Professional Documents
Culture Documents
Certificate
EXPERIMENT NO. 1
Objective
To get acquainted with the operation, construction, use and capabilities of a metallographic
microscope and polishing machine and study procedure of specimen preparation for
microscopic examination.
1.1 Definition
Metallography consists of the microscopic study of the structural characteristics of a metal or
an alloy. Metallography is the general study of metals and their behaviour, with particular
reference to their microstructure and macro-Structure.
Microstructure is the characteristic appearance and physical arrangement of a metal as
observed with a microscope.
Macrostructure is the appearance and physical arrangement as observed with the
naked eye or with a low power magnification.
Microstructure and Macrostructure of a metal or an alloy are closely interrelated with each
other and knowledge of both is essential for full understanding of any metal. Metallography
has wide scope and for the reason, a number of precise techniques (e.g. electron microscopy,
field ion microscopy, etc.) have been developed for the purpose.
1
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Metallurgical Microscope
As shown in Fig. 1.1, a horizontal beam of light from some light source is reflected, by
means of a plane-glass reflector, downward through the microscope objective onto the
surface of the specimen. Some of this incident light reflected from the specimen surface will
be magnified in passing through the lower lens system, the objective, and will continue
upward through the plane-glass reflector and be magnified again by the upper lens system,
the eyepiece. The initial magnifying power of the objective and the eyepiece is usually
engraved on the lens mount. When a particular combination of objective and eyepiece is used
at the proper tube length, the total magnification is equal to the product of the magnifications
of the objective and the eyepiece.
The objective, fitted at the down end of the body tube, resolves the structure of the metal
(specimen) whereas the eyepiece enlarges the image formed by the objective. Eyepieces are
made in a variety of powers, such as X5, X8, X10, etc., marked on the top of the eyepiece.
The source of light is inside the microscope tube itself. Light is diffused with the help of a
diffusing disc. The width of the light beam is controlled by the iris diaphragm. The incident
light strikes the plane glass reflector kept at 45° and is partially reflected down onto the
specimen. The rays of light get returned reflection from the (polished) specimen, pass
through the objective and glass reflector to form the final image which can be seen through
the eyepiece.
A photographic camera may be mounted above the eyepiece in order to record permanently
the metallographic structure of the alloy. The maximum magnification obtained with the
optical microscope is about 2000X.
3
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Metallurgical Microscope
Most electron microscopy is carried out by using transmission-type instruments that produce
images of r transparent replicas of the etched specimen or of very thin metal obtained by
various techniques. It is necessary for electron microscope specimen to be transparent to the
electron beam. Replicas are produced in plastic or some other suitable material, which
reproduces faithfully the contours of the polished and etched specimen.
Thin foils of the metals which work as (electron microscope) specimen are of 100-2000. A°
thickness and are prepared by several available methods, one of which is Ion Bombardment
technique and another is Electro polishing method.
Construction and Operation
4
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Metallurgical Microscope
An electron microscope consists of an electron gun and condenser and projector lens.
Vacuum is necessary to allow passage of the electron beam. Electrons emitted by a hot
tungsten-filament cathode are accelerated, to form a high velocity beam, by the anode.
Depending upon the density and thickness of the replica (specimen) at each point, some of
the electrons are absorbed or scattered wi.ile the remainders pass through, i.e., transmit.
The magnetic field of the objective lens focuses and enlarges the electron beam that has
passed through the replica. Some of the electrons in this image are brought into a second
focus on a fluorescent screen by the projector lens.
Fig. 1.4 shows the schematic arrangement of the specimen polishing machine available in the
laboratory. It is generally used after rough polishing of the specimen over fine emery papers.
Polishing is necessary to ensure a perfectly flat surface of the specimen, without any
scratches. A shining mirror like surface is required after polishing the specimen so as to get
the proper microstructure.
This machine consists of a cast iron disc mounted at the end of a vertical shaft. The shaft is
driven by an electric motor through pulleys and belt arrangement. The r.p.m. of the disc
available are 1400. A fine cloth is stretched over the top surface of the disc and is held in
position with help of a ring clamp. When in working, a fine abrasive powder suspended in
water is applied to the cloth on the revolving disc. The cloth is kept supplied with suspension
from a cylindrical container held above the disc. Alternatively, an abrasive paste may be
5
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Metallurgical Microscope
frequently applied to the cloth on the disc while supply of water may be regulated from the
cylindrical container to the disc. A P.V.C. tube brings liquid from the cylindrical container,
regulated by a cock, to the top surface of the disc. While polishing, the specimen is held
firmly in hand with a gentle pressure against the cloth on the revolving disc. This is
maintained so for a period as will permit mirror like finish on the surface of the specimen.
Thereafter, the specimen is washed with water and cleaned dry with alcohol. Care is taken
not to touch the polished surface with fingers, otherwise finger prints may be produced on
that surface requiring re polishing of the surface.
6
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Metallurgical Microscope
The emery papers should be of very good quality in respect of uniformity of particle size.
Four grades of abrasives used are: 220 grit, 320 grit, 400 grit and 600 grit (from coarse to
fine); the 320 grit has particle sizes (of the silicon carbide) as about 33 microns and 600 grit
that of 17 microns (1 micron = 10-4 cm).
The specimen is first ground on 220 grit paper, so that scratches are produced roughly at right
angle to those initially existing on the specimen and produced through preliminary grinding
or coarse filing operation. Having removed the primary grinding marks, the specimen is wash
free of No. 220 grit. Grinding is then continued on the No. 320 paper, again turning the
specimen through 900 and polishing until the previous scratches marks are removed. The
process is repeated with the No. 400 and No. 600 papers. Grinding with the No. 200, No. 320,
etc., papers could be done in the following ways:
a) The specimen may be hand-rubbed against the abrasive paper which is laid over a flat
surface such as a piece of glass plate.
b) The abrasive paper may be mounted on the surface of a flat, horizontally rotating
wheel and the specimen held, in the hand, against it.
In either case, the surface of the abrasive paper (with a water proof base) shall be lubricated
with water so as to provide a flushing action to carry away the particles cut from the surface.
6. Rough Polishing. A very small quantity of diamond powder (particle size about 6
microns) carried in a paste that is oil-soluble is placed on the nylon cloth-covered surface of a
rotating polishing wheel. The lubricant used during the polishing operation is specially
prepared oil. The specimen is pressed against the cloth of the rotating wheel with
considerable pressure and is moved around the wheel in the direction opposite to rotation of
the wheel to ensure a more uniform polishing action.
7. Fine Polishing. The polishing compound used is alumina (Al2O3) power (with a particles
of 0.05 microns) placed on a cloth covered rotating wheel. Distilled water is used as a
lubricant. Fine polishing removes fine scratches and very thin distorted layer remaining from
the rough polishing stage.
8. Etching. Even after fine polishing, the granular structure in a specimen usually cannot be
seen under the microscope; because grain boundaries in a metal have a thickness of the order
of a few atom diameters at best, and resolving power of a microscope is much too low to
reveal their presence. In order to make the grain boundaries visible, after fine polishing the,
metal specimens are usually etched. Etching imparts unlike appearances to the metal
constituents and thus makes metal structure apparent under the microscope.
7
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Metallurgical Microscope
Before Etching, the polished specimen is thoroughly washed in running water. Then, the
etching is done either by
Immersing the polished surface (of the specimen) in the etching Reagent or by
Rubbing the polished surface gently with a cotton swab wetted with the Etching
Reagent.
After etching, the specimen is again washed thoroughly and dried.
References
1. Material Science and Metallurgy by O. P. Khanna
2. Introduction to Physical Metallurgy by Sidney H. Avner
8
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Metallurgical Microscope
Questionnaire
1. What is metallography?
2. Write a short note on metallurgical microscope.
3. Write a short note on electron microscope.
4. Draw a neat sketch of metallurgical microscope.
9
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Microstructures
Date: ___ /___ /______
EXPERIMENT NO. 2
Objective
To understand what is micro examination, importance of micro examination and study
various ferrous and non-ferrous microstructures.
This is performed on samples either cut to size or mounted in a resin mold. The samples are
polished to a fine finish, normally one micron diamond paste, and usually etched in an
appropriate chemical solution prior to examination on a metallurgical microscope. Micro-
examination is performed for a number of purposes, the most obvious of which is to assess
the structure of the material. It is also common to examine for metallurgical anomalies such
as third phase precipitates, excessive grain growth, etc. Many routine tests such as phase
counting or grain size determinations are performed in conjunction with micro-examinations.
1
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Microstructures
2
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Microstructures
BRASS ALUMINUM
BRONZE GUNMETAL
References
1. Material Science and Metallurgy by O. P. Khanna
2. Introduction to Physical Metallurgy by Sidney H. Avner
3
Crystallography
Date: ___ /___ /______
EXPERIMENT NO. 3
Objective
To understand what is solid solutions, space lattices, crystal structure and bonding.
1. Crystal Structure Factor. The crystal lattice structure of the two (metal) elements should
same (i.e., both should be of b.c.c., f.c.c, or h.c.p. structure) for complete solubility, otherwise
the two solutions would not merge into each other. Also, for complete solid solubility the size
factor must usually be to than 8%.
2. Relative Size Factor. If two metals are to exhibit extensive solid solubility in each other it
is essential that their atomic diameters shall be fairly similar, since atoms is essential that
their atomic diameters shall be fairly similar, since atoms differering greatly in size cannot be
accommodated readily in the same structure (as a substitutional solid solution) without
producing excessive strain and corresponding instability. This is what is referred to when the
term size-factor is employed and extensive solid solubility is encountered only when the two
different atoms differ in size by less than 15%, called a favourable size factor (e.g., Cu-Ni).
If the relative size factor is between 8% and 15%, the alloy system usually shows a minimum
and if this factor is greater than 15%, substitutional solid solution formation is very limited.
3. Chemical-affinity Factor. The greater the chemical affinity of two metals, the more
restricted is their solid solubility. When their chemical affinity is great, two metals tend to
form an intermediate phase rather than a solid solution. Generally, the farther apart the
elements are in the periodic table, the greater is their chemical affinity.
4. Relative Valence (Valency) Factor. Consider two atoms, one with large valence electrons
and the other with small number of valence electrons. It has been found that the metal of high
valence can dissolve only a small amount of a lower valence metal, while the lower valence
metal may have good solubility for the higher valence metal.
For example, in the Al-Ni alloy system, both metals have f.c.c. structure. The relative size
factor is approximately 14%.However; Ni is lower in valence than Al and thus solid nickel
dissolves 5% aluminium, but the higher valence Al dissolves only 0.04% Ni.
Fig. 3.5 Lattice structure, space lattice, lattice points and unit cell.
There are fourteen space lattices i.e., there are only 14 ways in which points can be arranged
in space so that each has identical surroundings. These 14 space lattices are known as Bravais
space lattices.
Fig 3.6 A unit cell with x, y and z coordinate axis, showing axial lengths (a, b, and c) and
interaxial angles (α, β and γ).
The unit cell geometry is completely defined in terms of six parameters: the three edge
lengths a, b and c and the three interaxial angles α, β and γ. These are indicated in Fig. 35.8
and are sometimes termed the Lattice Parameters of a crystal structure.
On this basis, there are found crystals having seven different possible combinations of a, b,
and c and α, β and γ, each of which represents a distinct crystal system.
6
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Crystallography
5. Rhombohedral 3. Hexagonal 6. Monoclinic
7. Triclinic.
The lattice parameter relationships and unit cell sketches for each crystal system are given in
Table 3.1 on front page.
7
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Crystallography
Crystal system Axial Relationship Interaxial Angles Unit Cell Geometry
Cubic
Hexagonal
Tetragonal
Rhombohedral
Orthorhombic
Monoclinic
Triclinic
Table 3.1 Lattice Parameter Relationships and Figures Showing Unit Cell Geometries for the
Seven Crystal Systems
The cubic system, for which a = b = c and α = β = γ = 90°, has the greatest degree of
symmetry.Least symmetry is displayed by the triclinic system, since a ≠ b ≠ c and α ≠ β ≠ γ.
BCC and FCC structures belong to the cubic crystal system, whereas HCP falls within
hexagonal.
9
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Crystallography
At room temperature, iron exhibits BCC structure. Other metals possessing this
structure are V, Mo, Ta, W, etc.
2. Face-centered Cubic (FCC) Structure [Fig. 3.7(b)]
A face-centered cube has an atom at each corner of the cube and in addition, one atom
at the intersection of the diagonals of each of the six faces of the cube.
Since each corner atom is shared by eight adjoining cubes and each face atom is
shared by only one adjacent cube, the unit cell contains: 8 atoms at the corners x ⅛ =
1 atom and 6 face-centered atoms x 1/2 = 3 atoms so Total = 4 atoms
This shows that FCC structure is more densely packed than the BCC structure.
Packing factor (volume of atoms/volume of cell) for FCC structure is 0.74 whereas
that of BCC structure was 0.68. This also proves that FCC structure is more densely
packed than the BCC structure.
The lattice constant `a' of FCC structure is related to the atomic radius r by afcc = 4r/√2
The face-centered cube lattice, however, is unique in that it contains as many as four
planes of closest packing (111), each containing three close-packed directions <110>,
thus amounting to 12 physically distinct slip systems. No other structure possesses
such a large number of close packed planes and close-packed directions.
For this reason, metals possessing FCC structure can be plastically deformed at severe
rates. Metals possessing FCC structure are, Cu, Al, Pb, Ni, Co, etc.
11
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Crystallography
12
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Crystallography
13
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Crystallography
amount of heat which must be supplied to vaporize the solid i.e., the state of infinite
separation of atom.
Sr. No. Materials Type of Bond Bond Energy (KJ/mol)
1. Iron Metallic 401.30
2. Sodium chloride Ionic 639.50
3. Silicon dioxide Covalent 1692.90
4. Nitrogen Intermolecular (van der Waals) 7.8
Table 3.2 Bond energy values for different materials and bond types.
The strength of the interatomic bond influences the melting and boiling points of the
substances. The melting and boiling points of the substance increase with the strength of the
bond.
15
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Crystallography
-
Fig. 3.11 The arrangements of atoms in metallic bond
- The positive metal ions tend to repel each other and take up positions according to some
geometrical pattern, but at the same time they are held together by their mutual attraction for
the electron cloud.
- Metallic bond is the characteristic of the elements having small numbers of valence electrons,
which are loosely held, so that they can easily be released to the common pool (cloud).
- Metallic bond is non-specific and non-directional, acting equally strong in all directions.
- This leads to highly co-ordinate close-packed structures, accounting for the unique plastic
properties of metals and for their ability to form alloys.
- The opaque lustre of metals is due to the reflection of light by free electrons.
17
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Crystallography
Fig. 3.12 The arrangements of atoms in molecular bond
- Intermolecular forces account for the properties of liquids and many molecular solids ranging
from small molecular weight up to polymers. Intermolecular bonds do not involve the
transfer or sharing of electrons between atoms.
There are three types of intermolecular bonds, namely:
1. Dispersion bonds,
2. Dipole bonds, and
3. Hydrogen bond.
1. Dispersion bonds
- As electrons rotate around their nuclei, they tend to keep in phase; and since the electrons of
adjacent atoms in a molecule tend to repel each other, the result is that the molecule has a
small fluctuating net charge on each end. [As in Fig. 35.3 (i), the hydrogen molecule is
instantly charged negatively on the right end and positively on the left].
- The fluctuating charge on one molecule tends to interact with the fluctuating charge on a
neighbouring molecule, resulting in, a net attraction and thus the dispersion bond.
- Molecules of the inert gases, which consist of single atoms, are held together by dispersion
forces when the gases are solidified.
2. Dipole bonds
- Consider a molecule of hydrogen fluoride. There are two electrons that surround the positive
charges in the nucleus of the hydrogen atom and there are eight electrons surround the
nucleus of the fluorine atom i.e., electrons surrounded nucleus of fluorine more completely
than that of hydrogen.
