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Metallugy Basic
Metallugy Basic
Metallugy Basic
Basics of
Metallurgy
Metallurgy
Presented by
Touhidul Islam (17532)
Metallurgist, Refrigerator R&I
Metallurgy 1
Content
Topics Number of Slide
Metal Structure 10
Metal properties 15
Alloy 3
Steel & Cast iron 3
Aluminum alloys 4
Zinc base alloys 1
Heat treatment 5
Corrosion 9
Metal characterization 1
RoHS 1
Galvanizing 2
Q&A Session
Metallurgy 2
Metal parts Refrigerator
• MS tube • PPGI
• Aluminum tube • GI
• Copper tube • EGI
• MS sheet • PCM
• Aluminum Sheet • VCM
• SS sheet • Aluzinc/galvalume
• SS screw • Anodized aluminum
• MS screw • Tool steel (D2, DC53, M2)
• SS wire • Wrought alloy
• MS wire • Cast alloy
• Copper wire • aluminum foil
• SS spring • Copper capillary tube
• ZAM coating • Aluminum rod
• Zamac lock and hinge
Metallurgy 3
Engineering Materials
Major engineering purposes served by – Mg, Ti, Fe, Ni, Cu, Zn, Al, Pb
Metallurgy 4
Metal Structure
• Atomic structure- crystalline, amorphous, BCC, FCC
• Microstructure- Grain , Grain boundary
Metallurgy 5
Crystal structure
Metal Glass
Metallurgy 6
Crystal structure (SCC)
Metallurgy 7
Crystal structure (BCC)
Second layer over the holes of 1st layer Third layer over the holes of 2nd layer
Metallurgy 8
Crystal structure (FCC)
First layer Second layer over the triangular space of 1st layer Third layer over the triangular space of 2nd layer
Metallurgy 10
Crystal defects
Solid crystal forming Solid crystal growing Crystal meeting one another
solidification complete
Metallurgy 13
Microstructure
➢ Polycrystalline metal.
➢ The grains are separated by grain boundaries.
➢ The grain boundary impedes the dislocation motion.
➢ Polycrystalline metal is stronger than single crystal metal.
➢ The smaller the grain size the stronger the material will be.
Metallurgy 14
Metal properties
• Strength (YS, TS)
• Ductility (elongation)
• malleability
• Hardness
• Brittleness
• Toughness
• Fatigue
• Creep
• Elasticity
• Machinability
• Weldability
• Hardenability
• Castability
• Conductivity (electrical and thermal)
Metallurgy 15
Strength
Metallurgy 16
Strength
Metallurgy 17
Strength
Metallurgy 19
Ductility and Brittleness
Metallurgy 20
Ductility and Brittleness
Metallurgy 21
Hardness
Metallurgy 22
Hardness
Metallurgy 23
Hardness Test
Indenter
Metallurgy 26
Fatigue
Spring
Exercise instrument
Fan blade
Bandsaw blade
Bicycle peddle
Bicycle crank arm
Screw
Compressor Connecting rod
Railway Bridge
Aircraft
Cracking of materials and structural components due to cyclic (or fluctuating) stress.
