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Prepping and delivering Lecturer: Eng. Alexis MUHIRWA
RECOMMENDED TEXTBOOKS
R K Singal, Mridul Singal; Basics of Mechanical Engineering; 2007
Chandra P. Sharma, Engineering Materials: Properties and Applications of Metals and Alloys, 2004
Engineering Materials: properties and Selection; Author: Kenneth G. Budinski, Prentice Hall of India, 5th
Ed. 1998.
Kenneth G. Budinski and Michael K. Budinski, Engineering Materials: Properties and Selection, 2009; 9th
Edition
William D. Callister; Jr. John Wiley & Sons, Materials Science and Engineering - An Introduction; 2003.
Lawrence H. Van Vlack; Elements of Materials Science and Engineering; Addison-Wesley 1989.
John Schey Hardcover; Introduction to Manufacturing Processes; 1999
Peter J. Shull; Nondestructive Evaluation: Theory, Techniques, and Applications (Mechanical
Engineering); 2002
R.L. Timings; Engineering materials Vol1 and Vol 2; Longman 1989.
Norman E. Dowling, Mechanical Behavior of Materials, 2012, 4th Edition
B.S. Narang, Materials Science; CBS Publications, 1991 edition.
William D. Callister; Fundamentals of Materials Science and Engineering: An Integrated Approach, 2004
E.T.N. Bisanda, Introductory materials science Students reader, 2003.
D R H Jones and Michael F. Ashby; An Introduction to Properties, Applications and Design, 2011; Fourth
Edition
V. Raghavan, Materials Science and Engineering; Prentice Hall of India, 1999.
Vernon John, Introduction to Engineering Materials; Palgrave Macmillan, 2003.
K.M. Gupta, Materials Science and Engineering; Umesh Publishers, 2001.
Carl A. Keyser, Material Science in Engineering, CBS Publishers, 1989.
William D. Callister Jr. and David G. Rethwisch, Materials Science and Engineering: An Introduction, 2009,
8th Edition
Kenneth G. Budinsk, Michael K. Budinski; Engineering Materials: Properties and Selection (8th Edition),
2004
Richard W. Hertzberg, Richard P. Vinci; Deformation and Fracture Mechanics of Engineering Materials,
2012
Joachim Roesler, Harald Harders; Mechanical Behaviour of Engineering Materials: Metals, Ceramics,
Polymers, and Composites, 2007
charged: -1.6 x 10 Coulomb) to keep the atom as a whole neutral, the positive charge of the protons is
equal to the negative charge of the electrons.
Fig.0.1: A carbon atom has 6 protons and six neutrons in the nucleus, two electrons in the inner energy
level, and four electrons in the outer energy level.
When an atom is neutral, it has an equal number of protons and electrons. The neutrons carry no charge
and their number can vary. An element is a substance composed of atoms that have a given number of
protons that determines the elements identity, that is:
Atomic Number: Z = p =e. Every atom of hydrogen, for example, has one proton and one electron. Every
atom of carbon has six protons and six electrons.
Atomic mass also termed as atomic weight or mass number of an element is the combined mass of its
protons, neutrons, and electrons (A = e + n = p + n). E.g A Chlorine= 17+18=35; for Fe the atomic number of
iron is 26 (Z=26) and the atomic mass number is 56 (A = 56). This means that each iron atom has 26
electrons, 26 protons and 30 neutrons
Atoms of the same element may have different numbers of neutrons, but they will all have the same
number of protons atomic number (Z) or electrons. Thus atomic number is a fundamental property of
an atom.
Isotopes: Isotopes of an element have the same atomic number but differ in their atomic mass number
because, even though they have the same number of electrons and protons (electrically neutral), they
differ in the number of neutrons. Example of Ordinary Hydrogen: Hydrogen (H11): 1 electron, 1 proton
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and 0 neutrons whereas H2 Deuterium (H21) has one neutron: 1 electron,1 proton and 1 neutrons and H3
Tritium (H31) has two neutrons: 1 electron,1 proton and 2 neutrons; Chlorine35 has 18 neutrons and
Chlorine 37 has 20neutrons.
To calculate the mass of isotope, we use the following rule M = f1xm1 + f2xm2 + f3xm3 (f: isotope
proportionality content in the mixture and m: 1, 2, 3 corresponding atomic masses)
The atomic mass unit (amu) is often used to express atomic weight. 1amu is defined as 1/12 of the
atomic mass of the most common isotope of carbon atom that has 6 protons (Z=6) and six neutrons
(N=6). Mproton Mneutron = 1.66 x 10-24 g = 1amu. The atomic mass of the 12C atom is 12amu.
The atomic weight of an element = weighted average of the atomic masses of the atoms naturally
occurring isotopes. Atomic weight of carbon is 12.011amu. The atomic weight is often specified in mass
per mole.
A mole is the amount of matter that has a mass in grams equal to the atomic mass in amu of the atoms
(A mole of carbon has a mass of 12 grams). The number of atoms in a mole is called the Avogadros
number, Nav= 6.023 1023.
Nav= 1gram/1amu.
Example: Atomic weight of iron = 55.85amu/atom = 55.85 g/mol
The electrons usually remain within a well-defined region at a relatively constant distance from the
nucleus. These well-defined regions are called energy levels. Within various energy levels, there are
areas of different shapes, called orbitals, where there is a high probability that the electrons will be
found. Actually, we cannot tell how it moves, but only can say what is the probability of finding it at
some distance from the nucleus. Only certain orbits or shells of electron probability densities are
allowed. The energy level closest to the nucleus can hold a maximum of two electrons. The next level
can hold up to eight. The outer levels can hold more.
The electrons in the energy levels closest to the nucleus have a strong force of attraction to the protons,
i.e. they are stable. Sometimes, the electrons in the outermost energy level are not strongly held. Those
electrons are called valence electrons and they can be pushed or pulled from their energy level by a
force. These are the electrons that are typically involved when chemical reactions occur. For that
reason, they are largely responsible for the chemical behavior of the element.
On modern periodic table, Group number indicates the number of electrons available for bonding:
-
0: Inert gases (Helium,...krypton, xenon, radon) have filled sub-shells: chemically inactive
IA: Alkali metals (Li, Na, potassium, rubidium, cesium, francium) have one electron in outermost
occupied s-sub shell - eager to give up electron chemically active
- VIIA: Halogens (Fluorine, Bromine, Chlorine, Iodine, Astatine) missing one electron in outermost
occupied p shell - want to gain electron - chemically active.
Electronegativity is a measure of how willing atoms are to accept electrons: Sub-shells with one electron
have low electronegativity; sub-shells with one missing electron have high electronegativity therefore
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Metals are electropositive since they can give up their few valence electrons to become positively
charged ions.
0.1.2 Bonding energy and bonding forces
The interatomic
distance (rij) is expressed in Angstroms
Fig.0.4: Force and energy variation in terms of interatomic distances
Integrated Polytechnic Regional Center KIGALI Campus; Mechanical Engineering Dpt.;
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The electronvolt (eV) is the unit used to describe atomic bonding energy and is defined as energy lost or
gained by an electron when it is taken through a potential difference of one volt.
Mathematically; E = q V where, q=1.6x10-19 Coulombs and V=1volt
Hence, 1eV = 1.6x10-19 J
Fig.: Simple model of atomic structure for several elements : (a) hydrogen , (b) helium, (c) fluorine, (d)
neon, (e) sodium.
(2) For the p-sub-shell, l=1 can have the maximum of 6es. The symbol 2p, 3p, 4p denotes the p-sub
shell of first, second third and fourth energy levels respectively
(3) For d-sub-shell, l=2 thus the maximum is 10. The symbol 3d, 4d, 5d denotes the d-sub shell of third
and fourth energy levels respectively
(4) For f-sub-shell, l=3 hence the maximum is 14es. The symbol 4f, 5f denotes the f-sub shell of fourth
and fifth energy levels respectively
Exercise: An element with atomic number 50 has all its inner energy levels filled up except 4f level,
which is empty. Determine its expected valence? Soln.: its electronic configuration is : 1s2, 2s2, 2p6, 3s2,
3p6, 4s2, 3d10, 4p6, 5s2, 4d10, 5p2. The deficiency on 5p-level is 4 es, therefore the valence is -4. All
elements with similar electronic configuration can be placed in the same group, thus the significance of
atomic number lies in the classification of elements in arranging them in the periodic table.
0.1.4 Modern periodic table
The modern periodic table is divided into four blocks:
(a) S-block: elements whose valence electrons lie in s-sub shell (group IA: also named Alkali metals
with one valence electron, and IIA: two valence electrons)
(c) D-block: elements whose valence electrons lie in d-sub shell called transition elements, notably
groups IIIB, IVB,VB,VIB,VIB,IB and IIB. The group VIII consists of 3 sub-groups.
(d) F-block: elements whose valence electrons lie in f-sub shell. Elements with atomic number 58 to 71
are termed Lanthanides and those from 90 to 103 are actinides. These two series of elements
have similar properties they are placed in the bottom of periodic table.
Most substances dealt with in industry and everyday life are categorized as organic or inorganic:
Organic materials are usually derived from living things; they contain the element C (and usually
H) as key part of their structure (e.g.: Petroleum products, plants and animals).
Inorganic materials are those substances not derived from living things (e.g.: Sand, rock, water,
metal and inert gases).
The field of engineering materials deals with both areas: metallurgists and ceramists deal primarily with
inorganic substances; on the other hand; Plastic engineers deal primarily with organic substances. Basic
ingredients used to make both organic and inorganic materials are Elements. Many of these elements
have a little industrial importance.
-
Some of the elements are used as engineering materials in their pure elemental state. Metals
like Be, Ti, Cu, Au, Ag, Pt, Pb, Hg and many of refractory metal W, Ta, Mo, Hf are used to make
industrial items.
Many metals are used in pure state for electroplating durable goods, tools and electrical
devices: Cr, Ni, Cd, Sn, Zn, Os, Re, Rh.
C is used in industrial applications for motor brushes and wear parts and in the cubic form as
diamond for tools.
The inert gases in elemental form (ions and molecules) are used for industrial applications for
protective atmosphere and the like.
A larger percentage of engineering materials utilize the elements in combined forms; in alloys (a metal
combined with one or more other elements), in compounds (chemically combined elements with
definite proportions of the component elements) and to a smaller degree; in mixtures (a physical blend
of 2 or more substances). These combinations of the elements can be solids, liquids, or gases.
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Page 11
Example: CH4
Carbon has 4 valence electrons, needs 4 more H: has 1 valence electron, needs 1
more. Electronegativities are comparable. Same case applies to long hydrocarbon
chains polyethylene nC2H4 and diamond molecules. Solids with covalent bonding
generally possess high hardness and low electrical conductivity.
Fig.0.7: Covalent bond in Cl2 and CH4 molecules
Formation of covalent bonds: Cooperative sharing of valence electrons; Can be described by orbital
overlap; Covalent bonds are highly directional; Covalent bond model: an atom can covalently bond with
at most 8-N, N = number of valence electrons
Example: Cl2 molecule. ZCl =17 (1S2 2S2 2P6 3S2 3P5). N = 7, 8 - N = 1 can form only one covalent bond
They have a Low melting point, no conductivity and sometimes are not ductile.
(b) Ionic bonds: Strong Coulomb interaction among negative atoms (have an extra electron each) and
positive atoms (lost an electron). Example: Na+Cl-. Large difference in electronegativity required.
12
Na
NaCl
Cl
r
+q
EA = (qz) (-qz) /r
- q E = q2z /r2
R
Fig.0.8: Schematic representation of the formation of ionic bond between Na and Cl atoms
The atoms of one element give up their outer electron(s), which
in turn attracted to the atoms of some other element to increase
their electron count in the outermost shell to eight. This bond is
naturally provides a very Strong bond between atoms and as a
properties of solid materials with the ionic bonding include low
electrical conductivity and poor ductility.
Attractive coulomb interaction between charges of opposite sign:
13
Na has 11 electrons, 1 more than needed for a full outer shell (Neon): 11 Protons Na 1S2 2S2 2P6 3S1
donates e- so 10 e- left to become 11 Protons Na+ 1S2 2S2 2P6
Cl has 17 electrons, 1 less than needed for a full outer shell (Argon): 17 Protons Cl 1S2 2S2 2P6 3S2 3P5
receives e- so 18 e- to turn into 18 Protons Cl- 1S2 2S2 2P6 3S2 3P6
Ionic bonds: very strong, nondirectional bonds
Example: MgO, CaF2, CsCl
Is typical for elements that are situated at the horizontal extremities of the periodic table: Atoms
from the left (metals) are ready to give up their valence electrons to the (non-metallic) atoms from the
right that are happy to get one or a few electrons to acquire stable or noble gas electron
configuration.
Formation of ionic bond:
1. Mutual ionization occurs by electron transfer: Ion = charged atom (Lost or gained electrons); Anion =
negatively charged atom; Cation = positively charged atom
2. Ions are attracted by strong coulombic interaction: Oppositely charged atoms attract each other; An
ionic bond is non-directional (ions may be attracted to one another in any direction)
Ionic bonded materials have:
- High melting point and have poor conductivity; Hard, brittle (most ceramic): any mechanical
force that tries to disturb the electrical balance in an ionic crystal meets strong resistance, in
some special cases, however, significant plastic deformation can be observed, for instance: Nacl
single crystals can be bent by hand in water;
(c) Metallic bonds
It is the atomic bonding mechanism in pure metals and metal alloys. The metallic bonding involves the
sharing of outer shell electrons by all atoms to form a general electron cloud that permeates the entire
block. This bond exists in low valence metals; metal atoms are very small and tend to pack tightly. All
valence electrons in a metal are detached from atoms and combine to form an electron sea that
glues the positive ions together and it moves freely between the atom cores. This type of bonding is
non- directional (bonds form in any direction) thus atoms pack closely. As a result we have a high
ductility/plastic deformation of metals - the bonds do not break when atoms are rearranged
metals can experience a significant degree of plastic deformation.
Examples of metals with typical metallic bonding: Cu, Al, Au, Ag, etc. Transition metals in group VIII (Fe,
Ni, etc.) form mixed bonds that are comprising of metallic bonds and covalent bonds. As a result the
transition metals are more brittle (less ductile) than Au or Cu.
14
0.4.2 Secondary bonding: no e- transferred or shared. They are very small forces of attraction acting
between atoms in cases where the formation of ionic or covalent bonds is not possible. Bonding results
from Interaction of atomic/molecular dipoles and it is Weak ( 100 KJ/mol or 0.1 eV/atom)
The secondary bonding is also called van der Waals or physical (as opposite to chemical bonding that
-
involves e transfer or sharing). Permanent dipole moments exist in some molecules (called polar
molecules) due to the asymmetrical arrangement of positively and negatively regions (HCl, H2O). Bonds
between adjacent polar molecules permanent dipole bonds are the strongest among secondary bonds.
Polar molecules can induce dipoles in adjacent non-polar molecules and bond is formed due to the
attraction between permanent and induced dipoles.
Even in electrically symmetric molecules/atoms an electric dipole can be created by fluctuations of
electron density distribution. Fluctuating electric field in one atom A is felt by electrons of an adjacent
atom, and induce a dipole momentum in this atom.
This bond due to fluctuating induced dipoles is the weakest
(inert gases, H2, Cl2).
Typical example of Hydrogen bond in water: The H end of the
molecule is positively charged and can bond to the negative side
of another H2O molecule (the O side of the H2O dipole)
Fig.0.12: Hydrogen bond secondary bond formed between two permanent dipoles in adjacent water
molecules.
Basically similar forces also act between atoms which are already bounded in neighboring molecules,
15
giving rise to weak Van der Waals forces between long-chain molecules in polymers.
Examples of bonding in Materials:
Metals: Metallic
Ceramics: Ionic and Covalent
Polymers: Covalent and Secondary
Semiconductors: Covalent or Covalent and Ionic
The bonds that hold atoms or molecules together can be very specific and orderly i.e. highly regular
arrangement of atoms: atoms or ions, self-organized in a 3D periodic array (they have a crystal structure
.e.g.: Many metals), or they can be less well defined to mean that they not have a repetitive three
dimensional pattern of atoms: solid with considerable disorder in their structure (They are said to be
amorphous. E.g.: Plastics and glasses). Crystallinity or lack of same is measured by x-ray of electron
diffraction techniques.
16
Fig.: The three principle types of structural in which metallic elements crystallize: Body-Centered-Cubic,
Face-Centered-Cubic and Hexagonal-Closed-Packed.
The atoms that belong to the unit cell are called the basic atoms, its number is different from one shape
of arrangement to another, and this number can be found from the following equation:
Where N: is the number of the basic atoms in the unit cell; NC: is the number of the atoms in the corner;
NI: is the number of the atoms inside the cube; NF: is the number of the atoms in the center of the face.
When a solid has a crystalline structure, the atoms are arranged in repeating structures called unit
cells i.e. smallest repeating unit of the lattice. The cells form a larger three dimension array called a
lattice i.e. a 3-dimensional system of points that designate the positions of the components (atoms,
ions or molecules) that makes up the substance.
Fig.: Difference in structure between (a) crystalline and (b) noncrystalline materials.
2. Differences in melting and thermal expansion characteristics. It could be demonstrated by a metal
when it is melts. When the metal is molten an increase in volume compared to the materials solid
crystalline state. This effect is characteristic most materials when melted (a noble exception is ice; liquid
water is denser than ice).
0.2 MATERIAL STRUCTURE
0.2.1 CRYSTALLINE STRUCTURE OF SOLIDS
Va = 4r3/3=4(0.5a)3/3
1/8
18
Fig.: Body centred cubic structure cut through completely bonded atoms.
19
(
(
( )
[(
)
)
) ])
)
[( )
[( )
( )
20
]
(
(
[(
)
)
) ])
( ) ]
Fig.: Hexagonal structure with unit cell outlined, and showing relationship between a and c.
Example: The atomic radius of an iron atom is 1.238X10-10m. Iron crystallizes as BCC. Calculate the
lattice parameter of the unit cell, a. How many atoms are contained within the BCC unit cell? Also find
the atomic packing factor?
Soln.: For BCC unit cell
; therefore:
21
There are 9 atoms: 8 in the corners and 1 in the center of the cubic
[
) ]
Lattice
points
900
900
X
22
Y
1200
Tetragonal: a = b # c; = = = 900
Orthorhombic: a # b # c; = = = 900
Triclinic: a # b # c; # , # 900
Trigonal: a = b = c; = = # 900
Fig.0.23: August Bravais 14 standards unit cells to describe all possible lattice networks by variation of
the basic unit cell for the seven crystal systems
4 types of unit cell: primitive (P), Boy centred (I), Face-centred (F), Side centred (C)
23
Other properties of materials (electrical conductivity, thermal conductivity, elastic modulus) can
vary in a crystal with orientation (anisotropy).
0.2.3.1 A planes orientation, in every crystal system, is described in terms of coordinates through which
they pass, i.e. in space, it satisfies the equation: x/a + y/b + Z/c = 1, where a, b, c are the intercepts on
the x, y, z axes respectively. The intercepts are measured in terms of a unit length.
Any crystallographic plane can be designed by miller indices (hkl), wherein Miller suggested that it is
more useful to describe the orientation of a plane by the reciprocal of its numerical parameters rather
than by its linear parameters. Therefore, h = 1/a, k=1/b and l=1/c.