- This creates an electrical imbalance. Consequently, the center of positive charge and the
center of negative charge do not coincide, rather, remain separated. This way produces an
18
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Crystallography
electrical dipole.
- An electric dipole provides a mechanism for molecular bonding. The presence of a permanent
dipole moment increase the attraction forces between molecules and facilitates their closer
approach.
- A dipole bond is much weaker than the ionic bond but it is considerably stronger than the
dispersion bond.
3. Hydrogen bond
- Hydrogen bond is a special type of (strong) dipole bond that occurs between the molecules in
which one end is a hydrogen atom.
- The one electron belonging to the hydrogen atom is fairly loosely held, and if the adjacent
atom in the molecule is strongly electro-negative*, (*Electro negativity of an atom can be
defined as the power of attraction for the electron within a molecule). It may keep all the
electrons around itself, leaving the hydrogen atom in effect a positive ion.
- This tendency can produce a strong permanent dipole that can bond to other similar dipoles
with a force near that involved in the ionic bond.
- A good example of hydrogen bonding is water.Argon, calomel, Ice, paraffins and solid
carbon-di-oxide possess molecular bond.
References
1. Material Science and Metallurgy by O. P. Khanna
Questionnaire
1. What do you understand by bonding in solids? 1 Name the various types. Explain any
one of them.
2. Define: (i) Crystal structure (ii) Space lattice (ill) Unit cell
3. Explain with neat sketches three main types of crystal structure of metals giving some
examples for each type.
4. Explain type of solid solutions.
5. Name and explain the factors governing solubility in substitutional solution.
19
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
Date: ___ /___ /______
EXPERIMENT NO. 4
Objective
To identify the different types of material available for design ,manufacturing and processing
of various components based on structure-property-performance-processing relationships.
4.1 Introduction
Ferrous materials contain iron, and the one element people use more than all other is iron.
Ferrous materials are the most important metals/alloys in the metallurgical and mechanical
industries because of their very extensive use. The widespread use of ferrous alloys is
accounted for by three factors:
1. Iron containing compounds exist in abundant quantities within the earth's crust;
2. Metallic iron and steel alloys may be produced using relatively economical extraction,
refining, alloying and fabrication techniques; and
3. Ferrous alloys are extremely versatile, in that they may be tailored to have a wide
range of mechanical and physical properties.
The principal disadvantage of many ferrous alloys is their susceptibility to corrosion.
4.2 Classification
1
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
sand to contaminate the remelt process.
Pig (iron) for foundry use is roughly 50.8 x 22.8 x 10.1 cm (i.e., 20" x 9" x 4") in size.
Pig Iron, produced in a blast furnace, is the first product in the process of converting iron ore
into useful metal. The iron ore becomes pig iron when the impurities are burned out in a blast
furnace. Though still containing some impurities, pig iron has a high metal content.
Pig Iron, the product of blast furnace, has the following composition (approx.)
Carbon 3-4% Sulphur less than 1.0%
Manganese 0.1-1% Phosphorus 0.3-1.7%
Silicon 1-3% Iron Remainder
Pig Iron is the raw material for all iron and steel products. Pig iron is of great importance in
the foundry and in steel making processes.
1. Pig iron partly refined in a cupola produces various grades of Cast Iron.
2. By puddling or shotting processes, Wrought iron is produced from pig iron.
3. Steel is produced from pig iron by various steel making processes such as Bessemer, open-
hearth, oxygen, electric and spray steel making.
Pig iron is classified by chemical composition into three grades.
1. Basic pig iron
It is used for steel making and is low in silicon (1.5% max.) to prevent attack of the
refractory linings of refining furnaces and to control slag formation.
- Basic pig iron must be low in sulphur (0.04%) since sulphur is an active impurity in
steel and is not eliminated in the refining furnaces.
- Phosphorus normally is held to less than 1% and manganese to a range of 1 to 2%.
Carbon content varies from 3.5 to 4.4%.
2. Foundry pig iron
- It includes all the types that are used for the production of iron castings.
Foundry pig iron contains
Si 0.5 – 3.5 % S Up to 0.05%
C 3- 4.5 % P 0.035-0.9%
Mn 0.4 – 1.25 % Fe Remainder
3. Ferroalloys
- Ferroalloys are alloys of pig iron, each rich in one specific element. They are used as
additives, in iron and steel industries, to control or alter the properties of iron and
steel. Examples of ferroalloys are as follows:
2
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
1. Ferromanganese, which is pig iron that contains from 74 to 82% manganese.
2. Ferrosilicon, which is pig iron with 5 to 17% of silicon content.
4.4 Wrought iron
Wrought iron is a mechanical mixture of very pure iron and a silicate slag. Wrought iron is a
ferrous material, aggregated from a solidifying mass of pasty particles of highly refined
metallic iron with which a minutely and uniformly distributed quantity of slag is incorporated
without subsequent fusion.
Chemical composition of wrought iron would be:
C 0.02-0.03% P 0.05-0.25%
Si 0.02-0.10% Mn Nil-0.02%
Slag 0.05-.50% S 0.0084.02%
Properties
- Wrought iron is never cast. All shaping is accomplished by hammering, pressing,
forging, etc.
- Wrought iron is noted for its high ductility and for the ease with which it can be
forged and welded.
- The ultimate strength of wrought iron can be increased considerably by cold working
followed by a period of aging.
- Wrought iron possesses a high resistance towards corrosion.
- Wrought iron possesses the property of recovering rapidly from overstrain, which
enables it to accommodate sudden and excessive shocks without permanent injury. It
has a high resistance towards fatigue.
- The mechanical properties of wrought iron are largely those of pure iron. Because of
the nature of the slag distribution, however, tensile strength and ductility are greater in
the longitudinal direction or rolling direction than in the direction transverse to
rolling.
Fig. 4.1 shows the distribution of slag throughout the ferrite matrix in transverse section of
wrought iron.
- Structurally, wrought iron is a composite material; the base metal and the slag are in
physical association, in contrast to the chemical or alloy relationship that generally
exists between the constituents of other metals.
The form and distribution of (iron silicate) slag may be stringer-like, ribbon-like or platelets.
3
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
Characteristics
- Gray Iron basically is an alloy of carbon and silicon with iron.
- It is readily cast into a desired shape in a sand mould.
- It contains 2.5-3.8% C, 1.1-2.8% Si, 0.4-1% Mn, 0.15% P and 0.10% S.
- It is marked by the presence of flakes of graphite in a matrix of ferrite (Fig. 4.2) pearlite or
austenite.
5
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
Fig. 4.2 Gray iron showing graphite flakes (black) and ferrite (white portion).
- Graphite flakes occupy about 10% of the metal volume.
- Length of flakes may vary from 0.05 mm to 0.1 mm.
- When fractured, a bar of Gray Cast Iron gives gray appearance.
- Gray Iron possesses lowest melting point of the ferrous alloys.
- Gray Cast Iron Processes high fluidity and hence it can be cast into complex shapes and thin
sections.
- It possesses machinability better than steel.
- It has high resistance to wear (including sliding wear).
- It possesses high vibration damping capacity.
- Gray iron has low ductility and low impact strength as compared with steel.
- Gray cast iron has a solidification range of 2400-2000°F.
- It has shrinkage of 1/8 inch/foot (1 mm/100 mm).
- It associates low cost combined with hardness and rigidity.
- Gray cast iron possesses high compressive strength.
- It has excellent casting qualities for producing simple and complex shapes.
Applications
- Machine tool structures (bed, frame and details).
- Gas or water pipes for underground purposes.
- Cylinder blocks and heads for I.C. Engines.
- Rolling mill and general machinery parts.
- Frames for electric motors.
- Manhole covers, Tunnel segment.
6
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
- Ingot moulds.
- Sanitary wares.
- Piston rings.
- Household appliances etc,
Fig. 4.3 Ferritic malleable iron showing ferrite matrix and temper carbon (dark)
Characteristics
- Malleable CI is one which can be hammered and rolled to obtain different shapes.
- Malleable cast iron is obtained from hard and brittle white iron through a controlled
heat conversion process.
a) A ferritic malleable cast iron has Ferrite matrix.
b) A pearlitic malleable cast iron has Pearlite matrix.
c) An alloy malleable cast iron contains chromium and nickel and possesses high
strength and corrosion resistance.
- Malleable cast iron possesses high yield strength.
- It has high Young's modulus and low coefficient of thermal expansion.
- It possesses good wear resistance and vibration damping capacity.
- It can be used from - 60 to 1200°F.
- It has a solidification range of 2550--2065°F.
- It has shrinkage of 3/16 inch per foot (1.5 mm/100 mm).
- It has low to moderate cost.
- Malleable CI contains 2-3% C, 0.6-1.3% Si, 0.2-0.6% Mn, 0.15% P and 0.10% S.
7
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
Uses
- Automotive industry. - Universal joint yoke.
- Rail road. - Rear axle banjo housing.
- Agricultural implements. - Truck tandem axle assembly parts.
- Electrical line hardware. - Automotive crankshaft
- Conveyor chain links. - Crankshaft sprocket etc.
- Gear case.
Fig. 4.4 Nodular Cast Iron showing graphite nodules surrounded by ferrite (white)
Characteristics
- Unlike long flakes as in gray cast iron, graphite appears as rounded particles, or
nodules or spheroids in Nodular Cast Iron.
- The spheroidizing elements when added to melt eliminate sulphur and oxygen (from
the melt), which change solidification characteristics and possibly account for the
nodulization.
- Ductile cast iron possesses very good machinability.
- Soft annealed grades of Nodular cast iron can be turned at very high feeds and speeds.
- The properties of Nodular Cast Iron depend upon the metal composition and the
cooling rate.
- Nodular or Ductile Cast Iron contains 3.2-4.2% C, 1.1-3.5% Si, 0.3-0.8% Mn, 0.08%
P and 0.2% S.
- It possesses damping capacity intermediate between cast iron and steel.
- It possesses excellent castability and wear resistance.
Uses
8
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
- Paper industries machinery. - Valves and fittings.
- Internal combustion engines. - Steel mill rolls and mill equipment,
- Power transmission equipment. pipes
- Farm implements and tractors - Pumps and compressors.
- Earth moving machinery. - Construction machinery.
Fig. 4.5 White cast iron showing massive carbide areas (white) in fine pearlite (dark)
Characteristics
- White cast iron derives its name from the fact that its freshly broken surface shows a
bright white fracture.
- Unlike gray iron, white cast iron has almost all its carbon, chemically bonded with the
iron - as iron carbide, Fe3C. Iron carbide is a very hard and brittle constituent.
- Thus, white iron possesses excellent abrasive wear resistance.
- White iron under normal circumstances is brittle and not machinable.
- By using a fairly low silicon content, cast iron may be made to solidify as white iron.
- White iron castings can be made in sand moulds.
- White iron can also be made on the surface of a gray iron casting provided the
material is of special composition.
- If iron of proper composition is cooled rapidly, the free carbon will go in the
combined form and give rise to white iron casting.
- The white iron contains 1.8-3.6% C, 0.5-2.0% Si, 0.2-0.8% Mn, 0.18% P and 010% S
- The solidification range of white iron is 2550-2065°F.
- Shrinkage is 1/8 inch per foot (1 mm/100 mm).
- White iron (of a particular, chemical composition) is the first step in the production of
9
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
malleable iron castings.
Uses
- For producing malleable iron castings. For manufacturing those component parts
which require a hard and abrasion resistant material.
Fig 4.6 Plain carbon steel (0.20% C) showing ferrite grains and grain boundaries
- Plain carbon steel is an alloy of iron and carbon and it is malleable.
- Carbon steels are different from (cast) iron as regards the percentage of carbon.
- It contain from 0.10 to 1.5% C whereas (cast) iron processes from 1.8 to 4.2% C.
- Carbon steels can be classified as Low carbon steel (or Mild steel), Medium carbon
steel and High carbon steel.
4.10 Mild steel
Mild steels or low carbon steels may be classified as follows:
(1) Dead mild steel - C 0.05 to 0.15%.
- It is used for making steel wire, sheets, rivets, screws, pipe, nail and chain.
- It has a tensile strength of 390 N/mm2 and a hardness of about 115 BHN.
(2) Mild steel containing - C 0.15 to 0.20%
- It has a tensile strength of 420 N/mm2 and hardness 125 BHN.
- It is used for making camshafts, sheets and strips for fan blades, welded tubing,
forgings, drag lines etc.
(3) Mild steel C 0.20 to 0.30%
- It has a tensile strength of 555 N/mm2 and a hardness of 140 BHN.
- It is used for making valves, gears, crankshafts, connecting rods, railway axles, fish
10
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
plates, small forgings etc.
Uses
1. For making all types of cutting tools such as drills, taps, reamers, milling cutters,
broaches, power-saw blades, lathe, shaper and planer tool bits etc.
2. In forming dies, drawing dies, inserted heading dies, knives, chisels, high temperature
bearings and pump parts.
Ferrous alloys are consumed in exceedingly large quantities because they have such a wide range of
mechanical properties, can be fabricated with relative ease and are economical to produce. However,
they possess some distinct limitations, chiefly
1. A relatively high density; therefore heavier in weight,
2. A comparatively low electrical conductivity, and
3. An inherent susceptibility to corrosion in some common on environments.
Thus, for many applications it is advantageous or even necessary to utilize other alloys e.g., non-
ferrous alloys, having more suitable property combinations. On occasion, a distinction is made (in
non-ferrous alloys) between cast and wrought alloys. Alloys that are so brittle that forming or
shaping by appreciable deformation is not possible ordinarily are cast; these are classified as cast
alloys. On the other hand, those that are amenable to mechanical deformation are termed wrought
alloys.
In addition, the heat treatability of an alloy system is mentioned frequently. Heat-treatable designates
an alloy whose mechanical strength is improved b y precipitation hardening etc.
Non-ferrous metals/alloys are not iron-based. The more common non-ferrous materials are the
following metallic elements and their alloys:
1. Copper 4. Lead 7. Zinc
2. Aluminium 5. Nickel 8. Cobalt etc.
3. Magnesium 6. Tin
22
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
0.006% Ag, 0.01% Sb and less than 0.005% Bi, less than 0.020% Fe and remaining copper.
e) Oxygen free copper contains 0.005% Pb, 0.001% Ni, 0.001% Ag and less than 0.0005% and
0.001% Fe and Bi respectively. It is melted and cast in non-oxidising atmosphere.
Properties:
- Excellent resistance to corrosion.
- Non-magnetic properties.
- Easy to work, it is ductile a d malleable.
- Moderate to high hardness and strength.
- High thermal and electrical conductivity.
- It can be easily polished, plated and possesses a pleasing appearance.
- Resistance to fatigue, abrasion and corrosion.
- It can be soldered, brazed or welded.
- Very good machinability.
- Ease of forming alloys with other elements like Zn, Sri, Al, Pb, Si, Ni, etc.
Uses
- Copper is used for the Electrical parts, Heat exchangers, Screw machine products, for making
various copper alloys, such as brass and bronze, household utensils, etc.
Copper Alloys
- Copper alloys normally possess excellent corrosion resistance, electrical and thermal
conductivities and formability.
- Some copper alloys combine high strength and corrosion resistance, a combination desirable
for marine applications.
- Some copper alloys because of their wearing properties, high hardness or corrosion resistance
are used as surfacing metals.
- Some copper alloys are selected for decorative applications because of appearance.
- Elements such as aluminium, zinc, tin, beryllium, nickel, silicon, lead etc., form alloys with
copper.
- High copper alloys contain 96.0 to 99.3% copper.
- They possess enhanced mechanical properties due to the addition of small amounts of
alloying elements such as chromium, zirconium, beryllium and cadmium.
