPa.
It can be easily forged or welded. It is used for chains, crane hooks,
railway couplings, and water and steam pipes.
Chapter 1: Engineering Materials
Page 76
4. Steel
BATAAN
OF
BATAAN, CITY
OF
BALANGA C-2100
ItCOLLEGE
is an alloy
of iron and carbon,
with carbon content up to a
OF ENGINEERING
AND ARCHITECTURE
maximum of 1.5%. The carbon occurs in the form of iron carbide,
MECHANICAL ENGINEERING DEPARTMENT
because of its ability to increase the hardness and strength of the steel.
Other elements e.g. silicon, sulphur, phosphorus and manganese are also
present to greater or lesser amount to impart certain desired properties
to it. Most of the steel produced now-a-days is plain carbon steel or
simply carbon steel.
1.
2.
2.
3.
4.
5.
6.
4.
parts.
High
1.
2.
3.
4.
5.
molybdenum.
Utilize as cutting tools, dies for forming and shaping materials.
and
5. High Strength,
Low
Alloy Steels (HSLA)
BATAAN
PENINSULA
STATE
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
UNIVERSITY
BALANGA C-2100
COLLEGE
OF ENGINEERING
AND ARCHITECTURE
Contains
other alloying
elements such
as copper, vanadium, nickel and
MECHANICAL
ENGINEERING
molybdenum
combined in DEPARTMENT
concentration high as 10wt%
4. RPhosphorus.
It makes the steel brittle. It also produces cold
EPUBLIC OF THE PHILIPPINES
shortness inPENINSULA
steel. In low carbon
steels,UNIVERSITY
it raises the yield
BATAAN
STATE
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
point
BALANGA C-2100
and improves
the resistanceAND
to atmospheric
corrosion. The sum of
COLLEGE
OF ENGINEERING
ARCHITECTURE
carbon and phosphorus usually does not exceed 0.25%.
MECHANICAL ENGINEERING DEPARTMENT
1. RNickel.
It increases the strength and toughness of the steel.
EPUBLIC OF THE PHILIPPINES
These steelsPENINSULA
contain 2 to 5% nickel
and UNIVERSITY
from 0.1 to 0.5% carbon.
BATAAN
STATE
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
hardness with high strength and high elastic limit. It also imparts
corrosion-resisting properties to steel. The most common chrome
steels contains from 0.5 to 2% chromium and 0.1 to 1.5% carbon.
The chrome steel is used for balls, rollers and races for bearings
3. Tungsten. It prohibits grain growth, increases the depth of
hardening of quenched steel and confers the property of
remaining hard even when heated to red color. It is usually used
in conjunction with other elements. Steel containing 3 to 18%
tungsten and 0.2 to 1.5% carbon is used for cutting tools. The
principal uses of tungsten steels are for cutting tools, dies,
valves, taps and permanent magnets.
4. Vanadium. It aids in obtaining a fine grain structure in tool steel.
The addition of a very small amount of vanadium (less than 0.2%)
produces a marked increase in tensile strength and elastic limit in
low and medium carbon steels without a loss of ductility.
5. Manganese. It improves the strength of the steel in both the hot
rolled and heat treated condition. The manganese alloy steels
containing over 1.5% manganese with a carbon range of 0.40 to
Page 76
0.55% are used extensively in gears, axles, shafts and other parts
where high strength combined with fair ductility is required.
6. Silicon. The silicon steels behave like nickel steels. These steels
have a high elastic limit as compared to ordinary carbon steel.
Chapter 1: Engineering Materials
Page 76
OF
BATAAN, CITY
OF
BALANGA C-2100
machinery,
in I.C. engines,
springs and corrosion resisting
COLLEGE
OFvalves
ENGINEERING
AND ARCHITECTURE
materials.
8. Stainless Steel
Highly resistant to corrosion.
11wt% chromium required.
Applications: gas turbines, steam boilers, furnaces, aircraft,
missiles, nuclear power plant generating unit.
It is defined as that steel which when correctly heat treated and
finished, resists oxidation and corrosive attack from most corrosive
media.
a. Martensitic stainless steel. The chromium steels containing 12 to
Page 76
14 per cent chromium and 0.12 to 0.35 per cent carbon are the first
stainless steels developed. Since these steels possess Martensitic
structure, therefore, they are called Martensitic stainless steels.
These steels are magnetic and may be hardened by suitable heat
treatment and the hardness obtainable depends upon the carbon
Chapter 1: Engineering Materials
Page 76
content.
These steels can be easily welded and machined. When
REPUBLIC OF THE PHILIPPINES
formability,
softness,
etc. are required
fabrication, steel having
BATAAN
PENINSULA
STATEin UNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
0.12
per cent
carbon
is often
used in soft condition. With
COLLEGE
OFmaximum
ENGINEERING
AND
ARCHITECTURE
increasing carbon, it is possible by hardening and tempering to
MECHANICAL ENGINEERING DEPARTMENT
b. Ferritic
stainless steel. The steels containing greater amount of
REPUBLIC OF THE PHILIPPINES
chromium
(fromPENINSULA
16 to 18 per cent)
and about
0.12 per cent carbon
BATAAN
STATE
UNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
areCOLLEGE
called ferritic
stainlessAND
steels.
These steels have better
OF ENGINEERING
ARCHITECTURE
corrosion resistant property than martensitic stainless steels. But,
MECHANICAL ENGINEERING DEPARTMENT
butREPUBLIC
the most
widely used steel contain 18 per cent chromium and 8
OF THE PHILIPPINES
perBATAAN
cent nickel PENINSULA
with carbon content
as low UNIVERSITY
as possible. Such steel is
STATE
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
commonly
as 18/8 steel.
steels cannot be hardened
COLLEGEknown
OF ENGINEERING
ANDThese
ARCHITECTURE
by quenching; in fact they are softened by rapid cooling from about
MECHANICAL ENGINEERING DEPARTMENT
It is very strong and very tough ferrous metal and is exclusively used
for manufacturing of Gears, shafts, engine parts etc. This is one of the
most frequently used ferrous metals in industries because of its strength,
hardness and toughness.