E.g. consider a plane ABC with intercepts 1, 2 and 3 along x-x, y-y and z-z respectively
Planes orientation are 1,2,3 or a=1, b=2, c=3
Miller indices (1:1/2:1/3). By multiplying by the
denominators least common multiplier (LCM) 6,
we get alike plane belonging to the same family
of parallel planes abc(6:3:2). The ratio sign (:)
can be omitted to turn into digits (632)
Fig.0.25: Same family parallel planes and miller indices
Involved procedural routine for evaluation of miller indices of a crystal plane is as indicated:
a) Choose three axes parallel to edges of the unit cell and determine the intercepts of the plane with
the axis in terms of a, b and c. ensure that there is no intercept with the origin.
b) Calculate the reciprocals of the intercepts, h = 1/a, k = 1/b, l = 1/c then rationalize and clear all
fractions by multiplying each one of them with their LCM such that h, k, l are integers
c) Enclose the result in brackets (h k l), negative value should be written with a bar on top.
(001)
(010)
b
Z
Not allowed
Y (100)
X
Not allowed
Y
(00 )
Fig.0.26: Miller indices for three faces of the cubic unit cell
The other three faces are represented by shifting the origin of coordinated system to another corner of
unit cell; for example the plane EFGH may be represented by shifting the origin from point H to point
D. Consequently, minus value for a intercepts appear along x-x axis with b/c infinity intersections
along y-y and z-z axes. Similarly remaining two planes are evaluated (0 0) and ( )
25
Fig.0.27: Miller indices for three opposite faces of the cubic unit cell
As the six planes of the cubic unit cell are of the same geometry/form; they are represented by the
indices of one of the planes enclosed in curly brackets or braces {}. Hence, {100} will represent a set of
six planes of that unit cubic cell (100), (010), (001), ( 00), (0 0) and ( ). Similarly, {110} represents a
set of six planes (110), (101), (011), ( 0), (10 ) and ( ). These planes also represent diagonal planes.
Plane (110)
Planes ( 10)
Plane (101)
Plane (10 )
Plane (011)
Plane (01 )
Miller indices define a set of parallel planes as they have same miller indices
Miller indices of two parallel planes may also have the same ratio (e.g. 844 and 422 or 211)
Planes parallel to one of the co-ordinate axes has an intercept of infinity
Exercises
1. Compute the miller indices for the following planes [soln: the plane is parallel to y-y and z-z; (200)]
2. Draw the planes (112), (020), (120), (220), (221) and (211)
0.2.3.2 Crystal directions: A crystallographic direction can be defined as a line joining any two points of
the space lattice, or the line of intersection of two planes. In general, they are represented in terms of
three axes with references to the origin and a lattice point represents the lattice point. The directions
are represented by small set of integers enclosed in square blackest [ ] i.e. [hkl]. The procedure for
determining the directions is as summarized below:
(a) Establish axes system and Determine the coordinates of the beginning and end of the direction
vector AB. A(x1,y1,z1); B(x2y2z2)
27
(b) Evaluate the magnitude by subtracting negative coordinates of A from B. h = x2 x1; k=y2 y1; l=z2 z1
B (x2y2z2)
A(x1,y1,z1)
(i) Draw a straight line OD passing through the origin O and parallel to
the crystal direction RS, whose Miller indices are required to be
determined.
(ii) Take any point P on the line OD and draw perpendiculars PL, PM and PN on x-x and y-y axes
respectively
(iii) Find the intercepts of OL, OM and ON in terms of axial units
(iV) Reduce these intercepts in the smallest integers. This is done by dividing the values of three
intercepts with the least value of the three intercepts.
(V) Enclose the smallest integers in square brackets which represents the Miller indices of the line RS
[100], [010] and [001] represent directions along x-x, y-y and z-z axes respectively. The other 3 directions
are found by shifting origin to another corner; e.g. DH direction represented by swapping the origin at D,
HG at G and HE at E; the values of intersects become minus.
28
As all the crystal directions, in a cubic unit cell are of the same form, the Miller indices of such crystal
directions are represented by the indices of one of the crystal directions enclosed in a carat < >. Hence
<100> represents a set of six directions [100], [010], [001], [ 00] [0 0] and [00 ].
It is noticeable from 4 shown figures, every crystal direction is
perpendicular to the plane that they have same Miller indices: HD/[100]
with ABCD, HG/[010] with BFGC and HE/[001] with AEFB. As a conclusion;
in a cubic system, all the directions and planes with identical indices are
perpendicular.
For this leftward figure, HA [101], HC[110], HF[011] and HB[111]. Crystal
directions having negative values along x, y and z axis are likewise
represented
Fig.0.34: Some important crystal direction in a cubic unit cell
29
2. Calculate the atoms per unit cell of metallic Zinc. Draw (121) plane and <121> direction in a cubic
lattice.
Soln.: we know that Zinc has FCC structure. The total number of atoms per unit cell may be obtained as
follows: the FCC structure has 8 corners and 6 faces. It has an atom at each corner and another at the
centre of each face. The corner atom is shared by 8 cubes, and each atom at the face centre is shared by
2 cubes. The number of atoms in all six faces = 1/2 x 6 = 3, and number of atoms in all the corners = 1/8
x 8 = 1. Hence the total number of atoms = 3+1 = 4atoms.
Let h,k and l = intercepts along x-, y- and z- axis. We know that Miller
indices of given plane 1:2:1 =
or
Thus, the intercept along x-axis is one unit, one-half along y-axis and
one unit along z-axis. Knowing this, the (121) plane and its
perpendicular line (direction <121>) can be sketched as shown.
Noteworthy postulates to recall about Miller indices
If a plane has negative intercept, the negative number is denoted by a bar above the number.
Never alter negative numbers. For example, do not divide -1, -1, -1 by -1 to get 1,1,1. This implies
symmetry that the crystal may not have!
The crystal directions of a family are not necessarily parallel to each other. Similarly, not all
planes of a family are parallel to each other.
By changing signs of all indices of a direction, we obtain opposite direction. Similarly, by
changing all signs of a plane, a plane at same distance in other side of the origin can be obtained.
30
Multiplying or dividing a Miller index by constant has no effect on the orientation of the plane.
The smaller the Miller index, more nearly parallel the plane to that axis, and vice versa.
When the integers used in the Miller indices contain more than one digit, the indices must be
separated by commas. E.g.: (3,10,13)
By changing the signs of all the indices of (a) a direction, we obtain opposite direction, and (b)
a plane, we obtain a plane located at the same distance on the other side of the origin.
} is given by
ao
h l k
2
3.615
1 2 1
2
3.615
1.8 A0
4
2. [
) if
3. [
) if
) and (
5. To find out the angle between the two intersecting planes, we use the dot product:
| || |
| || |
E.g. Calculate the angle, and the line of intersection between the two planes (124) and (012)?
31
) (
)
(
6. Two planes (
7. Two directions [
) and (
] and [
) are normal if
] are normal if
where F is the free energy of a given system, H is the heat content or enthalpy and TS is the entropy, or
disorder, term. If a reaction takes place at a temperature T, we find the change in F (DF) related to a
change in H (DH), the heat content, and possibly also a change in TS (TDS).
Such is the case when defects are formed in a perfect solid: The energy distribution in a solid (MaxwellBoltzmann) suggests that a number of individual atoms may acquire enough thermal energy to be
displaced from the equilibrium lattice site into an interstitial position. Hence; Under temperature
activated processes, some atoms may leave their normal positions to occupy interstitial positions. This
process results simultaneously in the formation of a vacancy and an interstitial atom. The number of
vacancies (defects) at equilibrium Nd at a certain temperature T is given by:
(
);
Where N is the total number of atomic sites per cubic meter or per mole. Ed or H is the activation
energy necessary to form a defect. A is the proportionality constant, T is the absolute temperature (in
Kelvin) and k the Boltzmanns constant, (k=1.380 X 10 -23 JK-1)
This process of point defect formation requiring energy and leads to lattice strain which constitutes, as
discussed earlier, an increase in the heat content of the system (DH is positive and increases linearly
with the number of defects formed). The departure from perfection by the generation of defects leads
to disorder (DS is positive). The magnitude of disorder generated (DS) is very large during the initial step
from perfection to slight disarray, but the increase in disorder (with a given number of defects
33
state energy is
the probability that an atomic site is vacant varies in the same way. In a (molar)
crystal containing N atomic sites, the number nd of vacant sites is as already shown in equation.
Vacancies and interstitial atoms may be also triggered by Irradiation with x-rays; An imperfect packing
during crystallization; Plastic deformation; Quenching and Heating.
Point Defects in Pure Metallic Systems: They are defects of atomic dimensions. A much localized
interruption in the regularity of a lattice due to either: The absence of a matrix atom (vacancy), the
absence of a matrix atom and/or the presence of a matrix atom in the wrong place. The simplest point
defects are as follows:
Vacancy is an atom site, normally occupied in the perfect crystal, from which an atom is missing at a
certain crystal lattice position. Often the term vacancy is used to denote a so-called Schottky
defect, which is formed when an atom or an ion leaves a normal lattice site and repositions itself in
a lattice site on the surface of the crystal. This may be the result of atomic rearrangement in an
existing crystal at a high temperature when atomic mobility is high because of increased thermal
vibrations. A vacancy may also originate in the process of crystallization as a result of local
disturbances during the growth of new atomic planes on the crystal surface. Vacancies are point
defects of a size nearly equal to the size of the original (occupied) site; the energy of the formation
of a vacancy is relatively low - usually less than 1 eV.
Self-interstitial atom extra atom in an interstitial position;
Interstitial impurity atom extra impurity atom in an interstitial position between matrix atoms.
Substitution impurity atom impurity atom, substituting an atom in crystal lattice.
Whether a foreign atom will occupy a substitutional or interstitial site depends largely on the size of
the atom relative to the size of the site. Small atoms are usually interstitial impurities, while larger
atoms are usually substitutional impurities.
34
35
36
Fig.: Schematic presentation of a dislocation; the last row of atoms (dark) in the inserted fractional
plane
Line imperfections, or dislocations, in crystalline solids are defects that produce lattice distortions
centered about a line. A dislocation is simply the edge of an extra inserted fractional plane of atoms.
Normally the symbol is used to represent a positive and dislocation (extra fractional plane) and is
used to represent a negative dislocation (missing fractional plane).
The dislocation causes a displacement characterized by the burgers vector; b. the burgers vector is
perpendicular to the edge dislocation.
The plane in which a dislocation moves through the lattice is called a slip plane. With an applied shear
stress the dislocation moves, atomic row by atomic row, and one part of the crystal is displaced relative
to the other. When the dislocation has passed through the crystal, the portion of the crystal above the
slip plane has shifted one atomic distance relative to the portion below the slip plane. In other words,
the motion of the dislocation has caused the crystal to change its shape - to be permanently deformed
Fig.: Plastic deformation of crystalline solid by slip associated with stress induced motion of
dislocation
Plastic Deformation By Slip: When single crystals of metal (or semiconductor) are pulled in tension, they
will begin to deform (elongate) plastically at relatively low stress levels, and blocks of the crystals slide
over one another because of dislocation motion. Simultaneously, so-called slip lines appear on their
surface. It is found that deformation by slip occurs most easily on planes with high atomic density and
with large interplanar spacing, while the direction of slip is in all instances an atomically close-packed
37
direction. For FCC structures we therefore observe as the primary slip system {111} planes in <110>
direction, while in BCC structures the primary slip occurs on {110} planes in <111> directions. (It should
be noted that an alternate deformation mechanism is deformation twinning, presently not to be
considered.)
Dislocation Climb: Climb is the name given to the motion of dislocations when the extra half plane is
extended farther into a crystal or partially withdrawn from it.
Clearly, the climb process is not a
motion of the plane, but rather its
growth or shrinking as a result of
the addition of atoms or
vacancies respectively from the
environment of the dislocation
Figure 7 Dislocation climb by (a) loss of atoms to surrounding vacancies and (b) incorporation of
interstitial atoms.
Where dislocations come from?
Dislocations can be created by crystal mismatch in solidification. They can be introduced by External
stresses such as plastic deformation; they can occur by phase transformations that cause atomic
mismatch effects of adding alloy elements. The importance of dislocations to the metal user is that
dislocation interactions within a metal are a primary means by which metals are strengthened. When
metals deform by dislocation motion, the more barriers the dislocations meet, the stronger the metal.
Dislocations are seen and studied only with microscopic and etching techniques since they are atomic in
size.
a) Screw dislocation
It forms when one part of crystal lattice is shifted (through shear) relative to the other crystal part. It is
called screw as atomic planes form a spiral surface around the dislocation line. Slip plane (There is a slip
step produced when a dislocation reaches a free surface)
b
Slip plane
structure can be revealed by preferential chemical attack (etching, the grain boundaries dissolve more
rapidly, leaving a line marking their location.) at the grain boundaries, while the grain structure in
polyethylene is revealed by the use of polarized light.
The anisotropic properties of a crystal grain are discontinuous across a boundary. The atoms along the
grain boundary are more reactive because they possess more energy than interior atoms (lower packing
factor). The microstructure is characterized by grain size, grain shape and grain orientation. The grain
structure is usually specified by giving average grain diameter or by using a scheme developed by the
American Society for Testing and Materials (ASTM: American Society for Testing Materials)
Grain
Grain
Grain boundary
Grain
Fig.0.41: The atomic arrangement in crystals depicting the grain boundary and fine with Coarse grains
The grain size affects the area and length of the grain boundary. It also affects the strength of the
material. A fine grained structure has higher yield strength than coarse grained structure. According to
the Hall-Petch equation, y 0
ky
d
constant related to the stress required to create new dislocations and d is the average grain diameter.
The ASTM grain size N can be calculated from the equation N = 2 n + 3. Where n is the number of grain in
one square meter taken at a magnification of 100X. E.g.: how many grains in 1m2 at 100X for n = 3. N =
26 = 64
In polycrystalline samples the individual grains usually have a random crystallographic orientation with
respect to one another, and the grain structure is referred to as randomly oriented. In some instances,
however, the grains all have the same orientation to within a few degrees. In this instance the material
is said to have a preferred orientation or texture.
C. Phase Boundaries
A phase is defined as a homogeneous, physically distinct and mechanically separable portion of the
material with a given chemical composition and structure. Phases may be substitutional or interstitial
solid solutions, ordered alloys or compounds, amorphous substances or even pure elements; a
crystalline phase in the solid state may be either polycrystalline or exist as a single crystal.
Solids composed of more than one element may - and often do - consist of a number of phases. For
example, a dentists drill: a mixture of small single crystals of tungsten carbide (discontinuous) for good
40
abrasive characteristics surrounded by a matrix of cobalt (a continuous phase) for and good toughness
and impact resistance. Such polyphase materials are generally referred to as composite materials to
yields a structure with the desired properties.
The nature of the interface separating various phases is very much like a grain boundary. Boundaries
between two phases of different chemical composition and different crystal structure are similar to
grain boundaries, while boundaries between different phases with similar crystal structures and
crystallographic orientations may be analogous to low-angle grain boundaries in both energy and
structure.
The concept of a solid consisting of a continuous phase and a discontinuous phase (or phases) leads to a
simple classification of the various types of composite materials based on the structure (whether
amorphous or crystalline) of the continuous and discontinuous phases.
Continuous Phase
Crystalline
Discontinuous Phase/phases
Crystalline
Crystalline
Amorphous
Amorphous
Crystalline
Amorphous
Amorphous
Examples
All metallic systems such as cast iron, steel, soft solder, etc.;
most natural rocks such as granite and marble.
None of practical significance.
Most man-made ceramics such as building bricks and
electrical insulator porcelain, concrete, partially crystalline
polymers, some polymer-crystalline particle composites.
Fiberglass, asphalt, wood, hydrated cement, other gels.
Density ( )
mass(m)
density of themateria l
, Re lative(d )
or the mass of a
volume(V )
density .of . pure.water .at.4 0 C
42
43
Fig.1.3: Chisels shear blades with Rivet joining 2 metal bars together
Fatigue strength (endurance limit) or sometimes referred to as the fatigue limit, it is the maximum
stress amplitude in fatigue below which a material can endure an essentially infinite number of
stress cycles and not endure failure. Generally infinite life means more than 107 cycles to failure
Fig.1.5: A tensile test specimen with the same length before and after the application of the load
a: Stress (The internal resistance induced in the body when it is subjected to external forces). Types of
stresses: Tensile, compressive, bending and shear stress.
44
Uniform (necking) strain: it is the value of strain at which the area of the specimen begins having
different values at different points, i.e. necking starts
Elastic/youngs modulus, E is the slope of the initial, linear-elastic part of the stress-strain curve in
tension or compression. It is a measure of the rigidity of the material. It is the proportionality
constant of solids between elastic stress and elastic strain and it describes the inherent (natural)
stiffness of a material.
E=Elastic stress/Elastic strain.
For isotropic materials it is related to bulk modulus K and to shear modulus G:
(
)
(
)
, and hence E=K, and
Where is the Poissons ratio; commonly
( )
Yield strength: The stress at which a material exhibits a specified deviation fro proportionality of
the stress and strain (flow stress). An offset of 0.2% is used for many metals.
Upper yield point
Yield point
Lower yield point
Fig. 1.7: Yield strengths two possible statuses
Only certain metals have a yield point (metals with BCC crystal structure such as iron). If there is a
decrease in stress after yielding, a distinction may be made between upper and lower yield points.
Shear modulus is the initial, linear elastic slope of the stress-strain curve in shear. Also referred to
as modulus of rigidity or torsion modulus, its is the ratio of shear stress divided by the shear strain
in elastic region. G= Elastic shear stress/Elastic shear strain.
For isotropic materials it is related to youngs modulus E and to bulk modulus K and Poissons ratio:
(
)
(
)
(
)
,
When
( ) and
( )
Bulk Modulus, K, measures the elastic response to hydrostatic pressure. Ratio of mean normal
stress to the change in volume
(
(
)
)
, E= K, and
When
( )
Poissons ratio, , (dimensionless): it is the negative ratio of the thickness decrease divided by the
length increase as a result of a tensile stress applied to a material. Its value for many solids is close
to 1/3. For elastomers it is just under 0.5
Stiffness (rigidity): The resistance of a material to elastic deformation. It is measured as the area under
the elastic part of stress-strain curve. The rigidity can be also defined as a measure of a materials ability
not to deflect under an applied load. For example, although steel is very much stronger the cast iron the
latter material is preferred for machine beds and frames because it is more rigid and less likely to deflect
with consequent loss of alignment and accuracy. E.g.(see fig.): For a given load the cast iron bar deflects
less than steel bar. However, by increasing the load the Cast iron beam bar breaks, whilst steel bar
merely deflects a little further without breaking. Thus rigid material is not necessarily strong. Rigid
materials are often ductile.
46
Fig.1.9: a piece of mild steel strip bent at right angles which does not spring back straight again
Ductility: this term is used when a useful amount of plastic deformation occurs as a result of a
tensile load (Ability of a material to be drawn into wire). . The tensile ductility is the permanent
increase in length of a tensile specimen before fracture, expressed as a fraction of the original
gauge length, i.e it is the ability of a material to undergo large plastic deformation without failure,
also it can be expressed as reduction of area of the specimen during the tensile test.
Fig.1.10: Wire drawing process and comparative graphs between strength, ductility and toughness
stress
47
Superplasticity: a feature of materials to withstand plastic deformation over their limits at high
temperature (usually half of the melting temperature). This effect is caused by dynamic
recrystallization during deformation of the metal
Bauschinger effect: the process where the plastic deformation in one direction causes a reduction
in the yield strength when stress is applied in opposite direction
4. Brittleness: opposite property to ductility and malleability. The material shows little or no plastic
deformation before fracture when a force is applied.
Refer to Fig.: A steel rod can be bent but a grey cast iron rod snaps when you try to bend it.
Temper brittleness: A feature of some materials, which causes the material to become more brittle
after tempering. It can be obtained from the notch-impact test.
