.NG Mec 224 Properties of Mat Theory
.NG Mec 224 Properties of Mat Theory
.NG Mec 224 Properties of Mat Theory
VOCATIONAL EDUCATION
REVITALISATION PROJECT-PHASE II
NATIONAL DIPLOMA IN
MECHANICAL ENGINEERING TECHNOLOGY
PROPERTIES OF MATERIALS
COURSE CODE: MEC224
YEAR 2- SE MESTER 4
THEORY
THEORY
TABLE OF CONTENTS
WEEK 1
1.1 Reasons for the study of properties materials
1.1 Materials science and engineering
1.2 Types of material
1.2.1 Metallic
1.2.2 Polymeric (Plastic)
1.2.3 Ceramic Materials
1.2.4 Composite Materials
1.3 Summary
WEEK 2
2.0 Atomic structure and bonding
2.1 Structure of atoms
2.2 Atomic Numbers and Atomic Masses
2.3. Electronic construction of Atoms
WEEK 3
3.0 Electronic structure and chemical reactivity
3.1 Atomic and molecular bond
Bonds in Solids
Ionic bond
Covalent bond
Metallic bond
3.2. Types of crystals
Body centred cubic (bcc) structures
Face centred cubic (fcc) structures
Hexagonal close packed (hcp) structures
WEEK 4
4.0 Phase transformations
4.1 Equilibrium diagram cooling curves
4.2. The one-two-one and inverse lever rules
4.3. Types of equilibrium diagrams
Inter metallic compounds
Invariant systems
WEEK 5
5.1 Ingot Casting
5.2 Types of Steel Ingot
WEEK 6
6.1 Equilibrium or constitutional diagrams
6.2 Eutectic
6.2.1 Interpretation of equilibrium diagrams
6.2.2 Solid solution diagram
6.2.3 Combination types
6.3 Eutectic and solid solutions
6.4 Intermediate phases
WEEK 7
7.1. Properties of materials
Extraction of metals from ores
7.2. Beneficiation or preliminary, treatment of iron ore for smelting.
Cutting
Grinding
WEEK 8
8.0 Concentration of ores
(i) Heavy media separation process –
(ii) Magnetic Separation Process –
(iii) Washing with water to separate the ore from the waste.
(iv) Calcination
(v) Agglomeration
WEEK 9
9.1. Manufacture of pig iron
9.2. Composition of pig iron
WEEK 10
10.0 Steel making processes
10.1. Bessemer process
10.2. Open hearth process
WEEK 11
11.1. Cast iron
11.2. Chemical composition
11.3. Chemical composition
11.4. Alloy cast iron
WEEK 12
12.0 Properties and application of non ferrous metal
12.1 Non-ferrous metals
WEEK 13
13.0 Hot working and cold working processes
13.1. Mechanical shaping of metals
13.2. Hot rolling
13.3. Hot extrusion
WEEK 14
14.1. Cold working
14.0 Cold working processes
14.2. Types of cold working process
14.3. Cold pressing and deep drawing
14.4. Coining and embossing
14.5. Flow forming
WEEK 15
15.0 Properties and application of non metallic materials
15.1 Glass
15.1.1 Constituents of glass and their functions
WEEK 1
Materials science is primarily concerned with the search for basic knowledge about the
Knowledge of material so that the material can be converted into products necessary or
desired by society. The name materials science and engineering combines both materials
science and materials engineering and is the subject of this book. Materials science is at
the basic knowledge end of the materials knowledge spectrum and materials engineering
is at the applied knowledge end, and there is no demarcation line between the two.
Three-ringed diagram which indicates the relationship among the basic sciences (and
mathematics), materials science and engineering, and the other engineering disciplines.
The basic sciences are located within the first ring or core of the diagram, while the
the outermost third ring. The applied sciences, metallurgy, ceramics, and polymer science
are located in the middle or second ring. Materials science and engineering is shown to
form a bridge of materials knowledge from the basic sciences (and mathematics) to the
engineering disciplines.
For convenience most engineering materials are divided into three main classes: metallic,
polymeric (plastic), and ceramic materials. In this chapter we shall distinguish among
them on the basis of some of their important mechanical, electrical, and physical
these types of materials. In addition to the three main classes of materials, we shall
consider two more types, composite materials and electronic materials, because of their
1.2.1 Metallic
These materials are inorganic substances which are composed of one or more metallic
elements and may also contain some nonmetallic elements. Examples of metallic
elements are iron, copper, aluminum, nickel, and titanium. Non-metallic elements such as
carbon, nitrogen, and oxygen may also be contained in metallic materials. Metals have a
crystalline structure in which the atoms are arranged in an orderly manner. Metals in
general are good thermal and electrical conductors. Many metals are relatively strong and
ductile at room temperature, and many maintain good strength even at high temperatures.
Metals and alloys' are commonly divided into two classes: ferrous metals and alloys that
contain a large percentage of iron such as the steels and cast irons and nonferrous metals
and alloys that do not contain iron or only a relatively small amount of iron. Examples of
The picture below is a photograph of a commercial aircraft jet engine which is made in
primarily of metal alloys. The metal alloys used inside the engine must be able to
withstand the high temperatures and pressures generated during its operation. Many years
of research and development work by sciences and engineers were required to perfect this
Materials and materials processes have been associated with more efficient gas-turbine
engine propulsion performance over the past years. Metal-matrix and ceramic-matrix
networks. Structurally, most porymmeric materials are non-crystalline but some consist
polymeric material are poor conductors of electricity. Some of these materials are good
insulator and are used for electrical isolative applications. In genera, zolymeric materials
Ceramic materials are inorganic materials which consist of metallic and non-metallic
noncrystalline, or mixtures of both Most ceramic materials have high hardness and high-
temperature strength but tend to have mechanical brittle-ness. Lately, new ceramic
materials have been developed for engine applications. Advantages of ceramic materials
for engine applications are light weight, high strength and hardness, good heat and wear
The insulative property along with high heat and wear resistance of many ceramics make
the space shuttle. These ceramic materials thermally protect the aluminum internal
structure of the space shuttle during ascent out of and reentry into the earth's atmosphere
Composite materials are mixtures of two or more materials. Most composite materials
consist of a selected filler or reinforcing material and a compatible resin binder to obtain
the specific characteristics and properties desired. Usually, the components do not
Some of the predominant types are fibrous (composed of fibers in a matrix) and
reinforcements and matrices used to produce composite materials. Two outstanding types
reinforcing material in a polyester or epoxy matrix and carbon fibers in an epoxy matrix.
Schematically where carbon-fiber-epoxy composite material will be used for the wings
and engines of the new C-17 transport plane. Another example of the 56 of composites is
glass-reinforced polyphenylene sulfide (PPS) for oilfield fittings. This application utilizes
1.3 SUMMARY
engineering) form a bridge of materials knowledge between the basic sciences (and
with the search for basic knowledge about materials, whereas materials engineering is
The three main types of materials are metallic, polymeric, and ceramic materials. Two
other types of materials which are very important for modern engineering technology are
composite and electronic materials. All these types of materials will be dealt with in this
book.