Chapter 1: Engineering Materials
Page 76
10. Heat
Resisting Steels
REPUBLIC OF THE PHILIPPINES
The
steels which
can resistSTATE
creep UNIVERSITY
and oxidation at
BATAAN
PENINSULA
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
high
BALANGA C-2100
temperatures
and
sufficientAND
strength
are called heat resisting
COLLEGE
OFretain
ENGINEERING
ARCHITECTURE
steels.
cheaper
than other types of steels. It is particularly used for drilling
REPUBLIC OF THE PHILIPPINES
and
tapping operations.
BATAAN
PENINSULA STATE UNIVERSITY
c) Super
MAIN C
high
AMPUSspeed
, PROVINCE
steel.
OF BATAAN
This
, Csteel
ITY OF B
isALANGA
also C-2100
called cobalt high
COLLEGE OF ENGINEERING AND ARCHITECTURE
remove
strains
caused
by
cold
working
processes
like
ToREPUBLIC
remove
dislocations caused in the internal structure of the steel
OF THE PHILIPPINES
due
BATAAN
to hot working.
PENINSULA
MAIN CAMPUS, PROVINCE
OF
STATE UNIVERSITY
BATAAN, CITY
OF
BALANGA C-2100
ToCOLLEGE
improve OF
certain
mechanical
andARCHITECTURE
electrical properties.
ENGINEERING
AND
MECHANICAL ENGINEERING DEPARTMENT
Notes:
(a)
carbon content. It is 900C for pure iron, 860C for steels with
2.2% carbon, 723C for steel with 0.8% carbon and 1130C for
steel with 1.8% carbon.
Page 76
(b)
and
steel
containing
above
0.8%
carbon
is
called
hypereutectoid steel.
Chapter 1: Engineering Materials
Page 76
2. Annealing.
The PENINSULA
main objects of annealing
BATAAN
STATEare:
UNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
To
soften OF
theENGINEERING
steel so thatAND
it may
be easily machined or cold
COLLEGE
ARCHITECTURE
worked.
MECHANICAL ENGINEERING DEPARTMENT
To refine the grain size and structure to improve mechanical
properties like strength and ductility.
To relieve internal stresses which may have been caused by hot or
cold working or by unequal contraction in casting.
To alter electrical, magnetic or other physical properties.
To remove gases trapped in the metal during initial casting.
The annealing process is of the following two types:
a. Full annealing. The purpose of full annealing is to soften the
metal to refine the grain structure, to relieve the stresses and to
remove trapped gases in the metal.
In order to avoid decarburization of the steel during
annealing, the steel is packed in a cast iron box containing a
mixture of cast iron borings, charcoal, lime, sand or ground
mica. The box along with its contents is allowed to cool slowly in
the furnace after proper heating has been completed.
The following table shows the approximate temperatures
for annealing depending upon the carbon contents in steel.
Page 76
OF
BATAAN, CITY
OF
BALANGA C-2100
strength.
These steels have better elongation properties than the
REPUBLIC OF THE PHILIPPINES
normally
annealed steel.
BATAAN
PENINSULA
MAIN CAMPUS, PROVINCE
OF
STATE UNIVERSITY
BATAAN, CITY
OF
BALANGA C-2100
(a) To increase the hardness of the metal so that it can resist wear.
(b) To enable it to cut other metals i.e. to make it suitable for cutting
tools.
The process of hardening consists of:
(i) Heating the metal to a temperature from 30 to 50C above the
upper critical point for hypoeutectoid steels and by the same
temperature above the lower critical point for hypereutectoid
steels.
(ii)
article while
the rest of it is left as such. This type of treatment is applied
REPUBLIC OF THE PHILIPPINES
to gears,
ball bearings,
railway wheels,
etc.
BATAAN
PENINSULA
STATE
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
UNIVERSITY
BALANGA C-2100
Following
are theOF
various
surface or
case
hardening processes by means
COLLEGE
ENGINEERING
AND
ARCHITECTURE
of which the surface layer is hardened:
(a)
Carburizing
Carburizing process has evolved with advancements in heat
Cyaniding
Cyaniding is a case hardening with powdered potassium
cyanide
or
potassium
ferro-cyanide
mixed
with
potassium
Nitriding
Nitriding is a surface hardening accomplished by heating
Induction hardening
Induction hardening is a surface hardening technique in
which the surface of the metal is heated very quickly, using a nocontact method of induction heating. The alloy is then quenched,
producing a marten site transformation at the surface while
Page 76
(e) REPUBLIC
Flame
hardening
OF THE PHILIPPINES
Flame hardening
is used STATE
to harden UNIVERSITY
only a portion of a metal.
BATAAN
PENINSULA
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
Unlike
differential
hardening,AND
where
the entire piece is heated and
COLLEGE
OF ENGINEERING
ARCHITECTURE
then cooled at different rates, in flame hardening, only a portion of
MECHANICAL ENGINEERING DEPARTMENT
often
submicroscopic.
The
result
is
change
of
made
up of single martensite grains surrounded by pearlite. The
REPUBLIC OF THE PHILIPPINES
wood-grain
appearance
comes from
layers ofUNIVERSITY
different composition.
BATAAN
PENINSULA
STATE
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
Page 76
almost Ralike
except that the AISI uses prefixes B, C, D, and E to indicate
EPUBLIC OF THE PHILIPPINES
the method
of manufacturing
the carbon
grades.
BATAAN
PENINSULA
STATE
UNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
5 - Chromium steels;
6 - Chromium-vanadium
3 - Nickel-chromium
steels;
7 - Tungsten-chromium
steels;
4 - Molybdenum steels;
steels;
9 - Silicon-manganese
steels.
Page 76
For
Example, SAE 5130 indicates
REPUBLIC OF THE PHILIPPINES
containing
1% of chromium
and 0.30%
of carbon.
BATAAN
PENINSULA
STATE
UNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
prefix E (electric-furnace
steel)
and
the
suffix H (hardenability
standards for steel specifications. The American Iron and Steel Institute
(AISI) originally started a very similar system. Over time they used the
same numbers to refer to the same alloy, but the AISI system used a
letter prefix to denote the steelmaking process. The prefix "A" denotes
alloy basic open-heart. The prefix "B" denoted carbon acid Bessemer.