48
5. Hardness: ability of a material to withstand scratching, surface abrasion and indentation (local plastic
deformation) by another hard body. Often measured by pressing a pointed diamond or hardened steel
ball into the surface of the metal. It is generally defined as the indentor force divided by the projected
area of the indent measuring techniques: Brinell, Vickers, Rockwell, Shore etcIt is an indication of wear
resistance of a material.
Load
indentor
Specimen surface
Fig.1.13: Indentor with load in soft material penetration
Hardness is good indicator for controlling or comparison purposes, but has little meaning for scientific
purposes or calculations
Hardened steel ball only makes a small
indentation in the hard material but it
makes a very much deeper impression in
the softer material.
Fig.1.14: hardened steel ball being pressed first into hard, then soft material by the same load.
Strain hardening exponent: an increase in hardness and strength caused by plastic deformation at
temperatures below the recrystallization range. The measure is the exponent n in the equation
n
n
1=k 1 or ln=lnk + nln 1
Strain rate sensitivity: it is the measure for how fast strain hardening occurs when a material is
deformed plastically. It is defined as
(
)
[
]
(
)
Archard wear constant, kA(m/MN): the volume of material lost from one surface, per unit distance
slid is called the wear rate. The materials ability to resist wear is given by the Archard wear
constant, KA.
; where A is the area of the surface, p is the pressure.
49
Volume, V
P3
P
P2
P1
W=V/S
V
S
Area
6. Toughness (Impact strength): the ability of a material to withstand shatter i.e. absorbing energy
without rupturing (e.g.: rubber and most plastics). If a material shatters it is brittle (e.g.: glass).
Also defined as materials opposition to bending or
shearing without fracture. E.g. if a rod is made of
high-carbon steel then it will bend without breaking
under impact of the hammer, while if a glass rod, it
will break by impact loading as illustrated leftwards.
Usually, it is measured by the energy absorbed in a
notch impact test, but the area under the tensile
stress-strain curve is also a measure
Fig.1.16: A metal rod in a vice being broken by impact loading
50
Where Y is a geometric factor near unity; Measured in this way, Kc has well defined
values for brittle materials (ceramics, glasses, many polymers and low toughness
metals like cast ron). In ductile materials, a plastic zone develops at the crack tip,
which introduces new features into the way cracks propagates. This necessitates
more complex characterization. Nevertheless, for Kc are cited and are useful as a
way of ranking materials.
F
U
A0
U
L/L
If a material is loaded elastically to a maximum stress. It stores elastic energy per volume:
If it is loaded and then unloaded, it dissipates energy equivalent to the area of the stress-strain hysteresis
loop:
51
The cycle can be applied in many different ways-some fact, some slow. The values of usually depend
on the tome-scale or frequency of cycling.
8. Creep: Time-dependent deformation which occurs when materials are loaded above 1/3Tm (melting
temperature). Examples: turbine blades, steam generators. it is then slow and permanent deformation
due to constant stress at high temperature for a long period of time. This property is very used in boilers,
turbines and internal combustion engines.
Final stage
Primary
stage
Secondary
stage
52
Where
E.g.: soldering iron with a bit made of copper, the wooden handle remains cool as it has a low thermal
conductivity and resists to flow of heat energy.
Specific heat capacity Cp (at constant pressure:(J/KgK): the heat energy required to raise the
temperature of a unit mass (1kg) of the substance by one degree 10C (K) . It is measured by the
standard technique of calorimetry. E.g.: water requires more heat energy to raise its temperature
by any given amount than an equal mass of any other liquid; that is why water is used as a coolant.
Heat capacity (Cp), Q = mCpT
Specific heat = Cp/Atomic mass (Kg/Kg K)
Melting point, Tm: there are melting and recrystallization temperatures for all metals and alloys.
The melting point is the temperature at which a material turns from solid to liquid. Only pure
substances have a single melting temperature but alloys have a melting range of temperatures.
Usually, Tm for alloys is less that Tm of the parent metals
Fusibility: The ease with which materials will melt. Eg: Solder melts easily and so has a high fusibility
but fire bricks used for furnace linings only melt at very high temperatures, so they have low
fusibility such materials are called refractory materials and are used as thermal insulators (eg:
polystyrene).
55
1200
1000
Melting
temperature of
the metal
Liquid
800
Melting range
(Cu)
600
Melting
temperature
of the alloy
(Ag)
0
Ag
10
20
Mass % Cu
90
100
Cu
Glass transition temperature, Tg (k): a property of no-crystalline solids which do not have a sharp
melting point. It characterizes the transition from true solid to very viscous liquid in these materials.
Thermal diffusivity, a (m2/s): when the heat flow is not steady the flux depends on thermal
diffusivity
(
a heat, which is applied to the material, will be distributed among the material. At high and low
temperature differences will be equally quickly.
2. Electrical Properties: Resistivity, conductivity, dielectric constant, dielectric strength, relaxation time,
power factor. UI since U = I R but R = x L/A where : Resistivity, L: length, A: area.
Conductivity () = 1/ therefore R = L/ A
Electrical conductivity: property of materials to offer very little resistance to the flow of electrons
(electric current). Very bad conductors, such as PVC are called insulators.
Resistivity [10-8W.m] is the resistance offered by a unit cube of that material measured between
opposite faces. It describes the ability of a material to resist or oppose the transport of electrical
charge in response to an external electric field. It varies over a range: from 10-8W.m to more than
1016Wm for best insulators. The conductivity of metals and metal alloys improves as the
temperature falls. Conversely, non-metallic materials used for insulators become poorer insulators
with the temperature increase.
from the external field. The tendency to polarize is measured by the dielectric constant. Dielectric
constant is the degree of polarization or charge storage capacity of a material when subjected to an
electric field.
Permittivity: (dimensionless) it is the ratio of electric flux density in the dielectric to the electric field
strength of the charge.
3. Magnetic properties: Hysteresis, retentivity, permeability, susceptibility, coercive force, reluctivity.
Reluctance: It is the resistance of a magnetic circuit. good conductors have a low reluctance. Eg is
ferromagnetic materials made from iron, steel and associated alloying elements such as cobalt and
nickel.
Permeability: (no unit) it is the ease with which a material can be magnetized. 0 r Where
, 0, r are the absolute, free space and relative permeabilities. It varies with the magnetizing force.
58
5. Optical properties: materials features when they encounter the light. Reflection, refraction,
transmission, fluorescence, luster, luminescence, etc
If the oxide is protective, forming a continuous film without cracks over the surface, the reaction slows
don with time, as the oxygen cannot pass through this layer. The oxidation rate mainly depends on the
characteristic of this oxide layer, which can be describes by Pilling-Bedworth ratio.
Ao is the molecular weight of the metaloxyde, AM is the atomic weight of the metal, and are
corresponding densities.
If the Pilling-Bedworth ratio is smaller than 1, non-porous and protective oxide layer forms; If the ratio is
higher that 2 or 3 the layer breaks and is not protective any more
Flammability: Is a materials ability to suppress combustion. The number given as flammability
corresponds to a relative rating system, thus using it almost only for comparisons is reasonable.
Wet corrosion (caused by a reaction of metal with water, brine, acids and alkalis) is much more
complicated and cannot be defined by simple relations. It is more usually to scale the resistance by
relative values. Corrosion is effective in fresh water, organic solvents, sea water, strong acid, strong
alkalis, UV, weak acid and weak alkalis.
Metallurgical properties: phase rule, solid solution, crystallization rate, diffusion
This is the controlled heating and cooling of metals to change their properties to improve their
performance or to facilitate processing. An example of heat treatment is the hardening of a piece of high
carbon steel rod. If it is heated to dull red heat and plunged into cold water to cool it rapidly (quenching),
it will become hard and brittle. If it is again heated to dull red heat but allowed to cold very slowly it will
become softer and less brittle (more tough). In this condition it is said to be annealed.
After the heat treatment happened on the material it will be in its best condition for flow forming,
during flow forming (working) the grains will be distorted and this will result in most metals becoming
Work hardened if flow formed at room temperature. To remove any locked in stresses resulting from
the forming operations and to prepare the material for machining, the material has to be normalized.
2. Processing
Hot and cold working process will be referred to understand what is meant by terms hot and cold
working as applied to metals. Figure below shows examples of hot and cold working.
Dezincification of brass: Brass is an alloy of copper and zinc and when brass is exposed to a marine
environment for along time, the salt in the sea water pray react with the zinc content of the brass so as
remove it and leave it behind on spongy, porous mass of copper. This obviously weakens the material
which fails under normal working conditions.
Degradation of plastic: Many plastic degrade and become weak and brittle when exposed to the
ultraviolet content of sunlight. Special dyestuffs have to be incorporated into the plastic to filter out
these harmful rays.
Does the material selected meet the strength requirements for the functioning of the design?
Is it attractive?
There are many factors to be considered when selecting, but broadly, one starts with broad range of
materials, and then narrows it down as some materials are eliminated. These factors are:
(a) Physical properties like: Size, shape and weight according to the available space, processing way,
energy consumption.
(b) Mechanical factors: they are used as design criteria to prevent mechanical failure, such as
tensile, yield, impact, creep strength, modulus of elasticity, etc.
(c) Processing and fabricability: How material will be processed of fabricated to the desired shape
and size. (Casted, forged, machined, welded, etc). The designer ought to know the heat
treatment and finish processing.
(d) Life of component factors: the expected life of the component. Factors related to the type of
loading and environment of operation are considered, such as corrosion, oxidation, wear,
impact loading, etc. Designers often develop life prediction model for estimating expected
design life.
(e) Cost and availability: this is because we live in a market driven economy. Cost of transportation
will make expensive materials that are not locally available.
(f) Codes, statutory and other factors: codes are sets of technical requirements imposed on the
material. They are set by the customer or standardization bodies (ISO, DIN, ASME, ASTM, SAE,
BS, etc.). Statutory factors relate to local, state, and federal regulations and relate to health,
safety and environment requirements.
What type of material should be used for a particular application? The choice depends on a number of
properties:
2.1. Bulk mechanical properties
Stiffness - resistance to bending and elastic deformation
Yield strength - point at which irreversible shape change occurs
Tensile strength - point at which the material becomes unstable and fracture is imminent
Hardness - resistance to abrasion
Ductility - the amount by which a material may be extended before failure occurs
Fracture toughness - the resistance to crack propagation, i.e. the opposite of brittleness
Fatigue resistance - as continual variations in stress can cause failure
Creep resistance - as there is a gradual extension of materials under stress with time.
Density - important when weight is of concern.
62
Example 2: The connecting rod of a motor car engine. This is made from a special steel alloy. This alloy
has been chosen because it combines the properties of strength and toughness with the ability to be
readily forged to shape and finished by machining.
Thus the reasons for selecting the materials in the above examples can be summarized as : Commercial
factors such as: Cost, availability, ease of manufacture and Engineering properties of materials such as:
Electrical conductivity, strength, toughness, ease of forming by extrusion, forging and casting,
machinability and corrosion resistance.
64
NON-METALLIC
METALLIC
FERROUS
Cast Iron
Malleable Iron
Wrought Iron
NON - FERROUS
Cooper,
Aluminum,
Magnesium,
lead, zinc, Tin
ORGANIC POLYMERS
COMPOSITES
Eg: stone, brick,
cement, rubber,
Metal Ceramic
plastics, glass,
etc.
Metal reinforced metal
Ceramic polymer
Steel
Polymer cement
concrete
Fig. 2.1: Classification of engineering materials
65
ALLOYS
CERAMICS
FERROUS
Alloys containing
iron and steel
NON FERROUS
Alloys of
Aluminum,
Magnesium, lead,
zinc, Tin. Alloys of
Brass and Bronze
Brass (Cu + Zn),
Bronze (Cu + Sn,
Si, Be, Al, Ni)
Ferrous
Steel
Cast Iron
Wrought Iron
Metals
Metals
Al, Cd, Cr, Co, Cu, Au, Pb(lead), Mn, Mg, Mo, Ni, Pt, Ag(silver), Sn(tin), Ti, W, V, Zn
Brass (cu + Zn)
Non-ferrous
Phosphor bronze
Gun metal
Heat treatable (wrought)
Heat treatable (cast)
Alluminium alloys
Magnesium alloys
E.M
Plastics
Synthetic
Non-Metals
Natural
66
Thermosetting
Ceramics
Composites
Asbestos, colourants (dies & pigments), Coal, Cotton, Diamond, Emery, Gases (Ar, Methane, Ne, Ni,
O, He: air derivatives), Glues: animal derivatives, Gums: vegetable derivatives, granite, Mica, Oil,
Quartz, Rubber, Sapphire, Wood, Wool
67
METAL ALLOYS
FERROUS
Steels
Cast irons
Low alloys
Low-carbon
Plain
Medium-carbon
NONFERROUS
High alloys
Gray Ductile White Malleable
iron (nodular) iron iron
iron
High-carbon
Heat
Plain
treatable
Tool
Compacted
graphite
iron
Stainless
Specific names
Purest to 0.05
Wrought iron
0.05 to 0.15
0.15 to 0.30
Mild steel
0.30 to 0.70
Forgings
0.70 to 1.40
Semi-steel or semi-iron
4.50 to 6.67
Pig iron
6.67 or more
Ore
68
Typical applications
Engine blocks
Cast Iron
2.1.2 Non-Ferrous metals: they do not contain Fe and C as their constituents. Al, Cu, Ag, Au are good
conductors of electricity. Ag is most malleable, Au is most ductile and Chromium is corrosion resistant.
Zinc is used in metal plating, Tin is used to make bushes and Nickel imparts strength and creep
resistance.
Major properties of metals are:
They usually have a crystalline structure and are good thermal and electrical conductors
Many metals have high strength and high elastic module
They maintain their good strength at high and low temperatures
They also have sufficient ductility, which is important for many engineering applications
They can be strengthened by alloying and heat treatment
2.1.3 Alloys: Pure metals are rarely used in structural applications as alloys allow mechanical properties
to be tailored to meet particular requirements since they possess properties quite different from those
of their constituent metals. They are combination of two or more metals whether non ferrous or ferrous
(ferrous alone can be considered as alloys of Fe and C). Alloys are normally treated as solid solutions
of two metals. In some cases the atoms of the second metal occupy the sites normally occupied by the
first metal (a substitutional solid solution, e.g. brass, up to 30% zinc in copper); in others, the atoms of
the second metal occupy the gaps between the atoms of the first metal. They are found under ferrous
and non ferrous alloys depending on their base metal. The ferrous alloys are particularly important
materials, and these are broadly classed into: irons, containing <0.015 % carbon, steels, cast irons. Steels
themselves are normally described as:
Carbon steels (or mild steels). These contain just iron and some carbon, and have excellent mechanical
properties at moderate temperatures (but not necessarily at high temperatures). They also have poor
corrosion resistance. Carbon steels are cheap, readily available and easy to fabricate.
Stainless steels. There are a whole range of stainless steels containing different amounts of nickel and
chromium as well as other additives for special purposes. They are subdivided according to their
metallurgical structure, which depends on their chemical composition:
Ferritic: 13-20 % Cr ; no Ni ; <0.1 % C; Austenitic: 18-20 % Cr ; >7 % Ni ; variable C; Martensitic: 10-12 %
Cr ; <2 % Ni ; 0.2-0.4 % C
Austenitic steels are particularly important in the chemical industry due to their excellent corrosion
resistance (caused by a CrO2 layer at the surface).
Other types of steel which are intermediate in character between the carbon steels and stainless
steels for particular applications are: Low alloy steels: these contain up to 2.5 % chromium and
molybdenum; Chrome steels: these contain up to 12 % chromium; Nickel steels: these contain up to 9 %
nickel.
Other metal alloys that are widely used are those of alluminium, copper, nickel and titanium.
69
Dyes
Pigments
Cotton
Diamond
Emery
)
(
Gases
}
Natural materials
Glues (animal derivatives)
Gums (Vegetable derivatives)
Granites
Mica
Oil
Quartz
Rubber
Sapphire
Wood
Wool
70
2.2.1 POLYMERS
In Greek mer means a unit poly means manyPolymer = many units; Mono: one. Materials
generally known as plastics and rubbers are built up from (normally organic) monomeric building units
that bring about long molecular chains or networks.
We know that many organic materials are hydrocarbons; that is, they are composed of hydrogen and
carbon. Furthermore, the intermolecular bonds are covalent. Each carbon atom has four electrons that
may participate in covalent bonding, whereas every hydrogen atom has only one bonding electron. The
hydrocarbon molecules in polymers are comparatively gigantic often referred to as macromolecules in
which monomers (individual molecules) are linked up/bonded by chemical reaction through a process
named polymerization to form polymers.
Polymerization:
Ethylene (C2H4) is a gas at room temp and pressure but it transform to polyethylene (solid) by forming
active mer through reaction with initiator or catalytic radical (R).
1. Initiation reaction
(.) denotes unpaired electron (active site)
2. Rapid propagation ~1000 mer units in 1-10 ms
3. Termination when two active chain ends meet
each other or active chain end meet with initiator
or other species with single active bond
Replace hydrogen atoms in polyethylene:
polytetraflouroethylene (PTFE) Teflon
make
71
ceramics and metals because the molecular chains are bonded to each other with only rather than weak
electrostatic forces called Van der Waals bond.
Copolymers, polymers with at least two different types of mers, can differ in the way the mers are
arranged
72
Two types of isomerism are possible: stereoisomerism (atoms are linked together in the same order,
but can have different spatial arrangement) and geometrical isomerism (consider two carbon atoms
bonded by a double bond in a chain. H atom or radical R bonded to these two atoms can be on the same
side of the chain (cis structure) or on opposite sides of the chain (trans structure).
73
Fig.: possible molecular structures over covalent chain configurations with strength increasing from
left to right.
Linear Polymers: repeating units are joined together end to end in single chains. These long chains are
flexible. For linear polymers, there may be extensive van der Waals and hydrogen bonding between the
chains. Some of the common polymers that form with linear structures are polyethylene (synthetic
polymer: a plastic polymer of ethylene. Use: manufacture of containers, packaging, and electrical
insulation), polyvinyl chloride (PVC), polystyrene, polymethyl methacrylate (plexiglass), nylon, and the
fluorocarbons (Teflon)
Branched Polymers: synthesized so that side-branch chains are connected to the main ones and
considered to be part of the main chain molecule. They result from side reactions that occur during the
synthesis of the polymer. The chain packing efficiency is reduced with the formation of side branches,
which results in a lowering of the polymer density. Those polymers that form linear structures may also
74
be branched. For example, high density polyethylene (HDPE) is primarily a linear polymer, while low
density polyethylene (LDPE) contains short chain branches.
Cross-linked Polymers: adjacent linear chains are joined one to another at various positions by covalent
bonds. The process of cross linking is achieved either during synthesis or by a nonreversible chemical
reaction. Often, this cross linking is accomplished by additive atoms or molecules that are covalently
bonded to the chains. Many elastomers or polymeric rubbers are cross-linked (vulcanization process);
most thermosetting polymers
Network (3D molecular structure) Polymers: Multifunctional monomers forming three or more active
covalent bonds make three-dimensional networks. Actually, a polymer that is highly cross linked may
also be classified as a network polymer. These materials have distinctive mechanical and thermal
properties; the epoxies, polyurethanes, and phenol-formaldehyde belong to this group.
Polymers are not usually of only one distinctive structural type. For example, a predominantly linear
polymer might have limited branching and cross linking.
Plastics: Possibly the largest number of different polymeric materials come under the plastic
classification. Plastics are materials that have some structural rigidity under load, and are used in
general-purpose applications. Polymers falling within this classification may have any degree of
crystallinity, and all molecular structures and configurations (linear, branched, etc.) are possible.
However, to be considered plastics, linear or branched polymers must be used below their glass
transition temperatures (if amorphous) or below their melting temperatures (if semicrystalline), or
must be cross linked enough to maintain their shape.