Materials compete with each other for existing and new markets, and so the replacement of one
material by another for some application occurs. The availability of raw materials, cost of
manufacturing, and the developing new materials and processes for product; ire major factors
Let us now review some of the fundamentals of atomic structure since atoms are the basic
Atoms consist primarily of three basic subatomic particles: protons, neutrons, and
electrons. The current simple model of an atom envisions a very small nucleus of about
density so that the diameter of the atom is of the order of 10-10 m. The nucleus accounts
for almost all the mass of the atom and contains the protons and neutrons. A proton has a
mass of 1.673 x 10-2" g and a unit charge of +1.602 x 1(T19 coulombs (C). The neutron
is slightly heavier than the proton and has a mass of 1.675 x 10Jkg but no charge. The
electron has a relatively small mass of 9.109 x 10"2g (that of the proton) and a unit
charge of -1.602 x 100C (equal in charge but opposite in sign from the proton). Table 2.1
The electron charge cloud thus constitutes almost all the volume of the atom but accounts
for only a very small part of its mass. The electrons, particularly the outer ones,
determine most of the electrical, mechanical, chemical, and thermal properties of the
Atomic Numbers
The atomic number of an atom indicates the number of protons (positively charged
particles) which are in its nucleus, and in a neutral atom the atomic number is also equal
to the number of electrons in its charge cloud. Each element has its own characteristic
atomic number, and thus the atomic number identifies the element. Atomic numbers of
the elements from hydrogen, which has an atomic number of 1 to hahnium, which has an
atomic number of 105, are located above the atomic symbols of the elements in the
periodic table.
Atomic Numbers
The relative atomic mass of an element is the mass in grams of 6.023 x 1023 atoms
(Avogadro's number NA) of that element. The relative atomic masses of the elements
from 1 to 105 are located below the atomic symbols in the periodic table of the elements.
The carbon atom with 6 protons and 6 neutrons is the carbon 12 atom and is the reference
mass for atomic masses. One atomic mass unit (u) is defined as exactly one-twelfth of the
mass of a carbon atom which has a mass of 12 u. One molar relative atomic mass of
carbon 12 has a mass of 12 g on this scale. One gram-mole or mole (abbreviated mol) of
an element is defined as having the mass in grams of the relative molar atomic mass of
that element. Thus, for example, 1 gram-mole of aluminum has a mass of 26.98
THE ATOM
For many years scientists have been trying to develop an acceptable model of the micro-
and the macro-universe. To this point in man's history, as instruments are refined and
additional data are collected, the model of the macro universe is being expanded. Much
of this new information is deduced from energy that is continuously bombarding the
earth's surface.
If one reflects a moment much of what man suspected about the moon was only a built-
up model until it was confirmed by man's landing on its surface. It soon becomes
apparent that much of What we actually know is still only a small part of that which
actually exists.
In the same manner (hut man prefers to be able to assimilate his (miling of the macro-
universe into a model so that he may better understand it, so he has attempted to generate
For purposes of this text the model preferred is the one that views the atom as having
almost all it mask concentrated in a positively charged nucleus. In orbit about this
nucleus arc one or more negatively charged particles called electrons. The net charge of
the atom as whole is zero. The nucleus is envisioned to have a positively charged particle
called the proton. The number of protons in the nucleus remains unchanged for ii
particular element A neutrally charged particle, called the neutron, may also be found in
(he nucleus1. Together, the protons and neutrons are called nucleus. Thus the entire
positive charge appears- to he concentrated in the protons in the nueleus, which are
(C). Its mass is 9.108 x 1()--8 gram (g). The mass of the proton is I.673X 10-24g, and the mass
of the neutron is 1.675 x 10-4g. The mass is concentrated almost entirely in the nucleus.
Elements are designated according to their chemical symbols. Thus iron (Fe) has an
56
26 F
This atom would consist of 26 protons and 26 electrons and 30 neutrons. If we let A = 56
N = A-Z = 56-26 = 30
number because, even though they have the same number of electrons and protons
(electrically neutral), they differ in the number of neutrons. Thus hydrogen and its
Opposite charges attract each other, and the centrifugal forces would seem to cause the
electrons to want to fly out of orbit. Under normal conditions this centrifugal force would
To explain this unacceptable model, discrete energy orbits are assumed. If the electron is
found in one of these orbits, it will have a fixed energy value. In these fixed energy levels,
the electron does not radiate energy, and the energy level of the electron is balanced by
* A centripetal force is the reaction force to the centrifugal force. It is the force which
Inside the nucleus the charges are positive. Since positive charges repel, it would seem
that the nucleus should fly apart. However, this model of the atom dictates that there be
very large forces of attraction at work inside the nucleus. These binding forces are called
nuclear forces. Their magnitudes are much greater than the positive charges operating
As already indicated, this model also envisions the orbital electrons as possessing discrete
amounts of energy and therefore as being arranged in definite orbits dictated by the
energy required to keep that electron in that particular orbit. These orbits are referred to
as shells. The maximum number of electrons permitted in each shell is 2ttz. The symbol n
Thus the hydrogen atom has one electron in the first shell and helium has two electrons in
the first shell. According to Example 1, this closes the first (K) shell. Lithium has three
electrons. The first two will fill the K shell and the one remaining electron will start a
new shell L. Sodium, which requires 11 electrons, will have two electrons in the K shell,
eight in the L shell, and one in the M shell. Starting with potassium, this scheme deviates
somewhat as one progresses through the list of elements for the transition elements.
The capital letters K, L, M, N, O, P, and Q are used to designate the shells. Each shell is
again divided so that no more than two electrons may occupy one subdivision. If two
electrons occupy one energy level orbit, their spin must be in opposite directions. This
is equal to 1, 2, 3, 4, ...
The angular momentum of the electron is designated by letter and is called the second
quantum number. This angular momentum determines the subshell inhabited by the
electrons; /has values from 0 to (ra-1) and the subshell is 2(21+ 1). The subshells are
Two additional quantum Bombers are used to further define this model. mi indicates the
magnetic moment of the electron, has values of >H to 0 to —A and designates the orbit
within a sabshell corresponding to a particular energy leveL Af,, which may have values
of +i or -4, indicates the direction of spin of the electros upon its own axis.
Thus no two elements may have all four quantum numbers alike. The periodic table
(Table Z- 1) shows bromine (Br)35 as 4i240s. This is the N shell. A simple model is
shown in
The atomic model discussed so far was for electrically neutral atoms only and for atoms
in their ground state. It was noted, however, flat each of the n orbits has its own
characteristic energy level. If for some reason (an electric discharge) the electron in its
ground state is excited enough so that its energy level is increased, this increase of
strategy may be. Enough to knock it completely out of the atom. ob the other hand, it
major the energy :atom by some discrete amount and cause the electron to enter orbits.