The prefix "C" denoted open-hearth furnace, electric arc furnace or basic
oxygen furnace. The prefix "D" denotes carbon acid open-heart while "E"
denotes electric arc furnace steel.
Page 76
OF
BATAAN, CITY
OF
BALANGA C-2100
SAE
Type
Designation
Steel According
1xxx Table 1.4 Classification of
Carbon
steels to AISI
Standard
2xxx
Nickel steels
3xxx
4xxx
5xxx
6xxx
7xxx
8xxx
9xxx
86XX
87XX
93XX
94XX
97XX
Nickel-chromium steels
Molybdenum steels
Chromium steels
Chromium-vanadium steels
Tungsten steels
Nickel-chromium-vanadium steels
Silicon-manganese steels
Triple Alloy steels which include Nickel
(Ni), Chromium (Cr), and Molybdenum
(Mo).
These steels exhibit high strength and also
98XX
Page 76
Table1.4
1.4Classification
ClassificationofofSteel
SteelAccording
Accordingto
toAISI
AISI
Standard
Page
76
Table
Standard
Table 1.4 Classification of Steel According to AISI Standard
THE PHILIPPINES
AI REPUBLIC OF Types
of Steel
Alloy Elements %
OF
BATAAN, CITY
OF
BALANGA C-2100
10COLLEGE OF
Plain
Carbon
0.4 Mn
ENGINEERING
AND ARCHITECTURE
11
Free machining
0.7 Mn, 0.12 S
MECHANICAL
ENGINEERING DEPARTMENT
13
High Manganese
1.6 - 1.90 Mn
2
Nickel Steels
3.5 - 5.0 Ni
3
Nickel Chromium
1.0 - 3.5 Ni, 0.5 -1.75 Cr
40
Molybdenum
0.15 - 0.3 Mo
41
Chrome-Molybdenum
0.80 -1.1 Cr, 0.15 - 0.25 Mo
43
Nickel - Chrome 1.65 - 2.0 Ni, 0.4 - 0.9
46
5
61
81
Molybdenum
Nickel - Molybdenum
Chromium
Chromium - Vanadium
Nickel - Chrome -
86
Molybdenum
Nickel - Chrome -
0.08 - 0.15 Mo
0.4 - 0.6 Ni, 0.4 - 0.6 Cr,
Molybdenum
0.15 - 0.25 Mo
92
Silicon
1.8 - 2.2 Si
From the table above showing that the first digit indicates the type of
steel. Then the second one is the modification in alloys. Lastly, the two
digits remainings show the carbon content in percentage.
Prior to 1995 the AISI was also involved, and the standard
was
Page 76
AISI-SAE Designation
Type
Number
10xx
Carbon steels
Plain Carbon (Mn. 1.00%
max.)
Chapter 1: Engineering Materials
Page 76
Table 1.4
Table
Classification
1.5 SteelofAlloy
SteelDesignation
According to
System
AISI Standard
REPUBLIC OF THE11xx
PHILIPPINES
Resulfurized
Resulfurized and
BATAAN12xx
PENINSULA STATE UNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF rephosphorized
BALANGA C-2100
15xx
MECHANICAL ENGINEERINGrange
DEPARTMENT
1.00-1.65%)
Manganese steels
13xx
Mn 1.75
Nickel steels
23xx
Ni 3.50
25xx
Ni 5.00
Nickel-chromium steels
31xx
Ni 1.25; Cr 0.65, 0.80
32xx
Ni 1.75; Cr 1.07
33xx
Ni 3.50; Cr 1.50, 1.57
34xx
Ni 3.00; Cr 0.77
Molybdenum steels
40xx
Mo 0.20, 0.25
44xx
Mo 0.40, 0.52
Chromium-molybdenum steels
41xx
Cr 0.50, 0.80, 0.95; Mo
0.12, 0.20, 0.25, 0.30
Nickel-chromium-molybdenum steels
Ni 1.82; Cr 0.50, 0.80; Mo
43xx
43BVxx
47xx
81xx
86xx
0.25
87xx
88xx
93xx
TYPE
DESCRIPTION
The first digit is "1" as in 10xx, 11xx, and
Carbon Steels
12xx.
The
REPUBLIC OF THE94xx
PHILIPPINES
Ni 0.45;
Cr 0.40;
Mo 0.12 "1"
second digit
describes
processing:
97xx
Ni 1.00; Cr 0.20; Mo 0.20
BATAAN98xx
PENINSULA
STATE
UNIVERSITY
is resulfurized
and "2"
is resulfurized
Ni 1.00; Cr 0.80; Mo 0.25
MAIN CAMPUS, PROVINCE OF BATAAN, CITY OF BALANGA C-2100
and rephosphorized.
Nickel-molybdenum
steels
COLLEGE OF ENGINEERING
AND ARCHITECTURE
is 0.85,
"1" as1.82;
in 13xx
46xx The first digitNi
Mo and
0.20,is,
MECHANICAL ENGINEERING DEPARTMENT
Manganese
Steel
48xx
50xx
51xx
1.00, 1.05
The second digit is always
"3".
50xxx The first digit isCr"2"
0.50;
C 1.00
as in
23xx min.
and 25xx.
51xxx
Cr 1.02; C 1.00 min.
Nickel Steel52xxx The second digit
Cr designates
1.45; C 1.00the
min.
Chromium-vanadium
steels
percentage of nickel
in the steel.
61xx The first digit Cr
0.60,
0.95;
V and
is "3" as 0.80,
in 31xx,
32xx,
0.10, 0.15
Nickel33xx,
Tungsten-chromium steels
Chromium Steel
designates
the
72xx The second digit W
1.75; Cr 0.75
Silicon-manganese
steels
percentage of nickel
and chromium in the
92xx
Si 1.40, 2.00; Mn 0.65,
steel.
0.85;
0.00,and
0.65
The first digit0.82,
is "4"
as inCr40xx
44xx.
High-strength low-alloy steels
Molybdenum9xx The second digit
designates
the
Various
SAE grades
Boron steels
Steels
percentage
of molybdenum in the steel.
xxBxx
B denotes boron steels
Leaded steels
"5" as in
51xx steels
and 52xx.
xxLxx The first digitLis
denotes
leaded
Chromium Steel
The second digit designates the
percentage of chromium in the steel.
