TA 201 IIT Kanpur

Manufacturing Processes (TA201)

2017-18, Semester I
Instructor: Dr. Shobit Omar

Venue: L-20
Lecture 3
 TA 201 Lecture Schedule IIT Kanpur
Lecture Date Topics
1 1st August 2017 Introduction to Manufacturing
2 8th August 2017 Engineering Materials, Classification of
Materials, Structural and Properties,
3 22nd August 2017
Microstructure and Properties Correlations
4 29th August 2017
5 5th September 2017 Casting- Type of Casting, Design and Defects of
Casting
6 12th September 2017
Mid-Sem Solidification- Pure Metal & Alloys, Shrinkage
Exam 7 3rd October 2017 Joining Processes, Welding, Brazing & Soldering
8 10th October 2017
9 17th October 2017 Deformation Processes, Stress-Strain Curve,
Rolling, Forging, Sheet Metal Forming,
10 24th October 2017
Extrusion, Wire Drawing
11 31st October 2017
12 7th November 2017 Powder Metallurgy, Powder Production,
Sintering
End-Sem 13 14th November 2017 Plastic Injection Molding
Exam
TA201 22nd August 2017 Venue-L20 Lecture 3
 TA 201 Crystalline Materials IIT Kanpur
Crystal = Lattice + Motif
Lattice: An array of points in space such that every point has identical surroundings.
Two Important Properties of Lattices:
• Lattices are infinite
• Lattice have translational symmetry

Trnslationally periodic arrangement of points in space is called a lattice

Motif or Basis: An entity (typically an atom or a group of atoms) associated with
each lattice point
Lattice  how to repeat
Motif  what to repeat
Lattice Crystal
Translationally periodic Translationally periodic
arrangement of points arrangement of motifs
TA 201 Lattices & Crystal Systems IIT Kanpur
• Bravais Lattices  14 different ways to arrange
lattice points
• Crystal Systems  7 unique shapes that can be used
to fill 3-dimensional space.

TA201 22nd August 2017 Venue-L20 Lecture 3

TA 201 Grains and Grain Boundaries IIT Kanpur
In ideal case, unit cell repeats itself infinitely in all directions

Grain Boundary Phase Boundary

Surface

Boundary with grain Boundary with

Boundary with air
having same chemical grain having
composition and structure different chemical
composition

www.doitpoms.ac.uk www.doitpoms.ac.uk
www.doitpoms.ac.uk
TA201 22nd August 2017 Venue-L20 Lecture 3
TA 201 Concept of Phase IIT Kanpur
Phase is a physically distinctive How many phases are there
form of matter throughout in a glass jar containing ice
which the physical and chemical cubes and water?
characteristics remain uniform
example pure water

A distinct boundary exists between two phases

Phase 1 Phase 2

TA201 22nd August 2017 Venue-L20 Lecture 3

TA 201 Phase Diagram IIT Kanpur
Binary Phase Diagram of Cu- Ni

• Binary phase diagrams are

plotted between the composition
and temperature assuming
normal air atmosphere.
• Phases represented in phase
diagram are distinct and co-exist
in thermodynamic equilibrium.

How many phases are

present in the phase
diagram?

TA201 22nd August 2017 Venue-L20 Lecture 3

TA 201 Metals IIT Kanpur

Usually comprised of metallic elements and their alloys

Metals are essentially divided into two

groups
1. Ferrous metals: Comprised mainly of Fe
Iron: < 0.008% C
Steel: 0.008%-2.14% C
Cast Iron: 2.14-4 % C
2. Non-ferrous metals: all other metallic
elements and their alloys e.g. Cu, Ni, Al,
Mg, Ag etc.

TA201 22nd August 2017 Venue-L20 Lecture 3

TA 201 Phase Diagram IIT Kanpur
Fe-C (Fe3C) Phase Diagram

• Phase diagram of Fe-C is fairly

complex and we will consider
only the important part of the
phase diagram i.e., 6.7 mol.% C.
• Phases represented in phase
diagram are distinct and co-exist
in thermodynamic equilibrium.