When an atom loses one or more of its electrons, it is said to be ionized. When an
the excited state will jump back to its ground state with one jump or several jumps. If it
returns to its ground state in one jump [Fig. 2-2(a)], it will emit an amount of energy
characteristic of that jump. This packet of energy is called a quantum. If it returns to its
ground, state through several jumps each jump will require a release of a quantum of
Bonds in Solids
The atoms and molecules in a solid slate are more closely packed as compared to gaseous
and liquid states and are held together by strong mutuc. forces of attraction. These inter
atomic forces are electrostatic in nature and depend upon the electronic structure of
matter. When atoms come closer and finally unite to form molecules their electrons
arrangement of electrons gives rise to different types of bonds due to which atoms are
held together.
Ionic bonds are mainly formed in inorganic; compounds like NaCl and KOH etc. and
never in pure elements. An ionic bond is really the attractive force between a positive ion
and a negative ion when they are brought into close proximity, 'These tons, of course, are
formed when the atoms involved lose or gain electrons in order to stability their outer
electronegative, depending upon when they tend to lose Or gain electrons in order to
achieve this stable outer shell electrons configuration. Let us cons id or the combination
which take place between the Sodium (metal) and Chlorine (non-metal); to form Sodium
Chloride. The sodium has a single electron (n it) outer shell and this transfers to join the
seven electrons in the outer shell of Chlorine atom. This type of atomic interaction,
involving the outright transfer of one electron from another, leads lo formation of ions
which are held together by electrostatic nature of the binding force, the bond between
COVALENT BOND
The covalent bond is formed by sharing of electrons between atoms rather insister of
electrons. Only a few solids are held together by covalent bonds. Covalent bonding alone
is not sufficient to build three dimensional solids. The majority of solids incorporating
covalent bonds are bound also either by ionic or van der Waals' bonds.
An excellent example of covalent bonding is found in the Chlorine molecule (Fig. 21.10
a). Here the outer shell of each atom possesses seven electrons. Each chlorine atom
would like lo gain an electron and thus form a stable octet. This can be done by sharing
of two electrons between pairs of chlorine atoms thereby producing stable diatomic
molecules. The nature ol covalent bonds in the molecules of hydrogen (H2) and
METALLIC BOND
A metallic bond results from the sharing of variable number of electrons by a variable
number of atoms. The atoms in metal and alloys are held together by such bonds. This
type of bond is characteristic of the elements having small number of valence electrons,
which are loosely held. so Out the can be easily released to the common pool. The
of the metal contributes its valence electrons to the formation of an electron cloud that
pervades the solid metal. The valence electrons are not bonded directly to an individual
atom but they move freely in the sphere of influence of other atoms and are bound to
different atoms at different times and that too for a short time.
Schematic picture of the metal ions (positive) and that a', electron cloud (negative). The
cohesion of a metallic crystal is due to the attraction of the positive nuclei and the valence
electrons passing between them. A metallic bond thus conceived can exist only between a
large aggregate of metallic atoms and must therefore be non-directional. The high
electrical conductivity to metals is given by the free electrons moving freely in an electric
filed.
its 8 corners and another atom at the body centre. It is thus obvious, that each unit cell
shares 8 atoms one on each of its corners in addition to one atom at the body centre.
The common examples of this type of structure are a-iron (below 910°C), 5-iron (1400°C
to 1539°C), tungsten, vanadium, molybdenum, chromium and alkali metals (i.e. sodium
In this type of structure, the unit cell (in the shape of a cube) contains one atom at the
centre of its each face, in addition to one atom at each of its 8 corners as shown in Fig.
3.15. It may be noted that this type of structure does not contain any atom at the centre of
the unit cell. It is thus obvious that each unit cell shares 14 atoms.
The common examples of this type of structure are y-iron (910°C to 1400°C), copper,
silver, gold, aluminum, nickel, lead and platinum etc. The face centred cubic structures
In this type of structure, the unit cell contains one atom at each corner of the hexagonal
prism, one atom each at the centre of the hexagonal faces and three more atoms within
the body of the cell. It is thus obvious that each unit cell shares 14 atoms, and contains 3
atoms.
The common examples of this type of structure are magnesium, zinc, titanium,
A cooling curve is a graph of the structure of a pure metal o-r a combination of that metal
with another metal. The latter is called an alloy. Thus studying a particular cooling curve
yields data related to a particular combination of two or more metals of the entire
temperature range through which an alloy cools. If the characteristics of another alloy of
the same two metals are desired, the cooling curve for the never combination is needed.
Art equilibrium diagram is a composite of all cooling curves of all the possible
combinations of two or more metals. I", should be stressed that equilibrium diagrams are
related to the conditions of cooling that occur slowly enough to be considered stable —
Assume a closed system. If the ice at —10°F is heated, it absorb heat until the ice reaches
32°F, at which point it will begin 10 melt. The mixture of ice and water will remain at
32T, because all the heat is being used to melt whatever ice is being transformed to water
at 320F. Once all the ice has been transformed to water at 32°F, the heat added to the sys-
tem will be used to raise the temperature of the water to 2 !2T. At this point the heat will
all go toward transforming the water into steam at 212CF, The mixture of water and
steam remains at 212:F until all the water converts to steam, at which time the heat input
raises the temperature of the steam. The plot of this heating system.
The reverse mechanism takes place if the steam is in a closed system and if it is allowed
and 212°F are the temperatures on the curve at which phase changes occur.
Several definitions are in order at this time: (1) The elements that make up an alloy or the
chemical compounds that may be formed from these elements are called components.
They are considered components if chemical means are needed to separate them. (2) A
phase is a part of an alloy that does not require chemical methods to make that part dis-
tinguishable from other parts. That is, physical means can be used to distinguish the parts
of the alloy.
If a pure metal is heated and then cooled very slowly, its cooling curve may be plotted.
The curve ab represents the cooling of the melt. At temperature T and at point b. the pure
metal starts to precipitate out of solution. At point c the entire melt has transformed to the
solid pure metal. Note that curve be is level and (hat the phase change occurs at one
Two metals have been heated to point a, where both are liquid and are dissolved in each
other. On slow cooling they remain liquid until they reach Tlt at which temperature
solidification starts. At I2 the solidification has been completed, and the entire mixture is
a solid solution. The cooling of the solid continues to d. Point b is the point Where
where crystallization begins and is referred to as the liquidus point. Point c is the point on
the curve where final solidification takes place. It is referred to as the solidux point.
Another type of cooling curve is one that exhibits characteristics. This occurs when two
metals A and B are soluble in the liquid state but insoluble in the solid state.
In this mechanism the liquid solution starts to cool at a. At b, pure metal A starts to form
and precipitate out of the liquid phase. As the temperature drops from 7 to r3, pure metal
we say that the liquid remaining becomes richer in B. This mechanism of freezing results
At c the freezing is that of the remaining metals of A and B. The temperature remains
constant until all solidification is complete at d. Line de represents the normal cooling of
Several cooling curves of combinations of : metals ,4 and B. These curves have been
rotated through 90 degrees, and the points a and b have been projected to the back plane
as shown. That is. all points a are on the liquid line and all points b are on the solidus
'fine. When all the liquidus points are connected by a smooth line, and all the solidus
points are connected by another smooth line, the equilibrium diagram results.
