Department of Mechanical, Materials, Manufacturing Engineering

MMME1034: Materials & Manufacturing

Laboratory instructions and coursework (Autumn Semester)

Overview (read this!)

This handout details four laboratory classes namely, ML1, ML2, and ML3, and ML4. The
purpose of these laboratory classes is to introduce you to a number of experimental
techniques and to some of the more important aspects of materials behaviour. You will
make, form materials metals and polymers in ML1 and ML2 and then you will undertake two
laboratory sessions (ML32 and ML43) concerned with heat treatment and measuring the
properties of these materials using tensile, hardness and impact testing.
The results and findings from the laboratories both complement and supplement the lecture
material. What you learn in these sessions will be examined in the formal end of year
assessment. In addition to this, the laboratory activity forms the coursework component for
this module.
For your coursework you are required to answer all the questions in this laboratory handout
(which is also available to download from Moodle). It is suggested that you download and
edit this document so that it can be used as a template for your answers. You must submit
two individual hardcopy reports to the Student Support Office Faculty Office before the
deadline indicated for your group in appendix 3. Late submissions will be penalised in line
with University guidelines. Full details of hand in dates are on the lab timetable.
The laboratory assessment contributes 20% to the overall module mark. If you do not attend
one or more of the laboratory classes, you will not be awarded any marks for those sections
of the report.

 
 Processing of Materials (ML1/ML2)
Overview
This handout details three two experiments namely, rolling and, injection moulding, and heat
treatment of metals which you will do in your first and second materials laboratory class,
ML1 and ML2. In each of the sections pertaining to these experiments there is a section on
the background to the processing method, details of how to conduct the experiments and a
section on what is expected in the laboratory report.

Safety

This laboratory session has some hazards associated with it. Specifically:
1. Rolling mill. Hazard: hair, body parts or clothing are trapped in the rollers and drawn
through. Minimise risk by the following: tie up long hair and secure loose clothing; do not
push fingers through guards towards the rollers (only the aluminium samples). Should a
sample become stuck, turn the mill of at the wall before attempting to free it. Never attempt
to remove it whilst the mill is running.
2. Guillotine. Hazard: body parts removed. Minimise risk by ensuring that hands a clear of
the blades before cutting samples.
3. Fly-press. Hazard: body parts removed. Minimise risk by ensuring that hands a clear of
the blades before cutting samples.
4. Furnaces, Jominy end-quench, quench buckets. Hazard: burns. Minimise the risk by
wearing face visor, gloves and using tongs (all provided).
5. Injection moulder. Hazard: burns, trapped body parts. Minimise the risk by the
following: DO NOT touch the injection moulder when in operation for any reason. The
demonstrator will make any adjustments necessary. DO NOT let long hair, clothing,
jewellery etc come close to the injection moulder when in operation. All long hair should be
tied up.
1 INTRODUCTION TO ROLLING
Rolling is a common material forming process for metals, and forms part of the deformation
processing group of processes. It is commonly employed to bring stock from a larger ingot
size to the required thickness (in the form of sheet or plate), or it is used to form material into
a given shape (tubes and beams are commonly formed by rolling).
Rolling can be conducted either hot, warm or cold. What temperatures these designations
relate to depends upon the metal itself, and specifically its melting point. Hot and cold rolling
are very different processes. For example, in hot rolling, the rolling loads are much lower
than in cold rolling (the strength of metals tends to decrease as the temperature increases).
Also, during cold rolling, dislocations (line imperfections in the metal – see inset) are formed;
however in hot rolling, they are formed but are eliminated during the process by recovery and
recrystallisation. A high number of dislocations (commonly termed a high dislocation
density) in the final product results in high yield strength (and high hardness) but low
ductility. As such, the final properties of the material depend upon the way that it has been
processed.
In this part of the laboratory scheme for this module, an aluminium alloy will be cold worked
by rolling. You will also anneal the material (heat it to a temperature where recovery and
recrystallisation may occur) following rolling, in the laboratory on heat treatment. The
changes in properties associated with these processing steps will be looked at in subsequent
laboratory classes (ML3 and ML4).
Note: Annealing a cold rolled piece of material will not result in exactly the same properties
as hot rolling. However, it will give some impression as to what to expect.
1.1 Background
If a stress higher than the yield stress is applied to a metal, then permanent shape change
takes place – plastic deformation. At an atomic scale, plastic deformation is characterized
by planes of atoms moving with respect to each other.
Most metals are crystalline in nature (regular packing of atoms). The packing is not, however,
perfect and metals contain dislocations within the structure which can be visualised as
missing rows of atoms. These missing rows of atoms are crucial in terms of permanent
deformation of metals.
Figure 1 A dislocation in a metal being caused to move by the application of stress
Figure 1 shows a crystal with a missing row of atoms, termed a dislocation. If a shear stress
is applied as indicated, not all the bonds have to break at once, but instead rows of bonds can
break one at a time to allow easy passage of the dislocation through the material.
Macroscopically, if we observe plastic deformation, then on an atomic scale, dislocations
must have moved. Conversely, if we can change materials at the atomic scale so that
dislocations are prevented from moving, then macroscopically, we observe an increase in
yield stress. There is a direct link here between atomic scale processes and the macroscopic
materials properties.
During cold working of metals, the dislocation density (the length of dislocation per unit
volume of material) multiplies by several orders of magnitude. As the number of dislocations
increases, interactions between the dislocations decrease their mobility. Since dislocation
motion is the atomic basis of plastic deformation, this gives rise to increases in yield stress,
tensile strength and hardness. The material is said to work harden (see Figure 2).