Fatigue cracks can be initiated and propagated at stresses well below the yield strength of the material
Fatigue stages: Crack initiation, Crack propagation, Failure
Metallurgy 27
Fatigue
Ferrous (steel)
Metallurgy 29
Creep
Metallurgy 30
Alloy
• Mild Steel (MS)- Fe, C
• Cast iron- Fe, C
• Brass – Cu, Zn
• Bronze- Cu, Sn
• Stainless steel- Fe, C, Cr, Ni, Mn
• Tool steel- Fe, C, Cr, V, Mo
Metallurgy 31
Alloy
Metallurgy 32
Effect of alloying element
Element Positive Attributes Negative Attributes
Carbon Hardness, strength, hardenability Ductility, Weldability
Manganese Strength, hardenability Weldability, Machinability
Phosphorus Machinability Ductility, Toughness
Sulfur Machinability Impact Resistance
Chromium Corrosion and abrasion resistance Machinability
Molybdenum High Temperature Strength, pitting Machinability, Weldability
Copper Strength Forgeability
Vanadium Wear Resistance Ductility
Silicon Fluidity, elasticity, strength Decarburization, Machinability
Metallurgy 33
Steel and Cast iron
1400 C to 1538 C
912 to 1400 C
Below 912 C
Metallurgy 35
Steel Designation System
Table-1: Alloy steel Table-2: stainless steel
O Oil Hardening
Suffixes Process A Air Hardening
HR Hot rolled
D High carbon; high chromium D2
CR Cold rolled
S Shock resisting
CDS Cold drawn seamless
P Plastic mold P20
Q&T Quenched and tempered
H Hot working H13
TMT Thermo Mechanical Treatment
Metallurgy 36
Aluminum alloys
Metallurgy 37
Cast Aluminum Designation System
X XX .X
0 for castings (products)
1 for Ingots
Identity of the
specific alloy
Example:
Aluminum grade: 295.0
Temper Description
Designation
F As fabricated
O Annealed
H Stain hardened ( hardened by cold work)
W Solution heat treated (unstable)
T Thermally treated (stable)
Metallurgy 40
Zinc base alloy
Two important alloy
Metallurgy 41
Metal process
• Heat treatment • Welding
• Anodizing • Soldering
• Brazing
• Galvanizing
• Forming
• Casting • Forging
• Pickling • Rolling
• Sintering • Extrusion
• Drawing
• Etching
• Machining
• Hard chrome • Electroplating
plating
Metallurgy 42
Heat treatment
Metallurgy 44
Annealing and Normalizing
Metallurgy 45
Hardening Fe structure- BCC (at room temp)
FCC ( above 912 C)
BCC (above 1400 C)
Hardening transformation:
Metallurgy 46
Case hardening
Case hardening
methods:
1. Carburizing
2. Nitriding
3. Carbo-nitriding
4. Cyaniding
5. Induction
hardening
6. Flame
Gear
hardening
➢ Used to increase the hardness of
the outer surface of a metal.
➢ Wear resistant hard surfaces +
high core toughness
Metallurgy 48
Corrosion
Thermodynamically
unstable
Why do metals corrode??
Metastable
Metal extraction:
Corrosion: Metal
Reduction in
oxidation.
melting furnace.
Bond formation
Bond breaking
releases energy,
needs energy,
exothermic
endothermic
Energy level
process
process.
Stable
Corrosion products: Metal Every material tends to
Ore: Metal oxides,
oxides, sulfides etc. release energy to be stable
sulfides etc.
Metallurgy 49
Corrosion
Four essential Conditions
i. Anode
ii. Cathode
iii. Anode cathode contact
iv. electrolyte
Anode reaction:
M(s) = M+n (aq) + ne- (metal oxidation)
Cathode reaction:
• Hydrogen evolution, 2H+ (aq) + 2e-→ H2( )
• Oxygen reduction (acidic media), O2(g) + 4H+(aq) + 4 - → H2O
• Oxygen reduction (neutral/basic media), O2(g) + 4e- + 2 H2O→ 4OH- ( q)
• Metal ion reduction, M+3(aq) + - → +2 (aq)
• Metal deposition, M+ (aq) + - → ( )
Metallurgy 50
Forms of corrosion
➢ Uniform Attack
➢ Galvanic or Bimetallic Corrosion
➢ Crevice Corrosion
➢ Pitting
➢ Intergranular Corrosion
➢ Selective leaching
➢ Erosion Corrosion
➢ Stress-corrosion cracking
Metallurgy 51
Galvanic corrosion
Metallurgy 52
Galvanic corrosion
More active or
anodic
Example:
Bimetallic System Anode (corrodes) Cathode
Metallurgy 53
Uniform attack
Metallurgy 54
Pitting
Metallurgy 55
Corrosion test (SST, SWAAT)
Metallurgy 56
Metal characterization
Method Properties
Optical emission spectroscopy (OES) Composition
Metallurgy 57
RoHS
➢ RoHS- Restriction of Hazardous Substances
➢ European Union (EU) restricts the use of ten
hazardous materials.
➢ All applicable products in the EU market must pass
RoHS compliance.
Metallurgy 58
Galvanizing
Which one will corrode last?
Metallurgy 59
Galvanizing
Hot-dip Galvanizing Electrolytic Galvanizing
Product:
Product:
1. Screws
1. MS tube
2. EGI sheet
2. GI sheet
3. Aluzinc/Galvalume sheet
(55%Al)
Metallurgy 60
Q&A Session
Metallurgy 61
Metallurgy