Phases that exist in a particular region. The procedure is to draw a horizontal line fry that
starts at the solid boundary x and terminates at the liquid boundary y. The xy line itself
lies in a two-phase region. The two phases are solid and liquid.
It should also be noted that in our example the overall composition of the alloy P is
always 75 per cent metal A and 25 per cent metal B. Since there is only one phase
(liquid) for temperatures above TV the composition of the alloy is always liquid. The
same is true for the single-phase solid that exists below the temperature T3 for alloy P.
However, at the intersection z of the temperature line it and the composition line P, two
phases exist, namely liquid ami solid. The composition of the liquid phase and the solid
The line jcv, through point z, intersects the solidus line at x. If a perpendicular is dropped
from point x to the abscissa of the graph, it will be seen that the line shows the
composed of 90 per cent element A and 10 per cent element B (A + B must total 100 per
cent).
The line xy, through point z, also intersects the liquidus line at If a perpendicular is
dropped from y to the abscissa, the composition of the liquid will be seen to be 20 per
Inverse Lever Pule. It now becomes necessary to determine the percentages of each phase
that is present at various temperatures. Let us look at alloy P and determine the
percentages of L and 5 present at 7~3. The length of the line xy represents the sum of the
two phases as 100 per cent. The inverse rule states that the liquid phase can be calculated
by taking the length of the line xz and dividing this by xy. The solid phase may be
calculated by taking the length of the line zy and dividing this by xy. To get the
There are several combinations of liquid solubility and solid solubility states that yield
characteristic diagrams and may be classified with reference to their solid-liquid state
combinations. That is, the components that enter into an alloy may be insoluble, partially
soluble, or completely soluble in each other in the liquid or solid state. Several of these
Certain elements may exist as two separate phases in the liquid state and two distinct
phases in the solid state. This indicates a system completely insoluble in the liquid state
and completely insoluble in the solid state. The idealized equilibrium diagram,
practically zero. As the system cools below T,, solid As forms and precipitates out, and
two phases exist. At 72. solid Bs forms and exists as a separate phase with As.
Left portion of such a system. At the top of the diagram two liquids are shown existing as
separate phases. The non-vertical boundary lines would indicate a very slight solubility.
Systems that show this type of solubility combinations in the liquid and solid states are
Another system is that in which the components are partially soluble in the liquid state.
They may be partially soluble in the solid state, or they may be completely "soluble or
Figure 4-5 shows a diagram in which the elements are partially soluble in the liquid state
and insoluble in the solid state. For alloy X the single-phase liquid state exists above T.
Below the upper transformation line there exist two distinct liquid phases: one rich in
element A and the other rich in element B. The partial solubility in the liquid phases
exists in this region of the diagram. Below 7\, the ,4-rich phase solidifies, and a liquid-
solid combination exists. As the temperature drops below T2, B solidifies independently
Dartially soluble (L, + Lz) and the solid phases are partially soluble (a + ft). Thus, as the
two partially soluble liquids cool, A and B exist as partially soluble in each other as an
alpha (a) phase. The remaining liquid Z..J, solidifies as a partially soluble beta (β) phase.
Systems that show partial liquid solubility and partial solid solubility are zinc-bismuth,
Diagram in which the two components are partially soluble in the liquid state and
completely soluble in the solid state. That is, elements A and B combine to form a single
phase on cooling.
Another series of equilibrium diagrams is that in which the constituents are completely
soluble in the liquid state in combination with varying degrees of solubility in the solid
In some instances components may be completely soluble in the liquid state and
completely insoluble in the solid state. One such equilibrium diagram. Bismuth-cadmium
forms such a diagram. In this example, the metals A and B in the alloy X are completely
soluble above the liquidus line. As the temperature drops below the liquidus tine, A
precipitates out as heat is removed. At T the two metals A and B are evidently completely
insoluble in each other, since the cooling curves exhibit a flat, or hold. Below T, the
combination of 60 per cent A with 40 per cent B exists, the two solidify as a eutectic.
However, the eutectic also exhibits the fact that ,4 and B are completely insoluble in the
solid state.
The most common solubility combination of components is the case where the
components are completely soluble in the liquid state and partially soluble in the solid
and aluminum-silicon. The metals A and B are completely soluble in the liquid state and
that in no case is pure A or pure B formed, except at the terminal sides of the diagram.
The addition of alloys to pure metals may alter the dimensions or the configuration of
their lattice structures. The addition of alloying elements (solute) to a pure metal (solvent)
In some instances, solute atoms may displace solvent atoms in a solid lattice. When this
occurs, it is called a substitution solid solution. Since it is rare that the solute atoms are
the same size as the solvent atoms that they displace, the result is a distortion of the
lattice.
If elements are to be completely soluble in one another, they must have the same type of
lattice structure. The greater the size difference between the atoms of the two elements,
the less their solid solubility in substitutional solutions. That is, if atom A is larger than
atom 8, it will be less likely to substitute for a B atom in the lattice than would an atom C
whose size is more nearly the size of B. It is also true that the tendency toward the
substitutional solid solution. As the concentration of the solute increases, so does the
When the solute atoms lodge in the space between the solvent atoms the system is called
an interstitial solid solution. This happens when the solute atoms are small, about half the
diameter of the solvent atoms, and are able to fit in between the larger atoms in a Jattice.
Obviously, the size of the space between the solvent atoms, as well the size of the solute
chromium, manganese, molybdenum, ingsten, and vanadium are elements that lend
themselves to being the 'Ivent in the formation of interstitial solid solutions. Carbon,
hydrogen, >ron, nitrogen, and oxygen are atoms that have diameters small enough act as
the solute atoms in interstitial solid solutions. Iron, at room temperature, dissolves very
small amounts of carbon interstitially. Above 1333°F the lattice structure changes from
body-centered cubic lattice to face-centered cubic lattice, and the interatomic spacing
increases, which makes it possible for carbon to form interstitial solid solutions.
If the atoms are insoluble in each other, a mechanical mixture results. The intermetallic
compound results when the two, solute and solvent, atoms join each other. These space
lattices are very complex. They transform from the liquid phase to the solid compound
phase at a fixed temperature and at a fixed composition. They differ from chemical com-
pounds in that the rules of valence bonding, described earlier, do not apply. The
mechanical properties associated with intermetallic compounds are high strength and
hardness, low ductility, and low conductivity. As stated, intermetallic compounds form at
one temperature. the alloy of A and B that has a composition of 55 percent and 45 per
cent B freezes from the Jiquid directly to our intermetalJic compound. The region
characteristic of such a compound is a straight line that divides the diagram into two
distinct sections.