The advantages underlying plastics that propel their increased use are: their many useful properties,
couples with comparatively low cost, their low densities, their high resistance to chemical attack, their
thermal and electrical insulation properties, their ease of fabrication in to a wide variety of both simple
and complex shapes. However, they exhibit following vices: The low strength and elastic modulus
values, in compression with those of metals; the low softening and thermal degradation temperature;
their comparatively high thermal expansion coefficients.
Plastic materials may be either thermoplastic or thermosetting as sub-classification:
Thermoplastic: Heating the polymer vibrates the molecules and if they are not cross linked, the distance
between the molecules will increase and the Van der Waal forces will be reduced. This will make the
polymer soften so these types and be remoulded by heating. Thermo-plastics (nylon, polyethylene,
polyvinyl chloride, rubber, etc.) consist of molecules that have covalent bonding within each molecule
and van der Waals forces between them.
Thermosetting: During the moulding process, chemical changes occur and the molecules become cross75
linked forming a more rigid structure. Reheating will not soften the polymer. Thermo-sets (e.g., epoxy,
phenolics, etc.) consist of a network of covalent bonds. are relative inert and light, generally have a
high degree of plasticity, so named plastics.
Thermoplastics
Thermosets
Softened when heat treated and harden Become permanently hard after the initial
when cooled
heat-cooling cycle
Varying degree of ductility
Brittle
Can be recycled
Cannot be recycled
Elastomers/Rubber (elastic mers): These are virtually the same as thermosetting but they have a
very high degree of elasticity (elongates on stretching and regains its original shape after removal
the stress) and although they stretch easily compared to metals, they spring back into shape. The
tangled molecules tend to straighten when pulled but spring back when released.
Elastomers are long polymer chains above their glass transition temperature (a property of nocrystalline solids which do not have a sharp melting point). Polymers are generally soft at normal
temperatures but they can become hard and brittle when cooled. The temperature at which they
change from soft and flexible to hard and glassy, is called the glass transition temperature denoted T g.
Some polymers are hard and rigid at normal temperatures and these have many uses.
Fig.: The stress-strain behavior for brittle (A), plastic curve (B) and highly elastic/elastomeric polymers
(C) and a schematic tensile stress-strain curve for a semicrystalline polymer wherein Specimen
contours at several stages of deformation are included.
Curve A illustrates a brittle polymer, inasmuch as it fractures while deforming elastically. The behavior
for a plastic material, curve B is similar to that for many metallic materials; the initial deformation is
elastic, which is followed by yielding and a region of plastic deformation. Finally, the deformation
76
displayed by curve C is totally elastic; this rubber-like elasticity (large recoverable strains produced at
low stress levels) is displayed by a class of polymers termed the elastomers.
Elastomeric polymer chains can be crosslinked, or connected by covalent bonds. This process is
sometimes called vulcanization. Crosslinking is initiated by heat, light, or the addition of chemicals.
Crosslinking makes elastomers reversibly stretchable for small deformations. When stretched, the
polymer chains become elongated and ordered along the deformation direction. When no longer
stretched, the chains randomize again. The crosslinks guide the elastomers back to its original shape.
Returned to randomization
stretched
78
79
Injection Molding: Similar to extrusion, the polymers heated to the liquid state, but it is
prepared in metered amounts, and the melt is forced into a mold to create the part. It is not a
continuous process. Many toys are made by injection molding
Blow Molding: The melted polymer is put into a mold, and then compressed air is used to
spread the polymer into the mold. It is used to make many containers such as plastic soda
containers and milk jugs.
Compression Molding: Solid polymer is placed in a mold; the mold is heated and puts pressure
on the polymer to form the part.
Reaction Injection Molding: Liquid monomers are placed in the mold avoiding the need to use
temperature to melt the polymer or pressure to inject it. The monomers polymerize in the mold
forming the part.
Industrially Important Polymers
About 85% of the world plastics consumption consists of four polymers. These polymers are produced in
high volume at very low cost. They are all thermoplastics.
Polyethylene (PE): electrical wire insulation, flexible tubing, squeeze bottles
Polypropylene (PP): carpet fibers, ropes, liquid containers (cups, buckets, tanks), pipes
Polystyrene (PS): packaging foams, egg cartons, lighting panels, electrical appliance components
Polyvinyl chloride (PVC): bottles, hoses, pipes, valves, electrical wire insulation, toys, and
raincoats.
Examples of important polymers are polyethylene (PE), polymethylmethacrylate (PMMA, perspex),
nylon, polystyrene (PS), polyurethane (PU) and polyvinylchloride (PVC).
2.2.2 CERAMICS
The word ceramic is traced to the Greek term Keramos, meaning pottery or potter. Ceramics are
compounds between metallic and nonmetallic elements with a crystalline structure, usually processed
at a high temperature at some time during their manufacture. They are most frequently oxides, nitrides,
and carbides. For example, some of the common ceramic materials include aluminum oxide (or alumina,
Al2O3), silicon dioxide (or silica, SiO2), silicon carbide (SiC), silicon nitride (Si3N4), and, in addition, what
some refer to as the traditional ceramics those composed of clay minerals (i.e., porcelain), as well as
cement, and glass. Initially termed traditional ceramics, are those for which the primary raw material
is clay; products considered to be traditional ceramics are china, porcelain, bricks, tiles, and, in addition,
glasses and high-temperature ceramics. Of late, significant progress; a new generation of these
80
materials has evolved, and the term ceramic has taken on a much broader meaning (electronic,
computer, communication, aerospace, and a host of other industries rely on their use). Several common
ceramic objects are:
Fig.: Common objects that are made of ceramic materials: scissors, a china tea cup, a building brick, a
floor tile, and a glass vase.
Types and Applications of Ceramics:
Most ceramic materials fall into an application-classification scheme that includes the following groups:
CERAMIC MATERIALS
Glasses
Clay products
Refractories
Abrasives
Cements
Advanced ceramics
One of the most widely used ceramic raw materials is clay. This inexpensive ingredient, found naturally
in great abundance, often is used as mined without any upgrading of quality. Another reason for its
popularity lies in the ease with which clay products may be formed; when mixed in the proper
proportions, clay and water form a plastic mass that is very amenable to shaping. The formed piece is
dried to remove some of the moisture, after which it is fired at an elevated temperature to improve its
mechanical strength.
3) Refractories
Another important class of ceramics that are utilized in large tonnages is the refractory ceramics. The
salient properties of these materials include the capacity to withstand high temperatures without
melting or decomposing, and the capacity to remain unreactive and inert when exposed to severe
environments. In addition, the ability to provide thermal insulation is often an important consideration.
Refractory materials are marketed in a variety of forms, but bricks are the most common. Typical
applications include furnace linings for metal refining, glass manufacturing, metallurgical heat treatment,
and power generation. Of course, the performance of a refractory ceramic, to a large degree, depends
on its composition. On this basis, there are several classifications namely, fireclay, silica, basic, and
special refractories.
4) Abrasives
Abrasive ceramics are used to wear, grind, or cut away other material, which necessarily is softer.
Therefore, the prime requisite for this group of materials is hardness or wear resistance; in addition, a
high degree of toughness is essential to ensure that the abrasive particles do not easily fracture.
Furthermore, high temperatures may be produced from abrasive frictional forces, so some
refractoriness is also desirable.
Diamonds, both natural and synthetic, are utilized as abrasives; however, they are relatively expensive.
The more common ceramic abrasives include silicon carbide, tungsten carbide (WC), aluminum oxide
(or corundum), and silica sand.
5) Cements
Several familiar ceramic materials are classified as inorganic cements: cement, plaster of paris, and lime,
which, as a group, are produced in extremely large quantities.
The characteristic feature of these materials is that when mixed with water, they form a paste that
subsequently sets and hardens. This trait is especially useful in that solid and rigid structures having just
about any shape may be expeditiously formed. Also, some of these materials act as a bonding phase
that chemically binds particulate aggregates into a single cohesive structure. Under these circumstances,
the role of the cement is similar to that of the glassy bonding phase that forms when clay products and
some refractory bricks are fired. One important difference, however, is that the cementitious bond
develops at room temperature.
82
6) Advanced Ceramics
Many of our modern technologies utilize and will continue to utilize advanced ceramics because of their
unique mechanical, chemical, electrical, magnetic, and optical properties and property combinations.
General Properties
With regard to mechanical behavior, ceramic materials are relatively stiff and stiffnesses and strengths
are comparable to those of the metals. In addition, ceramics are typically very hard. On the other hand,
they are extremely brittle (lack ductility), and are highly susceptible to fracture. These materials are
typically insulative to the passage of heat and electricity, and are more resistant to high temperatures
and harsh environments than metals and polymers.
Ceramic materials are somewhat limited in applicability by their mechanical properties, which in many
respects are inferior to those of metals.
Brittle Fracture of Ceramics: The brittle fracture process consists of the formation and propagation of
cracks through the cross section of material in a direction perpendicular to the applied load. Crack
growth in crystalline ceramics may be either transgranular (i.e., through the grains) or intergranular (i.e.,
along grain boundaries); for transgranular fracture, cracks propagate along specific crystallographic (or
cleavage) planes, planes of high atomic density.
StressStrain Behavior: At room temperature, virtually all ceramics are brittle. Microcracks, the
presence of which is very difficult to control, result in amplification of applied tensile stresses and
account for relatively low fracture strengths (flexural strengths). This amplification does not occur with
compressive loads, and, consequently, ceramics are stronger in compression. The stress at fracture using
this flexure test is known as the flexural strength, modulus of rupture, fracture strength, or the bend
strength, an important mechanical parameter for brittle ceramics.
Hardness: One beneficial mechanical property of ceramics is their hardness, which is often utilized when
an abrasive or grinding action is required; in fact, the hardest known materials are ceramics.
Creep: Often ceramic materials experience creep deformation as a result of exposure to stresses (usually
compressive) at elevated temperatures. In general, the time deformation creep behavior of ceramics is
similar to that of metals; however, creep occurs at higher temperatures in ceramics. High temperature
compressive creep tests are conducted on ceramic materials to ascertain creep deformation as a
function of temperature and stress level.
2.3 COMPOSITES
2.3.1 INTRODUCTION
These are inorganic or organic, chiefly man-made materials made up from, or composed of, a
combination of different materials (Metal and ceramics, metal and polymers, ceramics and polymers or
others) on macroscopic level to take overall advantage of their improved or modified dissimilar
properties. Material property combinations and ranges have been extended by the development of
composite materials. Such a deliberate combination was understood by ancient civilizations. An example
83
of this was the reinforcement of air-dried bricks by mixing the clay with straw so as to reduce cracking
caused by shrinkage stresses as the clay dried out. In more recent times, horse hair was used to
reinforce the plaster used on the walls and ceiling of buildings in order to reduce the onset of drying
cracks.
According to this principle of combined action, better property combinations are fashioned by the
judicious combination of two or more distinct materials. Property trade-offs are also made for many
composites.
Nowadays, especially with the growth of the plastics industry and the development of high-strength
fibers, a new generation of extraordinary materials with vast range combinations of materials is
available for use . For example, carbon fiber reinforced frames for tennis rackets and shafts for golf clubs
have revolutionized these sports.
Most composites have been created to improve combinations of mechanical characteristics such as
stiffness, toughness, and ambient and high-temperature strength.
In a 'composite', the reinforcement material, in the form of rods, strands, fibers or particles, is bonded
together with the other matrix materials. For example, the fibers may have some of the highest moduli
and greatest strengths available in tension, but little resistance to bending and compressive forces. On
the other hand, the matrix can be chosen to have high resistance to bending and compressive forces.
Used together these two different types of material produce a composite with high tensile and
compressive strengths and a high resistance to bending
Moreover, Alloys of metals with non-metals could only occur if all the component materials were
miscible, that is, soluble in each other in the molten state. Composite materials can be made up from
materials that are not soluble in each other. Composite materials are not alloys. In its simplest form a
composite material consists of two dissimilar materials in which one material forms a matrix to bond
together the other (reinforcement ) material. The matrix and reinforcement (fibrous form or flake form)
are chosen so that their mechanical properties complement each other, whilst their deficiencies are
neutralized. For example, in GRP molding, the polyester resin is the matrix that binds together the glass
fiber reinforcement.
Generally speaking, a composite is considered to be any multiphase material that exhibits a significant
proportion of the properties of both constituent phases such that a better combination of properties is
realized.
to produce cutting tools and dies. For example, tungsten carbide embedded in cobalt makes a very
hard cutting tool and dies. They can be compacted into the required shape and then heated to
sinter them.( cobalt is hot enough to re-crystallize and form a matrix around the tungsten).
(b) Mortar and Concrete: mortar made from a hydraulic cement and sand reinforced with an
aggregate of chipped stones. Sand, gravel and stone are bonded into a matrix of cement that sets
and forms a light material strong in compression. Since it can be molded or laid down wet, it is an
ideal building material. The stones are crushed so that they have a rough texture and sharp corners
that will key into and bond with the mortar matrix. This basic concrete has a very high compressive
strength but is very weak in tension.
(c) Tarmac a matrix of gravel held in a matrix of tar, ideal for roads.
2.3.2.2 Fibre reinforcement composites
Brittle materials fail by cracks spreading through them with little resistance. Adding fibres
prevents the crack opening and spreading. Technologically, the most important composites are
those in which the dispersed phase is in the form of a fiber. Design goals of fiber-reinforced composites
often include high strength and/or stiffness on a weight basis. These characteristics are expressed in
terms of specific strength and specific modulus parameters, which correspond, respectively, to the
ratios of tensile strength to specific gravity and modulus of elasticity to specific gravity.
This method of reinforcement can range from the glass fibers used in GRP plastic moldings to the thick
steel rods used to reinforce concrete to improve its performance overall (tension in addition to
compression), metal reinforcing rods are added.
Consider a cylindrical rod made with fibers and a matrix material. Let the volume of the fibre be Vf and
the volume of the matrix be Vm. The volume of the resulting composite is Vc = Vf + Vm.
The mass of the fibre is: mf = f Vf
The mass of the matrix is: mm = m Vm
The mass of the composite is: mc = c Vc= f Vf + m Vm
c Vc= f Vf + m Vm = f Vf + m (Vc - Vm)
Examples are : Reinforced concrete; Glass reinforced plastics (GRP); Carbon fibers; Aramid fibers.
85
(i) Reinforced concrete: Concrete itself is a particle-reinforced material. Concrete is very brittle and
weak in tension so it is normally only used for support type structures (columns and solid floors). By
adding steel rods, the structure becomes stronger in tension and withstands some bending.
Hence bridges, unsupported floors and other structures where some
bending occurs can be made to take the tension. The resulting
structure is lighter than steel on its own.
Not only the amount of reinforcement but also its positioning (the
tension side is the side of the beam that is on the outside of the
'bend' when the beam 'gives' under the effect of an externally applied
load) of is important.
Fig.: Simple reinforced concrete beam.
Glass and carbon fibers when made new are very strong and flexible and if they are imbedded in a
matrix of plastic (thermosetting) they retain their high tensile strength. The result is a very strong
flexible and light structure. Many things are made from these materials such as boat hulls, tennis
rackets, fishing poles and so on.
(ii) Glass- reinforced plastic (GRP): This important composite material is produced when a plastic
material, usually a polyester resin is reinforced with glass fibre in strand or mat form.
The resin is used to provide shape, color and finish, whilst the glass fibers, which are laid in all directions,
impart mechanical strength. When a GRP moulding is correctly 'laid up', the thick, viscous resin
completely surrounds and adheres to the glass fibers of the 'chopped strand mat' or the woven fibre
glass cloth. The resin sets to give a hard. Rigid structure. To shorten the setting time a catalyst
(accelerator) is often added to the resin immediately before moulding.
To improve the appearance of the 'rough side' of
the moulding (the side not in contact with the
polished surface of the mould), a surfacing tissue
is added made up from finer strands of mat. As
shown, Glass-reinforced plastic is widely used for
products that require high strength to weight
ratios such as boat hulls, car bodies, gliders, etc. It
has the advantages of being resistant to most
environments and it can be used to form more
complex shapes than is possible in wood or sheet
metal.
3. Carbon fibers
These have a higher elastic modulus and lower density than glass fibers, and can be used to reinforce
composite materials having a higher strength to weight ratio for a wide range of lightweight, highstrength applications. E.g. they are used in the manufactures of gas turbine fan blades, racing car body
86
panels, high-performance tennis racket frames and high-performance golf club shafts.
2.3.3.1 A laminar composite is composed of two-dimensional sheets or panels that have a preferred
high-strength direction such as is found in wood and continuous and aligned fiber-reinforced plastics.
The layers are stacked and subsequently cemented together such that
the orientation of the high-strength direction varies with each
successive layer (E.g.: adjacent wood sheets in plywood are aligned
with the grain direction at right angles to each other). Laminations
may also be constructed using fabric material such as cotton, paper, or
woven glass fibers embedded in a plastic matrix. Thus a laminar
composite has relatively high strength in a number of directions in the
two-dimensional plane; however, the strength in any given direction
is, of course, lower than it would be if all the fibers were oriented in
that direction.
Fig.: The stacking of successively oriented, fiber-reinforced layers for a laminar composite.
Brittle materials such as concrete and ceramics are strong in compression but weak in tension since they
are susceptible to crack propagation.
Also the use of reinforcing fibers which hold the brittle matrix in compression, so an external tensile load
cannot open up any surface cracks and discontinuities
2.3.3.2 A sandwich panel consists of two outer sheets, or faces, relatively stiff and strong (typically
aluminum alloys, fiber-reinforced plastics, titanium, steel, or plywood) that are separated by and
adhesively bonded to a thicker core. They are designed to be light-weight beams or panels as the outer
sheets impart high stiffness and strength to the structure and they must be thick enough to withstand
88
Fig:. Schematic diagram showing the construction of a honeycomb core sandwich panel.
Strength and stiffness of honeycomb structures depend on cell size, cell wall thickness, and the material
from which the honeycomb is made.
89
The objective of each step in the processes of extracting a metal from its ores is to simplify the ore
compound. This is done, as has been outlined, by (1) separating the ore from the gangue, (2) driving
away certain ingredients by a heat short of fusion, and (3) fusing the ore one or more times in the
presence of certain re-agents called fluxes which combine with the non-metallic substances and allow
the liberated metal to separate and settle in an impure state. A metal thus obtained in the impure state
must be refined before it is used.
3.4.1 Smelting furnaces
They are built of common silica brick for the outer layers, and high grade refractory brick for the inner
layers. There are several modifications of furnaces for smelting ores of different metals, but all smelting
furnaces are included in the two general types of this class, namely, the blast furnace and the
reverberatory furnace. The main point of difference from the reverberatory furnace is that ore and fuel
are mixed in the blast furnace and are kept separate in reverberatory furnace.
Coke (50t)
Limestone (25t)
BLAST FURNACE
Blast furnace gas
Slag (30t)
Iron-bearing materials - The iron-bearing materials are usually iron ore, steelmaking slag, scrap.
Coke - The coke is added to provide the main chemical reagents (carbon and carbon monoxide)
for the iron ore reduction.
Flux - The flux, limestone and/or dolomite, is added to combine with ash in the coke and gangue
in the ores, to produce a slag that rises to the top of the pool of molten pig iron that collects in
the crucible.
Air supplies the oxygen for combustion of the coke as well as promoting the chemical reduction of the
iron oxide.