- A few typical high copper alloys are:
23
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
24
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
25
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
marked effect on the tensile strength, which is approximately the same as that of straight 60 :
40 brass, though lead tends to impair the weldability, ductility and impact strength.
- Leaded brass is used for: Keys, Lock-parts, Gears, Clock parts, Valve parts, Pipe unions,
Items for automatic water heaters.
(8) Naval brass
- Naval brass contains Cu 60%, Zn 39.25% and Sn 0.75%. The purpose of tin is to improve the
resistance to corrosion.
- Naval brass is used for structural applications and for forgings, especially in cases where
contact with sea water is likely to induce corrosion.
- Naval brass is obtainable as hot-rolled plate particularly for marine condenser plates, and in
the form of extruded rod for the production of machined or hot forged components. Both sand
and die castings are also available.
- Other applications of naval brass are: Propeller shafts, Valve stems, Pump impellers etc.
(9) Admiralty brass
- Admiralty brass contains 71% Cu, 28% Zn, and 1% Sn.
- It is used for decorative and architectural applications, screw machine products, heat
exchanger components, pump impellers etc.
26
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
27
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
Copper-based alloys
- The term bronze covers a large number of copper alloys with varying percentages of Sri, Zn
and Pb.
- Typical compositions of bearing bronze are: Cu 80%, Sn 10%, Pb 10%
- Bronze is one of the oldest known bearing materials.
- Bronze (a) is easily worked; (b) has good corrosion resistance; (c) is reasonably hard.
- Tin bronze (10 to 14% tin remainder copper) is used in the machine and engine industry for
bearing bushes made from thin walled drawn tubes.
- Copper-based alloys are employed for making bearings required to heavier pressures such as
in railways.
29
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
30
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
- It has a specific gravity of 1.74 and weighs only about 1 oz/cu in (1.73 gm/cu cm).
- Aluminium weighs 1.5 times more, iron and steel 4 times more, and copper and nickel alloys
5 times more.
- Magnesium has a melting point of 650°C.
- Magnesium is not employed in its pure state for use for engineering purposes because it is not
sufficiently strong. Usually it is necessary to use considerable thickness or utilize deep
sections so as to obtain adequate stiffness.
- Magnesium corrodes badly under many conditions and therefore need to be painted or given
some surface finish to avoid corrosion.
- Magnesium being costly, finds applications where light weight is a very important
requirement, such as in aircraft industry.
Magnesium Alloys
Magnesium is alloyed with elements such as Al, Zn, Mn, Zr, etc., to make it useful for engineering
applications. Alloying increases strength and corrosion resistance.
Properties
- High strength-to-weight ratio. - Good damping capacity.
- Good fatigue strength. - High thermal conductivity.
- Good dimensional stability. - Relatively high elect. Conductivity.
Uses
- For making parts such as airframes, engines, gear boxes, flooring, seating, etc., for
aeroplanes, helicopters, missiles and satellites.
- For parts such as engines, transmission pumps, differentials, floors and body panels of ground
transportation vehicles (trucks, etc.).
- For material handling equipments such as hand trucks, barrel skids, grain shovels, gravity
conveyors, foundry equipment, etc.
- For storage tanks and hoppers, ladders and scaffolds, electric drills, chain saws, power
hammers, etc.
- Moving parts of textile machines and printing equipment.
- Furniture, griddles, ladders and lawn movers.
- Typewriters, dictating machines, calculators, etc.
- Binocular and camera bodies.
31
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
Properties
- It has a low melting point of 327°C and density is 11.34 kg/dm3.
- It is very resistant to corrosion, against most acids, but not against HCl-HNO3 mixture.
- Its strength, hardness and elasticity are low, e.g., tensile strength 15 NNmm2, extensibility up
to 60%.
- It has low resistance to deformation but high formability, cold forming is preferred.
- Lead can be easily soldered, welded and cast. It can be spread over other metal surfaces.
- In addition lead has: Heavy weight, High density, Softness, Malleability, Lubricating
properties, High coefficient of expansion, Low electrical conductivity and poisnous.
Uses and applications of lead
- As an alloying element to improve the machinability of bronzes, brasses and free machining
steels.
- Tank linings for corrosion protection.
- Manufacture of storage batteries. - Lead sheathing of electric cable.
- Pipe and drainage fittings. - Low melting solders.
- Bearing metals. - Terne plate (lead-tin coated), etc.
- Lead compounds in paints. - Radiation protection (from x-rays).
Lead Alloys
- Lead alloys containing 8% to 10% Pb are used as bearing (antifriction) metals, in cable
sheaths, accumulation plates, etc.
- Antimony makes the alloy hard.
- Lead compounds include red lead and white lead.
- Lead glass (lead crystal glass) refracts light strongly.
Alloy Composition in % Uses
Lg Pb Sb 12 Sb 10.5-13, Cu 0.3-1.5, Ni In mechanical engineering, easily
(Bearing hard lead) 0-0.3, As 0-1.5, Rest lead soldered to steel, for lining
bearings.
Pb (Sb) Sb 0.2-0.3, Rest lead Drain pipes
Pb Sb As Sb 2.0-3.8, As 1.2-1.7, Rest Buckshot
lead
33
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
4.27 Nickel and Nickel Alloys
- The element nickel (along with the elements Fe and Co) constitute the transition
group in the fourth series of the periodic table.
- It has an atomic number of 28, an atomic weight of 58.71, density 8.908 g/cu cm at
20°C and melting point of 1453°C.
- The normal crystallographic system of nickel is F.C.C. at all temperatures.
- The usual commercial grade of wrought nickel ('A' nickel) nominally contains 99.0%
nickel + up to 0.4% cobalt, which traditionally are combined and reported as 99.4%
nickel.
- Commercially pure nickel is almost as hard as low-carbon steel.
- Nickel work-hardens rapidly when cold worked.
- With suitable modifications in temperatures, tools, pressures, rates etc., wrought
nickel is amenable to most of the fabrication processes used for mild steel. It can be
forged, rolled, bent, extruded, sheared, punched, spun, deep drawn, machined, ground,
polished and buffed.
Properties of Nickel
- Is a hard lustrous white metal.
- Possesses good corrosion and oxidation resistance.
- Has high tensile strength and can be easily formed hot or cold.
- Can take up high polish.
- Can be fabricated using processes similar for mild steel.
- Is ferromagnetic at ordinary and low temperatures but becomes paramagnetic at
elevated temperatures.
- Melting point ... 1453°C
- Density, gm/cu cm, at 20°C ... 8.908
- Coefficient of Thermal expansion x 10-6/°C (25 toJ00°C) … 13.3
- Tensile strength 65000 - 115000 psi (From hot (4565 to 8075 kg/cm2) to cold drawn)
- Modules of Elasticity ... 30 x 106 psi (2.11 x 106 kg/cm2)
- Hardness RB 40 to 100 (depends on whether Ni is hot rolled, annealed or cold drawn)
Uses of Nickle
- For corrosion protection of iron and steel parts and Zn-base die castings used in the
automotive field.
34
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
- In the chemical, soap, caustic and allied industries for the construction of evaporators,
tanks, jacketed kettles, heating coils, tubular condensers and many other processing
types of equipment.
- As an alloying element in both ferrous and non-ferrous alloys. Nickel is a strong
austenite stabilizer and with chromium is used to form the important AISI 300 series
of non-magnetic austenitic stainless steels.
- As a coating for parts subjected to corrosion and wear. Therefore the second
important use of nickel is in electroplating.
- In the incandescent lamp and radio industries.
- In electronic (vacuum electronic tubes) and low-current electrical applications.
- As permanent magnets.
Nickel Alloys:
Various nickel alloys are:
A. Nickel-Iron alloys D. Nickel-Chromium alloys
B. Nickel-Copper alloys E. Nickel-Molybdenum alloys
C. Nickel-Copper-Zinc alloys F. Super alloys
(A) Nickel-Iron alloys
- Nickel and iron form a series of alloys with thermal-expansion and magnetic
characteristics of commercial importance.
- Invar is the Trademark for an iron-nickel alloy containing 40-50% nickel and is
characterized by an extremely low coefficient of thermal expansion. Invar is used for
making precision instruments, measuring tapes, weights etc.
- The addition of 12% chromium, in lieu of some of the iron, produces an alloy
(Elinvar) with an invariable modulus of elasticity over a considerable temperature
range as well as a fairly low coefficient of expansion.
(B) Nickel-Copper alloys
1. The major nickel-based alloy with copper is Monel which nominally contains 66%
Ni, 31.5% Cu, 1.35% Fe, 0.90% Mn, plus residuals.
- Monel has a brighter appearance than nickel, is stronger and tougher than mild steel,
has excellent resistance to atmospheric and sea-water Corrosion and generally is more
resistant than nickel to acid, less resistant to alkalies and equally resistant to salts.
- Monel is used in architectural and marine applications where appearance and
35
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
corrosion resistance is important and in specialized equipment used by the food
pharmaceutical, paper, oil and chemical industries.
2. Several variations of monel have been produced to obtain an additional characteristic.
These include:
- An age-hardenable grade (K Monel),
- A free machining grade (R Monel),
- A hard-casting grade (H Monet),
- An age-hardenable casting grade (S Monel), etc.
3. Constantan, another alloy of nickel and copper contains 45% Ni and 55% Cu.
- Constantan has highest electrical resistivity, lowest temperature coefficient of
resistance, and highest thermal emf against platinum, of any of the copper-nickel
alloys.
- Uses in Electrical resistors, Thermocouples, Wheatstone bridges, etc.
(C) Ni-Cu-Zn alloys (Nickel-Silver)
- Nickel-copper-zinc alloys though known as nickel-silver, do not contain silver, and in
actuality they are brasses with sufficient nickel added to give a silvery white colour,
improved corrosion resistance and high strength.
- These alloys are used as low cost substitutes for silver in tableware and jewellery,
usually with silver or gold electroplate on the surface.
- Nickel silvers are also construction materials for many musical, drafting and scientific
instruments and are also used for marine and architectural applications.
(D) Nickel-Chromium alloys
- Nickel-chromium alloys with or without iron, form a series of corrosion and heat-
resistant materials.
- In this group the 80% Ni, 14% Cr, 6% Fe alloy (Inconel) with many modifications
resists progressive oxidation below 1093°C and is used in applications such as
furnace chambers, salt pots, aircraft exhaust manifolds, and high-temperature springs.
- It was originally developed for use in the milk industry as a corrosion-resistant alloy
and now is much used in many chemical industries because of its excellent corrosion
resistance.
- The 80% Ni, 20% Cr alloy (Chromel A, Nichrome V, Tophet A) and the 60% Ni,
16% Cr, 24% Fe alloy (Nichrome, Chromel C, Tophet C) form the bulk of materials
used for heater elements.
36
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
- The 90% Ni, 10% Cr (Chromel P) alloy in combination with alumel is much used as a
dependable base-metal thermocouple.
(E) Nickel-Molybdenum alloys
- Nickel-Molybdenum alloys such as Hastelloy A, Hastelloy C and Hastelloy D possess
very good resistance to corrosion.
Type of % Composition
Properties and Uses
Alloy Ni Mo Fe Cr W
Hastelloy A 57 20 20 - - High strength and ductility. Can be forged and
rolled. Resists attack of acids. Used in chemical
industry for equipments such as storage tanks
and for material handling and transportation.
Hastelloy C 54 17 5 15 4 Can he cast and machined. Resistant to HNO3,
free chlorine and acid solutions of salts such as
cupric and ferric. Used in chemical industry for
pumps, valves, spray nozzles etc.
(F)Super alloys
- The super alloys have superlative combinations of properties.
- These materials are classified according to the predominant metal in the alloy, which
may be cobalt, nickel or iron.
- Other alloying elements include the refractory metals (Nb, Mo, W, Ta), chromium
and titanium.
- Super alloys are at least five times as strong as steels routinely used for making
bridges and large buildings. They can withstand enormous strains and exhibit
remarkable resistance to metal fatigue. They possess high impact strength and
superior strength-to-mass ratio. They are probably the toughest materials ever
produced.
- Super alloys are used in aircraft turbine components, which must withstand exposure
to severely oxidizing environments and high temperatures for reasonable time
periods.
- Mechanical integrity under these conditions is critical; in this regard, density is an
important consideration because centrifugal stresses are diminished in rotating
37
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
members when the density is reduced.
4.28 Tin and Tin Alloys
Tin is it non-toxic white, soft and pliable metal adaptable to cold working such as rolling,
extrusion and spinning. Tin melts at a low temperature (231.9°C), is highly fluid when
molten and has a high boiling point (2270°C), which facilitates its use as a coating for other
metals. It can be electrodeposited readily on all common metals.
Properties:
- Boiling point ... 2270°C
- Specific gravity - α-form (gray tin) ... 5.77, β -form (white tin) ... 7.29
- Coefficient of linear expansion, 0°C ... 19.9 x 106
- Solidification shrinkage, % ... 2.8
- BHN 10 kg/5m, 180 sec - 20°C ... 3.9, 220°C ... 0.7
- Tensile strength, as cast 200°C 0.65 x 103 psi (45.65 kg/cm2)
15°C 2.1 x 103 psi (147.4 kg/cm2)
- 40°C 2.9 x 103 psi (204 kg/cm2)
- Tin has good resistance to acid corrosion. Therefore, it is used as a coating on steel
containers for food.
- Tin alloys with Cu, Sb, Bi, Cd and Ag and its hardness increases.
- Tin is usually sold as ingots; however, it can be obtained in a number of forms such as
granulated, mossy, fine powder, sheet, foil and wire.
Tin Alloys
(1) Soft Solders 20 to 70% tin and remaining lead.
Symbols Composition in % by weight Uses
and melting point range
L-Pb Sn 35 Sb containing Sn 34.5-35.5, Sb 0.5-2.0, Rest Solder for copper, tin, zinc,
antimony Pb 186°C-225°C used with soldering iron or
flame
L-Sn 50 Ph (Sb) Tin-lead Sn 49.5-50.5, Sb 0.12-0.5, Tinning, fine soldering,
solder low antimony Rest Pb 183°C-215°C electrical engineering
L-Sn 60 Pb Ag Sn 59.5-60.5, Ag 3.0-4.0, Rest Electronics, precision
Pb 178°C -180°C mechanics, production of
38
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
electrical appliances
- The eutectic alloy, with 63% tin is used extensively in electrical industry.
- Alloy with 50% tin is general-purpose solder.
- Lower tin solders (15-20% tin) are used as dipping solders for sealing automotive
radiator cores.
- Bi, Cd, Pb and tin alloys are used as fuses for fire-extinguishing equipment, boiler
plugs, etc.
(2) Copper-tin alloys (bronzes)
- Phosphor bronze containing 8-12% tin with small additions of phosphorus is used for
springs, condenser tubes, bearings, bushings and diaphragms.
- The gun metals, tin-bronze casting alloys with 1 to 6% Zn are used for valves and
fittings for water and steam lines.
- Babbitt bearing metals are essentially tin-base alloys.
(3) Aluminium-tin alloys
- The 6% tin-aluminium alloys can be bonded to steel by rolling.
- Low tin-aluminium alloys possess high fatigue strength and thus can carry fluctuating
loads.
(4) Pewter,
- It’s tarnish resistant alloy containing 7% antimony and 2% copper, is easy to cast and
to work into complicated shapes by spinning and hammering and is available as
plates, trays, bowls, pitchers, etc.
(5) Alloys of titanium
- Contains 2.5% Sn and 5% Al (or 13% Sn with 2.75% Al) find use in aircraft industry.
42
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Ferrous and Non Ferrous Material
Questionnaire
1. What is cast iron? Give composition, typical properties and uses of any three of the following
cast irons: (i) Grey cast iron (ii) White iron (iii) Malleable iron (iv) S.G. iron
2. Distinguish between plain carbon steel and alloy steel.
3. Give composition, important properties and uses of: Mild steel, medium carbon steel and high
carbon steel.