INVARIANT SYSTEMS
elements are in the required fixed percentages for a particular change in phase to take
place. In the binary system there are five such important reversible and invariant
These are invariant systems because they occur whenever an alloy has a fixed
composition. For example, at a temperature TB, anytime the composition of the liquid
phase is 40 per cent A and 60 per cent B, that liquid will transform directly into a two-
The inverse lever rule was discussed in Sec. 4-2. If this rule is applied to alloy R, it will
be seen that the liquid phase at e has the necessary 40 per cent A, 60 per cent B
such that its composition is z. As the alloy cools further to 7a, the composition of the
solid phase changes from z to x, and the liquid phase changes from q to y. It should be
remembered that the composition of each phase is determined by dropping a
perpendicular to the abscissa and reading the percentages of A and B. Thus the
percentage of B in the solid will increase from about z ~ 4 per cent to x = 6 per cent,
while the percentage of B in the liquid will be enriched from about q = 20 per cent to y =
30 per cent. The percentages of A in the solid and liquid will decrease accordingly. The
At 7'fi, the composition of the solid has moved from jc = 6 per cent B to w = 10 per cent
B, while the composition of the liquid has moved from y = 30 per cent B to e = 60 per
cent B. Thus the liquid has a eutectic composition at e of 40 per cent A and 60 per cent B,
As alloy R cools below TK, this eutectic liquid solidifies as if it were a pure metal [see
Fig. 4-2(a)]. The result is solid A and B in the form of an alpha (a) phase, and A and B in
Also, any alpha that solidifies above TK, between compositions A = 90 per cent and A ~
40 per cent, is called primary alpha. If beta solidifies above TE, between compositions A
There is still another movement that takes place. Below TV the a-phase is rich in
component B. It cannot hold all the A component as it cools and forces it out of the
lattice structure. In a like manner, some of the B component is forced out of the /3-phase.
which is A rich,
The composite analysis just discussed is shown in Table 4-2. The same analysis can be
eutectic liquid horizontal tine, there can be only eutectic composition between^ =90 per
It should also be noted that only at composition E does the eutectic, and only the eutectic,
form. To the left of E, A = 90 per cent to A = 40 per cent, the eutectic and a crystals
per cent, the eutectic and /3 crystals form. This is called a hypereutecnc structure.
WEEK 5
mould (Fig. 5.2) is the older. It is open at both ends, and when ready for use stands on a thick
cast-iron 'stool' which forms the bottom of the mould. Stripping of the ingot is thus relatively
easy, since it is only necessary to lift the mould from off the solid ingot, which is left standing on
the stool. 2.202 The newer big-end - u p type of mould (Fig. 5.3) is usually closed at the bottom
except for a round hole which is fitted with a tapered plug which facilitates the stripping of the
solid ingot. This type of mould is generally fitted with a
Steel is used for deep-drawing processes, tin-plate manufacture, and the production of
galvanized sheeting.
In a semi-killed ingot the oxygen content after partial deoxidation is lower Ian in a rimming
steel, so that the evolution of carbon monoxide tends to take place at a later stage in the
solidification process. The porosity produced ; largely instrumental in eliminating the pipe.
Moreover, impurities tend to e 'pushed' nearer to the top of the ingot by the evolved gas, so that
much of this impure material is cropped off. Thus some of the useful features of both completely
killed and rimming ingots are combined in a semi-killed ingot.
Some alloy steels and special forging steels are now vacuum de-gassed
in order further to improve their soundness, one method of de-gassing.
Here a stream of molten steel is drawn into a vacuum chamber which
contains the ingot mould. Reduction of the internal pressure within the
stream leads to its de-gasification. In this way the whole charge is treated
successively. Dissolved gases such as hydrogen and nitrogen boil off.
This upsets chemical equilibrium within the molten steel so that
reactions occur between oxides and silicates and dissolved carbon:
Silicates + C → Si + Co (Boils off).
Silicon thus liberated dissolves in the steel
WEEK 6
6.1 EQUILIBRIUM OR CONSTITUTIONAL DIAGRAMS
The solidification of an alloy generally occurs as a continuous process over a range of falling
temperature and even after becoming solid, constitutional changes of far reaching importance
may continue to take place. In a series of alloys such as the cupro-nickels or the carbon steels, it
is possible by plotting temperature against composition to represent graphically the changes
which take place during and subsequent to solidification. Such graphs, suitably annotated, are
known as equilibrium diagrams, and a knowledge of them is useful in the control of casting
operations and heat treatment processes. An objection to these diagrams, which is sometimes
raised, is that they deal with alloys in a stable or equilibrium condition, only realised by either
extremely slow cooling or very prolonged annealing, a condition rarely obtained in practice.
Nevertheless they do show the direction in which changes are likely to occur.
While often appearing complicated, the sections covering industrial alloys can be interpreted on
the basis of three simple types-eutectic, solid solution and peritectic, each characterised by a
definite arrangement of lines. They do not indicate the structural arrangement of the phases, i.e.
laminate, globules, films; nor do they indicate the velocity of reactions.
6.2 EUTECTIC
For the present purpose the lead-antimony system may be considered a simple eutectic, in which
the metals are completely soluble in the liquid and entirely insoluble in the solid state. The
equilibrium diagram is shown in Fig. 36. Alloys within the temperature-composition limits
above AEC are liquid and the boundary lines AE and EC, obtained from cooling curves, are
known as the liquidus. A characteristic of this diagram is that the liquidus consists of two
branches falling in temperature from the freezing point of the two metals to a minimum
intersection point, known as the eutectic point (E).
All the alloys become completely solid at the same temperature, corresponding to the
temperature at E, and the boundary ADEBC is known as the solidus. The areas ADE and CBE
represent alloys in a pasty condition -solid dendrites and liquid.
Consider the solidification of an alloy of composition x (40 % lead). At temperature tb seed
crystals of antimony are formed. The melt is consequently enriched in lead and is represented by
a point, such as Y1 (55 % lead). Its temperature must therefore fall to t2 if the dendrites are to
continue to grow by further deposition of antimony and consequent enrichment of the liquid in
lead. This process is repeated continuously until the composition and temperature are given by
point E. Further separation of antimony proceeds along an extension of CE (shown dotted),
reaching .a point E1 which is supercooled sufficiently below curve AE* to cause solidification of
lead with heat burst and cessation of growth of antimony. Lead crystals can continue to grow for
a very short time only since its separation along line AE soon enriches the alloy m antimony to a
point at which antimony must again separate. This process .of alternate solidification of minute
quantities of lead and antimony maintains the alloy at an almost constant temperature, until it is
completely solid, then normal cooling IS resumed as indicated by the cooling curves in Fig. 36.