linear linear
elastic elastic

plastic

Figure 2 Force – extension curve for an elastic-plastic material. As the force increases, the
material behaves in an elastic manner (if the force is removed, the material shape will return to its
original length) until it becomes plastic (where deformation is permanent). To keep it deforming
plastically, the force has to keep increasing. This is termed work (or strain) hardening.

As the material is deformed more and more the rate of hardening slows down, but
progressively increasing stresses are required to keep it deforming. The stress required to
produce the next increment of plastic strain is known as the flow stress. The general
relationship between true flow stress, f, and true strain, , in this range is given by,
n
σ f =σ o ε Equation 1

where, 0 and the work hardening exponent, n are material constants. You should note that
true stress and strain are different to engineering stress and strain (which we have covered in
the lectures). The true stress and strain are calculated from the force and displacement by
considering the instantaneous area or length of the sample (i.e. as it changes with
deformation) rather than the original dimensions of the sample (as is the case for engineering
stress and strain).

Fortunately, there is a relationship between flow stress and hardness that we can take
advantage of. A rough rule of thumb tells us that:
Hv 3 σf Equation 2
(remember to convert the units of hardness (normally kgf mm ) to MPa, by multiplication by
-2

9.81 – since 1 kgf is equivalent to 9.81 N). Equation 2 is not an exact relationship and needs
to be modified when going from one material to another or when comparing the same
material in fundamentally different conditions, but it is good enough for our purposes.

1.2 Analysis of the rolling process

When material is fed into the rolls, it might either “bite” and be drawn in, or just slip against
the rolls. The maximum reduction per pass (Δh) for which it is possible for the rolls to bite is
given as:
2
∆ h=μ r Equation 3