4. Give effects of following elements on cast iron: (i) Silicon (ii) Sulphur (iii) Phosphorus (iv)
Manganese (v) carbon.
5. Describe the effects of the following alloying elements on the properties of steel: (i)
Chromium (ii) Cobalt (iii) Manganese (iv) Nickel (v) Phosphorus.
6. What are the needs for alloying steels?
7. Give composition typical properties and uses of: stainless steel and high speed steel.
8. Write short notes on any three of the following: Heat resisting steels and Nickel steels
9. Give properties and applications of copper as an engineering material.
10. Describe important properties and uses of aluminium.
11. Discuss important properties and uses of any two of the following: (i) Nickel (ii) Tin
(iii) Zinc.
12. Give composition properties and uses of any three of the following: (i) brass (ii)
Muntz metal (iii) Manganese bronze (iv) Phosphor bronze.
13. (b) Distinguish between the Brasses and bronzes.
14. Discuss composition, properties and uses of any three of the following alloys: (i) Gun-
metal (ii) Phosphor bronze (iii) Aluminium bronze (iv) Nickel silver.
15. Briefly discuss the effects of the following as alloying elements on the properties of
aluminum: (i) Copper (ii) Silicon (iii) Magnesium (iv) Manganese.
16. Describe briefly any five heavy non-ferrous metals.
17. Write short notes on any Duralium.
18. What are the important requisite qualities of a satisfactory bearing alloy?
19. Write a short note on Nickel alloys.
20. Write short notes on Cobalt base alloys
43
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
Date: ___ /___ /______
EXPERIMENT NO. 5
Objective
To understand the concept of iron carbon diagram and TTT curve.
6.1 Introduction
- Alloys of the Iron-carbon system include steel and cast iron.
- Alloys with carbon content up to 2% are known as Steels whereas those having
carbon above 2% are called Cast-Irons.
- Alloys of the Iron-carbon system are of the most vital important to modern industry
due to their extensive, versatile applications.
- The Iron-carbon system provides the most prominent example of heat treatment and
property alteration based on polymorphic transformation and eutectoid
decomposition.
- Because of its outstanding commercial importance, the Iron-carbon system has been
studied in more detail than most all systems.
- The primary constituent of Iron-carbon system is the metal Iron.
1
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
Fig. 6.1 cooling curve for pure iron
In- its normal room temperature state, iron is B.C.C. in lattice arrangement, whereas at 908°C
it changes to F.C.C. and then at 1403°C back to B.C.C. again and vice versa.
One another change occurs at about 770°C (called the Curie point) at which the room
temperature magnetic properties of iron disappear and it becomes non-magnetic.
The iron remains non-magnetic until the temperature drops back below the Curie point upon
which its magnetic properties reappear.
- Fig. shows a cooling curve for pure iron with allotropic forms of iron marked over it.
- Iron is molten above 1539°C. It solidifies in the B.C.C. δ (delta) form.
On further cooling at 1400°C, a phase change occurs and the atoms rearrange themselves into
the γ (Gamma) form which is F.C.C. and nonmagnetic.
On still further cooling at 910°C, another phase change occurs from F.C.C. non-magnetic y
iron to B.C.C. non-magnetic α (alpha) iron.
Finally at 768°C, the α-iron (B.C.C.) becomes magnetic without a change in lattice structure.
6
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
7
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
Delta (δ) + liquid
Austenite
- The horizontal line at 2720°F shows the peritectic reaction.
- The eutectic reaction takes place at 2066°F and its equation may be written as
Lliquid
Austenite + cementite [Eutectic Mixture (ledeburite)]
- Eutectic point is at 4.3% carbon. Eutectic mixture is not usually seen in the
microstructure, because austenite is not stable at room temperature and must undergo
another reaction during cooling.
- The eutectoid reaction is represented by the horizontal line of 1333°F and (point) S
marks the eutectoid point. The eutectoid equation may be written as
Solid
Ferrite + cementite [Eutectoid Mixture (pearlite)]
8
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
All hypoeutectoid steels when cooled from austenite state will tra form into ferrite and
pearlite in the same way as explained above.
(2) Steel containing 0.83% C
Consider the transformation of a eutectoid steel containing 0. 83% carbon. It will remain
austenite up to the point S. The transformation will begin and end at the same temperature,
i.e., 1333°F (or 723°C). Since eutectoid steel contains 0.83% carbon initially, it follows that
the final transformed structure will be completely pearlite (see Fig. 6.5).
Fig. 6.5 Typical appearance of lamellar pearlite containing 0.83% carbon by weight, the
eutectoid composition
(3) Steel containing 1.2% C
Consider the transformation of hypereutectoid steel containing 1.2% carbon.
As the temperature drops and steel crosses Acm (i.e., upper critical temperature) line at point
d and moves towards e, the excess carbon above the amount required to saturate austenite
(i.e. 0.83%) is precipitated as cementite primarily along the grain boundaries (Fig. 6.4).
Thus above 1333°F, i.e., lower critical temperature line, the structure insists of austenite and
cementite.
As the temperature drops below 1333°F, the austenite has become less rich in carbon
(because of cementite precipitation), it contains only 0.83% carbon and it transforms to
pearlite as it does so in the cases of hypoeutectoid and eutectoid steels explained earlier.
The structure of hypereutectoid steel at room temperature consists of cementite and pearlite
(Fig. 6.4).
6.6 Transformation in Cast Iron
So far the discussions were only with regard to structures produced in steels by slow cooling
from austenite under equilibrium conditions.
9
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
In normal foundry practice, the rate of cooling is slightly faster and as a result more cementite
plates are nucleated and individual lamellae of pearlite become thinner and the structure is
called fine pearlite.
If castings are cooled at still faster rate to prevent transformation of austenite above
(approximately) 600°F, nartensite forms on further continuous cooling. Martensite is a hard,
strong and brittle constituent. It is a super-saturated solution of carbon in ferrite and the
presence of excess carbon distorts the normally cubic ferrite to a body-centered tetragonal
structure which is produced by a shear mechanism and is strained.
Transformations which take place in the structure of a cast iron containing 3% carbon is
shown in Fig. 6.4 and explained as under:
Case (a):
Cast iron containing 3% carbon is when cooled under rapid rate as a thin section of a sand
casting, from a temperature of about ?500°F, it begins to solidify with the formation of grains
of austenite. Austenite continues to solidify until the cast iron reaches the temperature of
2066°F. At this stage the alloy consists of 50% austenite and 50% liquid of eutectic
composition (austenite and cementite, i.e., ledeburite).
As the alloy cools below solidus, i.e., 2066°F, lledeburite (a form of eutectic consisting of
spheres of austenite embedded in cementite) freezes and cementite precipitates from austenite
because of the decreasing solubility of carbon in the austenite. This occurs between 2066 and
1333°F.
Cooling of the alloy below 1333°F involves the transformation of remaining austenite of
eutectoid composition (i.e., 0.83% C) to pearlite as explained earlier for steels.
Thus, the structure of alloy at room temperature consists of cementite, pearlite and
transformed ledeburite.
Cast iron of any composition between 2.0 to 4.3% carbon will solidify in exactly the same
way as has been described above.
Case (b):
If the above very cast iron is cooled at a slow rate, as usual, austenite will first form from the
melt (i.e., liquid) but eutectic freezing being slow, products of eutectic reaction will be
austenite and graphite [Fig. 6.6 (a)]. This is between 2066 and 1333°F.
As cooling continues, austenite gets depleted in carbon content and graphite flakes grow. At
1333°F, remaining austenite transforms to pearlite and the structure of the alloy at room
temperature looks as shown in Fig. 6.6 (b). It is pearlitic gray cast iron.
10
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
(a) (b)
Fig. 6.6 Microstructures of pearlitic gray cast iron
Case (c):
Phase changes in the same alloy when cooled at a very slow rate will be similar to case (b)
above, except that, at the eutectoid, (i.e., 1333°F) cooling will be sufficiently slow to permit
graphite to precipitate rather than pearlite. Although no new graphite flakes form, the one
present, grow in size. Instead of pearlite as in case (b), the matrix of the alloy solidified in
this case is ferrite and graphite flakes are embedded in it.
11
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
- Joins with carbon to form chromium carbide, thus adds to depth hardenability with
improved resistance to abrasion and wear
- Helps preventing corrosion and oxidation
- Adds some strength at high temperatures.
Molybdenum:
- Promotes hardenability of steel
- Makes steel fine grained
- Makes steel unusually tough at various hardness levels
- Counteracts tendency towards temper brittleness
- Raises tensile and creep strength at high temperatures
- Enhances corrosion resistance in stainless steels
- Forms abrasion resisting particles.
Vanadium:
- Promotes fine grains in steel
- Increases hardenability (when dissolved)
- Imparts strength and toughness to heat-treated steel.
- Resists tempering and causes marked secondary hardening.
Tungsten:
- Increases hardness (and also red-hardness)
- Promotes fine grain
- Resists heat
- Promotes strength at elevated temperatures.
Manganese:
- Contributes markedly to strength and hardness (but to a lesser degree than carbon)
- Counteracts brittleness from sulphur
- Lowers both ductility and weldability if it is present in high percentage with high
carbon content in steel.
Aluminium:
- Acts as a deoxidizer
- Produces fine austenite grain size
- If present in an amount of about 1%, it helps promoting nitriding.
- Cobalt:
- Contributes to red-hardness by hardening ferrite.
12
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
Copper: Copper (0.2 to 0.5%) added to steel
- increases resistance to atmospheric corrosion
- Acts as a strengthening agent.
Boron:
- Increases hardenability or depth to which steel will harden when quenched.
Silicon:
- Improves oxidation resistance
- Strengthens low alloy steels
- Acts as a deoxidizer.
Titanium:
- Prevents localized depletion of chromium in stainless steels during long heating
- Prevents formation of austenite in high chromium steels
- Reduces martensitic hardness and hardenability in medium chromium steels.
6.8 Effect of alloying elements on founding and other properties of ast iron
- Alloying elements are added to cast iron for attaining special properties such as
resistance to corrosion, heat and wear and to improve mechanical properties.
- Many alloying elements in cast iron will accelerate or retard graphitization and this is
one of the important reasons for alloying.
The Host common alloying elements in cast iron are, Cr, Cu, Mo, Ni, V, Mg, Mn and Zr.
Chromium: Chromium (0.15 to 1.0%) is used for
- Hardness
- Chilling power, i.e., depth of chill
- Improvement of wear resistance
- Strength
- Resistance to heat
- Chromium reduces and refines the graphite. However, chromium decreases
machinability.
Copper: Copper (0.5 to 2.0%)
- Toughens the matrix
- Increases the fluidity
- Tends to break up massive cementite and strengthens matrix
- Assists in control of chill depth
13
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
- Tends to increase and refine the graphite.
Molybdenum:
- In conjunction with Ni, Cu and Cr, Mo is used to produce high strength cast irons.
Molybdenum (0.3 to 1.0%)
- Improves mechanical properties like tensile strength, fatigue strength and hardness.
- Refines the graphite and pearlite
- Is a mild stabilizer of carbides
- Improves heat resistance
- Retards the transformation of austenite and thus increases hardenability and freedom
from cracking and distortion.
Vanadium: Vanadium (0.15 to 0.5%)
- Is a powerful carbide former
- Stabilizes cementite and improves the structure of the chill
- Reduces graphitization
- Improves tensile strength, transverse strength and hardness
- Adds resistance to wear and heat.
Nickel: Nickel (0.1 to 3.0%)
- Stabilizes austenite
- Refines pearlite and graphite
- Is a mild graphitizer
- Improves toughness and density of castings
- Minimizes extremes of hardness between light and heavy sections.
Magnesium: Magnesium (0.04 to 0.08%)
- Produces graphite in spheroidal form in as cast alloys
- Increases ductility.
Manganese: Manganese (0.3 to 1.25%)
- Stabilizes austenite
- Refines the graphite and pearlite
- Acts as a deoxidizer
- Refines grains
- Increases fluidity and density in castings.
Zirconium: Zirconium (0.10 to 0.3%)
- Assists formation of graphite
14
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
- Deoxidizes and improves the fluidity and density of castings
- Reduces hardness.
(a) (b)
Fig. 6.8 (a) Pearlite colonies (b) Edgewise growth
16
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
the steel. For example, the microstructure and properties of (quenched) steel are
dependent upon the rate of cooling which prevails during quenching.
As the cooling rate increases, the experimentally observed transformation temperatures are
lowered and metastable (non-equilibrium) phases may be formed. For example, at very high
rates of cooling in the Neel, a metastable phase called rnartensite can develop which, of
course, h,a.s no place in the Fe-C equilibrium diagram.
The principal source of information on the actual process of austenite decomposition under
non-equilibrium conditions is the TTT Diagram, which relates the transfonnation of austenite
to the time and temperature conditions to which it is subjected.
Steps to Construct a T.T.T. Diagram
1. Obtain a large number of relatively small specimens (cut from the same bar).
2. Place the samples in a molten salt bath held at the proper austenitizing temperature, [refer
Fig. 6.9]. For 1080 (eutectoid) steel, this temperature is approximately 1425°F. Specimens
are kept in the molten salt bath for long enough to form complete austenite
17
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
In microstructures shown in Fig. 6.10, both pearlite and martensite (white portion) can be
seen. Pearlite is the result of isothermal heat treatment and its amount depends upon the time
permitted for isothermal reaction to continue. Martensite is the result of water quenching of
the specimen after the isothermal heat treatment.
6. When a large number of specimens isothermally reacted for varying time periods are
metallographically examined, the result is the Reaction Curve as shown in Fig. 6.10
18
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
\Fig. 6.11 TTT diagram for the decomposition of austenite in eutectoid (0.8% C) steel
- Austenite is stable above A1 temperature line, and below this line, austenite is
unstable, i.e., it can transform into pearlite, bainite or martensite.
- In addition to the variations in the rate of transformation with temperature, there are
variations in the structure of the transformation products also.
- Transformations at temperatures between approximately 1300°F and 1020°F (550°C)
result in the characteristics lamellar microstructure of pearlite. At a temperature just
belowAI line, nucleation of cementite from austenite will be very slow, but diffusion
and growth of nuclei will proceed at maximum speed, so that there will be few large
lamellae and the pearlite will be coarse.
However, as the transformation temperature is lowered i.e., it is just above the nose of the C-
curve, the pearlite becomes fine.
- At temperatures between 1020°F and 465°F (the approximate, Ms temperature line),
transformation becomes more sluggish as the temperature falls, for, although austenite
becomes increasingly unstable, the slower rate of diffusion of carbon atoms in
austenite at lower temperatures outstrips the increased urge of the austenite to
transform. In this temperature range the transformation product is bainite.
Bainite consists, (like pearlite) of a ferrite matrix in which particle of cementite are
embedded. The individual particles are much finer than in pearlite.
19
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
The appearance of bainite may vary between feathery mass [Fig. 40. 16 (c)] of fine cementite
and ferrite for bainite formed around 900°F; and dark acicular (needle-shaped) crystals [Fig.
40.16 (d)] for bainite formed in the region of around 600°F.
At the foot of the TTT diagram, there are two lines Ms, (240°C or 465°F) and Mf (-50°C).
Ms, represents the temperature at which the formation of martensite will start and MJ, the
temperature at which the formation of martensite will finish during cooling of austenite
through this range. Mf is a fairly low temperature.
- Martensite is formed by the diffusionless transformation of austenite on rapid cooling
to a temperature below 465°F (approximately) designated as Ms Temperature.