Specific chemical reactions in the blast furnace:
(1) Production of the reducing gas
(
(
93
(
)
)
(
(
)
)
(
)
(
The parts of this furnace are designated as follows, viz.: S: Shaft. This extends from the top down to the
part of largest diameter. B: Boshes. This is the tapered portion below the shaft. Water is circulated
through each bosh plate, by a system of external piping, to allay the intense heat at that part of the
furnace and thus prevent injury to the bosh walls. Y: Tuyere holes. These openings conduct into the
furnace the air of the blast. They are metal tubes surrounded by a helix of pipe through which water
circulates to keep the end of the tuyere from melting in the furnace.
M: Hot blast main. This is a pipe, made of iron plates and
lined inside with refractory brick. It encircles the furnace,
delivering highly heated air from the blast stove to the
tuyeres. H. Hearth. This is the part of the furnace below the
line of tuyere holes which receives molten slag and metal,
and when the slag, which floats on the metal, reaches the
height of the cinder notch C, it is drawn off. T. Tapping
hole. Metal is taped from the hearth through this hole. In
tapping, an iron bar is used to dig out the clay plug stopping
the hole, and when the metal has run out, another plug is
forced in to stop the hole. G: Gas main or "down comer," a
brick-lined pipe leading away the gaseous products of the
blast and delivering them, through the dust catcher, to the
gas main, Q, which distributes them to the blast stoves. J:
Shaft lining. This lining is of highest quality refractory brick
(fireclay). D: Silica brick body. The furnace body is encased
in plate steel marked D. K: Cone. This is a cone-shaped
hollow cast iron ring built into the top or "throat" of the
furnace.
Fig.3.4: Main parts of a blast furnace
L: Bell, a cast iron cone suspended by a heavy chain from the lever N. This cone closes the throat of the
furnace and is opened for admitting materials of the furnace charge. R: Stand pipe. Before lowering the
bell to admit a new charge to the furnace, the lid of the stand pipe is raised to relieve the gas pressure at
the top of the furnace. This obviates the escape of gas and flame from the furnace throat.
The refractory materials commonly used in all branches of smelting, refining and melting of metals,
including the processes of steel making, and in heating furnaces, are: Silica (common sand), SiO2; Silicate
94
95
Although 2 substances may be completely soluble in one another in the molten state, it does not
necessarily mean that the liquid solution solidify to give a homogeneous solid phase or solid solution.
They may be: totally insoluble or totally soluble in one another when solid is partially soluble in one
another when solid or combine with one another to form a compound.
3.2.1.1 SOLID SOLUTIONS
Most metals are completely and mutually soluble (they are miscible) in the liquid state, that is when
they are molten. Some such as copper and nickel, not only form solutions in the molten or liquid state
but remain in solution upon cooling and solidifying to become solid solutions. Solid solution is a phase,
where two or more elements are completely soluble in each other. Solid solution formation usually
causes increase of electrical resistance and mechanical strength and decrease of plasticity of the alloy.
Depending on the ratio of the solvent (matrix) metal atom size and solute element atom size, two types
of solid solutions may be formed:
3.2.1.1.1 Substitutional solid solution (unlimited solubility): If the atoms of the solvent metal and solute
element are of similar sizes (not more, than 15% difference), Atoms of the solute can substitute atoms
of the solvent without causing any changes to the lattice structure.
According to Hume-Rothery laws, the factors leading to its formation are as follows:
- Atomic size: Atoms of the solvent and solute must be approximately of the same size (not differ more
than 15%).
- Electrochemical series: there is only a small difference in charge between alloying components (their
charges not very dissimilar). They have nearly the same electro-negativity otherwise they will form
compounds.
- The elements must have the same type of crystal lattice structure
- No relative difference in valence, valence electrons difference promotes the formation of compounds.
(a)
(b)
(c)
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Fig.4.1: Substitutional solid solution: (a) FCC crystal of copper (b) FCC crystal of Nickel (c)
Substitutional solid solution of Cu and Ni.
3.2.1.1.1 Interstitial solid solution (Limited solubility): If the atoms of the alloying elements are
considerably smaller, than the atoms of the matrix metal, interstitial solid solution forms, where the
matrix solute atoms are located in the spaces between large solvent atoms. Thus, it is formed when
atoms of small radii fit into the spaces or interstices of the lattice structures of larger solvent atoms
(>1A). e.g: H, B, C, N and O. The lattice tends to expand when an interstitial solid solution is formed. E.g:
Carbon in the iron limited to just about 2% at 11300C, the fact that these atoms occupy interstitial
positions, restricts slip movements of atom planes.
Carbon
interstitial
atom in
BCC
- Multi system: It means that alloying have three and more than those metals.
Upon cooling into the solid state, binary alloys can be classified into the following types.
Simple eutectic type: The two components are soluble in each other in the liquid state but are
completely insoluble in each other in the solid state.
Solid solution type: The two components are completely soluble in each other both in the liquid
state and in the solid state.
Combination type: combines some of the characteristics of both the previous types. The two
components are completely soluble in the liquid state, but are only partially soluble in each other in
the solid state.
We are going to consider these three types of binary alloy systems and their phase equilibrium diagrams
99
Solution
10
0
0
Nacl + Sol
Nacl.2H2O + Sol
Ice + Sol
Ice + Nacl.2H2O
-20
10
30
40
% Nacl
Fig.: unary P/T phase diagram for Water and binary phase diagram H2O Nacl
Applying Gibbs phase rule: P + F = C +2, P: number of phases (ie, solid, liquid, or gas); C: number of
components; F: Degree of freedom
Water:
a) At the triple point: P = 3 (solid, liquid, and gas); C= 1 (water); P + F = C + 2. F = 0 (no degree of freedom)
b) liquid-solid curve: P = 2, 2+F = 1 + 2, F= 1; One variable (T or P) can be changed
c) Liquid, P =1, So F =2
Two variables (T and P) can be varied independently, and the system will remain a single phase
Further the equilibrium conditions are obtained to draw the PD by extremely slow heating and cooling
so that if a phase change is to occur, sufficient time is allowed.
Below classification is according to the relation of the components in the liquid and solid states
1. Components completely soluble in the liquid state
completely soluble in the solid state
Insoluble in the solid state: the eutectic reaction
Partly soluble in the solid state: the eutectic reaction
100
2.
3.
4.
101
First solid
T1
Tie line
T2
Last liquid
CL
Cs
(
(
(
(
)
)
)
)
= 66.67%
= 33.33%
(2) Consider, the points X and Y, to determine the number of degrees of freedom using the phase rule.
Point X, in the region above the liquidus, Number of components, C = 2, since it is a binary system
of Bi and Sb, number of phases, P = 1 (liquid), applying the rule, F=C+2-P = 2+2-1 = 3 degrees of
freedom
2. Point Y, between the liquidus and solidus, C=2, P = 2, applying rule, F=C+2-P = 2+2-2 = 2 degrees
of freedom.
103
Fig.: Complete solubility of Cu and Ni; Plotting equilibrium diagrams from cooling curves for Cu-Ni
solid solution alloys. Cooling curves and equilibrium diagram.
The Cu-Ni system is both a classical and a practical example since the monels, which enjoy extensive
commercial use, are Cu-Ni alloys. Many practical materials systems are isomorphous.
This system is composed of 3 distinct phase areas separated by transformation lines (i) Liquid, (ii) liquid
and solid solution and (iii) solid solution. Consider a solidification of an alloy with 40% Ni: (1) above the
liquidus line, the two metals go into a liquid solution Ni and Cu atoms are homogeneously distributed in
this liquid solution. When the alloy is cooled to just below the liquidus temperature, some tiny solids
and solid solution begin to form in the liquid solution (2). Further drop of temperature leads to
104
formation of more solids and growth of the crystals until only very little liquid remains (3) and (4). As the
alloy cools below the solidus temperature, any remaining liquid is solidified to solid solution (5).
Equilibrium cooling and/or heating of solid solution alloy, with its development of microstructure:
Lets consider the very slow cooling, under equilibrium conditions of a particularly 70A-30B to observe
the phase change that occur
This alloy at temp T0 is a homogeneous single-phase liquid solution (fig a) and remained so until
temp T1 is reached. Since T1 is on the liquidus line, freezing or solidification now begins. The first
nuclei of solid solution to form, 1, will be very rich in the higher melting point metal A and will be
composed 10 of 95A-5B (rule 1 and 2), just after the start of solidification, the composition of the
liquid is 69A-31B (fig b)
Fig.: The slow cooling of &0A-30B alloy with microstructure at various points of solidification
105
4.3.1.2 Complete insolubility in the solid state (Eutectic type): Although metals A & B are mutually
soluble in the liquid state, both components retain their individual identities of crystals of A and crystals
of B in the solid state, i.e. when a liquid solution of fixed composition, solidifies at a constant
temperature, forms a mixture of two or more solid phases. This process is reversible, the reaction is
expressed as:
Eutectic system refers to a specific alloy composition that freezes at a lower temperature than any other
composition. The eutectic temp and composition determine a point on the phase diagram, where a
106
liquid solidifies into two different solid simultaneously called as eutectic point.
Fig. : Cooling curves for for a series of two metals insoluble in solid state
The line joining the points where solidification begins is referred to as the liquidus and that the line
joining the points where solidification is complete is referred to as the solidus.
This type of equilibrium diagram gets its name from the fact that at one particular composition (E), the
temperature at which solidification commences is a minimum for the alloying elements present. With
this composition the liquidus and the solidus coincide at the same temperature, thus the liquid changes
into a solid with both A crystals and B crystals forming instantaneously at the same temperature. This
point on the diagram is called the eutectic, the temperature at which it occurs is the eutectic
temperature, and the composition is the eutectic composition. The eutectic composition is a unique alloy
that gives the lowest melting point in the system and its cooling curve looks like that of the pure metal.
Alloy C is a mixture of pure metal A and the eutectic mixture, and its cooling curve in the liquid-solid
phase zone is similar to that of a solid solution.
Alloy C, at the liquidus solids rich in metal A are crystallized. When the eutectic temperature T E is
reached, a eutectic reaction takes place, where all the remaining liquid is transformed in a solid solution
of composition E. The eutectic alloy E is a duplex structure containing crystals of A and B side by side. It
crystallizes without going through two phase stage that would otherwise delay the crystallization (it is
often used in solders and fuses).
Many casting alloys are eutectic alloys as the liquid can be melted and poured into a mould at low
temperature; this minimizes heat required for melting and the products have less casting defect such as
gas porosity. Cast iron and most cast aluminum alloys are eutectics.
However sometimes eutectics are brittle and may affect the overall alloys ductility. Brittle failure during
cold working of alloys, that results from the fracture of the eutectic phase in grain boundaries is called
Cold shortness. In some cases, they result into material failure during forging, as the eutectics may
melt far below the forging temperature. This type of failure is called hot shortness.
107
Fig.: (a) lamellar, (b) rodlike, (c) globular, and (d) acicular (or needlelike).
Congruent melting intermediate phase (Equilibrium diagrams with intermediate compounds):
Two components may also form an intermediate compound at certain composition. When one
phase changes into another phase isothermally (i.e., at constant temp) and without any change in
chemical composition, it is said to be congruent phase change or congruent transformation. The
109
110
Consider a 25% Sn, 75% Pb alloy at 230C as drawn below. Continuing with the same alloy at the same
temperature; Finding Relative Amounts (proportions of the phases): To find the weight percent of a
phase, use the tie line as a lever with fulcrum at the point of interest and lever ends at the phase
compositions.
Alloys that contain 0-2%Sn solidify to form a single phase solid solution and remain so even after the
alloy has cooled to room temperature. Alloys containing between 2 and 19%Sn also solidify to produce a
single solution .
To determine the relative amounts of the two phases, erect an ordinate at a point on the composition
scale which gives the total or overall composition of the alloy. The intersection of this composition
vertical and a given isothermal line is the fulcrum of a simple lever system. The relative lengths of the
lever arms multiplied by the amounts of the phase present must balance. As an illustration, consider
alloy I in fig. The composition vertical is erected at alloy I with a composition of e% of B and (100e)% of
A. This composition vertical intersects the temperature horizontal (Te) at point e. The length of the line
feg indicates the total amount of the two phases present. The length of line eg indicates the
amount of solid.
111
10
15
opposite leg 15
(100%) 60%
total length
25
15%
25%
Fig.: (a) Lead Tin (Pb & Sn) phase diagram, (b) Its microstructure
Eutectic reaction: L +
Peritectic reaction: + L
+L
L
Monotectic reaction: L1 L2 +
L1
L2
+ L2
Eutectoid reaction: +
Peritectoid reaction: +
+
+
Eutectic reaction: when a liquid solution of fixed composition, reversibly solidifies at a constant
temperature, forms a mixture of two or more solid phases
Peritectic Reaction: A liquid and solid react isothermally to form a new solid on cooling, the reaction
expressed in general as;
Eutectoid Reaction: A solid phase transforms on cooling into two new solid phases
Peritectoid reaction: The two different solid phase on cooling transforms into a new solid phase,
115
Invariant Reactions:
-ferrite solid solution of carbon in iron. Maximum concentration of carbon in -ferrite is 0.09 % (14930C)
temperature of the peritectic transformation. The crystal structure of -ferrite is BCC.
117
Fig. Cooling curves for pure iron showing allotropic behavior of iron
Isomorphous systems contain metals which are completely soluble in each other and have a single type
of crystal structure. It is important to note that metals often show polymorphism: different structures
are more stable at different temperatures. For instance, -Fe, which is BCC, is stable up to 906C, -Fe,
which is FCC, is stable up to 1401C, and then -Fe is stable again up to the melting point at 1530C. A
third form of iron, -Fe, is HCP, and may be formed at high pressures.
118
Fig.: Electron matrix of a metal atom and crystalline structures (i.e. metals) atoms are arranged in unit
cells 4 common cells shown above
3. Properties include: good conductors of electricity and heat, not transparent, quite
strong yet deformable
4. How do Metal Crystals Fail? Answer: Slip due to dislocations
119
120
Fig.: Iron Iron carbide phase equilibrium diagram illustrating ferrous metal carbon ranges
This figure strictly should be called the iron iron carbide diagram but conventionally it is called the
iron-carbon phase diagram. It seems to be the same as in the case of two components partially miscible
in solid state.
The difference is the structural changes resulting from iron being allotropic - that is, it can exist in more
than one form. These structural changes take place at 9100C and 14000C:
-
These lattice changes of structure are accompanied by change in volume as the atoms in crystal lattice
rearrange themselves.
When carbon content is less than 0.005% in Fe C alloys at room temperature, they are considered to
be pure iron (soft, ductile and weak) it is used only for magnetic devices.
121
Steels have low carbon limits approximately 0.06 2%C. Fe C alloys with carbon content greater than
2% are Cast irons; above this carbon level casting is about the only way that a useful shape can be made
since the high carbon makes the iron alloy too brittle for rolling, forming, shearing or other fabrication
techniques.
Phase
Carbon
solubility
Name
Structure
Ferrite
Low,
up
to
0.0218 wt. %C %
-iron
BCC
Austenite
Up to 2.11 wt.
%C
-iron
FCC
Cementite
Fe:C = 3:1
Fe3C
Intermetallic
orthorhombic
Pearlite
Fixed C. content
(e.g.:0.76%)
Alternating
layers ,Fe3C
Temp
>727C
<727C
Strength
Ductility
Weak
Very ductile
Weak
Very ductile
Strong
Low
brittle
Btn
Fe3C
and
ductility,
122
Cementite (Iron carbide phase): an excess of carbon combines with iron to form iron carbide (Fe3C).
This is true up to the limit of 1.7%C at room temperature, beyond which the excess carbon is
precipitated out as free or uncombined carbon flakes of graphite.
Thus, steels can be defined as those alloys of iron and carbon in which the entire carbon content is
combined with the iron in solid solution or as iron carbide (or both) and that no free carbon is present.
Since the maximum amount of carbon which can combine totally with iron is 1.7%; it follows that any
carbon in excess of this figure will precipitate out as graphite flake and the resulting material will not be
steel but cast iron.
The solid solution of austenite transforms to ferrite and Cementite at the eutectoid point of 723 0C when
0.83C is present. The crystals which are precipitated out have a lamellar structure consisting of alternate
layers of ferrite and Cementite. This lamellar structure is referred to as Pearlite and it is the toughest
structure which can exist in plain carbon steels. When the carbon content is 0.83%, the steel consists
entirely of Pearlite and it has maximum toughness. Steels with C</> 0.83 are Hypo/hyper-eutectoid
steels.
properties. Since pig iron and scrap are cheap and no expensive refinement process; cast iron is a useful
low cost material compared to steel. Hence, despite its relatively low strength and brittleness, they are
extensively used as engineering materials, following their cheapness, ease of melting and casting (high
fluidity makes it easy to cast into intricate shapes); very good machineability and a high damping
capacity when resistance to wear and compressive strength are required.
It will be noticed that a eutectic of austenite and cementite which contains 4.3% carbon is formed at
1131 C. (This eutectic point, like the eutectoid composition in the case of steel at 0.83% carbon, may be
moved farther to the left of the diagram by the elements present, so that a cast iron containing less than
4-3% carbon may be of eutectic composition)
It is weak in tension but strong in compression and hence used in machine beds, which bears the
whole of structural weight of a machine without affecting the operators accuracy.
125
austenite changes into Pearlite, thus at room temperature the composition of the iron is Pearlite and
Cementite, White Cast Iron due to its white appearance when freshly fractured. The hardness of
Cementite makes it difficult to machine and its use is limited mainly where abrasion and wear resistance
is required. It has a high compressive strength, and when its annealed, it becomes malleable cast iron.
2) White irons: They are exceptional alloy hard, but brittle and not weldable. It is not often used,
except as the basis for the production of malleable irons by heat treatment, although portions of many
sand castings are made to solidify while, by the insertion of cells in the sand mould, in order to produce
hard and wear resistance surfaces in parts of the casting. Hence their use is limited to wear-resistant
applications such as rollers in rolling mills.
3) Malleable cast iron: As their name implies, malleable cast irons have increased malleability and
ductility, increased tensile strength, and toughness. Produced from white cast irons by a variety of heattreatment processes, namely black-heart, white heart and pearlitic processes; all these processes
consists in heating up to 800-9000C, then cooling white cast iron very slowly over a long period of time
depending upon the final composition and structure required. High temperature incubation causes
cementite to decompose and form ferrite and graphite. Thus these materials are stronger and tougher
than white cast iron with appreciable amount of ductility. It can be welded, machined, is ductile, and
offers good strength and shock resistance. Typical applications of malleable cast irons include: railroad,
connecting rods, marine and other heavy-duty services.
4) Nodular cast iron (duty iron/ductile or Spheroidal graphite iron): Alloying additions are of prime
importance in producing this materials. Small additions of Mg or Ce (cerium from Lanthanide series) to
the gray cast iron melt before casting can result in graphite to form nodules or sphere-like particles. The
graphite flakes become redistributed throughout the mass of the metal as fine spheroids of graphite. It
gets this name because its carbon is in the shape of small spheres, not flakes. This makes it both ductile
than gray cast irons and malleable. Its also stronger and weldable. Matrix surrounding these particles
can be either ferrite or pearlite depending on the heat treatment. Typical applications include: pump
bodies, crank shafts, automotive components, etc.
5. Chilled cast iron: In some castings, in order to have a hard durable surface, the casting is chilled. Such
castings are produced by burying iron plates in the mould; as a result, the metal coming in contact with
these plates will be cooled rapidly and will be harder than the rest of the casting. Chilled castings are
used to some extent as wheel of rail road cars.
INFLUENCE OF ALLOYING ELEMENTS ON THE PROPERTIES OF CAST IRON
Carbon: in the cast iron the carbon may be present in two forms: as free carbon/graphite, and as a
combined carbon/iron carbide. Cast iron in which entire carbon is in free State is called grey cast iron. It
is soft and easily machinable. When the carbon is in the combined state in the form of iron carbide, we
get white cast iron. It is hard, brittle and un-machinable.