Eutectic Point: Liquid phase

transforms to two distinct phases
L→α(s)+β(s)
Eutectoid Point: A single solid phase
Steel Cast Iron transforms to two distinct phases
(0.02-2.11 wt.% C) (2.11-4 wt.% C)
δ(s)→α(s)+β(s)
Fundamentals of Modern Manufacturing: Materials, Mikell P. Groover
TA201 22nd August 2017 Venue-L20 Lecture 3
TA 201 Fe-C (Fe3C) Phase Diagram IIT Kanpur
δ-ferrite is stable above
1395oC and possesses BCC
structure. It melts at 1538oC.

γ-austenite is stable above

727oC and possesses FCC
structure with the maximum
solubility of 2.14 wt.%

α-ferrite is a stable form of

iron at room temperature
and possesses BCC structure
with the maximum solubility
of 0.022 wt.%
Fe3C or cementite is a
Mechanical properties depend on the microstructure intermetallic compound with
i.e., how the ferrite and Fe3C are mixed. the melting point of 1380oC.
TA201 22nd August 2017 Venue-L20 Lecture 3
TA 201 Microstructure in Fe-C alloy IIT Kanpur
The microstructure of steel is dependent on composition and heat treatment
Microstructure of Euctectoid Steel

Thick light layers are

the α-ferrite phase

Formation of Ƴ(s)→α(s)+Fe3C(s)
pearlite

Formation of thin
dark color lamellae of
Fe3C

TA201 22nd August 2017 Venue-L20 Lecture 3

TA 201 Microstructure in Fe-C alloy IIT Kanpur
Microstructure of Hypo-euctectoid Steel Microstructure of Hyper-euctectoid Steel

TA201 22nd August 2017 Venue-L20 Lecture 3

TA 201 Phase Transformation IIT Kanpur
Microstructural change is dependent on kinetics i.e., rate of heating or cooling

Phase Transformation

Diffusion-dependent Diffusion-dependent Diffusionless phase

phase transformation phase transformation transformation which
with no change in phase with change in phase produce phase by
composition or the composition or the cooperative small
number of phases number of phases displacement of all
atoms in structure.

Example: Example: Eutectic Example: Martensite

Solidification of pure reaction phase transformation
metal

TA201 22nd August 2017 Venue-L20 Lecture 3

TA 201 Kinetics of Phase Transformation IIT Kanpur
The process of phase transformation involves:

• Nucleation of the new phase: Formation of stable small particles

(nuclei) of the new phase
• Growth of new phase at the expense of the parent phase

Avrami Equation

TA201 22nd August 2017 Venue-L20 Lecture 3

TA 201 S-shaped Curve IIT Kanpur
Let us consider cooling of austenite through eutectoid point

Ƴ(s)→α(s)+Fe3C(s)

Why at high
temperature it
takes more time
to form pearlitic
microstructure?

TA201 22nd August 2017 Venue-L20 Lecture 3

TA 201 Temperature, Time and IIT Kanpur
Transformation Diagrams

Several isothermal S-
shaped curves are required
to construct TTT diagram

TA201 22nd August 2017 Venue-L20 Lecture 3

TA 201 TTT Diagrams (Cont..) IIT Kanpur

Coarse pearlite microstructure

at higher temperature is
formed due to high diffusion
and low nucleation rate

Fine pearlite microstructure at

lower temperature is formed
due to high nucleation rate and
slow diffusion

TA201 22nd August 2017 Venue-L20 Lecture 3

TA 201 Bainite Microstructure IIT Kanpur
If the temperature is low enough (<540oC) , bainite rather than fine pearlite is
formed.

Upper bainite is
formed between 300-
540oC and consists of
needles of ferrite
separated by long
cementite particles

Lower bainite is
formed between 200-
300oC and consists of
thin plates of ferrite
containing fine rods of
cementite.

TA201 22nd August 2017 Venue-L20 Lecture 3

TA 201 Martensitic Microstructure IIT Kanpur

• Martensite is formed the

austenite is rapidly cooled
to room temperature.
• Phase transformation
does not involve diffusion
• Amount of martensite
formed is dependent on
the temperature

FCC (Face-Centered Cubic)

Austenite transforms to BCT
(Body Centered Tetragonal)
Martensite

TA201 22nd August 2017 Venue-L20 Lecture 3