The martensitic transformation differs from the other transformations in that it is not time
dependent and occurs almost instantaneously, the proportion of austenite transformed to
martensite depends only on the temperature to which temperature to which it is cooled. For
example the approximate temperature transforms to martensite are 330°F and 240°F
respectively.
Fig. 6.13 shows the effect of cooling rate on the formation of different reaction products e.g.,
pearlite, bainite and martensite
20
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
22
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
24
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
(d) Lower Bainite in eutectoid steel formed upon reaction at temp. near the martensite range
Fig. 6.16 (a) & (c) Formation of upper bainite (b) & (d) Formation of lower bainite
6.13 The Martensite Transformation
- Martensite is a metastable phase of steel, formed by transformation of austenite below Ms
temperature
- Martensite is an interstitial supersaturated solid solution of carbon in iron having a body-
centered-tetragonal lattice (Fig. 6.18).
- Martensite is normally a product of quenching.
25
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
- During most phase transformations, diffusion occurs to produce a difference in
concentration between the two (or more) phases involved. However, at low temperatures,
where diffusion occurs slowly, greatly super cooled solids can transform by the
martensitic mechanism, in which diffusion may be completely absent. In this type of
transformation the second phase has the same composition as the matrix, but it forms a
different crystal structure by shearing action within the matrix.
- Martensite is the result of a shear-type transformation with virtually no diffusion.
- Martensite is characterized by an acicular or needlelike pattern (Fig. 6.17).
26
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
- Ms and Mf temperatures are influenced by the carbon content steel and both decrease
with increasing carbon content. Ms and Mf temperatures do not depend upon the cooling
rate.
- One may visualise the transformation of austenite to martensite as a transition stage in
the change from the F.C.C. structure of austenite to B.C.C. structure of ferrite.
- The low temperature at which martensite forms greatly decreases the chance for
carbon atoms to diffuse out of the lattice; hence they remain in solution in the
transition lattice. The excessive supersaturation of carbon distorts the normal BCC
structure to body-centered tetragonal(Fig. 6.18).
27
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
2. The transformation proceeds only during cooling and ceases if cooling is interrupted.
Thus martensite transformation depends only upon the decrease in temperature and is
independent of time.
The amount of martensite formed with decreasing temperature is not linear. The number of
martensite needles produced at first is small, then the number increases and finally near the
end, it decreases again (Fig. 6.19).
Actually, martensite forms from austenite as individual platelets (needles) as temperature
decreases. Each platelet is formed in a short time interval (perhaps less than a micro-second).
Additional transformation on continued cooling is by formation of additional plates rather
than by growth of existing plates.
3. Martensite transformation of a given alloy cannot be suppressed, nor can the ms
temperature be changed by varying the cooling rate.
4. Martensite is probably never in a condition of real equilibrium, although it may persist
indefinitely at or near room temperature.
5. Martensite transformation associates high rates of nucleation and crystal growth at
low temperatures.
28
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Iron Carbon System
- The martensite transformation, for many years, was believed to be unique for steel.
However, in recent years, martensite transformation has been found in a number of
other alloy systems such as Fe-Ni, Cu-Zn, and Cu-Al.
- The martensite transformation is therefore recognized as a basic type of reaction in
the solid state and the term martensite is no longer confined only to the metallurgy of
steel.
References
1. Material Science and Metallurgy by O. P. Khanna
Questionnaire
1. Explain any five of the following terms: (I) Ferrite (ii) Pearlite (iii) Cementite (iv)
Austenite (v) Ledeburite (vi) Martensite (vii) Troostite (viii) Bainite (ix) Sorbite (x)
Spheroidite.
2. Draw simplified iron-carbon diagram and briefly explain it. Interpret various
transformations when a liquid solution containing 0.5%C in iron is cooled to room
temperature.
3. Explain the Pearlite transformation.
4. Explain importance of TTT Diagram?
5. Describe various steps to construct a TTT diagram.
6. Explain bainaite transformation
7. Explain martensite transformation.
29
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Non Destructive Tests
Date: ___ /___ /______
EXPERIMENT NO. 6
Objective
To understand the procedure of Non Destructive tests.
6.1 Introduction
A nondestructive test is an examination of an object in any manner which will not impair the
future usefulness of the object. Although in most cases nondestructive tests do not provide a
direct measurement of mechanical properties, they are very valuable in locating material
defects that could impair the performance of a machine member when placed in service. Such
a test is used to detect faulty material before it is formed or machined into component parts,
to detect faulty components before assembly, to measure the thickness of metal or other
materials, to determine level of liquid or solid contents in opaque containers, to identify and
sort materials, and to discover defects that may have developed during processing or use.
Parts may also be examined in service, permitting their removal before failure occurs.
1
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Non Destructive Tests
4. Indication: A means of indicating or recording the signals from detector.
5. Interpretation: A method of interpreting these indications.
While there are a large number of proven nondestructive tests in use. This section will
concentrate on the most common methods and on one recent development.
The most common methods of nondestructive testing or inspection are:
Radiography
Magnetic-particle inspection
Fluorescent-penetrant inspection
Ultrasonic inspection
Eddy current inspection
2
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Non Destructive Tests
2. A target (anode) located in the path of electrons,
3. A means of regulating tube current to control the no. of electrons striking the target.
4. A voltage difference between the cathode and anode which will regulate the velocity
of the electrons striking the target and thus regulate the wavelength of x-rays
produced.
The first two requirements are usually incorporated in an x-ray tube. The use of x-rays for the
examination of a welded plate is shown schematically in Fig. X-rays are potentially
dangerous, and adequate safeguards must be employed to protect operating personnel.
A radiograph is a shadow picture of a material more or less transparent to radiation. The x-
rays darken the film so that regions of lower density which readily permit penetration appear
dark on the negative as compared with regions of higher density which absorb more of the
radiation. Thus a hole or crack appears as a darker area, whereas copper inclusions in
aluminum alloy appear as lighter areas.
While the radiography of metals has been used primarily for the inspection of castings and
welded products, it may also be used to measure the thickness of materials. Fig. 10.3 shows a
simple radiation thickness gauge
5
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Non Destructive Tests
magnetic field transverse to the long axis of the workpiece is readily produced by passing the
magnetizing current through the piece along this axis.
Direct current, alternating current, and rectified alternating current are all used for
magnetizing purposes. Direct current is more sensitive than alternating current for detecting
discontinuities that are not open to the surface. Alternating current will detect discontinuities
open to the surface and is used when the detection of this type of discontinuity is the only
interest. When alternating current is rectified, it provides a more penetrating magnetic field.
The sensitivity of magnetic-particle inspection is affected by many factors, including strength
of the indicating suspension, time in contact with the suspension, time allowed for indications
to form, time subject to magnetizing current, and strength of the magnetizing current.
All machine parts that have been magnetized for, inspection must be put through a
demagnetizing operation. If these parts are placed in service without demagnetizing, they will
attract filings, grindings, chips, and other steel particles which may cause scoring of bearings
and other engine parts. Detection of parts which have not been demagnetized is usually
accomplished by keeping a compass on the assembly bench.
6
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Non Destructive Tests
Another method is to use a fluorescent penetrant. The major steps in fluorescent penetrant
inspection are shown in Fig. 10.6. The steps are exactly the same as described previously
except that the penetrating liquid contains a material that emits visible light when it is
exposed to ultraviolet radiation. Lamps that emit ultraviolet are called black lights, because
the visible light they might normally emit is stopped by a filter, making them appear black or
dark purple. When the part to be inspected is viewed under black light, the defect appears as a
bright fluorescing mark against a black background
Fig. 6.8 Oscilloscope pattern for the pulse-echo method of ultrasonic inspection
8
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Non Destructive Tests
The pulse-echo method uses only one transducer which serves as both transmitter and
receiver. The pattern on an oscilloscope for the pulse-echo method would look similar to that
shown in Fig. 6.8. As the sound wave enters the material being tested, part of it is reflected
back to the crystal where it is converted back to an electrical impulse. This impulse is
amplified and rendered visible as an indication or pip on the screen of the oscilloscope. When
the sound wave reaches the other side of the material, it is reflected back and shows as
another pip on the screen farther to the right of the first pip. If there is a flaw between the
front and back surfaces of the material, it will show as a third pip on the screen between the
two indications for the from and back surfaces. Since the indications on the oscilloscope
screen measure the elapsed time between reflection of the pulse from the front and back
surfaces, the distance between indications is a measure of the thickness of the material. The
location of a defect may therefore be accurately determined from the indication on the screen.
In general, smooth surfaces are more suitable for the higher-frequency testing pulse and
thereby permit detection of smaller defects. Proper transmission of the ultrasonic wave has a
great influence on the reliability of the test results. For large parts, a film of oil ensures proper
contact between the crystal searching unit and the test piece. Smaller parts may be placed in a
tank of water, oil, or glycerin. The crystal searching unit transmits sound waves through the
medium and into the material being examined. Close examination of the oscilloscope screen
in this picture shows the presence of three pips. The left pip indicates the front of the piece,
the rights pip the back of the piece, and the smaller center pip is an indication of a flaw.
Ultrasonic inspection is used to detect and locate such defects as shrinkage cavities, internal
bursts or cracks, porosity, and large nonmetallic inclusions. Wall thickness can be measured
in closed vessels or in cases where such measurement cannot otherwise be made.
9
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Non Destructive Tests
Fig.6.7 Eddy Current Test
Eddy current techniques are used to inspect electrically conducting materials for defects,
irregularities in structure, and variations in composition. In eddy current testing, a varying
magnetic field is produced if a source of alternating current is connected to a coil.
When this field is placed near a test specimen capable of conducting an electric current, eddy
currents will be induced in the specimen. The eddy currents, in turn, will produce a magnetic
field of their own. The detection unit will measure this new magnetic field and convert the
signal into a voltage that can be read on a meter or a cathode-ray tube. Properties such
hardness, alloy composition, chemical purity, and heat treat condition influence the magnetic
field and may be measured directly by a single coil.
An important use for eddy current testing is sorting material for heat treat variations or
composition mix-ups. This application requires the use of two coils (see Fig. 10.9). A
standard piece is placed in one coil and the test piece in the other coil. Acceptance or
rejection of the test piece may be determined by comparing the two patterns on the
oscilloscope screen. Eddy current testing may be used to detect surface and sub-surface
defects, plate or tubing thickness, and coating thickness.
References
1. Material Science and Metallurgy by O. P. Khanna
2. Introduction to Physical Metallurgy by Sidney H. Avner
Questionnaire
1. What is non-destructive testing? Describe any two tests for detecting surface defects
of materials or components.
2. Name amd explain any two tests for detection of internal defects.
3. Write short notes on: (i) Magnetic particle test. (ii) Gamma-ray radiographic test. (iii)
Acid pickling test. (iv) Dye-penetrant test.
4. What factors may be varied in taking a radiograph with x-rays?
5. In a radiograph, what will be the difference in appearance of gas cavities, cracks, and
impurities?
6. What are the limitations of magnetic-particle inspection?
7. What are the limitations of fluorescent-penetrant inspection?
10
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Non Destructive Tests
8. What are the limitations of ultrasonic inspection?
9. Explain the difference between through-transmission and pulse-echo methods of
ultrasonic inspection.
10. Which nondestructive testing method is best suited to determine the wall thickness at
the bottom of a steel tank?
11. Which nondestructive testing method should be used to sort out bars of mixed steel?
11
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
EXPERIMENT NO. 7
Objective
To understand the concept of heat treatment and case hardening processes.
7.1 Definition
Heat treatment is a stage in the fabrication of structures and is often forgotten; but it has
perhaps more wide-reaching and important ramifications than many of the other stages in the
fabrication of structures or components.
1
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
7.5 annealing
Definition
Annealing, primarily is the process of heating a metal which is in a metastable or distorted
structural state, to a temperature which will remove the instability or distortion and then
cooling is (usually at a slow rate) so that the room temperature structure is stable and/or strain
free.
Purpose
- Inducing a completely stable structure (full annealing)
- Refining and homogenising the structure.
- Reducing hardness.
- Improving machinability.
- Improving cold working, characteristics (process annealing) for facilitating further
cold work.
- Producing desired microstructure.
- Removing residual stresses.
- Removing gases.
- Improving mechanical, physical, electrical and magnetic properties.
Concept
- When applied to ferrous alloys, the term annealing, generally implies fill annealing.
- When applied to non-ferrous alloys, the term annealing implies a heat treatment
designed to soften an age-hardened alloy by causing a nearly complete precipitation
of the second phase in relatively coarse form.
- Any process of annealing will usually reduce stresses, but if the treatment is applied
for the sole purpose of such relief, it should be designated stress relieving.
(A) Stress relieving
3
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
- Stress relief annealing (or stress relieving) relieves (essentially eliminates) stresses
produced by casting, quenching, machining, cold working, welding, etc.
- Stress relief annealing applies equally well to ferrous and nonferrous metals.
- Stress relief is often desirable when a casting is liable to change dimensions to a
harmful degree during machining or use. Stresses if not relieved might later cause
warpage or even failure of the casting.
- Thermal stress relieving requires heating the casting to a temperature at which
relaxation of the elastic (residual) stress is brought about by plastic deformation
corresponding to the elastic strain.
- Stress relieving does not affect the metallurgical structures of the castings and is
essentially one of creep; the temperature required for stress relief of a casting varies
from 0.3 MP to 0.4 MP where MP is the melting point of the cast metal or alloy
- Stress relief is also known as Recovery.
(B) Process annealing
- Process annealing is usually subcritical (operation takes place below the lower critical
temperature) annealing and is applied to remove the effects of cold work, to soften
and permit further cold work as in sheet and wire industries.
- Ferrous alloys are heated to a temperature close to, but below the lower limit of the
transformation range (550-650°C), are held at that temperature and then cooled
usually in air in order to soften the alloy for further cold working as in wire drawing.
- Process annealing associates with it only partial recrystallisation of the distorted
ferrite and since mild steel contains only a small volume of strained pearlite, a high
degree of softening is induced.
- Process annealing does not involve any phase 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; cast-iron annealing pots may be
used, with their lids being luted on with clay.
- Fig. 7.1 shows temperatures for various heat-treating processes.
4
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
Fig. 7.3 Spheroidized annealed (1%) steel showing spheroidized cementite in a ferrite matrix
The spheroidized condition is produced by one of the following methods:
1. Heating steel and then its prolonged holding at a temperature just below the lower
critical line (between 650 and 700°C).
- Whilst no basic phase change takes place, surface tension causes the cementite part of
pearlite to assume a globular form (Fig. 43.2), in a similar way to which droplets of
mercury behave when mercury is spilled on a flat surface.
- If some form of quenching treatment is given to steel prior to spheroidizing, the steel
will be sphroidized more quickly and will produce much smaller globules of
cementite.
- Small cementite globules tend to improve surface finish during machining and also
are dissolved more quickly when a carbon steel tool is ultimately heated for
hardening.
2. Heating and cooling steel, alternately between temperatures that are just above and
just below the lower critical line.
3. Heating to a temperature above the lower critical line (i.e., between 730-770°C) with
subsequent holding at this temperature followed by slow cooling, at a rate of 25 to
30°C per hour, to 600°C.
(D) Full annealing
Full annealing implies annealing a ferrous alloy by austenitizing (heating to austenite
condition) and then cooling slowly (in the furnace itself) through the transformation range.
The austenitizing temperature for hypoeutectoid steels is usually between 723°C (1333°F)
and 910°C (1670°F); and for hypereutecoid steels, austenitizing temperature is between
723°C (1333°F) and 1130°C (2066°F).
Full annealing, thus, involves:
- Heating steel to proper annealing temperature in the austenitic zone.