127
To heighten their adaptability, they are not solely alloys of iron and carbon but complex alloys in which:
- Earth-extracted impurities such as sulphur (maintained below 0.1% for the most foundry purposes as
too much sulfur trigger unsound casting. It makes the cast iron hard and brittle) and phosphorus (rarely
allowed to surpass 1%. It contributes fusibility and fluidity but induces brittleness)
- Alloy elements with a significant influence on the properties of the casting such as Silicon: up to 3%
concentration. It provides the formation of free graphite soft black form of carbon; i.e. a soft dark
carbon that conducts electricity, occurs naturally as a mineral and also produced industrially. Use:
batteries, lubricants, polishes, electric motors, nuclear reactors, carbon fibers, pencil lead which makes
the iron soft and ease machinable. It also produces sound castings free from blow holes, because of its
high affinity for oxygen. It can also be alloyed with Manganese: often kept below of 0.75%, it makes the
cast iron white and hard.
Alloying elements
Silicon
Sulphur
Manganese
Phosphorus
Nickel
Chromium
Molybdenum
Vanadium
Strength and hardness, stabilizes the carbides and reduces their tendency to
decompose at high temperature so used in heat resisting castings
Copper
Reduces the possibility of cracking and distortion bse it is not quench hardened
so used in abrasion resisting components. Machined by grinding
1.1.1.2 STEELS
Steel is made by oxidizing away the impurities that are present in the iron produced in the blast furnace.
129
Fig.: Slow Cooling of Plain-Carbon Steels: Transformation of a 1.2% C hypereutectoid and 0.4% C
hypoeutectoid with slow cooling.
Problems
(1) A 0.45%C hypoeutectoid plain-carbon steel is slowly cooled from 950 C to a temperature just
slightly above 723 C. Calculate the weight percent austenite and weight percent proeutectoid ferrite
in this steel.
130
Steel is an alloy of iron and carbon containing up to 1.7 % of carbon. When the alloying element is only
carbon, the steel is referred to as plain carbon steel and it is classified following the percentage of
carbon it contains:
131
Low or soft Carbon Steel or mild steel (Carbon content up to 0.35 % C):
This steel is the softest and most ductile metal and can be rolled, punched,
sheared, and worked when either hot or cold. It is easily machined and can be
readily welded by all methods. It is used for rivets and solid drawn steel tubes
bolts, nuts, screws, shafts, couplings, water pipes, piston rods, lead screw of
lathe etc. It does not harden to any great amount; however, it can be easily
case- or surface-hardened
Properties of mild steel: i) It is strong in tension and compression, in shear and
hence used in rivets for light and heavy work. It processes high ductility,
malleability and toughness. (ii) It can be easily welded and forged and can be
produced in bar of any type. (iii) It can be easily machined.
Medium Carbon Steel (Carbon content from 0.35 to 0.65%C).
This steel may be heat-treated after fabrication. It is used for general machining
and forging of parts that require surface hardness and strength (with increasing
carbon content the strength and hardness increase but ductility decreases and
the welding properties and machineability become poorer).
It is made in bar form in the cold-rolled or the normalized and annealed condition. During welding, the
weld zone will become hardened if cooled rapidly and must be stress-relieved after welding.
High Carbon Steel (Carbon content from 0.65 to 1.7%)
This steel is harder and less tough. It used in the manufacture of drills, taps, dies, springs, and other
machine tools and hand tools that are heat-treated after fabrication to develop the hard structure
necessary to withstand high shear stress and wear. It is manufactured in bar, sheet, and wire forms, and
in the annealed or normalized condition in order to be suitable for machining before heat treatment.
This steel is difficult to weld because of the hardening effect of heat at the welding joint, except
grinding can be done only the annealed state.
Tool Steel (carbon content from 0.90 to 1.70 percent)
This steel is used in the manufacture of chisels, shear blades, cutters, large taps, woodturning tools,
blacksmiths tools, razors, and other similar parts where high hardness is required to maintain a sharp
cutting edge. It is difficult to weld due to the high carbon content. Tool steels are of two varieties: Plain
carbon tool steel, high speed steel
- Plain carbon steel (0.9 to 1.3% of carbon), it was at one time the only tool steel available, but its
use is newly restricted. These steels are cheap and harden at low temperature. They are used
for press tools and applications where the conditions are not severe.
132
The cutting tool steels mostly used nowadays are high-speed steels. High-speed steel is a selfhardening steel alloy (18% tungsten, 4% chromium, 1% vanadium and about 1% carbon, and rest
iron) that can withstand high temperatures without becoming soft. High-speed steel is ideal for
cutting tools because of its ability to take deeper cuts at higher speeds than tools made from
carbon steel. High-speed steels are not exceptionally hard; in fact, plain carbon steel can easily
be made to give a greater hardness, but whereas the hardness of plain carbon steel will fall off
at temperature greater than about 2500C to 3000C, the high speed steels retain their hardness
up to about 6000C. They are used for tools for lathe, milling machine cutters, twist drills, files,
etc.
Wrought iron: Wrought iron is pig iron from which most of the carbon has been removed. It contains
only about 0.04% carbon. It is tough; however, it can be bent or twisted very easily. It is also corrosion
resistant. It was used mostly in ornamental ironwork, such as fences and handrails, because it is welded
or painted easily and it rusts very slowly; horses shoes, nails, chain and crane hooks, and door hardware
it has been largely replaced with the use of hot-rolled low-carbon steel.
Alloy Steels
Steel is manufactured to meet a wide variety of specifications for hardness, toughness, machineability,
resistance to corrosion, tensile strength, and so forth. Manufacturers use various alloying elements to
obtain these characteristics. Thus , Beside the carbon with its specific amount for each carbon steel
classification, other elements can be chiefly added to the iron so as to provide excellent mechanical
properties for structural materials alloys steels.
Alloys steels are classified into two major types depending on the structural classification:
Low alloy steels
Low alloy steels contain a few percent (typically between 1 and 7%) of elements such as Cr, Ni, Mo and V.
This category includes chromium steels (containing up to 5% Cr and 1% Mo) and nickel steels (containing
up to 5% Ni).
Low alloy steels are generally weldable by most processes, as long as adequate precautions (important
to know the composition of the material) are taken to avoid defects, but it is important to know the
service, joint configuration and the subgroup of the material type.
High alloy steels
(i) High-speed tool steels
Tungsten and chromium form very hard and stable carbides. Both elements also raise the critical
temperatures and, also, cause an increase in softening temperatures. High carbon steels rich in
133
these elements provide hard wearing metal-cutting tools, which retain their high hardness at
temperature up to 600C. A widely used high-speed tool steel composition is containing 18% of
tungsten, 4% of chromium, 1% of vanadium and 0.8% of carbon .
It is a subset of tool steels, commonly used in tool bits and cutting tools. It is often used in power saw
blades and drill bits. It is superior to the older high carbon steel tools used extensively through the
1940s in that it can withstand higher temperatures without losing its temper (hardness). This property
allows HSS to cut faster than high carbon steel, hence the name high speed steel. At room temperature,
in their generally recommended heat treatment, HSS grades generally display high hardness (above
HRC60) and abrasion resistance (the process of wearing away by friction).
generally linked to tungsten and vanadium content often used in HSS) compared to common carbon and
tool steels.)
Tungsten Carbide
Tungsten carbide is the hardest man-made metal. It is almost as hard as a diamond. The metal is molded
from tungsten and carbon powders under heat and pressure. Tools made from this metal can cut other
metals many times faster than high-speed steel tools.
(ii) Stainless steels
When chromium is present in amounts in excess of 12% , the steel becomes remarkably anticorrosive,
owing to protective film of chromium oxide that forms on the metal surface. There are several types of
stainless steels, and these are summarized below:
a) Ferritic stainless steels contain between 12- 25% of chromium and less than 0.1% of carbon.
b) Martensitic stainless steels contain between 12-18 % of chromium, together with carbon contents
ranging from 0.1 to 1.5 %
c) Austenitic steels contain both chromium and nickel. When nickel is present, the tendency of nickel to
lower the critical temperatures over- rides the opposite effect of chromium, and the structure may
become wholly austenitic.
(iii) Merging steels
These are very high-strength materials that can be hardened to give tensile strengths up to
1900MPa .They contain 18% of nickel, 7% of cobalt and small amounts of other elements such as
titanium, and the carbon content is low, generally less than 0.05% . A major advantage of merging
steels is that after the solution treatment they are soft enough to be worked and machined with
comparative ease.
134
Nickel: This is used for grain refinement (In polycrystalline materials, each separate crystal is called
a grain and the areas of mismatch between adjacent crystals are called grain boundaries), to add
strength, and to promote the formation of free graphite. Thus it toughens the casting.
Chromium: This stabilizes the combined carbon (cementite) present and thus increases the
hardness and wear resistance of the casting. It also improves the corrosion resistance of the
casting, particularly at elevated temperatures. As in alloy steels, nickel and chromium tend to
be used together because they have certain disadvantages when used separately which tend
to offset their advantages. However, when used together the disadvantages are overcome, whilst
the advantages are retained.
Copper: This is used very sparingly as it is only slightly soluble in iron; however, it is useful in
reducing the effects of atmospheric corrosion.
Vanadium: This is used in heat-resisting castings as it stabilizes the carbides and reduces their
tendency to decompose at high temperatures.
Molybdenum: it dissolves in the ferrite and, when used in small amounts (0.5 %), it improves the
impact strength of the casting. It also prevents decay at high temperatures in castings containing
nickel and chromium. When molybdenum is added in larger amounts it forms double carbides,
increases the hardness of castings with thick sections, and also promotes uniformity of the
microstructure.
Types of steel
Chrome-Nickel steels
Molybdenum steels
Tungsten steels
Permanent magnets (4 to 5%
tungsten and 0.5 to 0.7%
carbon)
General purpose steel
Chrome-Nickel-Molybdenum
steels
Manganese steel (>1%Mg))
Toughness,
abrasion.
desulphuriser
resistance
to Machinery parts subjected to
Deoxidizer, severe wear, as crushing and
grinding machinery and in
railways crossings.
Silicon-Manganese steels (1.25 Depth hardness and toughness Springs
to 2.5% Si, 0.5 to 0.65%C, 0.6 to under impact and fatigue
0.9% Mg)
resistance
Table: general characteristics of common alloys
Glossary about effects of alloying elements in steel
In general, alloying elements are added to steels in order to accomplish the following purposes:
-
136
To develop special properties such as: magnetic and electrical characteristics; high strength at
high temperature; steels that are austenite at room temperature
To stabilize the iron-carbide in steel by adding chromium, vanadium, titanium, manganese,
tungsten, or molybdenum in varying amounts, depending on the end use of the product.
To promote graphitization by the addition of silicon, aluminium or copper.
Nickel: In amount of from 30 t0 50 per cent reduces the thermo expansion and magnetic
permeability of alloys, while from 1 to 5 per cent it increases the hardenability. It has also the
characteristics of graphitizing and producing a corrosion resistant, tough steel alloy. In addition,
it slows down the austenite to pearlite transformation.
Cobalt: It improves high temperature properties of steel. It also added to high speed, heat
resistant steel, tending to decrease hardenability in steel.
Chromium: Provides effective corrosion and oxidation resistance. In addition it improves the
wear resistance of steels and increases its hardenability.
Aluminum: Is usually added to produce the completely deoxidized, killed steel. It also increases
steels resistance to oxidation.
Manganese: In amount of 0.30 to 1.50 per cent is a good deoxidizer, while in high amounts it
increases the hardenability of steel.
Molybdenum (also titanium, niobium, and vanadium): Increases the wear resistance and
strength of the steel at high temperature. It also increases hardenability.
Copper: Is used mainly to improve corrosion resistance, for it dissolves only in the ferrite and
does not form carbides. It improves also machinability of steel.
Lead: In a small amounts however like copper, it improves the machinability of steel.
Sulfur: Improves the machinability of steel in amounts of from 0.10 to 0.30 per cent, together
with 0.60 to 1.50 per cent of manganese, by means of deformation of manganese sulfide.
Phosphorus: Is used to increase corrosion resistance of steel in some structural grades, when in
a present of small amount of copper.
Silicon: Dissolve mainly in the ferrite and it has a substantial strengthening effect
1. Work hardening: (a) Cold working result in creation of more dislocations which strengthen the
material
2. Solid solution strengthening: Substitutional or interstitial atoms cause lattice distortion, hindering
movement of dislocation.
3. Grain size refinement: the finer the grain size the higher the strength (Hall-Petch equation)
4. Transformation hardening
5. Irradiation hardening and 6. Dispersion (Age or precipitation) hardening: Formation of a secondary
phase that distorts lattice and blocks dislocation movement. Precipitation hardening is also called age hardening
because it involves the hardening of the material over a prolonged time. The precipitates form when the solubility limit is exceeded.
Small inclusions of secondary phases strengthen material. Lattice distortions around these secondary phases impede dislocation motion
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139
change to a mechanical mixture, or change to a combination of the two, depending on the type of metal
and the rate of cooling. All of these changes are predictable. For that reason, many metals can be made
to conform to specific structures in order to increase their hardness, toughness, ductility, tensile
strength, and so forth.
Heat treatment processes
1. Annealing
2. Spheroidizing
3. Normalizing
4. Hardening
5. Tempering
6. Case hardening or surface hardening
a. Carburizing
d. Induction hardening
b. Carbonitriding
e. Flame hardening
C. Nitriding
f. laser hardening
1. ANNEALING: It is the process of softening of hard metal by heating to a high temperature followed by
slow cooling.
Purposes of annealing:
a) To soften a steel or metal piece so that it may be more easily machined or cold worked, make
them more ductile and tough.
b) To relieve internal stresses caused by cold working of metal, hence restore ductility of cold
worked steels
c) To refine the grain size and structure to improve mechanical properties.
d) To homogenize the structure and prepare for subsequent other heat treatments (Machining
finish taken by annealing surface is not as good as of normalized steel surface)
e) To remove gases trapped in the metal during initial casting
Processes involved in annealing:
(a) Heating the steel to a prescribed temperature 300C to 500C above the upper critical temperature
for hypo-eutectoid steel and by the same temperature above lower critical temperature for
hyper-eutectoid steels. Heating produces austenite or austenite along with cementite and very
slow cooling produces soft pearlite mixed with ferrite or cementite depending upon carbon
percentage of steel
(b) Holding it for some for the required period of time at the temperature so that internal changes
may take place. The time allowed is 1 to 2 minutes for each mm of section of the piece being
annealed.
(c) Allow it to cool down slowly back to room temperature. Steel must be cooled very slowly to
produce maximum softness. This can be done by burying/dipping the hot part in sand, ashes, or
some other substance that does not conduct heat readily (packing), or by shutting off the
furnace and allowing the furnace and part to cool together (furnace cooling).
Medium
Severity of quenching
hardness
142
Air
Small
Small
Oil
Moderate
Moderate
Water
Large
Large
143
(a)
(b)
Soaking
A3
1
Slow cooling to Room
500-7000C Heating
temperature c<0.8%
A1
Soak
Cool slowly
Hypereutectoid
steels c>0.8%
Time
1100-12000C
(c)
A3
A1
A1
(d)
6-8 hours
Air Cooling
600 C
A3
Soak 1
Dissolution into
A1
Soak 2
(e)
Complete to P
Quenching
transformation
Heating a metal piece to a temperature just above (300C to 500C, that temp. is higher than either
the hardening or annealing temperatures) the upper critical temperature to reduce grain sizes
(of pearlite and proeutectoid phase) and make more uniform size distributions.
- It is kept at that temperature for about 15minutes and then allowed to cool down in air. This
process provides a homogeneous structure in low and medium carbon steels. The homogeneous
structure provides a high yield point, ultimate tensile strength and impact strength with lower
ductility to steels. Heating produces austenite and cooling produces finer pearlitic structure as
compared to annealing along with ferrite or cementite depending upon the carbon percentage
of steel.
Machining finish taken by the surface of normalized steels is generally better.
-
4. HARDENING: A ferrous metal is normally hardened by heating the metal to the required temperature
(300C to 500C above the upper critical temperature) for both hypo and hyper-eutectoid steel. Depending
upon its thickness, it is held at this temperature for a time and then rapidly cooled by plunging the hot
metal into a suitable cooling medium like water, oil, brine, or a current of air from blower or compressor.
To harden low and medium carbon steel, a very rapid quenching rate is necessary like quenching, in
water baths. But oil is generally used as the quenching medium for high carbon and many alloy steels.
The rapid cooling, convert most of the austenite into martensite which is hard and more stable than
austenite at ordinary temperatures.
The hardening process increases the hardness (wear resistance) and strength of metal, but also
increases its brittleness.
5. TEMPERING
Steel is usually harder than necessary and too brittle for practical use after being hardened. Severe
internal stresses are set up during the rapid cooling of the metal. Steel is tempered after being hardened
to relieve the internal stresses and reduce its brittleness.
Tempering is the process used to impart toughness to steel while retains most of hardness to increase
its usefulness by improving its shock resistance. Tempering requires the reheating of steel after being
hardened to temperature below its lower critical temperature followed by a fair rapid cooling in water
or oil.
Tempering consists of heating the metal to a specified temperature and then permitting the metal to
cool. The rate of cooling usually has no effect on the metal structure during tempering. Therefore, the
metal is usually permitted to cool in still air. Temperatures used for tempering are normally much lower
than the hardening temperatures. The higher the tempering temperature used, the softer the metal
becomes. High-speed steel is one of the few metals that become harder instead of softer after it is
tempered.
- Low tempering: only for stress relief, obligatory for hardened metals
- Medium temperature tempering: Reduces hardness by transforming martensite to Bainite.
Toughness and ductility are increased.
145
High tempering temperature: almost all martensite is transformed to Bainite and fine pearlite.
Material is very ductile and tough, with improved fatigue properties.
Soaking
Soaking
A3
A1
Air cooling
Heating
A3
A1
c>0.8%
NORMALIZING
DIRECT HARDENING
- Stable
A3
650
500
450
0
350
A1
-P
Pearlite
-B
Bainite
High temp.
Medium temp.
250
150
Low temp.
Ms Unstable()
Mf
Martensitic
Water quench Oil quench Air cool
Furnace cool
TEMPERING
A3
A1
Pearlite
-B
Bainite
Ms
Mf
MARTEMPERING (martensite) AUSTEMPERING (Bainite)
decomposes and deposits hardener element into the surface of a steel. Then, when the part is cooled
rapidly, the outer surface layers or case becomes hard, leaving the, inside of the piece (inner cores) soft
but very tough.
6.1 CARBURIZING OF STEELS
It involves the introduction of additional carbon into the surface of mild steel, effectively producing a
composite material consisting of low carbon steel with a thin case, about 0.5 0.7 mm in thickness, of
high carbon steel, this was the principle of case-hardening that have been used for centuries in the
conversion of mild or wrought iron to steel by the cementation process.
In the carburization process for steel, carbon is introduced into the surface of low-carbon steel, typically
containing 0.1 to 0.2 % carbon. The carbon content of the carburized surface layer or case normally is
increased to about 0.8 to 1.0 % C. The carbon is introduced into the steel at temperatures above the
upper transformation temperature where the steel is FCC-austenitic.
The steel must be in the austenitic condition where there is appreciable interstitial solid solubility of
carbon in austenite. The solubility of carbon in iron varies with temperature, and in Fe-C alloys ranges
from about 0.8% at 723C to about 2.0% at 1148C. Alloying elements can affect the solubility of carbon
in iron. Below 723C, carbon has a very low solubility in BCC ferrite (about 0.02% maximum), and thus
carburizing is not possible. Carburizing is usually done in the 850 to 950C range, although temperatures
as low as 790C and as high as 1095C can be used.