Chromium The first digit is "6" as in 61xx.
Table 1.6 Type and Description of Steels
Vanadium Steel
The second digit designates the
percentage of chromium and vanadium in
TungstenChromium Steel
SiliconManganese Steel
the steel.
The first digit is "7" as in 72xx.
Page 76
percentage
C h a p t e rof1silicon
: E n gand
i n emanganese
e r i n g M ain
terials
the steel.
These steels contain three alloys.
The first digit can be "4", "8", or "9"
Page 76
As
shown, the AISI / SAE steel designation system gives
REPUBLIC OF THE PHILIPPINES
information
about the
chemical composition
the steel (alloy type and
BATAAN
PENINSULA
STATEofUNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
carbon COLLEGE
content). OF
However,
in manyAND
cases,
this is not enough information
ENGINEERING
ARCHITECTURE
for the purchasing company to procure the steel. The ASTM specification
MECHANICAL ENGINEERING DEPARTMENT
demonstrated
but
fabrication
methods
will
not
be
A number system or series to identify carbon and alloy steel had been
developed by Society of Automotive Engineers (SAE) and American Iron
and Steel Industry (AISI). Steel are names based on their alloying
elements and carbon content.
Page 76
The
last 2 numbers shows the carbon content in points (100 points
REPUBLIC OF THE PHILIPPINES
equal 1BATAAN
percent).
OF
BATAAN, CITY
OF
BALANGA C-2100
Numbe
Range of Number
r
a) Carbon steel
Carbon steel SAE-AISI
1XXX
Plain Carbon
10XX
Free machining
11XX
(resulphurized)
Resulphrized, rephosporised
12XX
b) Alloy Steel
Manganese
Molybdenum
C-Mo(0.25% Mo)
CR-Mo(0.70% Cr, 0.15% Mo)
Ni-Cr-Mo(1.8% Ni, 0.65% CR)
Ni-Mo(1.75% Ni)
Ni-Cr(0.45% Ni, 0.2% Mo)
Ni-Mo(3.5% Ni, 0.25% Mo)
13XX
4XXX
40XX
41XX
43XX
46XX
47XX
48XX
Chromium
0.5% Cr
1.0% Cr
1.5% Cr
Corrosion-heat resistant
5XXX
50XX
51XX
52XX
514XX
5120-5152
52095-52100
(AISI 400 Series)
Chromium-Vanadium
1% Cr, O.12% V
6XXX
61XX
6120-6152
Page 76
Silicon Manganese
0.85% Mn, 2% Si
92XX
9255-9262
Triple-alloy Steels
0.55% Ni, 0.50% Cr, 0.20%
86XX
8615-8660
REPUBLIC OFMo,
THE PHILIPPINES
0.55% Ni, 0.50% Cr, 0.25%
87XX
8720-8750
BATAAN PENINSULA STATE
UNIVERSITY
MAIN CAMPUS
Mo, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
COLLEGE
OFCr,
ENGINEERING
ARCHITECTURE9310-9317
3.25%
Ni, 1.2%
0.12% Mo AND93XX
AISI
Application
0.45% Ni, MECHANICAL
0.4% Cr, 0.12%ENGINEERING
Mo
94XXDEPARTMENT
9437-9445
0.45%
Ni, 0.15% Cr, 0.2% Mo
97XX
9747-9763
Designation
1.00 AISI
% Ni,
0.8%
Cr,
0.25%
Mo
98XX
2330
Bolts, studs, tubing subjected to9840-9850
torsional
Boron (~0.05% Mn)
XXBXX
stress
AISI 2340
Quenched and tempered shafting connecting
AISI 3130
machine parts
Shafts, bolts, steering knuckles
AISI 3140
AISI 3150
AISI 3240
AISI 3300
series
AISI 4063
AISI 4130,
4140
AISI 4340
AISI 4640
after welding
Page 76
Gears, propeller-shafts, knuckles shapes
8740
NON-FERROUS METALS
We
have already discussed that the non-ferrous metals are those
REPUBLIC OF THE PHILIPPINES
which contain
a metal
other than ironSTATE
as their chief
constituent. The nonBATAAN
PENINSULA
UNIVERSITY
MAIN CAMPUS, PROVINCE
BATAAN, CITY
OF
OF
BALANGA C-2100
ferrous COLLEGE
metals are
usually employed
industry due to the following
OF ENGINEERING
AND in
ARCHITECTURE
characteristics:
Ease
of
fabrication
(casting,
rolling,
forging,
welding
and
machining),
Resistance to corrosion,
Electrical and thermal conductivity, and
Weight.
Page 76
OF
BATAAN, CITY
OF
BALANGA C-2100
1. ALUMINUM
MECHANICAL ENGINEERING DEPARTMENT
It is white metal produced by electrical processes from its oxide
(alumina), which is prepared from a clayey mineral called bauxite. It is a
light metal having specific gravity 2.7 and melting point 658C. The
tensile strength of the metal varies from 90 MPa to 150 MPa.
Aluminum Alloys
The aluminum may be alloyed with one or more other elements
like copper, magnesium, manganese, silicon and nickel. The addition of
small quantities of alloying elements converts the soft and weak metal
into hard and strong metal, while still retaining its light weight. The main
aluminum alloys are discussed below:
a) Duralumin. It is an important and interesting wrought alloy. This
alloy possesses maximum tensile strength (up to 400 MPa) after
heat treatment and age hardening. After working, if the metal is
allowed to age for 3 or 4 days, it will be hardened. This phenomenon
is known as age hardening.
b) Y-alloy. It is also called copper-aluminum alloy. The addition of
copper to pure aluminum increases its strength and machinability. It
is mainly used for cast purposes, but it can also be used for forged
components like duralumin. Since Y-alloy has better strength (than
Page 76
copper.
Due to its light weight and good mechanical properties, it is
REPUBLIC OF THE PHILIPPINES
mainly
used forPENINSULA
aircraft and automobile
components.
BATAAN
STATE
UNIVERSITY
d) Hindalium.