where  is the coefficient of friction between the rolls and the work piece and r is the roll
radius (in this case 32.5mm). This equation indicates that to achieve a large reduction in
thickness of the sample each time you put it through the rolls, you need friction to be high to
get it to “bite” rather than slip.
The rolling load needed to deform the material (P) can be approximated by:
P=Y b √ ∆ h r Equation 4
where Y is the average stress required to cause material flow (for large reductions in
thickness you may assume this stress is mid-way between the yield and failure stresses) and b
is the width of the sample. This equation shows that the rolling load will increase for stronger
materials, wider samples and as the reduction in height and roll radius increase. We can see
from these two equations that high friction enables us to make large reductions per pass BUT
the penalty is high rolling loads.
We cannot control the rolling load applied but there is of course a limit to the load (or more
correctly power) than can be applied by the motor to drive the rolls. This power available is
converted into work done on the material through the torque applied to the rolls multiplied by
the angular velocity of the rolls. During one revolution of the roll, the rolling force P moves
around a circle of radius a (see Figure 3).
Since there are two work rolls, the work done per revolution of the rolls (work = force and
distance moved along line of action) is given by:
W =2× ( 2 π a ) P Equation 5
The dimension a is given by the following:

a= √
∆hr
Equation 6
2
(which ties in logically with Eq. 4 if you think about it).
If the rolls rotate at a rate of N Hz (i.e. N revolutions per second) (and remembering that
power, Q, is equal to the rate at which work is done), then:
Q=4 π a P N Equation 7
It should be noted that there may be inefficiencies in both transmission of the machine power
to the rolls and in the deformation process (i.e. the generation of heat).

a
r
P

Figure 3 Schematic diagram of rolling process showing the rolling force P acting along a tangent to
a circle of radius a

1.3 Rolling Experiments

You are provided with a strip of material of a fully annealed aluminium alloy (Grade 6082).
Measure the thickness of the strip accurately (t0).
Cold roll the strip of aluminium provided, progressively reducing it's thickness by
approximately 0% (i.e. as-received), 10%, 20%, 40%, 60% and 75%. At each stage, cut off
samples of approximately square section. Deburr the edges.
Accurately measure the thicknesses of each sample, so that you can calculate the exact
reduction in thickness.

For each case, reformulate the data in terms of the true rolling strain, ε T which is defined as
follows:
 ε T =−ln
( )
t
to
Equation 8

where t is the thickness of the sample and t 0 was the original thickness before rolling. You
will determine the hardness of these materials in one of the next materials laboratory
sessions.
Following the 75% reduction in thickness, punch three tensile samples from the sheet. (one of
these will be annealed – see section 3). You will be able to explore the tensile properties of
the as-rolled and annealed samples in one of the next materials laboratory sessions.

1.4 Rolling Report (27 marks)

Answer the following questions:
Q1 Fill up the following table based on the results collected from experiments. (5 marks)
Thickness 10% 20% 40% 60% 75%
reduction
(%)
Number
of rolling
attempts
Desired
thickness
td (mm)
Actual
thickness
t (mm)
True
rolling
strain εt

Q2 Explain the difference in using large diameter roller to small diameter roller. (6 marks)
Q3 Describe the advantages of using cluster rollers versus single large diameter roller for
rolling of thin paper sheet. (Minimum 4 advantages) (6 marks)
Q4 If the roller is powered by electrical motor, how do the following affect the maximum
reduction per pass? (10 marks)
 Increased rolling speed
 Decreased sample width
 Work hardening of the material being rolled
 Heat treating (annealing) the aluminium alloy
 Decreasing the size of the rollers
2 INTRODUCTION TO INJECTION MOULDING
Injection moulding is the most widely used process for high-volume production of
thermoplastic polymer parts. (A thermoplastic is a polymer which can be repeatedly heated to
form a viscous melt and cooled to solidify). The polymer is heated (by a combination of
electrical heating and deformation) and then forced in this viscous state into a cavity in a
closed mould. The mould is made of at least two parts; the part is cooled and once solidified,
the mould is opened and the component removed by the action of ejector pins.
The key considerations in moulding are (i) quality of the part and (ii) cost of the part (made
up of material costs and costs of manufacture).
Changes in processing conditions can lead to improvements or degradation of accuracy,
shape, surface finish and many other part properties and characteristics. One of the major
activities of manufacturing engineering is the assessment of the effects of changing process
parameter values on part characteristics.
There are three objectives for this lab exercise: (1) to become familiar with injection
moulding; (2) to examine the effects that changing processing conditions and part design can
have on the moulding operation; (3) to examine commercially available injection moulded
parts using the technique of birefringence to understand flow in the mould.
In this laboratory session, you will be moulding High Impact Polystyrene (HIPS). Some
relevant properties of HIPS are given in Table 1.
Table 1 – Typical properties of polystyrene
Property Symbol Unit Value