% C in steel Approx Annealing Temperatures (°C)
6
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
0.10 to 0.50 950 to 815
11.50 to 0.80 815 to 760
0.90 to 1.50 760 to 780
- Holding the steel object at that temperature for a definite period of time depending
upon its thickness or diameter (about 2.5 to 3 minute per mm thickness) so that it
becomes completely austenitic; and then
- Cooling very slowly the steel object through the transformation range, preferably in
the furnace or in any good heat-insulating material, till the object acquires a low
temperature. Because of very slow cooling involved, annealing comes close to
following the Fe-C equilibrium diagram.
Slow cooling associated with full annealing enables the austenite to decompose at low
degrees of super cooling so as to form
- A pearlite + ferrite structure in hypoeutectoid steels,
- A pearlite + cementite structure in hypereutectoid steels
Full annealing
- Refines grains.
- Removes strains (from forgings and castings)
- Induces softness and machinability.
- Improves formability.
- Improves electrical and magnetic properties.
7.6 Normalizing
Normalising or air quenching consists in heating steel to about 40-50°C above its upper
critical temperature (i.e., A3 and Acm line) and , if necessary, holding it at that temperature for
a short time and then cooling in still air at room temperature (Fig. 7.1)
Normalising differs from full annealing in that the rate of cooling is more rapid and there is
no extended soaking period.
The type of structure obtained by normalising will depend largely on the thickness of cross
section as this will affect the rate of cooling. Thin sections will give a much finer grain than
thick sections.
Normalising produces microstructures consisting of ferrite (white network) and pearlite (dark
areas) for hypoeutectoid (i.e., up to about 0.8% C) steels (Fig. 7.4).
For eutectoid steels, the microstructure is only pearlite and it is pearlite and cementite for
hypereutectoid steels.
7
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
Fig. 7.4 Normalized 0.5%, C steel (heated to 982"C and air cooled)
Purpose
- Produces a uniform structure.
- Refines the grain size of steel, which may have been unduly coarsened at the forging
or rolling temperature.
- May achieve the required strength and ductility in steel that is too soft and ductile for
machining.
- Reduces internal stresses.
- Improves structures in welds.
- Produces a harder and stronger steel than full annealing,
- Eliminates the carbide network at the grain boundaries of hypereutectoid steels.
- In general, improves engineering properties of steels.
8
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
- Hardens steel to resist wear.
- Enables steel to cut other metals.
- Improves strength, toughness and ductility.
- Develops best Combination of strength and notch-ductility.
Hardening procedure
Steel with sufficient carbon (0.35 to 0.70%), Is heated 30 to 50°C above A3 line (Fig. 7.1), Is
held at that temperature from 15 to 30 minutes per 25 mm of cross-section, Is cooled rapidly
or quenched in a suitable medium (e.g., brine, water, oil, etc), To produce desired rate of
cooling, and A suitably hardened steel.
The degree of hardness produced in steel depends upon
- Composition of steel (0.35 to 0.50% C steels harden more).
- Nature and properties of quenching medium.
- Quenching temperature.
- Size of the objective to be quenched.
- Homogeneity of austenite.
- Degree of agitation.
- Rate of cooling.
Alloying elements (e.g., Ni, Cr, Mn, etc.) when added to steel increase the depth of
hardening; they do so by slowing down the transformation rates. Thus alloy steel can be
hardened by much less drastic quenching than is necessary for plain carbon steel.
Structure of hardened steels
Depending upon the factors affecting hardness (and listed above):
1. A very rapid rate of cooling forces carbon to remain in solution and austenite
transforms to martensite.
2. Comparatively slower rate of cooling produces fine pearlie and still slower cooling
rate gives rise to coarse pearlite.
Quenching Rate Of Structure Hardness Ultimate Tensile
Media Cooling Produced Obtained Rc Strength MN/m2
Water Very fast Martensite 65 1725
Oil Low Very fine pearlite 35 1100
Air Medium Fine pearlite 25 865
Furnace Cool Very slow Coarse pearlite 15 520
9
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
Pearlite is harder than austenite (or ferrite) and martensite is harder than pearlite. This
accounts for the increased hardness of the (quenched) steel.
Quenching Medium
- A quenching medium is one into which heated metal objects are plunged in order to
withdraw heat from the objects rapidly.
- The quenching medium (for hardening) must provide for a cooling rate above the
critical value (such as curves g and e in Fig. 40.13) to prevent austenite decomposition
in the pearlite, etc.
- In the martensite transformation temperature range, cooling should be slower to avoid
high internal stresses, warping of the hardened part and cracking.
10
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
Quencing Medium Cooling rate relative to that of water at 18°C
720 to 550°C 200°C
10% Caustic soda (NaOH) 2.06 1.36
Water at 0°C 1.60 1.02
Water at 18°C 1.00 1.00
Oil (Rapseed) 0.30 0.055
Water at 100°C 0.044 0.71
Air 0.028 0.007
Quenching severity relative to still water as 1.0 for various conditions of quench.
Method of cooling Oil Water Brine
No agitation of piece or No circulation of liquid 0.25 – 0.30 0.9 – 1.0 2
Mild circulation or agitation 0.30 – 0.35 1.0 – 1.1 2 – 2.2
Good circulation 0.40 – 0.50 1.4 – 1.5
Violent circulation 0.80 – 1.10 4 5
The rate of heat transfer from a hot metallic body into the quenching fluid depends upon the
body itself, i.e., the body’s
1. Size and shape: thin section will cool fast and transform to martensite completely.
2. Temperature.
3. Thermal conductivity.
4. Specific heat.
5. Surface condition.
Stages of Quenching
Stage-l: Vapour-blanket cooling stage.
- The temperature of the metal is so high that the quenching medium is vaporized at the
surface of the metal and a thin stable film of vapour surrounds the hot metal.
- Job is cooled by conduction and radiation through the gaseous film and since vapour
films are poor heat conductors, the cooling rate is relatively slow through this stage.
Stage 2: Vapour-transport cooling stage.
- This stage starts when the metal has cooled to a temperature at which the vapour film
is no longer stable.
11
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
- Vapour-blanket is broken intermittently, allowing liquid to touch the hot metal at one
instant but soon being pushed away from it by vapour bubbles. TI e bubbles escape
from the surface and the liquid touches the hot metal again.
- In the stage, since hot metal surface is wetted by the quenching liquid, violent boiling
occurs that generates bubbles on the surface of the metal being cooled.
- Very rapid cooling takes place in this stage that soon brings the metal surface
temperature below the boiling point of the liquid.
Stage-3: Liquid Cooling Stage.
- Third stage begins when surface temperature just reaches the boiling point of the
quenching liquid.
- Cooling in this stage takes place by simple convection and conduction.
- The rate of cooling decreases as the temperature of the metal falls.
- The rate of cooling is slowest in this stage.
7.8 Tempering
- Quench hardening produces structures – martensite and retained austenite.
- The martensitc formed in quench hardened steel is exceedingly brittle, hard and highly
stressed; the cracking and distortion of the hardened article is liable to occur after
quenching. For this reason, the use of steel in this condition is inadvisable except in cases
where extreme hardness is required.
- Secondly, quench hardened steel besides containing martensite has some retained
austenite too. Retained austenite is, also, an unstable phase and as it changes with time,
dimensions may alter e.g., dies may alter 0.125 mm.
- It is therefore necessary to return towards equilibrium after quench hardening, by heating
the (hardened) steel to a temperature below the lower critical temperature (A1); this is
tempering.
- Tempering requires
1. Heating hardened steel below the lower critical temperature
2. Holding it at that temperature for 3 to 5 min. for each mm of thickness or diameter;
3. Cooling the steel (in water, oil or air) either rapidly or slowly except in case of steels
susceptible to temper brittleness.
[Note: Temper brittleness is generally used to describe the notch impact intergranular
brittleness induced in some steels by slow cooling after tempering above about 600°C and
also from prolonged soaking of tough material between about 400°C and 550°C. Temper
12
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
brittleness seems to be due to the segregation of solute atoms to the grain boundaries on slow
cooling from 600°C]
Essentially the tempering reaction can be pictured as the change from carbon atoms dispersed
in the martensite to precipitated carbide particles of increasing size.
Purpose:
- Relieve residual stresses.
- Improve ductility.
- Improve toughness.
- Reduce hardness.
- Increase % elongation.
Theory of Tempering
Quench hardened steel produces structures-martensite and retained austenite. These being
unstable phases have a tendency to change to a stable structure. This change cannot take
place at room temperature because of the low mobility of atoms at this temperature. As the
temperature of hardened steel is raised (for tempering) the mobility of atoms increases and
the phases tend to pass into a stable/equilibrium condition. For this change to occur both
temperature and time are important variables, but temperature is far the more important
variable, and the time of tempering usually adopted is about one hour.
- Tempering consists of heating the hardened steel to some temperature below A1 for
about one hour to produce tempered martensite.
- Essentially the tempering mechanism/reaction can be pictured as the change from
carbon atones dispersed in the martensite to precipitated carbide particles of
increasing size Fig. 7.5 indicates a number of stages by which this change is believed
to occur
- When the fresh martensite is heated to below the critical temperature, it becomes
softer and more ductile and internal stresses are relieved. Little benefit is derived
below 150°C.
Stages of Tempering
1. At low tempering temperatures (Approx. 80-200°C) a hexagonal close-packed carbide
(called epsilon carbide) begins to form, and with this rejection of carbon the crystal
structure of martensite changes ultimately from tetragonal to the body-centered-cubic
characteristic of ferrite.
13
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
2. The second stage at about 200 to 300°C, depending upon the steel is characterized by
transformation of the retained austenite to bainite.
Fig. 7.5 Changes in structure and hardness that accompany the tempering of eutectoid
carbon steel.
14
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
15
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
- Is used for components such as (i) Connecting rods, (ii) Shafts, (iii) Gears, etc.
Temper Colours
Temp., °C Colour Type of Component
220 Pale yellow Hack saws, scrapers.
230 Straw Planning and slotting tools.
240 Dark straw Shear blades, drills, paper cutters.
250 Light brown Metal shears, punches, dies.
270 Purple Axes, gimlets, augers.
280 Deeper purple Cold chisels (for steel & C.I.) chisel for woods
290 Bright blue Screw drivers
300 Dark blue Springs, wood saws.
- The tempering of quenched steel, in fact, is sometimes controlled by observation of
the temper colours (e.g. straw at 230"C, blue at 300°C, etc.) produced on the clean
(steel) metal surface when heated.
- Temper colours are produced due to interference effects of thin films of oxide formed
during tempering.
7.9 Interrupted quenching
The continuous rapid cooling (Quenching) to room temperature ordinarily used to cause
martensite formation has the disadvantages of
- Setting up severe quenching stresses. (which are the result of contraction during cooling
and expansion caused by martensite)
- warping and distorting the object, and
- Promoting crack formation in the steel.
If instead of rapid cooling, slow air cooling is employed, definitely the quenching stresses
will become minimum, but one will have to go for steel with sufficient hardenability to form
martensite on air cooling; and such steels, i.e., air hardening steels are expensive.
In other words, to obtain desired hardness in a given object either one should select a less
costly steel, rapidly cool it and take the risk of creating severe quenching stresses or one
should go for expensive air hardening steel and decrease the stresses by cooling the steel in
air.
For example, air hardening steels are selected in making complex dies for which preliminary
machining cost is high therefore it is economical to protect the investment in machining
16
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
operations by using an air hardening steel that can be hardened with a minimum danger of
developing stresses, distortion or cracking.
One more, comparatively less costlier, alternative to achieve the desired hardness with
reduced stresses is to use steels of moderate hardenability and subjecting them to an
interrupted Quenching Procedure.
Interrupted quenching is a two-stage process. The piece is first quenched in a medium which
cools it rapidly past the nose of the TTT diagram (Fig. 7.7).
After that, the piece is further quenched in a second medium which cools it rapidly enough
(but much more slowly than the first medium) to avoid the bainite transformation.
The most generally useful type of interrupted quenching is called Martempering.
7.10 Martempering
In Martempering, steel is
1. Heated to above the critical range to make it all austenite; is then
2. Quenched into a salt bath maintained at a temperature above the Ms and is held at this
temperature long enough until the temperature is uniform across the section of the
workpiece (i.e., from surface to core) without transformation of the austenite; and
3. subsequently cooling the workpiece in air through the martensite range (Fig. 7.7).
17
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
- Large sections cannot be heat treated by martempering because the time required to
obtain temperature uniformity (of workpiece surface and its core) exceeds the start of
transformation of austenite into bainite.
- Actually, in practice, in order to utilize benefits of martempering, alloying elements
are added to steel. Otherwise the critical cooling rate is too fast and the benefits of the
martensite hardness cannot be realized in parts that are large or even medium in size.
7.11 Austempering
- Austempering is not a hardening treatment.
- Austempering is another type of interrupted quenching, that forms Bainite (and not
martensite). In structure and properties, however, the bainite thus formed closely
resembles tempered martensite.
- In general, steels treated thus are tougher and more ductile than steels of tempered
martensite having equal hardness and tensile strength.
- Fig. 7.7. Shows the austempering process.
- However, a major limitation is that size is restricted to relatively thin selections so
that the entire piece can quickly attain the temperature of quenching bath.
- For steels of high hardenability, larger sections can be used.
- An additional disadvantage is the relatively long time required for the isothermal
transformation of austenite to bainite.
- Tempering is rarely needed after austempering.
Austempering consists in
- heating the steel above the critical range to make it all austenite; is then
- quenched at a critical cooling rate into a salt bath or lead bath held in the bainite range
(usually between 205°C and 425°C);
- the steel piece remains in the bath until the austenite is completely transformed to
bainite and then it is
- Allowed to cool to room temperature, the rate being immaterial.
Advantages of Austempering
- Greater ductility and toughness (impact strength) along with high hardness.
- Less distortion.
- Less danger of quenching cracks because the quench is not very drastic.
18
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
7.12 Case hardening and surface treatment processes
Introduction
Numerous industrial applications such as cams, gears, etc., require a hard wear resistant
surface called the case and a relatively soft, tough and shock resistant inside, called the core.
No plain carbon steel can possess both these requirements at the same time; because a low
carbon steel, containing about 0.1% carbon, will be tough, whilst a high carbon steel of 0.9%
or more carbon will possess adequate hardness when suitably heat treated.
However, both these requirements may be met by employing a low carbon steel with suitable
core properties and then adding (or penetrating) Carbon, Nitrogen or both to the surface of
the steel part in order to provide a hardened case (or layer) of a definite depth. These
treatments are known as Case Hardening.
The processes used to create hardened cases are:
1. Carburizing 3. Cyaniding
2. Nitriding 4. Carbonitriding
Another method to obtain tough core and hard case in a steel part is to take medium carbon
steel in the normalized condition and then introduce local hardness at the surface by some
hardening processes such as.
3. Flame hardening.
4. Induction hardening.
Surface treatments involve applying coatings to the surface of metals/alloys in order to
- Improve corrosion, heat or wear resistance,
- Rebuild worn or undersized parts,
- Serve as an ornamental finish,
- Lengthen the useful life of a part manufactured from a low cost material having
surface characteristics unsuited for a given installation.
Coatings may be broadly classified as
(a) Metallic coatings obtained by
- Hot dipping - Impregnating - Facing
- Electroplating - Spraying - Cladding
(b) Non-metallic coatings, which include
- Oxide coating - Vitreous enamel coating.
- Phosphate coating
19
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
7.13 Carburizing
Carburizing is a method of introducing, carbon into solid iron-ha ,r alloys such as low carbon
steels in order to produce a hard case (surface). Carburizing is also called cementation.
- Carburizing increases the carbon content of the steel surface by it process of
absorption and diffusion.
Process
- Low carbon steel (about 0.20% carbon or lower) is heated at 87() l 925°C in contact
with gaseous, solid or liquid carbon containing sub stances for several hours.
- The high carbon steel surface (thus obtained) is hardened by quenching from above
the AI temperature.