MAIN CAMPUS
It, is
PROVINCE
an alloy
OF of
BATAAN
aluminum
, CITY OFand
BALANGA
magnesium
C-2100 with a small
COLLEGE OF ENGINEERING AND ARCHITECTURE
Copper-tin alloys (Bronze). The alloys of copper and tin are usually
termed as bronzes. The useful range of composition is 75 to 95%
copper and 5 to 25% tin. The metal is comparatively hard, resists
Chapter 1: Engineering Materials
Page 76
surface
wear and can be shaped or rolled into wires, rods and sheets
REPUBLIC OF THE PHILIPPINES
very BATAAN
easily. In corrosion
resistant properties,
bronzes are superior to
PENINSULA
STATE UNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
brasses.
Some OF
of the
common types
bronzes are as follows:
COLLEGE
ENGINEERING
ANDof
ARCHITECTURE
a) Phosphor bronze. When bronze contains phosphorus, it is
MECHANICAL ENGINEERING DEPARTMENT
corrosion
made fromPENINSULA
this bronze.
BATAAN
STATE UNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
e)
Aluminum
bronze. It is an
alloy
of copper and aluminum. The
COLLEGE
OF ENGINEERING
AND
ARCHITECTURE
aluminum bronze with 68% aluminum has valuable cold
MECHANICAL ENGINEERING DEPARTMENT
The zinc is added to clean the metal and to increase its fluidity.It is not
suitable for being worked in the cold state but may be forged when at
about 600C. The metal is very strong and resistant to corrosion by water
and atmosphere. Originally, it was made for casting guns. It is
extensively used for casting boiler fittings, bushes, bearings, glands, etc.
Chapter 1: Engineering Materials
Page 76
5. LEAD
OF
BATAAN, CITY
OF
BALANGA C-2100
It is
a bluishOF
grey
metal having
specific
gravity 11.36 and melting
COLLEGE
ENGINEERING
AND
ARCHITECTURE
point 326C. It is so soft that it can be cut with a knife. It has no tenacity.
MECHANICAL ENGINEERING DEPARTMENT
b) Lead-base alloys,
c) Tin-base alloys, and
d) Cadmium-base alloys
8. ZINC BASE ALLOYS
Chapter 1: Engineering Materials
Page 76
The
most of the die castings are produced from zinc base alloys.
REPUBLIC OF THE PHILIPPINES
These BATAAN
alloys can be
casted easily STATE
with a good
finish at fairly low
PENINSULA
UNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
temperatures.
They
have also considerable
strength and are low in cost.
COLLEGE
OF ENGINEERING
AND ARCHITECTURE
The usual alloying elements for zinc are aluminum, copper and
MECHANICAL ENGINEERING DEPARTMENT
of
their
high
mechanical
strength
properties,
corrosion
resistance, etc.
10.
TITANIUM
There are three structural types of titanium alloys:
a) Alpha Alloys are non-heat treatable and are generally very
weld-able. They have low to medium strength, good notch
toughness, reasonably good ductility and possess excellent
mechanical properties at cryogenic temperatures
b) Alpha-Beta Alloys are heat treatable and most are weldable.
Their strength levels are medium to high. Their hot-forming
qualities are good, but the high temperature creep strength is
not as good as in most alpha alloys.
c) Beta or near-beta alloys are readily heat treatable,
generally weldable, capable of high strengths and good creep
resistance to intermediate temperatures. Excellent formability
can be expected of the beta alloys in the solution treated
Page 76
condition.
Beta-type
alloys
have
good
combinations
of
11.
COBALT-CHROMIUM-TUNGSTEN-MOLYBDENUM
REPUBLIC OF THE PHILIPPINES
ALLOYS
BATAAN
WEAR-RESISTANT
MAINalloys
CAMPUSfeature
, PROVINCE
These
a
OF BATAAN
, CITY OF B
ALANGAmakes
C-2100them ideal for
wear
resistance
which
metal-cutting operations. Their ability to retain hardness even at redMECHANICAL ENGINEERING DEPARTMENT
heat temperatures also makes them especially useful for cutting tools.
12.
PRECIOUS METALS
These include silver, gold, platinum, palladium, iridium, osmium,
rhodium, and ruthenium, and their alloys. These alloys are produced
under technical and legal requirements. Gold alloys used for jewelry are
described in karats. The karat is the content of gold expressed in twentyfourths. An 18-karat gold alloy would contain 18/24 gold (75 percent by
weight). Other than jewelry, there are many industrial uses for precious
metals.
13. TRUE BRASS
True Brass sinks or protects bench tops where a large amount of acid
is used. Lead-lined pipes are used in systems that carry. This is an alloy
of copper and zinc. Additional corrosive chemicals, frequently, lead are
used in alloyed elements, such as aluminum, lead, tin, iron, manganese,
form to increase its low-tensile strength. Alloyed with or phosphorus, are
added to give the alloy specific tin, lead produces a soft solder.
14. BRONZE
Brass is a combination of 84% copper and 16% tin and was the best
Page 76
many cases,
there is no real distinction between the composition of
REPUBLIC OF THE PHILIPPINES
bronze BATAAN
and that of brass.
PENINSULA
MAIN CAMPUS, PROVINCE
OF
STATE UNIVERSITY
BATAAN, CITY
OF
BALANGA C-2100
Metal
parts for nuclear reactors, internal-combustion engines,
REPUBLIC OF THE PHILIPPINES
valves, BATAAN
superheatedPENINSULA
steam equipment;
oil stills,UNIVERSITY
chemical and petroleum
STATE
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
processes,
and similar
service are stressed
at temperatures ranging from
COLLEGE
OF ENGINEERING
AND ARCHITECTURE
200 to 1800oF. Ceramics usually are used for higher operating
MECHANICAL ENGINEERING DEPARTMENT
temperatures. The metals used for such parts must be specially selected
from those materials which retain a large percentage of their strength at
high temperatures and which do not creep excessively.
Thermosetting
plastics STATE
are those
which are formed
BATAAN
PENINSULA
UNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
into
BALANGA C-2100
shapeOF
under
heat and pressure
and results in a permanently
COLLEGE
ENGINEERING
AND ARCHITECTURE
hard product.