Density  kg m-3 1050

Thermal conductivity k W m-1 K-1 0.18

Heat capacity cp J kg-1 K-1 1400

Viscosity  Nsm-2 500

2.1 Mould filling and ejection

The process of successful injection moulding requires several key steps. As the molten
polymer is injected (under pressure) into the mould, it must be able to flow into all the fine
channels that form the required detail of the part (or the runners, gates, etc.). Flow behaviour
of this type can be modelled in a simple way using the Hagen–Poiseuille equation which
relates the pressure difference, P, required to produce flow of a liquid with viscosity , at a
volumetric flow rate, Q, through a channel of length, L, and radius, r.

Equation 9
At the same time that the molten metal is flowing, heat is being extracted from it through the
“cold” mould. The rate at which this occurs depends upon the thermal properties of the
material, the temperature of the melt on injection and the mould temperature. It also depends
upon heat transfer from the polymer to the mould (the interface thermal resistance).
To successfully produce a part, all regions of the mould must be filled with the liquid before
it cools sufficiently to solidify (or becomes too viscous to move under the applied pressure).
Optimum processing conditions such as melt and mould preheating temperature and applied
pressure need to be found (through trial and error and/or numerical modelling) for a given
geometry of the part and given material type.
Once a part has solidified it still needs to cool to such an extent that it is strong and stiff
enough to be ejected from the mould (and often drop into a container) without damage
(warping, bending etc). The temperature at which this becomes possible is called the
demoulding temperature and how quickly this can be reached is also dependent upon the
geometry and thermal properties of the part. This step often takes much longer than the
mould filling process and hence has a strong influence on the time taken to produce a part
(cycle time).

2.2 Weld Lines

In injection moulded parts, if the polymer flow is split and rejoins, we observe a weld line
(two flows of polymer come into contact). The weld line is often a line of weakness as the
polymer may not bond well across the weld line (depending upon its temperature and the
pressure when it rejoins). The diagram below shows the formation of weld lines in two
situations, and also how careful positioning of the gate can avoid weld lines.

Figure 4 Schematic diagram showing the effect of mould design on formation of weld lines

Weld lines can be made stronger by using higher pressures and melt temperatures and also
having them in a part where the polymer is hottest when the flows come together (i.e. close to
a gate rather than further from it).
2.3 Observation of Structure in Injection Moulded Parts
Polymers are chain-like structures. These chains are normally curled in randomized
directions. However, the chains can be made to line up in processing. This tends to increase
strength in the direction of the alignment, but decrease it perpendicular to the alignment. As
such, the properties are not the same in all direction (anisotropic).
In Figure 6, the polymer is injected at the gate (a). However, as the polymer comes into
contact with the mould wall, it freezes; as such, flow then continues through the centre to fill
the mould. The velocity at the boundary of the melt and solid is zero and in the centre of the
melt has a higher value; the velocity gradient is thus highest near to the wall – this results in
high levels of shear and high alignment of the polymer chains (b). Part (c) of the figure shows
the resulting levels of shear in the fluid across the section (and thus levels of alignment (d)).