Surface- hardening techniques for steels: gas carburizing, carbonitriding, nitriding, and induction surface
heating. Then localized surface-hardening techniques such as flame and laser hardening will be treated.
After carburizing, the workpiece is usually quenched to produce a martensitic structure in the case. Thus,
the carburizing treatment can produce steel with a hardened surface (case) and a core with low strength,
high ductility, and toughness typical of low-carbon steel.
The case-hardening consists in surrounding the component with suitable carbon material and heating it
to above its upper critical temperature for long enough to produce a carbon enriched layer of sufficient
depth.
The case-hardening process has
two distinct steps, as shown:
- Carburising ( the additional of
carbon)
- Heat treatment (hardening and
core refinement)
Fig:. Case hardening : (a) carburizing, (b) after carburizing, (c) after quenching component.
Solid, liquid and gaseous carburizing media are used. The nature and scope of the work involved will
govern which media is best to employ.
Applications:
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Carburizing is widely used in industry for machine components such as gears, bearings, and shafts where
surface resistance to wear and contact and bending fatigue is required. Carburizing is also used for
heavy-duty gears where good fracture toughness is needed in addition to wear and fatigue resistance.
The selection of steels for carburizing depends on many variables such as carbon and alloy content,
grain growth characteristics, machinability, and cost. Both plain-carbon and low-alloy steels containing
about 0.20% carbon are the most common carburizing steels. Plain-carbon steels are satisfactory for
many applications where distortion of the workpiece is not critical and where high-strength core
properties are not required. The most common alloying elements for carburizing steels are nickel (0.53.5%), chromium (0.4-1.4%), and molybdenum (0.1-0.3%). Steels containing (0.1-0.3%) sulfur are often
used for improved machinability.
Carburizing in solid media "Pack-carburizing"
As it is usually called, involves packing the components into cast-iron or steel boxes along with the
carburizing material so that a space of approximately 50 mm exists between the components. The lids
are then luted on to the boxes, which are slowly heated to the carburizing temperature for between 900
and 950 C. they are maintained at this temperature for up to five hours, according to depth of case
required.
Carburizing media vary in composition, but consist essentially of some carbonaceous material, such as
wood or bone charcoal or charred leathers together with an energizer which may account for up to 40%
of the total composition. This energizer is usually a mixture of sodium carbonate ("soda ash") and
barium carbonate, and its purpose is to accelerate the solution of carbon by the surface layer of the
steel. It is thought that carburization proceeds by dissociation of carbon monoxide which will be present
in the hot box. When the gas comes into contact with the hot steel it dissociates thus:
The atomic carbon deposited at the surface of the steel dissolves easily in the metal. In this method of
carburizing the thickness of the surface is between 0.05 1.55 mm. If it is necessary to prevent any
areas of the component from being carburized, this can be achieved by electro-plating these areas with
copper to a thickness of 0-075-0-10 mm; carbon being insoluble in solid copper at the carburizing
temperature.
When carburizing is complete the components are quenched or cooled slowly in the box, according to
the nature of the subsequent heat-treatment to be applied.
Carburizing in a liquid bath (Cyaniding)
Liquid-carburizing is carried out in baths containing from 20 to 50% sodium cyanide, together with up to
40% sodium carbonate and varying amounts of sodium chloride i.e. low carbon steel is immersed in a
molten salt bath consisting of Nacl, Na2C03 and Na CN. This cyanide-rich mixture is heated in pots to a
temperature of 870-950 C, and the work, which is contained in wire baskets, is immersed for periods
varying from about five minutes up to one hour, depending upon the depth of case required. The carbon
and especially the nitrogen diffuse into the surface of steel. Nitrides on the surface of steel make it
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152
Applications: in general it is used when large numbers of symmetrically shaped parts are to be surfacehardened. using induction heating surface hardening are crankshafts, camshafts, axle shafts, gears,
cams, and valve seats.
FLAME HARDENING
Localized surface hardening (oxy-acetylene torch for local heating and quenching of part that need to be
surface hardened) can also be achieved in medium- and high-carbon steels and some cast irons by rapid
local heating and quenching, used for C>0.35%.. The principle of flame hardening a steel workpiece is to
quickly heat its surface to the austenitic temperature range and then rapidly quench the workpiece to
produce a martensitic structure on the surface layer. In flame hardening the surface layer of steel is
quickly heated by the direct impingement of a high-temperature flame by using, for example, an
oxyacetylene or oxyhydrogen torch.
The quenching action after heating is accomplished by a combination of heat extraction by the cold
metal beneath the case and by an external quenching medium. Steels for flame hardening usually
contain 0.4 to 0.75% carbon, and since there is no change in composition, the steel to be flamehardened is selected for both case and core properties. Since the core structure is not affected by the
surface treatment, the core properties must be developed by proper heat treatment before the surface
treatment. In general, a hard surface layer of martensite is produced and a softer inner core that has a
ferrite-pearlite structure.
A carriage moves over the work piece so that the
surface is rapidly heated by an oxy-acetylene or an
oxy-propane flame. The same carriage carries the
water-quenching spray. Thus the surface of the
work piece is heated and quenched before its core
can rise to the hardening temperature. This
process is often used for hardening the slideways
of machine tools, such as gears, spindles and pins,
that are confidently treated by this process, since
they can be spun between centers.
Fig.: The principle of flame hardening for Surface hardening with flame hardening (Shorter process).
It has the following advantages: Only desired areas are affected, short time process, even very large
pieces can be hardened.
Applications: Flame hardening is applied to a wide diversity of ferrous workpieces. Some examples are:
(i) Parts so large as to make conventional furnace heating impractical such as large gears, dies, and rolls
and (ii) Small sections or areas of a part that require surface hardening such as the ends of valve stems
and push rods and the wearing surfaces of cams and levers.
153
LASER HARDENING
In laser hardening the surface of the steel workpiece is heated into the austenitic region without a
change in composition. The heat source is a laser which generates an intense localized heating. The
workpiece itself acts as a cooling sink, and no external quenching medium is required. Laser heating is
usually used to produce a shallow layer of martensite on the steel workpiece.
Commonly, a traveling laser beam at a controlled speed moves across the surface to be hardened. The
case depth is usually shallower than those produced by induction and flame hardening.
Advantages of laser hardening include the ability to harden relatively small areas in complex shapes, e.g.,
small bores. A disadvantage of the process is the cost of the laser.
Fig.: Heat-treatment temperature Ranges of Classes of Carbon Steels in Relation to the Equilibrium
Diagram.
Surface Hardening comprises of thermochemical treatments to harden surface of part (carbon,
nitrogen). It is also called case hardening. Case Hardening - create C- or N- rich outer layer in steels by
154
atomic diffusion from the surface. Makes harder outer layer and also introduces compressive stresses.
May or may not require quenching. Interior remains tough and strong
Reasons to Surface Harden:
Increase wear resistance
Increase surface strength for load carrying (crush resistance)
Induce suitable residual and compressive stresses
Improve fatigue life
Impact resistance
Methods to Surface Harden
Heat Treatment: Induction, Flame, Laser, Light, Electron beam
Case Hardening: Carburizing; Cyaniding, Carbonitriding, Nitriding
Heat Treatment
Procedure (typically for medium to high carbon steels)
- Heat surface to austenize (interior stays below austenite transition temperature)
- Cool to form surface martensite ( Interior is not modified and Surface is in compression)
- Subsequent tempering typically done
Characteristics
Hardened depth depends on Frequency (for induction heating effects the depth of the skin. E.g.
1,000Hz 4.5-9mm, 1,000,000 Hz 0.25-0.8mm
Heat flow (flame)
Surface Rc 50-60 (martensite or tempered martensite)
Interior Rc 10-20 (pearlite-ferrite)
Case Hardening
Reasons: Easy to control depths; Good for complicated parts; Mass production compatible; Can use
with low carbon steels (cheaper and tougher)
Steel Crystal Structures:
155
Fig.: Microstructures of annealed carbon steel. (a) About 0.2%C, (b) about 0.6%C. the light areas are
ferrite and the dark are pearlite.
Fig.: Microstructures of carbon steels (a) ferrite: pure iron and low carbon steel(x100). Austenite has
156
about the same microscopic appearance. (b) Pearlite: an annealed 0.8%C steel is 100% pearlite. The dark
lines are Fe3C; the light areas are ferrite (x1300). (c) Martensite: quench-hardened steels (x500).
Heat Treatment of Steels
Heat Treatment Methods
Furnaces
Fuel-fired - parts exposed to combustion products
Electric
Batch or continuous
Vacuum - prevents oxidation of surface
Salt bath
Fluidized bed - particles suspended by gas flow - improves heat transfer
Flame; Electron or laser beam heating, Induction heating, High-frequency (HF) resistance heating
157
158
159
The Carbon atoms fit into interstitial spaces in the FCC Austenite structure schematically shown below.
Note the distortion of the Fe atoms [0.258-nm diameter] around the Carbon atoms [0.154-nm diameter]
since the voids are 0.104-nm diameter.
160
Sol: (a) The specimen is cooled rapidly to 433 K and left for 20 minutes. The cooling rate is too rapid for
pearlite to form at higher temperatures; therefore, the steel remains in the austenitic phase until the M s
161
Temperature is passed, where martensite begins to form. Since 433 K is the temperature at which half
of the austenite transforms to martensite, the direct quench converts 50% of the structure to
martensite. Holding at 433 K forms only a small quantity of additional martensite, so the structure can
be assumed to be half martensite and half retained austenite.
(b)The specimen is held at 523 K for 100 seconds, which is not long enough to form bainite. Therefore,
the second quench from 523 K to room temperature develops a martensitic structure.
(c) An isothermal hold at 573 K for 500 seconds produces a half-bainite and half-austenite structure.
Cooling quickly would result in a final structure of martensite and bainite.
(d) Austenite converts completely to fine pearlite after eight seconds at 873 K. This phase is stable and
will not be changed on holding for 100,000 seconds at 873 K. The final structure, when cooled, is fine
pearlite.
HEAT TREATMENTS OF STEELS
HARDENING
Direct hardening
Austenitize and
quenching
Diffusion hardening
Carburize (diffuse C)
Nitride (diffuse N)
Boronize (diffuse B)
Selective
Special species (Diffuse
Austenitize and
V, Si, etc.
quenching: Flame;
Carbonitriding (Diffuse C+N)
Induction; Laser;
Ferritic nitrocarburizing
Electron beam
(Diffuse C+N)
SOFTENING
CONDITIONING
Recrystallization
Stress relieving
Annealing: Process;
Full; Spheroidizing;
Normalizing
Spring aging
Tempering:
Austempering;
Martempering
Steam treating
Cryogenic
treatment
DIRECT HARDENING
When a piece of steel, containing sufficient carbon, is cooled rapidly from above its upper critical
temperature it becomes considerably harder than it would be if allowed to cool slowly.
This involves rapidly quenching the steel, from a high temperature into oil or water. Hypereutectoid
steels are heated to (30- 500C) above the upper critical temperature prior to quenching. It is possible
that some cementite grain boundaries.
Consequently, hypereutectoid steels are hardened by quenching from (30- 50 C) above the lower critical
temperature. At this temperature the structure because one of spheroidal cementite particles in an
162
austenite matrix.
The degree of hardness produced can vary, and is dependent upon such factors as the initial quenching
temperature; the size of the work; the constitution, properties and temperature of the quenching
medium; and the degree of agitation and final temperature of the quenching medium.
Austenitizing and quench: Heat to austenite
range. Want to be close to transformation
temperature to get fine grain structure
Austenitizing again taking a steel with .6%
carbon or greater and heating to the
austenite region.
Rapid quench to trap the carbon in the crystal
structure called martensite (BCT)
Quench requirements determined from
isothermal transformation diagram (IT
diagram).
Get Through Hardness
For this particular steel want to cool from about 1400 F to <400 F in about 1 second!
Quenching: Depending on how fast steel must be quenched (from IT diagram), the heat treater will
determine type of quenching required: Water (most severe); Oil, Molten Salt, Gas/ Air (least severe),
Many phases in between. Ex: add water/polymer to water reduces quench time, Adding 10% sodium
hydroxide or salt will have twice the cooling rate.
Selective Hardening:
Same requirements as austenitizing: Must have sufficient carbon levels (>0.4%), Heat to austenite region
and quench
Why do?
- When only desire a select region to be hardened: Knives, gears, etc.
- Object to big to heat in furnace! Large casting w/ wear surface
Types: Flame hardening, induction hardening, laser beam hardening
164
] , is used to
Steady state diffusion: the diffusion flux does not change with time.
165
D: Diffusion coefficient (area/time) is the measure of mobility of diffusing species.; dc/dx: concentration
; where
=a diffusion
process to occur;
depends on material system it is the activation energy for diffusion (J/mol or
eV/atom), R is the gas constant (8.31 J/mol-K or 8.6210-5 eV/atom-K) and T is absolute temperature (k).
The above equation can be rewritten as
( )
( )
The activation energy Qd and preexponential
D0, therefore, can be estimated by plotting
lnD versus 1/T or logD versus 1/T. Such plots
are Arrhenius plots.
Fig.: Plot of the logarithm of the diffusion coefficient versus the 1/T for Cu in Au.
(b) How diffusion occurs
166
To move from lattice site to lattice site, atoms need energy to break bonds with neighbors, and to cause
the necessary lattice distortions during motion from site to another. This energy comes from atomic
vibrations (Eav ~ kT)
167
Fig.: Atomic migration by a mechanism of vacancy migration (Before and after). Materials flow (the
atom) is opposite the vacancy flow direction.
Interstitial diffusion (depends on temperature). This is generally faster than vacancy diffusion because
there are many more interstitial sites than vacancy sites to jump to. Requires small impurity atoms (e.g.
C, H, O) to fit into interstices in host.
Charcoal forms CO2 gas which reacts with excess carbon in charcoal to form CO. CO reacts with lowcarbon steel surface to form atomic carbon. The atomic carbon diffuses into the surface. Must then be
quenched to get hardness
Fig.: Microhardness Through Case zone: Determination of carburized or carbonitrided case depth by
microhardness survey
Fig.: Microstructure through carburized surface. 0.20%C-steel pack carburized at 17000F for 6 hours
and furnace-cooled. Etched in 2% initial (30X)
Other rare carburizing methods:
- Gas carburizing - use of propane or other gas in a closed furnace - makes thin layer (0.005 - 0.030 in)
- Liquid carburizing - molten salt bath containing sodium cyanide, barium chloride - thickness between
other two methods
2. Nitriding: Nitrogen diffused into surface of special alloy steels (aluminum or chromium) being treated.
Nitrogen reacts with steel to form very hard iron and alloy nitrogen compounds. Nitride compounds
169
precipitate out. Process does not require quenching big advantage. The case can include a white layer
which can be brittle disadvantage. It is More expensive than carburizing. Reduction process:
Types: Gas nitriding - heat in ammonia and Liquid nitriding (Carbonitriding) - dip in molten cyanide bath
(Cyaniding)
change and the constituents ferrite and cementite remain present in the structure throughout the
process.
Process annealing is generally carried out in either batch-type or continuous furnaces, usually with an
inert atmosphere of burnt coal gas, though cast-iron annealing "pots" are still used, their lids being luted
on with clay.
(ii) Full annealing for forgings, Large castings and weldments: lower temp (1,000F), slow cooled. It is the
treatment given to produce the softest possible condition in a hypoeutectoid steel. It involves heating
the steel to a temperature within the range 30 50 C above the upper critical temperatures and then
allowing the steel to cool slowly within the furnace. This produces a structure containing coarse pearlite.
This results in the formation of fine grains of austenite that transform into relatively fine grains of ferrite
and pearlite or pearlite and cementite (depending upon the carbon content) as the steel is slowly cooled
to room temperature, usually in the furnace.
Full annealing is an expensive treatment and when it is not absolutely essential for the steel to be in a
very soft condition, but a reasonably soft and ductile material is required, the process known as
normalizing is used instead.
Ferrite, which then begins to precipitate in accordance with the equilibrium diagram, deposits first at
the grain boundaries of the austenite, thus revealing, in the final structure, the size of the original
austenite grains. The remainder of the ferrite is then precipitated along certain crystallographic planes
within the lattice of the austenite. This gives rise to a directional precipitation of the ferrite, as shown in
figure below. and Plate , representing typically what is known as a Widmanstatten structure.
Fig.: The structural effects of heating a steel casting to a temperature just above its upper critical ,
followed by cooling to room temperature.
172
This type of structure was first encountered by Widmanstatten in meteorites, which may be expected to
exhibit a coarse structure in view of the extent to which they are overheated during their passage
through the upper atmosphere. .The mesh-like arrangement of ferrite in the Widmanstatten structure
tends to isolate the stronger pearlite into separate patches, so. that strength, and more particularly
toughness, are impaired. The main characteristics of such a structure are, therefore, weakness and
brittleness, and steps must be taken to remove it either by heat-treatment or by mechanical working.
Hot-working will effectively break up this coarse as-cast structure and replace it by a fine-grained
material, but in this instance we are concerned with retaining the actual shape of the casting. Heattreatment must therefore be used to effect the necessary refinement of grain.
This operation need a very specific controlling on the heat temperature of annealing because if any fault
is across, it will make some undesired phases in the steel such as: Over heating, Burning (Excessive over
heating), and Under-qunealing
(iii) Spheroidised annealing at subcritical temperatures. The Spheroidised condition is produced by
annealing the steel at a temperature between 650 and 700 C, just below the lower critical temperature.
During this treatment cementite forms as spheroidal particles in a ferrite matrix, putting the steel into a
soft, but very tough, condition.
Since the temperature involved are sub critical no phase changes take place and spheroidization of the
cementite is purely a surface tension effects. This is referred to as the a spheroidization of pearlitic
cementite
The fine grain structure resulting from the more rapid cooling associated with normalizing gives
improved strength and toughness to the steel but reduces its ductility and malleability. The increased
hardness and reduced ductility allows a better surface finish to be achieved when machining. (The
excessive softness and ductility of full annealing leads to local tearing of the machined surface.)
The type of structure obtained by normalizing will depend largely upon the thickness of cross-section, as
this will affect the rate of cooling. Thin sections will give a much finer grain than thick sections, the latter
often differing little in structure from an annealed section.
Although highly successful, this procedure tied up an excessive amount of working capital and space and
nowadays heat treatment is preferred as the work in progress is turned round more quickly.
4. Tempering: A quench-hardened plain carbon steel is hard, brittle and hardening stresses are present.
In such a condition it is of little practical use and it has to be reheated, or tempered, to relieve the
stresses and reduce the brittleness. This temperature will remove internal stress setup during quenching,
remove some, or all, of the hardness, and increase the toughness of the material.
Almost always done following heat treat as part of the austenitizing process. Because of lack of
adequate toughness and ductility after heat treat, high carbon martensite is not a useful material
despite its great strength (too brittle). Tempering causes the transformation of martensite into less
brittle structures. Unfortunately, any increase in toughness is accompanied by some decrease in
hardness. Tempering always tends to transform the unstable martensite back into the stable pearlite of
the equilibrium transformations. Thus it imparts a desired amount of toughness and ductility (at the
expense of strength)
Typical HT steps:
- Austenize: Heat into stable single phase region and HOLD for uniform chemistry single phase
austenite.
- Quench: Rapid cool crystal changes from Austenite FCC to Martensite BCT which is hard but
brittle.
- Temper: A controlled reheats (BELOW AUSTENITE REGION). The material moves toward the
formation of a stable two phase structure tougher but weaker.
- Quench: The properties are then frozen in by dropping temperature to stop further diffusion
Tempering temperatures below 2000C only relieve the hardening stresses, but above 2200C the hard,
brittle martensite starts to transform into a fine pearlitic structure called secondary troostite (or just
'troostite'). Troostite is much tougher although somewhat less hard than martensite and is the structure
to be found in most carbon-steel cutting tools.