Characteristics
- Case depth is about 0.05 inch (1.27 mm).
- Hardness after heat treatment is Re 65.
- Carburizing causes negligible change in dimensions.
- Distortion may occur during heat treatment.
Uses:
In the case hardening of Gears, Camshafts, Bearings.
Methods
There are three general methods of carburizing, depending upon the form of the carburizing
medium, namely
A. Pack Carburizing employing solid carburizing medium.
B. Gas Carburizing employing suitable hydro-carbon gases
C. Liquid Carburizing employing fused baths of carburizing salt
The choice of a particular method out of the three listed above depends upon:
1. The characteristics of the case which are desired,
2. The equipment available,
3. The quantity of parts which is to be handled.
A. Pack Carburizing
Pack carburizing involves packing the components into cast iron or eel boxes along with the
carburizing material so that a space of approximately 50 mm exists between the components.
20
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
Carburizing medium consists essentially of wood, or bone charcoal or charred leather,
together with an energizer (a mixture of sodium carbonate and barium carbonate) which may
account for up to 40% of the total composition.
The energizer accelerates the carburizing process.
After the components and the carburizing medium have been packed in the boxes, the lids are
luted on to them and the boxes are then slowly hated to the carburizing temperature, between
900 and 950°C, and then kept at that temperature up to five hours depending upon the depth
of case desired. When carburizing is complete, the parts are quenched or cooled slowly in the
boxes, depending upon the nature of the subsequent heat-treatment to be applied.
Fig. 7.1 shows the relationship between Time and Temperature of carburizing treatment and
the depth of case produced.
Fig. 7.1 Relationship between depth of case, carburizing temperature and time of treatment.
21
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
The mechanism by which carburization proceeds involves following stages:
1. Formation of carbon monoxide (CO) in the box containing carburizing material when
heated to between 900 and 950°C.
2. Dissociation of CO with the evolution of atomic carbon
2CO CO2 + C atm
3. Enrichment of the steel surface layer with carbon
2CO + 3Fe Fe3C + CO2
(CO2 thus liberated reacts with the carburizing material to form more CO at the
expense of the charcoal)
Although the reaction may be represented in this manner, in this manner carbon is not
in the form of iron carbide, but instead is in the form of elemental carbon dissolved in
gamma iron, forming austenite.
4. Diffusion of carbon, absorbed by the steel surface, deep into the metal. The rate of
diffusion of carbon in austenite, at a given temperature, is dependent upon the
diffusion coefficient and the carbon concentration gradient. Of course the higher the
temperature, the more rapidly carbon will be diffused.
If it is desired to prevent any area of a component from being carburized, that area
1. May be electroplated with copper to a thickness of 0.075-0.10 mm because carbon is
insoluble in copper at the carburizing temperature;
2. Should be coated with a mixture of fireclay and ignited asbestos made into a paste
with water and then allowed to dry on the surface before the component is carburized.
B. Gas Carburizing
Principles
- Gas carburizing can be applied in mass production. It is readily adaptable to all types and
configurations of steel parts in either batch or continuous operation.
- In gas carburizing, components are heated at about 900°C for three or four hours in an
atmosphere containing gases which will deposit carbon atoms at the surface of the
components.
- The most commonly used atmosphere for gas carburizing consists of approximately 20%
CO, 40% hydrogen and 40% Nitrogen.
- This endothermic atmosphere is applied both as a source of carbon from CO and as a
carrier gas to dilute hydrocarbon gas such as methane (or propane) which is used both as
a source of carbon and to control 'ace chemical reactions.
22
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
- The gaseous atmosphere can be generated as follows: A neutral carrier gas is first
prepared by burning town gas with the correct amount of air to give complete
combustion. The resulting combustion gases are cooled and passed over silica gel to
remove water vapours. CO2 is removed by passing over heated coke or charcoal at
1000°C or by absorption in an organic solvent such as ethanolamine or tetramine.
- The product thus left, which is mainly CO, N, and H2 is termed the carrier gas and a
proportion of propane or butane or methane is added to it to give the necessary
carburizing mixture.
- Gas carburizing requires specially designed atmosphere-tight furnace capable of
maintaining a positive pressure of atmosphere to prevent the infiltration of air. Furnace is
provided with a fan to circulate the atmosphere throughout the heating chamber.
- Following major reactions take place during the process of Gas carburizing.
3Fe + 2CO
Fe3C + CO2
Fe3C + 2H2
3Fe + CH4
3Fe + CO + H2 Fe3C + H2O
CO2 + CH4
CO + 2H2
CH4 + 3Fe
Fe3C + 2H2
- By suitable adjustment of time, temperature and gas composition, the case depth can be
varied to suit the work in hand.
- The depths of case vary from 0.25 mm on articles for light work, 0.5-1.0 mm for much
automobile work, to 0.37 mm for roller bearings and ball races where compressive
stresses are high.
Advantages of Gas Carburizing
- Pack carburizing cannot be accurately controlled with regard to case depth and it
requires considerable labour in the packing, loading and unpacking of boxes. Gas
carburizing eliminates these handicaps and in addition eliminates pack material,
which results in more favourable heat treatment economies.
- Labour costs are lower than in pack carburizing.
- Heating is more rapid and uniform than in pack carburizing.
- The carbon potential can be closely controlled.
- Less time is required than pack carburizing, since there is no need to pack and handle
boxes containing workpieces to be treated. For the same reason, the floor space
required is less.
23
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
- Gas carburizing provides cleaner surroundings, closer quality control and greater
flexibility of operation in comparison with pack carburizing.
- Gas carburizing may be feasibly mechanised.
Disadvantages of Gas Carburizing
- As compared to pack carburizing, higher skilled personnel arc required to maintain
the necessary controls.
C. Liquid carburizing
Principles
- Carburizing in liquid baths is of comparatively recent origin and is an outgrowth of the
older process of cyaniding.
- Liquid carburizing is employed principally for relatively shallow cases (0.104.25 mm)
which can be produced at lower cost by this process than with pack or gas carburizing.
- Liquid carburizing is carried out in baths containing 20 to 50% Sodium Cyanide, together
with up to 40% Sodium carbonate and varying amounts of Sodium or Barium Chloride.
- This cyanide-rich mixture is heated to a temperature of 870-950°C and the workpieces
contained in wire baskets are immersed into the liquid bath for periods varying from
about 5 minutes to one hour, depending, upon the depth of case required.
- The following chemical reaction perhaps occurs in liquid carburizing
2NaCN + 2O2 Na2CO3 + 2N + CO
- Dissociation of CO at the steel surface then takes place with the same result as in pack-
carburizing.
- Moreover, nitrogen, in atomic form, also dissolves in the surface and produces an
increase in hardness by the formation of nitrides.
- Thus in liquid carburizing, like cyaniding (or carbonitriding) both C and N are added
to the steel surface.
- However, liquid carburizing may be distinguished from Cyaniding by the character
and composition of the case produced.
- In cyaniding, case is higher in nitrogen and lower in carbon; the reverse is true in
liquid carburizing.
- Cyanide cases are seldom to a depth greater than 0.25 mm; liquid carburizing permits
cases as deep as 6.25 mm.
Advantages of liquid carburizing:
Liquid carburizing offers advantages of
24
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
- Rapid heat transfer
- Low distortion
- Negligible surface oxidation or decarburization
- Rapid absorption of carbon and nitrogen
- Uniform case depth and carbon content
- Reduced time for steel to reach the carburizing temperature.
- Flexibility to handle a wide range of parts of varied design and varied case depths.
Disadvantages of liquid carburizing
- Cyanide salts are highly poisonous when taken internally (even as fumes) or when in
contact with open wounds.
- Molten cyanide explodes on contact with water, so all work should be dried carefully
before it is placed in the liquid bath.
- Parts need thorough washing after treatment to prevent rusting.
Applications
- Gas carburizing is particularly suitable for mass production of thin cases in small and
medium size parts.
Heat treatment after carburizing
- Because of prolonged heating at a high temperature in the carburizing operation, both
the core and the case exhibit overheated structures, which are unsatisfactory for
severe service. The carburized parts are therefore heat-treated
1. To refine the core.
2. To refine and harden the case.
- To refine the grain of the core and consequently toughening it, the part is heated to just
above its upper critical temperature (about 870°C for the core) when the coarse ferrite-
pearlite structure will be replaced by refined austenite crystals. The component is then
water or oil quenched to give a fine dispersion of ferrite in martensite.
- Then, for refining the case, the component is again heated to about 760°C so that the
coarse martensite of the case changes to fine grained austenite. Quenching then gives a
fine-grained martensite in the case.
- Finally, the component is tempered at about 200°C to relieve any quenching strains
present in the case.
- The above treatments, are highly desirable from a theoretical approach, but generally the
heat treatment of a case-harden, it steel is modified as under:
25
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
1. Component may be quenched direct from the carburizing temperature and then given
a low temperature tempering to remove quenching strains. This treatment serves well
in case of steels with slow grain growth at the carburizing temperature.
2. Component may be slowly cooled from the carburizing temperature and then reheated
to 760°C and water quenched.This treatment will give a soft ductile core and hard
case. OR
3. Component may be slowly cooled from the carburizing temperature, reheated to
820°C, water quenched and then tempered at 200°C to give a fairly (not maximum)
tough core and hard case.
7.14 Nitriding
Nitriding accompanies the introduction of nitrogen into the surface of certain types of steels
(e.g., containing Al and Cr) by heating it and holding it at a suitable temperature in contact
with partially dissociated ammonia or other suitable medium. This process produces a hard
case without quenching or any further at treatment.
Process Characteristics
- Case depth is about 0.381 mm.
26
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
- Extreme hardness (Vickers 1100),
- Growth of 0.025-0.050 mm occurs during nitriding.
- Case has improved corrosion resistance.
Uses:
- Valve seats - Aircraft engine parts
- Guides - Aero engine cylinderst
- Gears - Crank pins and journals
- Gauges - Moulds for plasters
- Bushings - Aero crankshafts, air screw shafts
- Ball races
Table shows that steels suitable for nitriding must contain such alloying elements as Al, Cr
and V to form hard nitrides because iron nitride does not confer hardness to any extent.
27
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
7.15 Cyaniding
In cyaniding, carbon and nitrogen are introduced into the surface of steeI by heating it to a
suitable temperature and holding it in contact with molten cyanide to form a thin skin or case
which is subsequently quench hardened.
Characteristics of the process
- Case depth is about 0.25 mm.
- Hardness is about Re 65.
- Negligible dimension change is caused by cyaniding.
- Distortion may occur during heat treatment.
Uses
- Screws
- Nuts and bolts
- Small gears
- Plain carbon or alloy steels containing about 0.20% C usually hardened by cyaniding
Process
- Low carbon steel is heated between 800 and 870°C in a molten sodium cyanide bath
for a period of between 30 min and 3 hour, depending upon the depth of case
required.
- Quenching in oil or water from this bath hardens the surface of steel.
- In cyaniding, the bath usually-contains 30% NaCN, 40% Na2CO3 and 30% NaCl.
- This mixture has a melting point of 1140°F (615.6°C) and remains to stable under
continuous operating conditions.
- This mixture, when used at temperatures ranging from 787 to 898°C, composes to
free carbon and nitrogen which are then absorbed into the steel to form a hardened
carbide-nitride case.
2NaCN + 2O2
Na2CO3 + CO + 2N
2CO CO2 + C
2NaCN +O2 2NaCNO (Sod. cyanate)
29
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
NaCN + CO2
NaCNO + CO
3NaCNO NaCN + Na2CO3 + C + 2N
- In order to obtain hardness after cyaniding, it is necessary to quench directly into oil
or water from the cyaniding bath.
- In cyaniding, nitrogen imparts inherent hardness, whereas the increased carbon
content makes the surface of steel respond to a quenching treatment.
- Probably the greatest use of cyaniding is for parts that arc to be subjected to relatively
light loads and that require improvement in the surface-wear resistance.
7.16 Carbonitriding
- Cases (surfaces) that contain both carbon and nitrogen are whereas produced by liquid
salt baths in cyaniding, they are produced by the use of gas atmospheres in
carbonitriding.
- Carbonitriding implies introducing carbon and nitrogen into a solid ferrous alloy by
holding above Act in an atmosphere that contains suitable gases such as hydrocarbon,
carbon monoxide and ammonia.
- The carbonitrided alloy is usually quench-hardened.
- Metals Usually Hardened by Carbonitriding. Plain carbon steels containing about
0.20% carbon.
Process characteristics
- Case depth is about 0.5 mm.
- Hardness after heat treatment Re 65.
- Negligible dimensional changes.
- Distortion is less than in carburizing or cyaniding.
Uses: Carbonitriding mostly uses for Gears, Nuts, Bolts
Process
Carbonitriding is a modification of gas carburizing process because anhydrous ammonia gas
is added to the furnace atmosphere to cause both Carbon and Nitrogen to be absorbed by the
surface of steel at the carbonitriding temperature.
- The atmospheres used in carbonitriding usually comprise a mixture of carrier gas,
enriching gas (about 5%) and ammonia (about 15%).
30
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
33
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
The danger of either overheating or burning the surface of the metal by flame hardening may
be avoided by inducing heat electrically in the surface of the metal. Induction hardening
involves:
- Heating medium carbon steel by means of an alternating magnetic field to a temperature
within or above the transformation range (the hardening temperature is about 750 to
800°C). Followed immediately by quenching.
- This process may be applied for both surface hardening and full annealing.
- The principle of induction hardening is similar to that employed in the induction melting
of steels by the high frequency induction process in which heat is produced by currents
induced in the metal charge itself.
- Heat generated in the metal by induction is mostly confined to the outer surface of the
component to be induction hardened.
- The higher the frequency of current, the closer the heat is to the surface of the component.
At 50 cycles/second, the effective current flow through a surface layer of about 7.5 mm
deep, whilst at 10,000 cycle/second, the surface layer is reduced to 0.5 mm deep.
Procedure
High frequency currents are generated using
- Motor generators with frequencies of 1,000 to 10,000 cycles/second and capacities to
10,000 kW.
- Spark gap oscillators with frequencies of 100,000 to 400,000 cycles/second and
capacities to 25 kW.
- Vacuum-tube oscillators operating at 500,000 cycles per second with output
capacities of 20 to 50 kW.
The component part to be induction hardened (i.e., heated) is placed in the so called Inductor
or Inductor coil or Work coil (Fig. 7.6).
- Inductor coil comprises one or several turns of copper tube or busbar and is water
cooled. When high frequency (alternating) current is passed through the inductor coil,
it sets up a magnetic field (the intensity of which varies periodically in magnitude and
direction).
- As the alternating magnetic lines thread through the surface of the component (being
heated) placed in the inductor coil, they induce in component's surface an alternating
current of the same frequency but reversed in direction. Heating results from the
resistance of the metal (of the component) to passage of these currents.
34
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
- The high frequency induced currents tend to travel at the surface of the metal. This is
known as skin effect.
- The component is held stationary in the inductor coil and the whole of the surface of
the component is heated simultaneously. The temperature of the surface layer rises to
above its upper critical temperature (the hardening temperature is about 755°C for a
0.5% carbon steel approximate values i.e., austenite range) in a few seconds.
- The surface of the component (after it has been heated to the required temperature) is
then quenched by pressure jets of water which pass through the holes existing in the
inductor block (Fig. 7.6). As after flame hardening, the induction hardened
component also needs be stress relieved.
Advantages
- Time required for hardening a component is sharply reduced. The heating time varies
between 1 and 5 seconds.
- It can be applied to both external and internal surfaces.
- Components may be heated with practically no scaling and distortion.
- Higher hardness can be' obtained in a given (%C) steel than with thermal heating.
- A hardness of about 60 Re may be obtained in certain types of steels to a depth of
about 3 mm.
- Through proper design of the heating coils, the shape of the hardened portion can be
controlled very closely.