Aluminum
casting alloys are listed in many specifications of various
REPUBLIC OF THE PHILIPPINES
standardizing
agencies.
These include
Federal
Specifications, Military
BATAAN
PENINSULA
STATE
UNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
Specifications,
SpecificationsAND
andARCHITECTURE
SAE Specifications, to mention
COLLEGEASTM
OF ENGINEERING
some. The numbering systems used by each differ and are not always
MECHANICAL ENGINEERING DEPARTMENT
shall
first
consider
the
4-digit
wrought
aluminum
alloy
identification system.
Chapter 1: Engineering Materials
Page 76
TablePENINSULA
1.9 Wrought Aluminum
Alloy Designation
System
BATAAN
STATE
UNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
Alloy Series
Principal Alloying Element
MECHANICAL ENGINEERING DEPARTMENT
1xxx
99.000% Minimum Aluminum
2xxx
Copper
3xxx
Manganese
4xxx
Silicon
5xxx
Magnesium
6xxx
Magnesium and Silicon
7xxx
Zinc
8xxx
Other Elements
9xxx
Unused Series
NOTE:
The first digit (xxxx) indicates the principal alloying element, which
has been added to the aluminum alloy and is often used to describe the
aluminum alloy series. (Example:1000 series, 2000 series, 3000 series up
to 8000 series.
The second single digit (xxxx), if different from 0, indicates a
modification of the specific alloy, and the third and fourth digits (xxxx)
are arbitrary numbers given to identify a specific alloy in the series.
(Example: In alloy 5183, the number 5 indicates that it is of the
magnesium alloy series, the 1 indicates that it is the 1 st modification to
the original alloy 5083 and the 83 identifies it in the 5xxx series.)
The only exception to this alloy numbering system is with the 1xxx
series aluminum alloys (pure aluminums) in which case, the last 2 digits
Page 76
Cast alloys
Chapter 1: Engineering Materials
Page 76
The
cast alloy designation system is based on a 3-digit plus
REPUBLIC OF THE PHILIPPINES
decimalBATAAN
designationPENINSULA
(xxx.x).
MAIN CAMPUS, PROVINCE
OF
STATE UNIVERSITY
BATAAN, CITY
OF
BALANGA C-2100
(Example:
356.0)OF ENGINEERING AND ARCHITECTURE
COLLEGE
Alloy Series
Principal Alloying Element
MECHANICAL ENGINEERING DEPARTMENT
1xx.x
99.000% minimum Aluminum
2xx.x
Copper
3xx.x
Silicon Plus Copper and/or
Magnesium
Silicon
Magnesium
Unused Series
Zinc
Tin
Other Elements
4xx.x
5xx.x
6xx.x
7xx.x
8xx.x
9xx.x
NOTE:
The first digit (xxx.x) indicates the principal alloying element,
which has been added to the aluminum alloy.
The second and third digits (xxx.x) are arbitrary numbers given to
identify a specific alloy in the series. The number following the decimal
point (xxx.x) indicates whether the alloy
is a casting (.0) or an ingot (.1 or .2). A capital letter prefix indicates a
modification to a specific alloy.
(Example:Alloy
A356.0:
the
capital
(Axxx.x)
indicates
Page 76
The 56 (Ax56.0)
identifies the alloy within the 3xx.x series, and the .0 (Axxx.0) indicates
that it is a final shape casting and not an ingot.)
Chapter 1: Engineering Materials
Page 76
DIFFERENT
KINDS OF TESTING
REPUBLIC OF THE PHILIPPINES
OF
BATAAN, CITY
OF
BALANGA C-2100
Destructive MECHANICAL
testing
ENGINEERING DEPARTMENT
Destructive testing is a type of testing used in manufacturing that
ultimately destroys the sample being tested. Used to determine the
soundness, safety, and lifespan of products, destructive testing is often
used to test welds, but is probably most well-known as a method to test
car safety. Destructive testing comes in three forms: stress, or stability;
impact, or safety; and hardness, or resistance, tests.
Designed to find weaknesses that are not immediately apparent,
destructive testing is usually much more decisive than non-destructive
testing. When dealing with mass-produced items, this form of testing is
also less expensive than other methods because only a small handful of
the product will be destroyed. When dealing with other products,
however, this method can be expensive. Destructive tests may be
conducted on a product at any time in its development, from beginning
research to production-ready stages.
ARcrash
test is a form of destructive testing usually performed in
EPUBLIC OF THE PHILIPPINES
order to
ensure safe
design standards
in crashworthiness
and crash for
BATAAN
PENINSULA
STATE
UNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
variousCOLLEGE
modes ofOF
transportation
or AND
related
systems and components
ENGINEERING
ARCHITECTURE
MECHANICAL ENGINEERING DEPARTMENT
crack.
Many
materials are capable of either ductile or brittle failure,
REPUBLIC OF THE PHILIPPINES
depending
upon thePENINSULA
type of test andSTATE
rate andUNIVERSITY
temperature conditions.
BATAAN
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
They possess
a ductile/brittle
transition
that actually shifts according to
COLLEGE
OF ENGINEERING
AND ARCHITECTURE
these variables.
The Brinell
Hardness
Test
BATAAN
PENINSULA
MAIN CAMPUS, PROVINCE
OF
STATE UNIVERSITY
BATAAN, CITY
OF
BALANGA C-2100
The
BrinellOF
hardness
test method
consists of indenting the test
COLLEGE
ENGINEERING
AND ARCHITECTURE
material with a 10 mm diameter hardened steel or carbide ball subjected
MECHANICAL ENGINEERING DEPARTMENT
to a load of 3000 kg. For softer materials the load can be reduced to
1500 kg or 500 kg to avoid excessive indentation. The full load is
normally applied for 10 to 15 seconds in the case of iron and steel and
for at least 30 seconds in the case of other metals. The diameter of the
indentation left in the test material is measured with a low powered
microscope. The Brinell harness number is calculated by dividing the
load applied by the surface area of the indentation.