Tempering above 4000C causes any cementite particles present to "ball-up" giving a structure called
sorbite. This is tougher and more ductile than troostite and is the structure used in components
subjected to shock loads and where a lower order of hardness can be tolerated, for example springs. It is
normal to quench the steel once the tempering For most steels, cooling form the tempering
temperature may be either cooling in air, or quenching in oil or water. Some alloy steels, however, may
be become embrittled if slowly cooled temperature has been reached. from the tempering temperature,
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Two of the most important are Alluminium and copper since they not only form the bases of many
important alloys, but they are widely used in their own right as pure metals.
5.5.1 ALLUMINIUM AND ITS ALLOYS
Pure Alluminium is a weak, ductile material with a low density. Its electrical conductivity is second only
to copper for conductors of the same mass. Its thermal conductivity and light reflectivity are quite high.
It is also highly resistant to corrosion against many types of attack which are harmful to other metals;
this is due to the formation of a very adherent homogeneous and transparent film on a fleshly cut
surface caused by the high affinity of Alluminium to oxygen. This oxide layer is amphoteric (can behave
as either basic or acidic oxide). Alluminium is an FCC material therefore it has numerous (12) slip
systems, leading to good ductility.
The wear resistance of Alluminium, as suspected from its low yield stress and hardness, is not good. The
fatigue strength is not high. Its low modulus of elasticity must be considered when cold working due to
the springback when unloaded.
Because of its creep strength that limits its use to fairly low temperatures (1750C recommended) and the
low strength that makes it of little use as a structural material, aluminum alloys are preferred.
Effects of alloying elements in alluminium
-
They provide better casting characteristics (fluidity and gas tightness) in casted alloys: silicon
They improve mechanical properties: copper, nickel. Copper raises also strength at high
temperatures (use in piston castings and heat exchangers). The highest strength alloy of
Alluminium is the one containing 5-6% zinc with slammer amount of magnesium and copper.
- They improve corrosion resistance: Magnesium, manganese or small amounts of chromium
- They improve machineability: Lead and bismuth
Aluminum and its alloys are produced and used in many shapes and forms. The common forms are
castings, sheet, plate, bar, rod, channels, and forgings. Aluminum alloys have many desirable qualities.
They are lighter than most other metals and do not rust or corrode under most conditions. Aluminum
can be cast-forged, machined, and welded easily.
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The principal use of commercially pure copper is in the electrical industry where it is made into wire or
other such conductors in radiators and heat exchangers. It is also used in the manufacture of nonferrous
alloys such as brass, bronze, and monel metal. Typical copper products are sheet roofing, cartridge
cases, bushings, wire, bearings, and statues.
Effects of alloying elements in copper.
Zinc, tin, alluminium and silicon are among the most frequently used solid solution hardeners for
copper.
-
Zinc increases strength. Muntz metal is an alloy containing 40%zinc. The alloys of copper and
zinc are known as brasses (used in cartridge casings, musical instruments, etc). They are more
susceptible to stress and erosion corrosion and not more resistant compared to pure copper.
Tin: improves hardness and strength of copper (>10% tin impairs ductility). It has a high cost.
The bronzes are copper alloys involving elements such as tin, alluminium, silicon and nickel.
They have a high degree of corrosion resistance. Tin-bronze alloys are made up by copper and
tin together with a deoxidizer to prevent tin oxidation during casting or hot working which
would result in weak, scratchy bronze. Two deoxidizers are commonly used:
Phosphorus in the phosphor-bronze alloys
Zinc in the gunmetal alloys
Brass and bronze: Brass, an alloy of copper and zinc (60 to 68 percent copper and 32 to 40
percent zinc), has a low melting point and high heat conductivity. There are several types of
brass such as naval, red, admiralty, yellow, and commercial. All differ in copper and zinc content.
All may be alloyed with other elements such as lead, tin, manganese, or iron and all have good
machinability and can be welded. Bronze is an alloy of copper and tin and may contain lead,
zinc, nickel, manganese, or phosphorous. It has high strength, is rust or corrosion resistant, has
good machinability, and can be welded.
Alluminium: the behavior of the copper alloys containing increasing amounts of alluminium is
similar to that of tin alloys. Alluminium bronzes are more expensive than tin-bronzes but more
corrosion resistant at high temperatures due to the aluminum oxide film that forms on its
surface. They are also more ductile and can be cold worked into tubes for boilers and
condensers in steam and chemical plant.
- Nickel: imparts a white color to copper, raises the hardness of copper. Constantan is an alloy of
copper with 45%Ni, it is used for resistors and for thermocouples. Cupro-nickel alloys are
relatively expensive copper-based alloys, but their strength, ductility and corrosion resistance
make them highly suitable for applications such as high-duty boiler and condenser tube and
resistance wires.
Monel metal: this contains traces of Fe and manganese, high corrosion resistant at high
temperatures. Used for chemical plant and marine applications
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Nickel silvers: up to 20%zinc which reduces the cost and imparts a silvery appearance when highly
polished. Used for domestic table cutlery as alternative to stainless steel.
Nickel with the super alloys: Inconel (Ni-Cr-Fe); hastelloy (Ni-Mo-Fe-Cr)
-
Silicon: produces effects similar to those of zinc, tin and alluminium when alloyed with copper.
However, limits of solubility are lower, hence embrittlement occur at lower concentrations.
- Tellurium metal, non-metal sulphur and lead (act as lubricant in bearings) increase machinability
to a good surface finish.
5.5.3 MAGNESIUM AND ITS ALLOYS
Magnesium is the lightest of the engineering metals (1.7g/mm3). It is HCP with only 3 slip systems and
characteristic brittleness. Except for ductility, the properties of pure magnesium are superior to those of
pure aluminium. But magnesium does not respond to heat treatment and mechanical working as
alluminium. Magnesium is considered to be generally weaker than steel and alluminium, although some
alloys of magnesium are stronger than alluminium alloys. For that reason, its structure requires
members of greater section thickness in order to be of the same load-carrying capacity. Properties like
wear resistance, fatigue strength, creep strength (low melting temperature 6500C) and corrosion
resistance are poor.
Magnesium alloys are produced and used in many shapes and forms, for example, castings, bars, rods,
tubing, sheets and plates, and forgings. Their inherent strength, light weight, and shock and vibration
resistance are factors which make their use advantageous. The weight for an equal volume of
magnesium is approximately two-thirds of that for aluminum and one-fifth of that for steel. Magnesium
has excellent machining qualities; however, care must be taken when machining because the chips are
highly flammable. Magnesium fires bum so hot that they cannot be extinguished by conventional fire
extinguishers.
Effect of alloying elements in magnesium
Magnesium alloys contain:
Alluminium: produce a precipitation-hardenable alloy in which the precipitate resembles to pearlite of
steel >7%Aluminium. In solid solution, exerts a slightly hardening effect
Zinc: Solid solution hardener and improves corrosion resistance.
Manganese: in small controlled amounts, improves resistance to attack by salt water.
5.5.4 LEAD
Lead is used mainly in the manufacture of electrical equipment such as lead-coated power and
telephone cables and storage batteries. Zinc alloys are used in the manufacture of lead weights,
bearings, gaskets, seals, bullets, and shot.
Many types of chemical compounds are produced from lead. Among these are lead carbonate (paint
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pigment) and tetraethyl lead (antiknock gasoline). Lead is also used for X-ray protection (radiation
shields). Lead has more fields of application than any other metal. It can be cast, cold worked, welded,
and machined. Lead has low strength with heavy weight.
5.5.5 TIN
The major use of tin is in coating steel. It is the best container for preserving perishable food. Tin, in the
form of foil, is often used in wrapping food products. A second major use of tin is as an alloying element.
Tin is alloyed with copper to produce bronze, with lead to produce solder, and with antimony and lead
to form babbitt. Tin can be die cast, cold worked, machined, and soldered; however, it cannot be
welded.
5.5.6 NICKEL
Nickel is used in making alloys of both ferrous and nonferrous metals. Chemical and food processing
equipment, electrical resistance heating elements, ornamental trim, and parts that must withstand
elevated temperatures are all produced from nickel containing metal. Alloyed with chromium, it is used
to make stainless steel. Nickel alloys are readily welded by either gas or arc methods and can be
machined, forged, cast, and easily formed.
5.5.7 COBALT-CHROMIUM-TUNGSTE-NMOLYBDENUM WEAR-RESISTANT ALLOYS
These alloys feature a wear resistance which makes them ideal for metal-cutting operations. Their ability
to retain hardness even at red-heat temperatures also makes them especially useful for cutting tools.
Common cutting tools will lose their edge at high heat, whereas this alloy group is actually tougher at
red heat than it is when cold; as a result, higher speeds and feeds may be used when machining with
tools made with these alloys.
5.5.8 PRECIOUS METALS
These include silver, gold, platinum, palladium, iridium, osmium, rhodium, and ruthenium, with 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 twenty-fourths. 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.
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Summary
Metal
Aluminium
Density
3
(Kg/m )
2700
Melting point
(C)
660
Cooper
8900
1063
Lead
11300
328
Silver
960
Tin
Properties
Typical uses
7300
232
7100
420
Chromium
7500
1890
Cobalt
8900
1495
Manganese
7200
1260
Molybdenum
9550
2620
Nickel
8900
1158
The base of brass and bronze alloys. It is used extensively for electrical
conductors and heat exchangers such as motor car radiators
Electric cable sheaths the base of solder alloys. The grids for accumulator
plates. Lining chemical plant. Added to other metals to make them freecutting
Widely used in electrical and electronic engineering for switch and relay
contacts
coats sheet mild steel to give 'tin plate' Used 1 soft solders One of the bases of
'white metal' bearings An alloying element In bronzes
Sheet extensively to give galvanized iron. The base of die-casting alloys. An
alloying element in brass
Used as an alloying element in high-strength and corrosion resistant steels.
Used for electroplating
Used as an alloying element in super high speed steels and in permanentmagnet alloys
Used to de-oxidize steels and offset the effects of the impurity sulfur. Larger
amounts improve wear resistance
Used as an alloying element in high-strength nickel-chrome steels to Improve
mechanical and heat - treatment properties. It reduces mass effect and
temper -brittleness
Used as an alloying element to improve the strength and mechanical
properties, of steel. Tends to unstabilise the carbon during heat treatment,
and chromium has to be added to counteract this effect in medium and highcarbon steels. Used for electroplating
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182
183
The yield stress is the stress at the yield point; that is, the load at B divided by the original cross-section
area of the specimen. Usually, a designer works at 50 per cent of this figure to allow for a 'factor of
safety'.
From C to D extension is no longer proportional to the load, and if the load is removed little or no spring
back will occur. Under these relatively greater loads the material is showing plastic properties.
The point D is referred to as the 'ultimate tensile strength' when referred to loadextension graphs or the
'ultimate tensile stress' (UTS) when referred to stress strain graphs. The ultimate tensile stress is
calculated by dividing the load at D by the original cross-sectional area of the specimen. Although a
useful figure for comparing the relative strengths of materials, it has little practical value since
engineering equipment is not usually operated so near to the breaking point.
From D to E the specimen appears to be stretching under reduced load conditions. In fact the specimen
is thinning out (necking) so that the 'load per unit area' or stress is actually increasing. The specimen
finally work hardens to such an extent that it breaks at L
In practice, values of load and extension arc of limited use since they apply only to one particular size of
specimen and it is more usual to plot the stress-strain curve. (An example of a stress strain curve for a
low-carbon steel is shown in the previous figure.
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185
Fig.: comparison of the compressive and tensile strengths of gray cast iron and concrete, both of
which are brittle materials
7.1.3 Bend tests: to assess whether a material meets fabrication requirements or whether it has desired
design strength. Hence they are classified as:
(a) Ductility (cracking) test to assess the ductility or to verify that the minimum plasticity required of a
material is exceeded. It can be found by using tensile test for determining the percentage elongation.
Another way is a simple bend test. Different ways are applied like close bend, angle bend, 1800 bend and
reverse bend tests. For the last 3, formers of specified nose radius are used.
Fig.7.4 : (a) Close bend test (b) Angle bend test (c)1800 bend test
(b) Transverse tests. It is applied to brittle materials such as cast iron which are highly sensitive to notch
so break in a section away from the gauge length when tensioned. The use of a 3 or 4-point bend test
enables to evaluate critical values of tensile stress required to cause rupture.
186
Fig.7.7 : (a) A rod of high-carbon (1%) steel in the annealed (soft) condition will bend when stuck with
a hammer (UTS 925MPa). (b) After hardening and lightly tempering, the same piece of steel will
fracture when hit with a hammer despite its UTS having increased to 1285MPa
Two types:
- The Izod test: 10mm square notched specimen is used. The striker of pendulum hits the
specimen with KE of 162.72J at a vel. Of 3.8m/s.
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The Charpy test: in Izod test the specimen is supported as a cantilever, but in the
Charpy test it is supported as a beam. It is stuck with a KE of 298.3J at a velocity of 5m/s
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BHN
D
2
d2
P
Dt
BHN
D 2 1 cos
P
K , for ferrous metals K=30.
D2
b)Vickers hardness: uses diamond pyramid indenter (it is very hard approximately 6000BHN) with an
angle of 1360 between opposite faces. VHN = load/projected surface area of indentation.
2 P sin
2 1.854 P
VHN
2
d
d2
Where P=applied load (kg), d= average length of diagonals (mm), : angle between opposite faces of the
diamond pyramid (1360). There are 3 types of Vickers indentations: Perfect, barreled and pin-cushioned
indentations.
Fig.7.11: Types of Vickers indentations: (a) perfect (b) barreled and (c) pin-cushioned
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c) Rockwell tests: the most widely used since it is quick, simple and direct reading. The indenter is either
a conical shaped diamond cone (brale) with an apex angle of 1200 (for hard materials) or a hardened
steel ball (for softer materials). Its principle is to compare the difference in depth of penetration of the
indenter when using forces of two different values. The minor load (preload) is 10Kg and major loads are
60,100 or 150kg.
HR
k h1 h0
c
Where k = 0.2 for brale and 0.26 for the steel ball, h1, h2: depth of penetration if indenter after the
removal of the major load, and under application of the pre-load, c: the value for scale divisions
(0.002mm).
7.2 NON DESTRUCTIVE TESTING (NDT)
NDT called so bse they are used to establish the fitness of a component or structure for a particular
engineering service without affecting its performance. They detect flaws (break in continuity of a
material, which may be not significant); and/or defects (a flaw which creates a substantial risk or
failure).
They are six:
7.2.1 Visual examination: The most widely used (about 90% of NDT). It is possible to locate and identify
those defects that are visible to the eye. Adequate lighting and accessibility and sometimes, magnifying
lenses are pre-requisites. The accuracy depends on the skills of the operator. It can identify such defects
as surface cracks, scabs, surface porosity, warping and twisting, inadequate filling of the mould.
7.2.2 Dye Penetrant tests (used in plastics and glass): Discontinuities such as cracks that penetrate to
the surface of the material are detected by dye penetrant tests.
The old technique was that of immersing the casting in a bath of hot paraffin of low viscosity and high
surface tension. After being drawn into finest defects by capillary attraction, the cast is removed,
cleaned after which it is painted with whitewash. Paraffin seeping out from the cracks, will discolor the
whitewash and reveal surface defects.
190
Fig.7.13: The die penetrant test: (a) a penetrant fills the gap or crack, (b) excess penetrant is removed
from surface and (c) the penetrant is attracted out by a powder developer.
Two types of penetrants can be used: (i) Fluorescent dies, viewed in black (UV) light, and (ii) water
washable colored dies for ordinary light visibility. The developing solution (white powder) spayed onto
the surface reacts with the dye drawing it from the cracks, and it is observed bse it changes the colour
or bse it fluoresces under ultraviolet lamps.
7.2.3 Magnetic particle inspection (MPI)
Magnetic particle testing detects defects surface and near surface (not more than 10mm below the
surface) discontinuities of ferromagnetic materials. A magnetic field is induced in the metal to be tested,
producing line of flux. A metal is placed in a coil; pass the current through the metal or touching the
metal with a yoke or probe. A discontinuity will cause flux leakage in the magnetic field, creating local
north and south poles that attracts magnetic powder particles
Fig.7.14: Magnetic particle inspection techniques: (a) Electromagnetic yoke, (b) Current flow, (c)
Current prods and (d) Magnetizing coil
191
Fig.7.15 : (a) Orientation of the magnetic field (b) Detecting faults perpendicular to the component
surface.
7.2.4 Eddy currents
When a conducting material is placed into an alternating field, eddy currents are induced in it. These
eddy currents in turn, produce a secondary alternating field. The effect of this secondary field is to
influence or to modify the primary field. This modification can be detected in changes in current and the
impedance, and forms the basis of the eddy current test.
If an alternating magnetic field is linked with any metal object, eddy current will be induced in the
metallic object by electromagnetic induction. A high frequency alternating current is made to flow
through a small coil; as a result, a high frequency alternating field is set up around the coil. This field
induces small electric currents (EC), which circulate in the component and produce magnetic fields in
their own right. These secondary fields react with the field of the induction coil and affect the flow of
current through that coil. The resultant current remains constant as well as there is no change in section
or composition as the induction coil is moving across the component. However, if the induction coil
moves over a crack or other fault in the component, the eddy-current system will be temporally disrupt
and resulting current in the coil will change.
changes dimensionally in the presence of alternating magnetic field) or a piezoelectric effect (certain
crystals such as quartz change dimensionally when small electric currents pass through them), the latter
can act as both transmitter and receiver due to their reversibility.
The pulses of high frequency oscillations are driven into the component by the transducer; when the
sound waves meet any discontinuity, the waves are reflected back into the transducer where they are
converted into electrical pulses which can be displayed. The position of discontinuity from the front and
back faces can be determined.
Fig.7.17 : Principles of iltrasonic testing : (a) Ultrasonic testing (b) Typical VDU displays.
Techniques used:
(i) The shadow method: Transmitting and receiving probes are on opposite sides of the specimen. The
reduction in amplitude shows a defect. No debt or location of defect.
(ii) The reflection or pulse echo method: the transducer probe (transmitter and receiver combined) is
placed on one side. Defect echo is received before that of the boundary signal.
(iii) Transmission with reflection method: its suitable for locating vertical defects in welds. Two
transducers are mounted in one or two probes and used in tandem (employs 2 shear waves) or
delta (employs a shear and compression probe in combination).
Fig.7.19: Tandem and delta technique used in transmission with reflection methods
7.2.6 Radiography
A radiograph is a record of differences in intensity of a radiation produced on a firm. This film is used as
a NDT object for discovering the presence of flaws or defects in a solid material. The X-rays (generated
by accelerating electrons to very high velocities in vacuo and bombarding a suitable material) and
gamma rays (originated from splitting atomic nuclei) are the electromagnetic waves used in industrial
radiography. They can penetrate solid objects bse of their short wavelength (higher frequency than
radio and light waves).
Absorption: the magnitude of radiation absorbed is dependent on the atomic number of element, the
thickness of the specimen and the energy of radiation (wavelength). The basic law of absorption is as
expressed
I I 0 e x Where Io: incident intensity of radiation; I: the transmitted intensity; x: the specimen
thickness and : linear absorption coefficient = m.r (m is the mass absorption coefficient and r is the
physical density of the material)
Consider the radiation intensity across an object shown in fig.: The radiation is more intense in regions
with shortest travel, in accordance to the inverse square law of absorption described by the equation
K
where K is a constant depending on the density of the material.
x2
194
Fig.7.21 : Use of radiography : (a) General arrangement ; (b) Apearance of film after development.
195