Similarly, any alloy between E and A (13 to 0 % antimony) commences to solidify on reaching
line AE by forming lead dendrites and the resIdu~1 melt is gradually enriched in antimony until
point E IS reached, when It
Fig. 6.2: Equilibrium diagram for two metals completely soluble in the liquid and solid states
Zone refining is a process used for purifying metals, particularly silicon and germanium for
transistors. It uses the fact revealed in Fig. 41, namely that the first crystals deposited are much
purer in one component than the liquid at the same temperature. A narrow zone in a bar of the
impure metal is melted at one end and caused to move along the bar so that metal is melting into
the zone on one side and freezing out at the other. The first solid frozen out is purer than the
average composition while the liquid becomes enriched in solute which is deposited at the other
end of the bar. Repeated cycling in one direction can reduce the impurity to below 1 part in 108•
Peritectic diagram
In many systems of alloys a reaction takes place, at a definite temperature, between the definite
proportion of the solid already deposited and the residual melt (BP: BA in Fig. 44) to form
another solid solution or compound of a composition intermediate between that of the first solid
and the liquid. This is known as a peritectic reaction and it gives rise to a diagram such as is
shown below.
If the effect of coring is ignored any alloy up to 13-2 % tin (A) will solidify as described for a
solid solution, as will also alloys with more than 25·5 % tin .
Consider alloy x; primary crystals y form and as the liquid cools the solid (0() changes to A, while
the liquid changes its composition along the liquidus CP to P. The liquid which remains (Ax2 to
Px2) rt'acts with the solid crystals A to form a new intermediate phase (B). Since X2 lies between
A and B, all the liquid P will be used up before the crystals A, and the alloy will then consist of
solid x and ~ crystals of composition A and B respectively. An alloy of composition Z again
commences to solidify by depositing 0( solid solution which changes in composition to A at
798°C. Theoretically, these 0( crystals are then completely converted to ~ crystals of
composition B, since Z lies between Band P, and the excess liquid P , solidifies by depositing ,
which changes in composition along solidus BR to Zl.
In practice these peritectic reactions rarely go to completion owing to the fact that primary 0(
crystals become coated with a skin of which prevents the diffusion of the tin rich material to
the central regions. Even in alloys of composition Z, a core of 0( remains. A typical example of
this effect for an alloy of 30 % copper in tin. The Cu3Sn (0:) is coated with Cu3Sn3 (7) and the
background is eutectic of 7) + Sn.
WEEK 7
MAGNETITE- (Fe3 04) (Ferrous ferric oxide) color (Green, blue). This contains about
72.4% Iron when pure. It is magnetic and this feative makes it easy for its exploration.
HAEMATITE – (Fe2 03) (Ferric Oxide) colour (Red, black and green) this contains about
70% Iron.
LIMINITE – (2Fe2O3 .3H2O) Ferric Oxide colour (yellow, red, brown and black) this is
another type of Ore which is among the hydroxides Ores and has a composition ranging from
about 60% Iron.
SIDERITE – (FeCo3) Iron Carbonate colour (Green, brown and yellow) this contains about
48% Iron and is in the family of Carbonate Ore.
1. CUTTING – Is accomplished by crushers such as gyrators and jaw crusher. The iron
ore is broken into smaller suitable pieces by large crushers. The purpose is to avoid handling
of problems due to oversize.
2. GRINDING – Is the process whereby coarse material are reduced to fine powders. For
grinding we have ball mills, steel rod mills e.t.c
Grinding is mainly carried out in ball mills or in similar equipment (tube,
peddle, and rod mill).the typical ball shape is a barrel shaped vessel rotating on it’s
horizontal axis. It has special replaceable cylindrical liners, lifters, and end plates and is
loaded to just under half full with balls of steel or cast iron.
The linings and end walls have traditionally been made of high alloyed steels including
13% Mn “Hadfield” steel or special iron. The section being design of replacement in so far as
is possible.
8.1. CONCENTRATION –
This is the removal as much as possible, the earthly waste or gangue which would other
wise take up useful space in the blast furnace and thus reducing output one of the processes
for concentration of ores are:-
(iv) CALCINATION –
This involve roasting in an excess air. This operation is effected in a kiln and is usually
applied to ores which contain a large amount of moisture or carbon dioxide. Calcinations of
the hydrated ores drive off moisture and combined water and leaves the ore more porous.
These substances may cause irregular working in the blast furnace and are best removed
before the ore is smelted. This operation also helps to remove sulphor by oxidizing it to
sulphur dioxide. This converts ferrous carbonate to ferrous oxide.
(v) AGGLOMERATION –
During the processes mentioned above, a large amount of iron may be found in the resulting
dust. This dust rich in iron can be reclaimed but cannot be charged into the blast furnace in
dust form. This is because the dust will fill up the spaces between the winps of the charge
thus impeding the upward flow of gases or may be blown out of the furnace.
Agglomeration may be defined as method of coalescing small iron particles lost driving
concentration under the influence of heat to form large particles or masses. The dust can be
conditioned as follows to enable it be charged into the furnace.
(i) Sintering –
The principal raw material for all ferrous metals (cast iron, wrought iron and steel) is Pig
Iron. Pig Iron is extracted from Iron Ore. The first stage in the production of pig iron is to
reduce iron ore to iron. This operation is termed smelting which is carried out in a container
called blast furnace. Blast furnace is a reltical steel shell that is roughly cylindrical in shape
and is lined with a refractory material. Modern blast furnaces are about 30 meters tall (taller
than a 12 storey building) and 9 meters in diameter.
The materials (iron ore, coke and limestone) are fed into the furnace, and are often called
the charge. The solid raw materials are charged in alternate layers from the top surface.
Iron ore – This forms about 1/20 of the earth crust and is sort of rock containing iron.
It has relatively low melting point ranging from 1130 – 1250 C. this is advantageous
because it can be easily melted, requires less-fuel and more easily operated in furnaces. This
makes it economically a cheap material on account of its cheap refining process.
The fluidity property of this material increase its ability to easily fills intricate moulds
completely. This property gives cast iron good casting impression more than can be obtained
from molten steel. While shrinkage in the mould is much less, thus permitting the production
in thin section and intricate casting.
Cast iron is a brittle material, therefore it cannot be used in those part which are subjected
to shocks. The properties of cast iron which makes it a valuable material for engineering
purposes are its low cost, good casting characteristics, high compressive strength, wear
resistance, and excellent mach inability. Has a reasonable degree of corrosion resistance at
low and elevated temperatures. It is a rigid material with partially self lubrication properties
on account of the presence of graphite. The compressive strength of cast iron is much greater
than its tensile strength compressive = 400 to 1000 MPa
Tensile = 100 to 200 MPa
It has ability to absorb and dampenvibration modification of cast iron structure can be made
by varying the cooling rate, in the mould, by varying the composition at a suitable stage in its
molten state or by heat treatment. As a result of these modification processes, cast iron is
now available in the following grades.
Grey cast iron-contains about 3-3.5% carbon. The grey colour is due to the fact that the
carbon is present in the form of free graphite. Here carbon exists in free form called graphite
as resort of rate. The existence of graphite in the microstnucture is in flake form on a matrix
of ferrite or pearlite or a combination of these two background.
Properties
High compressive strength and no doctility low tensile strength. Machineability – it is
cassily machined. A very good property of grey cast iron is that the free graphite in its
structure acts as a lubricant. Due to this reason, it is very suitable for those parts where
sliding to make good casting.