Vickers Hardness Test
The Vickers hardness test method consists of indenting the test
material with a diamond indenter, in the form of a right pyramid with a
square base and an angle of 136 degrees between opposite faces
subjected to a load of 1 to 100 kgf. The full load is normally applied for
10 to 15 seconds. The two diagonals of the indentation left in the surface
of the material after removal of the load are measured using a
microscope and their average calculated. The area of the sloping surface
of the indentation is calculated. The Vickers hardness is the quotient
obtained by dividing the kgf load by the square mm area of indentation.
DIFFERENT FORM OF NON-DESTRUCTIVE TESTING
Non-destructive Testing is one part of the function of Quality Control
Page 76
used for
100% checking of material in a production quality control
REPUBLIC OF THE PHILIPPINES
system.BATAAN
OF
BATAAN, CITY
OF
BALANGA C-2100
Visual inspection
Ultrasonics
Page 76
In thickness
checking the reflections from the wall surfaces are
REPUBLIC OF THE PHILIPPINES
measured.
In defect
detection reflections
cracks, voids and
BATAAN
PENINSULA
STATE from
UNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
inclusions
are detected
and assessed.
COLLEGE
OF ENGINEERING
AND ARCHITECTURE
Ultrasonics C Scan
For the ultrasound techniques, internal damage is detected by the
attenuation or reflection of 1-25MHz ultrasonic waves. The selection of
which technique to use (through transmission or pulse echo) depends on
the accessibility of the surfaces of the component. The C-scan technique
is one of the most useful techniques available. Here, the relative
attenuation of ultrasonic waves across a component surface creates a
plan view of any damage contained within the component. Some
systems require components to be removed from structures and
immersed in a water bath which acts as a medium for ultrasonic
transmissions. Other systems allow the component to be examined
without being removed.
X-ray
X-ray methods are based on the attenuation of X-rays. Die
penetrants such as diodobutane (DIB) can be used to aid damage
visibility in certain composites. This is usually practical if some cracking
is evident at the surface, allowing a path for the die to penetrate into the
internal damage. Fine detail of damage can often be extracted using this
technique, however, in some situations penetrants can potentially act as
Page 76
isothermal
contour lines to
REPUBLIC OF THE PHILIPPINES
be
identified.
For
non-destructive
investigation
the emissivity
of a damage
area will
be different to that of
BATAAN
PENINSULA
STATE
UNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
an undamaged
An external AND
heatARCHITECTURE
source, such as a quartz lamp
COLLEGE area.
OF ENGINEERING
flash, is used. The rate of decay of heat conduction differs from
MECHANICAL ENGINEERING DEPARTMENT
Lamb Waves
Page 76
ultrasonic
waves and changes in velocity as a function of frequency use
REPUBLIC OF THE PHILIPPINES
analysisBATAAN
to identify PENINSULA
the wave dispersion
related
to bending and tension
STATE
UNIVERSITY
MAIN CAMPUS, PROVINCE
OF
BATAAN, CITY
OF
BALANGA C-2100
stiffness.
COLLEGE OF ENGINEERING AND ARCHITECTURE
Dye is drawn into any surface breaking defects which are then
highlighted by the application of a developer which draws the dye back
out of the defect. This NDT method can only detect defects which are
open to the inspection surface. Dye penetrant is the preferred surface
technique for non-magnetic materials. Dye penetrant is better suited to
the detection of volumetric defects like pits but is more susceptible to
the surface condition than magnetic particle inspection.
Eddy Currents
When an alternating current is passed through a coil close to a
component surface, eddy currents are induced and produce a back EMF
on the current in the coil.
Any defect in the component which restricts the eddy current flow alters
the balance between the applied and back EMFs and can be detected.
flux.
Magnetic particles sprayed onto the surface are attracted to these
defects identifying their position.
Radiography
MAIN CAMPUS, PROVINCE OF BATAAN, CITY OF BALANGA C-2100
COLLEGE OF ENGINEERING AND ARCHITECTURE
Radiography
is the detection
of material
loss by the variation in
MECHANICAL
ENGINEERING
DEPARTMENT
applied radiation, g or x-ray, passing through a component and
impinging on a film.
SAMPLE PROBLEMS
7. The ability
of the material to transmit heat energy by conduction.
REPUBLIC OF THE PHILIPPINES
Answer.
Thermal
Conductivity
BATAAN
PENINSULA
MAIN CAMPUS, PROVINCE
OF
STATE UNIVERSITY
BATAAN, CITY
OF
BALANGA C-2100
Answer. Stiffness
Answer.
Toxicity
REPUBLIC OF THE PHILIPPINES
16. It is defined
MAIN CAMPUS
as ho
, PROVINCE
easily something
OF BATAAN, C
will
ITY OF
burn
BALANGA
or ignite,
C-2100
causing fire or
COLLEGE OF ENGINEERING AND ARCHITECTURE
combustion.
Answer. Flammability
23. It provides the formation of free graphite which makes the iron soft and
easily machinable
Answer. Silicon
Chapter 1: Engineering Materials
Page 76
OF
STATE UNIVERSITY
BATAAN, CITY
OF
BALANGA C-2100
25. It is the purest iron which contains at least 99.5% iron but may contain
MECHANICAL ENGINEERING DEPARTMENT
up to 99.9% iron.
Answer.
Copper
REPUBLIC OF THE PHILIPPINES
34. It is a
Mbluish
AIN CAMPUS
grey
, Pmetal
ROVINCE
having
OF BATAAN
specific
, CITY gravity
OF BALANGA
11.36
C-2100
and melting point
326C.
Answer. Lead
35. It is brightly shining white metal; it is also soft, malleable and ductile.
Answer. Tin
36. It is one of the highest melting point of the light metals and has an
elasticity of approximately 1/3 greater than that of steel.
Answer. Beryllium
37. It is very flexible and can withstand considerable wear an suitable
conditions also used for power transmission belting and as a packing or
as washers.
Answer. Leather
38. This type of testing used in manufacturing that ultimately destroys the
sample being tested.
Answer. Destructive testing
39. It is a testing of an object's ability to resist high-rate loading
Answer. Impact testing
40. It the properties of a material that enables it to resist plastic
deformation, usually by deformation.
Page 76
Answer. Hardness
41. This test method consists of indenting the test material with a diamond
cone or hardened steel ball indenter.