35
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
- Depth of hardening can be controlled by selecting current of appropriate frequency
Frequency, cycles/second 1000 4000 10,000 120,000 500,000
Depth of hardening (mm) 6.0 3.0 2.5 1.5 0.751'
- Hard case and tough core is obtained.
- Induction hardening process can be made nearly automatic so that it can be carried out
with unskilled labour.
Disadvantages
- Cost of equipment is high.
- Steels having less than 0.40% carbon cannot be induction hardened.
- Irregular shaped components cannot be handled easily and economically.
- It is beneficial in mass production only.
- It associates high maintenance costs.
- Before induction hardening the component needs some treatment, e.g., normalising.
Applications
Typical parts hardened by this method are
- Piston rods - Camshafts - Automobile parts
- Crankshafts - Spur gears
- Pump shafts - Cams
36
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
2. To obtain a combination of properties not available in either metal alone. For example
in copper-clad steel wire, copper exterior provides high electrical conductivity and
good corrosion resistance, while the steel core provides high tensile strength.
3. The principal objective for cladding is to produce a corrosion resistant surface. For
example Alclad is the name applied to aluminium alloys which are clad with pure
aluminium to improve corrosion resistance.
4. Cladding is also employed for making bimetal strips for temperature control devices.
Available forms
Clad metals are available in strip, sheet, foil, plate, wire, rod, tube form etc.
Methods of cladding
1. Rolling
a) Roll bonding, cold
b) Roll bonding, Hot
Cladded duralumin is obtained by placing the duralumin ingot between two sheets of
pure aluminium and rolling this pack (or sandwich together). This pack is hot rolled to
a thickness of 6 mm and then cold rolled with intermediate process annealing
operations.
2. Extrusion. This method is used for making tubing. Mechanical assemblies (or
electroplated metals) are extruded together.
3. Continuous brazing. In this method the brazing alloy distributed between strips is
fused as strips are continuously heated and rolled.
4. Casting. This method consists of one metal being cast against another, generally by
centrifugal casting process.
5. Welding. In this method, one material is deposited on the other and it may be rolled
afterwards.
6. Explosive bonding. Here the detonation action of a sheet of explosive drives the base
metal and coating metal together and bonds them. This method has made available
titanium, nickel and stainless clad steel in large plates.
Applications for clad metals
Cladding Base metal Applications
1. Copper Stainless steel To improve thermal properties for
heaters and heat exchangers.
2. Pure aluminium Wrought Reflectors, cooking utensils, chemical
37
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
aluminium (Alclad) equipment, marine applications.
3. Stainless steel Carbon and low For improved corrosion resistance of
alloy steel storage and mixing tanks and process
equipment.
4. Stainless Steel Aluminium Cookware, automotive trim and
chemical process vessels.
5. Titanium Steel Chemical process equipment.
6. Silver Unlimited variety For use as an electrical contact.
7. High chrome carbide Carbon and low Wear plates in chutes, conveyors and
stainless steel alloy steel earth-moving equipment.
7.20 Faced coatings
Metal facing or hard surfacing is the operation of welding metal to the surface of a part in
order to:
1. Improve abrasion, corrosion or heat resistance of the surface;
2. Improve resistance to wear, erosion, galling, cavitation and chemical reactions;
3. Rebuild worn or eroded parts.
Facing materials
1. High carbon and high alloy steels.
2. Cobalt and Nickel-base alloys.
3. Carbides of tungsten, tantalum and boron mounted in suitable alloy binders to
increase their toughness.
4. Copper base alloys, etc.
Base metals
Almost any steel or cast iron, but usually a medium carbon steel.
Surfacing methods
1. Oxyacetylene process. It is used where it is necessary to achieve a surface with the
minimum of required finishing. It is especially good in applying crack-free
applications of non-ferrous alloys.
Tungsten carbide particles are put in a mild steel tube and in the tube melts under the
flame, the tungsten carbide particles become fused to the surface in a matrix of mild
steel.
2. Inert gas process. It is used where a flawless deposit is required, mainly on new
construction.
38
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
3. Atomic hydrogen process. It is preferred where a large mass of metal requires a
small overlay of hard surface.
4. Submerged arc process. It is used where, in large quantities the facing material is to
be deposited.
5. Manual metal arc process. It is quick, economical, easily adaptable and the one most
frequently used for short jobs.
6. Plasma arc process. Because of its very high temperatures, this process greatly
extends the capabilities of surfacing.
Applications
Metal Coating Thickness Applications
1. Resistance to wear
- Molybdenum 0.25 mm Splined shaft (53 mm dia.)
- Babbit 1.00 mm Refrigeration pistons 990 mm dia.)
2. Resistance to corrosion
- Aluminium 0.20 mm Bridge dams.
- Zinc 0.20 mm Overhead crane.
3. Resistance to corrosion and wear
- Monel 1.0 mm Turbine shaft (100 mm dia.)
- Phosphor bronze 1.0 mm Gas compressed piston (380 mm dia.)
4. Resistance to heat and corrosion
- Aluminium 0.15 mm Exhaust stack in chemical plants
- Nikrome and Al (separate Layer) 0.50 mm Lead-annealing pans.
References
1. Material Science and Metallurgy by O. P. Khanna
39
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Heat Treatment Processes
Questionnaire
1. Define heat treatment. List various objectives of heat treatment.
2. Explain what you understand by the following regarding heat-treatment of steel: (i)
Lower critical temperature (ii) upper critical temperature (Ui) critical range.
3. Write short notes on important factors in the heat-treatment of steel.
4. Give definition, purposes and process for the following heat-treatment operations for
steel: (i) Annealing (Ii) Normalising.
5. Distinguish between normalising and annealing in the following respect: (i)
Temperature for heating (ii) Heating and soaking time (Iii) Rate of cooling (iv)
Manners of cooling (v) Structural changes involved (vi) Applications.
6. Give purposes, process and structural changes involved in the fallowing heat-
treatment processes for steel: (i) Hardening (Ii) Tempering
7. Give reason why low carbon steel cannot be hardened practically by hardening
operation.
8. Describe any two of the following surface hardening processes used for low-carbon
steels: (i) Case- hardening (ii) Nitriding (iii) Cyaniding.
9. Differentiate between 'hardening' and 'case-hardening' processes.
10. Discuss the following surface hardening processes used for medium and high carbon
steels: (i) Induction hardening (ii) Flame hardening.
11. What are the requisites of a good quenching medium? Discuss various quenching
media used in the heat treatment of steel.
40
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Powder Metallurgy
Date: ___ /___ /______
EXPERIMENT NO. 8
Objective
To understand the concept of powder metallurgy.
6
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Powder Metallurgy
Atomization is used mostly for low melting point metals because of the corrosive action of
the metal on the orifice (or nozzle) at high temperatures.
(2) In Reduction process, the compounds of metals (usually oxides, e.g., iron oxide) are
reduced with CO or H2 at temperatures below the melting point of the metal (e.g., iron) is an
atmosphere-controlled furnace. The reduced product is then crushed and ground.
Sponge-iron powder is produced this way.
Fe3O4 + 4C = 3Fe + 4CO
Fe3O4 + 4CO = 3Fe + 4CO2
Copper powder can be produced by the same method i.e., by heating copper oxide in a stream
of hydrogen,
Cu2O + H2 = 2Cu + H2O
Powders of W, Mo, Ni and CO are also manufactured by reduction process. Reduction
process is a convenient, economical and flexible method and perhaps the largest volume of
metallurgical powders is made by the process of oxide reduction.
(3) Electrolysis is principally used for the production of extremely pure powders of copper
(and Iron). Electrolysis is similar to electroplating. For making copper powder, copper plates
are placed as anodes in a tank of electrolyte, whereas aluminium plates are placed into the
electrolyte to act as cathodes. High amperage produces a powdery- deposit of anode metal on
the cathodes.
After a definite time period, the cathode plates are taken out from the tank, are rinsed to
remove electrolyte and are dried. The (Cu) deposit on the cathode plates, is then scraped off
and pulverized to produce powder of the desired grain size.
(4) Crushing requires equipments such as stamps, hammers, jaw crushers or gyratory
crushes. Various ferrous and non-ferrous alloys can be heat-treated in order to obtain a
sufficiently brittle material which can be easily crushed into powder form.
(5) Milling operation is carried out by using equipments such as ball mill, impact mill, eddy
mill, disk mill, vortex mill, etc. Milling (or grinding) can be classified as comminution of
brittle, friable, tough and hard materials and pulverization of malleable and ductile metals.
A ball mill is a horizontal barrel-shaped container holding a quantity of balls which, being
7
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Powder Metallurgy
free to tumble about as the container rotates, crush and abrade any powder particles that are
introduced into the container.Generally, a large mass to be powdered, first of all, goes
through heavy crushing machines, then through crushing rolls and finally through a ball mill
to produce successively finer grades of powder.
(6) Condensation of metal powders. This technique can be applied in the case of metals,
such as Zn, Cd, and Mg, which can be boiled and the vapour are condensed in a powder form.
A rod of metal (say Zn) is fed into a high temperature flame. The vaporized droplets of metal
are allowed to condense on to a cool surface of a material to which they will not adhere.
This method is not very useful for large-scale production of powder.
8.9 COMPACTING
After blending and mixing, the next step is that of compacting or pressing the powders into
their semi-finished form preparatory to sintering.
The purpose of compacting is to consolidate the powder into the desired shape and as closely
as possible to final dimensions, taking into account any dimensional changes that result from
sintering. Compacting also imparts
1. The desired level and type of porosity, and
2. Adequate strength for handling.
Powders are compacted by using high pressures. The degree of pressure depends upon:
1. The required density of the final product, and
2. The ease with which the powder particles will weld together.
9
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Powder Metallurgy
Compacting pressures may be applied in the following ways:
1. Die Pressing
2. Roll pressing
3. Extrusion
1. Die pressing is done in special presses that include a feed hopper for the powder, the
shaping die to form the product, an upper punch and a lower punch to apply correct pressures
onto the powder being compacted.Weighed- quantity of powder is placed in the die through
the hopper and is compressed under pressure ranging from 8 to 158 kg/sq. mm.
10
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Powder Metallurgy
References
1. Material Science and Metallurgy by O. P. Khanna
Questionnaire
1. Briefly describe various steps in the production of a product through powder-
metallurgy process.
2. Briefly describe any five engineering products produced by powder metallurgy.
3. Briefly give advantages and disadvantages of powder metallurgy process.
4. Why is particle-size distribution important in the packing of powders?
5. Discuss the importance of particle shape on the properties of sintered compacts?
6. List the three common methods of powder production and discuss their influences on
the properties of the final product.
7. Contrast mechanical and hydraulic compacting presses with regard to advantages,
disadvantages, and applications.
15
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Powder Metallurgy
8. Why is sintering carried out in a controlled-atmosphere furnace?
9. Why do elevated temperatures tend to favor the sintering process although sintering
forces tend to decrease with increasing temperature?
10. What are the advantages and disadvantages of hot pressing as compared with cold
compacting and sintering?
11. Give' three specific applications of powder metallurgy parts. Describe how these parts
may be manufactured by other methods, and give the advantages of the powder
metallurgy method.
12. Why is pore size important in the manufacture of self-lubricating bearings? How may
pore size be controlled?
16
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Jomeny end quench test
EXPERIMENT NO. 9
Objective
To understand the concept of hardenability and obtain the hardness distribution curve with
the help of Jomeny End quench test apparatus.
9.1 Hardenability
When a steel piece of a larger cross section is heated to austenite temperature and then
quenched, the cooling rate decreases from the surface to the interior. Martensite is obtained at
the surface due to the highest cooling rate. But it is not possible to get a martensitic structure
at the centre due to the relatively slow cooling rate. Hence, a gradient of hardness exists from
the surface to the centre. Since every grade of steel has its own transformation characteristics,
the depth of penetration of hardness across the cross section differs. The measure of this
property is termed as hardenability of steel.
Hardenability is defined as the relative ability of steel to be hardened by quenching and it
determines the depth and distribution of hardness across the cross section. Hardenability
should not be confused with maximum hardness of steel.
Hardenability is a very useful and important property of steel. It determines the rate at which
the given steel should be quenched. Maximum hardness is mainly a function of carbon
content. Hardenability of steel depends on
1. Composition of steel
2. Method of manufacture
3. Section of the steel
4. The quenching media
5. Quenching method
In industry, a simple experiment called Jominy end quench test (named after Walter Jominy,
American metallurgist) is used to determine the hardenability of steel.
9.2 Equipment
1. Electric Furnace
2. Jominy End Quench Test Fixture
3. Jominy Specimens (Made as per ASTM standard)
4. Rockwell Hardness Testing Machine
1
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Jomeny end quench test
Fig 9.1 Apparatus used in the test and Standard form of test piece
5. Remove the Jominy specimen from the fixture and grind a flat on the side of the
specimen.
6. Mark points on the ground surface at an interval of 1.6 mm distance from the
quenched end as shown in Figure 10.11.
7. Take readings at an interval of 1.6 mm intervals. Near the quenched end, this interval
is reduced to 0.8 mm as hardness values vary rapidly.
8. The results are expressed as a curve of hardness value versus distance from the
quenched end (Jominy distance). This curve is called the Jominy hardenability curve.
2
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Jomeny end quench test
Fig. 9.3 Hardenability curves for five different steels, each containing 0.4% C and
varying alloy compositions
3
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Jomeny end quench test
High hardenable steel retains large hardness values, for a relatively long distance. Fig. 10.11
shows the typical Jominy curves for different steels having the same carbon content, but
differing in alloy composition.
All these steels have identical hardness at the quenched end (57 HRC) because hardness is a
function of carbon content. But hardenability is low for plain carbon steel because the
hardness drops off more steeply after a short Jominy distance. By contrast, the changes in
hardness for other alloys are more gradual. That is, the high quenched hardness would persist
to a much greater depth. Comparatively, alloy A is more hardenable than others.
Hardenability Band
A Jominy curve is strictly valid only for steel having a particular chemical composition and
average grain size. But, during industrial production of steel, there is always a slight variation
in chemical composition and average grain size from one batch to another. This result in
some scatter in the measured hardenability data, and these data are plotted as a band rather
than as a single curve. Hardenability curves of all batches lie in this range. These bands are
termed as hardenability bands.
Cooling rates at distances from the water-cooled end of the standard end-quench
hardenability test bar
4
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
Jomeny end quench test
Cooling rate at different locations inside the bar of varying cross sections such as round, flat
or square is correlated with the cooling rate at different distances along the quenched end of
the Jominy bar. Fig. 10.13 shows cooling rate as a function of diameter at the surface, three
quarter radius, mid radius and centre position for cylindrical bars quenched in mildly agitated
water and oil. The equivalent Jominy distances are included along the bottom axis.
(a) (b)
Fig. 9.4 CRC for cylindrical bars quenched in mildly agitated (a) Water (b) Oil
Use of Hardenability Data
1. By using the hardenability curves and cooling rate curves, the hardness existing at a
particular section in a steel specimen after quenching could be predicted. For example, the
centre of the 75mm diameter round bar quenched in oil has a cooling rate of 5.6°C/s. Since
the centre of the round bar has the same cooling rate as a Jominy test bar at a point 25mm
from the quenched end, the hardness at the two positions are the same. The hardness at 25mm
from the quenched end is found from the hardenability curve of that steel. This is equal to the
centre hardness of a 75mm bar after quenching.
2. These curves are also used to select a particular type of steel to meet a minimum hardness at a
given location in a part quenched under given conditions.
References
1. Material Science and Metallurgy by O. P. Khanna
2. Introduction to Physical Metallurgy by Sidney H. Avner
5
Material science and Metallurgy (2131904)
Department of Mechanical Engineering
Darshan Institute of Engineering & Technology