Good resistance to corrosion. It is hard and britle because of the graphite flakes in its
structure. The brittleness of grey cast iron slops this material being use where shock loads
are likely to be encountered.
Es – Natural for machine beds and frame, machine tool bodies, automobile cylinder blocks,
crank case, brake drum, pipes and pipe fitting and agricultural implements.
11.2. CHEMICAL COMPOSITION – high silicon, low sulphur
White Cast Iron – contains 2-2.3% carbon nongragca. The carbon combine with iron in the
form of hard iron carbide known as cementile, which is the hardest consititivent of iron. The
cementite is caused bu rapid or quick cooling of molten iron when fracture, the broken
surface appears whites hence the name white cast iron. The carbon is completely dissolved in
iron forming a solid solution of martensitic. This however to some extentent depends on the
carbon content.
Uses
It is used for inferior casting and in place of car wheels. Is also used as raw material in the
production malleable cast iron and wrought iron. Crushing machine parts as rolls for
crushing grains grinding mill plate, furnace components.
hypereutetic
Properties
Ductile – may be bent without breaking or fracture. Its tensile strength is usually higher than
that of grey cast iron.
Uses
Are used for making thin or (small) castings particularly where shock words are likely e.g
pipe fittings, door hinges, locks, brake supports, parts agricultural machinery, hubs of wagon
wheels, small fittings for railway rolling stock e.t.c.
The malleable cast iron is available in three forms through heat treatment of white cast iron
because of it extreme hardness which render the iron much sufter. White hearth, Black
hearth and Pearlitic, the names being descriptive of the microstructure.
Surface carbon is oxidized (decarburized) by contain with the ore, combinig with oxygen and
escaping as carbon dioxide gas. Much of the combined carbon at the center diffuses
outwards and is also oxidized, and in heavy sections or core, any remaining carbon will form
a combination of ferrite evenly or nodules. The iron is very whit after this process – hence
the name ‘White heart’.
Properties
High tensile strength
Good ductility
Good machinability
Uses
Wheel hub, steering column housing for agric machines, brakes and thread grides for lextile
machines. Ack heart malleable cast iron if the white iron has a low carbon content, the
process used is called ‘Black heart’ process to which no attempt is made to remove the
carbon. The cast iron are closely packed to container with non – reactive (inert) materials
such as crushed slag or gravel to prevent cecarburization of the surface and annealing takes
place at 850-940C, with a soaking period of between 3 to 4 days. The cementite decomposed
into iron and fine graphite, which is precipited in the form of nodules within the iron. The
dull black appearance of the metal gives it the name ‘Black heart’.
BLACK HEART
Properties
High tensile strength
Good ductility
Uses
Automobile industries, axle boxes, brake parts, coupling for rail way rolling stocks and
pedals, rear axle housings, wheel hubs, differential carries pearlitic malleable cast iron – is
made by heat treating white.
Properties
High tensile strength is greater than any other found of cast iron.
Ductile
Readity machineable.
Uses
Pipes, fittings for gas, oil, water, sewage and chemicals. Automobile parts cylinder blocks,
crankshafts, connecting rods, exhaust manifolds, water pumps, timing gears, gearbox casings,
steering boxes etc
3. ZINC
Us bluish -white (lustrous) metals Zinc ore are widely distributed throughout the world and much
of the extraction is from the sulphide ores Zinc often associated with lead, silver and sometimes
gold.
PROPERTIES
Melting point 420 0C
It shows extremely good resistance to atmospheric corrosion.
It is brittles coarse and crystalline, easiest corrosion
USES
It is used for covering steel sheets to form galvanizes in due to it high resistance to atmospheric
corrosion. The covering is done by dipping the sheets, wire, nails and piping into a molten zinc
bath after initial fluxing
When rolled into sheets, zinc is used for roof covering and for providing a damp proof non-
corrosive lining to container. Use in the manufacture of brasses. And in due field to produce
automotive parts (carburetors), soldering flux, battery cans washing machine parts, padlocks and
model toys.
4. TIN
Is silvery white, produced from tinstone (SnO2). When bar of tin is bent, a sound called ‘cry’ of
tin is heard.
PROPERTIES
Melting point 232oC
It is soft, malleable and ductile. It can be rolled into very thin sheet (foil). Good corrosion
resistance in moist atmospheric condition. When polished has a high light reflectivity. It has a
crystalline structure.
USES
It is used as a protective coating on other metals, such as iron and steel sheets to form tin plate,
mainly in the canning industry. Is used for food stuff containers because the tin resists attack by
fruit juices.
It is used in making soft solders.
It is used for making tin foil used as moisture proof packing.
5. LEAD
Produced from galena (Lead Sulphide PbS). Has a bright silvery grey (lustrous, shining) colour.
When cut, the surface soon tarnishes (oxidize) to drill grey when exposed to air.
PROPERTIES
Is one of the heaviest common metals with specific gravity of 11.36. It has a low melting point of
327oC. low strength and low electrical conductivity. It is very soft and malleable and is easily cut
with a knife high corrosion resistance. Lead is resistant to many acids, but oddly enough, is
attacked by pure water.
USES
Used for making solders e.g. plumber and tin man’s solder. As lining for acid tanks sheaths
(cover) for power and telephone cables. In manufacture of connectors and grids in and acid
batteries. It is used in chemical and plumbing industries. Is a good insulator against nuclear
radiation.
6. NICKEL
Silvery white metal capable of taking a high polish. Its specific gravity is 8.85 and melting point
1425oC
PROPERTIES
Resistance to corrosion and oxidation. It resists the attacks of most of the acids. But it dissolves
readily in nitric acid. Strong and harder than iron.
USES
It is used extensively for electroplating. It’s most important application is in the manufacture of
stainless and alloy steels for b decorative and corrosion protection.
7. PURPOSES
Is the lightest metal used as an engineering material with specific gravity of 1.74 while is about
two-thirds that of aluminum. Its melting (650oC) point is slightly lower than that of aluminum
and readily combines with oxygen.
PROPERTIES
It is harder than aluminum. It soft, Low tensile strength. It is preferable when it is light in weight
is important, because of its low density of 1.74
USES
In aircraft and missile industries for the production of rockets, signals and flares. It is employed
in photographic flash bulbs and thermite bulbs.
8. MAGNESIUM
Magnesium plates are used to prevent corrosion by saltwater in underwater fittings on ship hulls.
Magnesium rods, when inserted in galvanized domestic water tanks, will prolong the life of the
tank.
Most important non-ferrous alloy
9. ALLOY
Is a mixture of two or more metals.
10. COPPER ALLOYS
Brass—colour (yellow)
Is an alloy of 60% copper and 40% zinc. There are many different grades employed for special
purpose the properties and colour depend upon the protections of the two elements. Example the
60% copper and 40% zinc is called yellow brass
PROPERTIES
Cast well, corrosion resistance
USES
Water pipe filtings, electrical (plug pins) fittings, screws, nuts, bolts hinges, door handles, keys
Bronze – colour (dark yellow)
Is an alloy of 90% copper and 10% tin called phosphor bronze.