Figure 5 Schematic diagram showing polymer flow and its observation within a moulding

Such alignment of polymers chains can be seen using a property of the polymers known as
birefringence. We can explore this using a plane polariscope. The more aligned the polymer
chains are, the more birefringent is the material at that point; different levels of birefringence
result in different colours in the pattern (when using white light to illuminate). Where we see
thin coloured bands (i.e. rapidly changing colour), we know that the level of birefringence
(and thus chain orientation) is changing rapidly. Weld lines can be readily observed using a
polariscope.
For background information on birefringence you should refer to appendix 1 (this
information is to supplement your understanding of the laboratory and is not something
we would expect you to learn for this module).
2.4 Injection Moulding Experiments
The Machine include heating the plastics metal it flow radially in high pressure, inject into
mould. The mould closed with solidified from Melton metal and open the mould to allow to
remove the part.
The main parts of machine are hopper, Reciprocating Screw, mould Clamp, Heated Extruder
barrel, Nozzle. The Hopper part feed the unmelted plastic metal to barrel unit. The hopper
have remove the moisture and also remove any iron thinks. The Screw contain which the
heater barrel, the thermoplastic is gradually melted in the combination of heating barrel.
(Figure 6)
The Thermoplastic is moved by rotating screw in front of heater barrel. The Barrel is heated
by electrical resistance heater. The Barrel is Remove the Gases from melting parts. The
reciprocating screw having three Stages of melting metal.

Figure 6 The schematic of injection moulding machine

The screw has three sections. FEED ZONE, COMPRESSION ZONE and METERING
ZONE. (Figure 7)
 In the compression zone the material is gradually compressed. It therefore rubs
against the barrel wall. This sets up shearing forces on the material.
 Plastic material under shear changes its viscosity. This is SHEAR THINING
characteristic of plastics.
 Melt is then homogenised in metering zone.
 At the tip of the screw, non-return valve is fitted. It allows the melt to flow ahead
through this valve while screw is rotated.
 Non return valve does not allow the melt to slip back through it to the screw channel.
 Figure 7 Three zone of on the injection screw

Examine the effect of temperature and injection stroke on the moulding quality. It is
suggested that temperatures of 190oC, 230oC and 250oC are investigated.
The maximum injection pressure is 1200 bar and the injection pressure on the machine is
rated as a percentage of this. For each temperature, increase the injection stroke in stages (5
mm, 10 mm, and 5 mm) until the quality of the moulding is visibly impaired.
Examine the effect of temperature and stroke of the quality of parts produces and look for
moulding defects e.g. short moulding, thin mouldings, bended, roughened surfaces and
flashing.

2.5 Injection Moulding Report (29 marks)

You should answer the following questions about injection moulding and include them in
your report.
Q1. Draw a sketch of the component moulded, marking clearly the following features: (i)
runner, (ii) sprue, (iii) gate, (iv) and ejector pins’ marked (4 marks)
Q2. (a) Describe and explain the defects of short mouldings and flashing. (4 marks)
(b) Tabulate your results of section 2.4. (9 marks)
 Temperature Injection Injection stroke (mm)
(oC) outputs 5 10 30
190 Type of
defects
Cycle time (s)
Injection
pressure (bar)
230 Type of
defects
Cycle time (s)
Injection
pressure (bar)
250 Type of
defects
Cycle time (s)
Injection
pressure (bar)

Q3. For a given component geometry, injection pressure and moulding temperature,
comment on the ease of mould filling and the length of the cycle time when moulding
materials with the following properties; (6 marks)
a) High thermal conductivity, high viscosity
b) Low thermal conductivity, low viscosity

Q4. High pressure die casting of aluminium and injection moulding of polymers are very
similar process (in that molten material is forced under pressure to fill and solidify in a metal
mould). By considering the property data for molten aluminium in Table 2 below and the
property data for polystyrene in Table 1, state, with reasoning, how you expect the following
to vary for the two different processes. (6 marks)
a) Injection temperature
b) Injection pressure
c) Cycle time
Table 2 – Typical properties of aluminium
Property Symbol Unit Value