Answer. Rockwell hardness test
Chapter 1: Engineering Materials
Page 76
42. This test method consists of indenting the test material with a 10mm
diameter
MAINhardened
CAMPUS, PROVINCE
steel orOFcarbide
BATAAN,ball
CITYsubjected
OF BALANGAto
C-2100
a load of 3000 kg.
COLLEGE OF ENGINEERING AND ARCHITECTURE
43. This material is do not become hard with the application of heat and
pressure and no chemical change occurs
Answer. Thermoplastic
44. Is the use of high frequency sound waves in a similar manner to sonar
or radar?
Answer. Ultrasonic
45. Material emits infrared radiation whose intensity is dependent upon its
absolute temperature.
Answer. Thermography
46. It is another form of annealing in which cementite in the granular form
is produced in the structure of steel.
Answer. Spheroidising
47. It the process that has involved with advancement in heat treatment
techniques that have improve the hardness and durability of products.
Answer. Carburizing
48. It is a case of hardening with powdered potassium cyanide or potassium
ferro-cynide mixed with potassium bicarbonate substitute for the carbon.
Page 76
Answer. Cyaniding
49. This kind of plastic are formed into shape under heat and pressure and
results in a permanently hard product
Chapter 1: Engineering Materials
Page 76
Answer.
Thermosetting plastic
REPUBLIC OF THE PHILIPPINES
50. It is an
MAIN
optical
CAMPUS
holography
, PROVINCE OF
technique
BATAAN, CITY
that
OF monitors
BALANGA C-2100
differential motion of
COLLEGE OF ENGINEERING AND ARCHITECTURE
applied.
Answer. Sheraography
Terminolo
Annealing.
used
to
generic
denote
term
heat
gies
structure
and,
consequently,
from
an
intimate
elements.
to recrystallizes.
of
modifying
the
Bronze.
A copper-rich copperREPUBLIC OF THE PHILIPPINES
tin alloy.
BATAAN
lying electron
energy band
PENINSULA STATE
UNIVERSITY
OF
BATAAN, CITY
OF
BALANGA C-2100
is not completely
COLLEGE OF ENGINEERING AND ARCHITECTURE
that
filled with
electrons.
Copolymer.
Capacitance.
The
charge-
consists
of
polymer
two
or
that
more
dissimilar
chains.
mer
the
surface
carbon
used
in
D
Diamagnetism. A weak form
of induced or nonpermanent
magnetism
for
magnetic
which
susceptibility
the
is
negative.
Diffusion. Mass transport by
atomic motion.
Dislocation. A linear crystalline
units
to
build
together
Doping.
alloying
materials
The
of
intentional
semiconducting
with
controlled
concentrations
of donor or
REPUBLIC OF THE PHILIPPINES
acceptor
impurities.PENINSULA
BATAAN
MAIN CAMPUS, PROVINCE
OF
parallel
alignments
of
neighboring
STATE
UNIVERSITYmagnetic
BATAAN, CITY
OF
BALANGA C-2100
moments.
COLLEGE OF ENGINEERING AND ARCHITECTURE
Ductility. A measure of a
material's
ability
to
undergo
before fracture.
length-to-diameter
ratio
E
Elastomer.
Filler.
polymeric
and
reversible
elastic
deformations.
For
an
inert
foreign
or
modify
its
properties.
Firing.
Electronegativity.
An
high-temperature
hammering.
factor
for
which
crack
extensions occurs.
Page 76
Ferromagnetism.
Permanent
Co),
which
result
from
the
Chapter 1: Engineering Materials
Page 76
both the
internal energy and
REPUBLIC OF THE PHILIPPINES
entropyBATAAN
of a system.PENINSULA
MAIN CAMPUS, PROVINCE
OF
Homopolymer.
A
polymer
STATE
UNIVERSITY
BATAAN, CITY
OF
BALANGA C-2100
condition
without
crystallizing.
Hydrogen
Bond.
glass
subsequently
secondary
interatomic
strong
bond
and
devitrified
(crystallized).
Insulator
(electrical).
Hardenability . A measure of
the depth to which a specific
ferrous alloy may be hardened
wide
quenching
from
energy
band
gap.
Glass-ceramic .A fine-grained
formed
same type.
critical temperature.
amplification
by
stimulated
emission of radiation.
Page 76
Hardness.
The
measure
of
by
surface
indentation or by abrasion.
Chapter 1: Engineering Materials
Page 76
Magnetization.
The total
REPUBLIC OF THE PHILIPPINES
magneticBATAAN
moment perPENINSULA
unit volume
Plastic
Deformation.
STATE
UNIVERSITY
of material.Also,
a measure
ofOF
the
MAIN CAMPUS
, PROVINCE
BATAAN, CITY OF BALANGA C-2100
Deformation that is permanent
COLLEGE OF ENGINEERING AND ARCHITECTURE
contribution to the magnetic
or nonrecoverable after release
MECHANICAL ENGINEERING DEPARTMENT
H field.
Poisson's Ratio. For elastic
Martensite. A metastable Fe-C
composition
of
that
stress.
is
consisting
the
product
diffusionless
of
(athermal)
Polycrystalline.
Referring to
Point.
The
Metal.
The
electropositive
high
molecular
weight
the
these elements.
Paramagnetism. A relatively
on
stress-strain
curve
at
Page 76
which
alignment
(magnetic)
of
atomic
with
an
dipoles
the
straight
line
applied
magnetic field.
Chapter 1: Engineering Materials
Page 76
measure
of
material's
resistance
to the passage of
BATAAN PENINSULA STATE
UNIVERSITY
Recrystallization.
The
MAIN CAMPUS, PROVINCE OF
BATAAN, CITY OF BALANGA C-2100
electric current.
COLLEGE
OFset
ENGINEERING
formation
of a new
of strain- AND ARCHITECTURE
MECHANICAL
ENGINEERING DEPARTMENT
free grains within
a previously
Rupture.
Failure
cold-worked material; normally
accompanied
by
an annealing heat treatment is
plastic deformation.
necessary.
that
is
significant
Viscoelasticity. A type of
deformation exhibiting the
mechanical characteristics of
viscous flow and elastic
deformation
Page 76