PROPERTIES
Cast well, good resist surface wear bearing material, bronzes are superior to brasses in corrosion
resistance. Bronzes are more costly than the brasses and hence are used only when cheaper alloys
do not prove to be satisfactory.
USES
Bearing sleeves and bushes, water pump castings, warm
11. TIN ALLOY
Tin man’s solder:
Is an alloy of 62% tin and 38% lead soft, little strength
USES
For making solder
12. ALIMINIUM ALLOY
Duralumin –colour (grayish white)
Is an alloy of 96% Aluminum and 4% copper.
PROPERTIES
Light, cast well, medium strength.
USES
Aircraft parts, Engine cylinder head, Crank cases, pistons, window frames.
13. ZINC ALLOY
Die – cast metal – colour (grey)
Is an alloy of 4% Aluminum and 96%.
PROPERTIES
Weak, cast well, brittle
USES
Petrol pumps, car door handles, carbureting wing mirrors, low cost cast parts.
Working involves the manipulation of material when in the solid state it usually
produces mechanical properties that are better than those of a cast material.
Working metal must be ductile or malleable, or be made so as a result of
heating or heat treatment. They are often of a simple micro structure. Shaping
of metal can be divided into two.
Hot working operations and cold working operations
Hot working can be carried out more rapidly, since less power is required.
While cold working process, in the other hand are used in the final stages of
shaping of materials, so that a high quality surface finish can be obtained or
suitable strength and hardness developed in the material.
The grain structure produced by working is different from that of casting.
The figure below illustrates the grain structure a casting. The grain at the
outside are small due the rapid cooling and those just below the surface are
columnar because the grow towards the core, which is the last to solidify, the
grain at the core are coarse and equiaxed because the core will cool very slowly.
(Worked) wrought parts usually display grain flow or grain fibre, when teset
along the grain they show a greater strength than across the grain and by
arrangeing the grain fibre, the required directional strength can be obtained.
Advantages
Less amount of energy is needed for hot working of metal.
The coarse grain structure is refined
Materials are left in the fully annealed condition and are suitable for cold
working there by making deformation easy.
Scales are formed on the surface which gives some protection against corrosion
during storage
Porosity in metal is eliminated.
Disadvantages
Poor surface finish rough and scaly
Dimensional accuracy is due to shrinkage on cooling
Due to distortion on cooling, hot working leads to geometrical inaccuracy.
Damage to tools from abrasive scale on metal surface
Low strength and rigidity for metal considered
Fully annedled condition of the material coupled with a relatively coarse grain
leads to a poor finishes
Hot working equipment and maintainace cast are high
TYPES OF EXTRUSION
Direct extrusion – In this process the hot billet is placed into the container and
the ram or piston moved forward which now force the billet to move relative to
the container wall. There is frictional force between the billet and the container
wall. The billet pass under pressure through the die to produce the section
replice of the opening on the die
Indirect extrusion – Is similar to direct extrusion exce that the extruded part is
forced through the ram. Less force required by this method, since there is no
frictional force between the billet and the container. The weakening of the ram
when it is made hallow and the impossibility of providing adequate support for
the extruded part constitute limitation of this process.
2. DRAWING – This is used for the production of wire, rods and tubing. This
is a process of reduction of diameter of rod or wires by passing it through an
orifice in a die. Is exclusively a cold working process, because it relies on
the ductility of the annealed material being pulled or drawn through a die
with a reducing diameter. In the manufacture of wire, the material is pulled
through the die by winding it on to a rotating drum. While In the production
of tube the bore is maintained by the use of a mandrel. The material is
lubricated with or soap before it enters the die aperture. Drawing die are
made from high carbon steel, tungsten, carbide and diamond.
Cold pressing is very widely used and alloys which are not quite sufficiently
ductile for deep drawing are generally suitable for shaping by simple press
work. Sheet metal can be pressed into shape between formers as chown in
figure below. Motor car bodies are produced I this way.
15.1 GLASS
Glass may be defined as a hard, brittle, transparent material chiefly composed of silica,
combined with varying proportion of oxides of sodium, potassium calcium, magnesium, iron and
other. Material
15.1.1 CONSTITUENTS OF GLASS AND THEIR FUNCTIONS
1. Silica – Is the principal constituent of glass if silica alone is used in the manufacture of
glass, it could be fused only at a very high temperature but it would give a good glass on
cooling. However, it is imperative to add some alkaline materials (sodium or potassium
carbonate) and lime in suitable proportions to make the molten silica glass sufficiently
viscous to make it amply workable and resistant against weathering agencies.
2. Sodium – Is an alkaline material, added in suitable proportion to reduce the melting point
of silica and to impart viscosity to the molten glass.
3. lime- I added in the form of chalk its imparts durability to the glass in place of lime,
sometimes, lead oxide is also added it makes the glass bright and shining.
4. Manganese Dioxide – Is added in suitable proportion to correct the colour of glass due to
the presence of iron in raw materials of glass.
5. Cullet – Is old broken glass of the same type as that which is intended to be prepared. It is
added in small quantity to provide body to the glass.
6. Colouring Substance- While manufacturing a coloured glass, a suitable colouring
substance is added at fusion stage to provide the desired colour to the glass.
WOOD/TIMBER
Withstands shocks and bumps.
PROPERTIES
Good material for compression member, non conductor of heat and electricity, light weight,
easy to shape, suitable for sound proof.
APPLICATIONS- Tool handles, foundry patterns, packaging, furnitures, rafters, ladders,
doors, windows.
CERAMIC
High compressive strength
PROPERTIES
High strength at high temperature, hard, brittle, high resistance to wear, good electrical
insulation properties, high melting point, good chemical stability, good thermal stability.
High corrosion resistance.
APPLICATIONS- Extrusion dies, cutting tools, refractory materials, sanitary wares,
abrasives, insulators and semi-conductors.
GLASS
PROPERTIES
Hard, brittle, transparency, crystalline, resistance to corrosion, poor resistance to thermal
shock.
APPLICATIONS- Laboratory wares, bottles, mirrors, lenses, windows, thousands fo
items in the body of a guided missile are made of glass. Glass linings are applied on
equipments likely to be affected by chemical corrosion such as valves.
ASBESTOS
PROPERTIES
Brittle, fire resistant, heat resistant does not break down under heat.
APPLICATIONS- Roofing sheets, ceiling, fire proof pants, building sheets, break linings,
tiles.
RUBBER
Plasticity of rubber makes it amenable to all manufacturing process.
PROPERTIES
Elastic, electrical insulator, strong and tough, highly impermeable to both water and air, great
resistance to acids, petroleum products etc.
Applications- Transmission belt, seals, packings, tyres and tubes, hose pipes, thermal
insulation
Damping pad for engine mounting.
Thermal insulation.