Density  kg m-3 2300

Thermal conductivity k W m-1 K-1 200

Heat capacity cp J kg-1 K-1 1000

Viscosity  N s m-2 1x10-2

3 INTRODUCTIONS TO HEAT TREATMENT OF METALS

3.1 Heat treatment of cold worked structures

Metals are made up of atoms which are packed in regular fashion; this ordered material is
described as being crystalline. A bulk crystalline material is normally made up of small
regions of these crystals, randomly orientated with respect to each other to make up the whole
body. Each of the regions is termed a grain. Figure 7 shows schematically how grains fit
together in a bulk material; this type of material is termed polycrystalline since it is made up
of lots of individual crystals. In the regions between grains, the atoms do not pack together so
well – these regions are called grain boundaries. The crystalline bonding in the grain
boundaries is not perfect; as such grain boundaries are regions of high energy within the
structure.

Figure 7. (left) A schematic diagram of the grain structure in a bulk polycrystalline material. Each grain is a
single crystal, and the boundaries between these three-dimensional regions are the grain boundaries. The
grain boundaries are regions where the crystalline structure breaks down. (right) a micrograph of the grain
structure of a low carbon steel.

Cold worked structures (materials with high dislocation densities) are metastable which in
this case means that they wish to reduce their internal energies by reducing the density of
stored dislocations. For most metals at room temperature, this will not occur; as such whilst
they are not stable (in equilibrium) they are metastable (they won’t move towards
equilibrium). However, they can move from this metastable state to a stable state (i.e. reduce
the dislocation density) if the temperature is raised. The processes involved are driven by
diffusion, which is a thermally activated process involving the motion of atoms (in this case,
in the solid state). The rearrangement of the atoms means that the dislocations can be
annihilated as a completely new grain structure forms (recrystallisation). When metals
recrystallise, their grain size is reduced and the dislocation density decreases.
Recrystallisation requires diffusion to occur. As the temperature rises the rate of diffusion
increases according to the Arrhenius equation,

(−Q
RT ) Equation 9
D=D o e
where D is the diffusion coefficient, Do is a constant, Q is the activation energy for the
process, R is the gas constant (8.314 J mol -1 K-1) and T is the absolute temperature (in
Kelvin).

It is not until the temperature reaches the, so called recrystallisation temperature that the
material begins to restore itself rapidly. New crystal grains are nucleated and grow into the
cold worked metal until it is completely converted to a new set of grains with a low
dislocation density. In this condition, the material is once again soft (low yield strength) and
ductile. The process is known as annealing.
As a rough approximation, the diffusion distance, x, of an atom in a time t is given by
x=√ D t Equation 10

3.2 Heat treatment of steels

Some properties of steels are highly dependent upon their heat treatment. Heat treatment for
steels often involves a cycle of heating, cooling (quenching) and in some cases reheating
(tempering).
Steels are Fe-C based alloys in which the carbon content typically lies between 0.05 and 1.0
wt.%C. Elements such as Mn, Ni and Cr are often added for various purposes. Many of the
useful properties of steel are derived from the fact that at high temperature (above about
900oC), all the carbon dissolves in the metal (even though it is still a solid). The high
temperature phase is called austenite.
The equilibrium form of steel at low temperatures is made up of an iron phase (called ferrite)
which now has a very low solubility for carbon. As such, on cooling from the high
temperature austenite, the carbon precipitates out of solution to form Fe3C. This requires the
carbon atoms to move around to form these phases – this movement occurs by diffusion,
which is rapid at elevated temperatures. The ferrite-Fe3C mixture is relatively soft and ductile
(getting harder as the proportion of Fe3C increases with increasing carbon content).
However, if the high temperature austenite is cooled very rapidly (we call such a rapid cool a
quench), the carbon does not have much time at elevated temperature to diffuse, and thus it
gets trapped in the low temperature ferrite structure (this structure is known as martensite).
The carbon is not soluble in such a structure, and its presence causes a great deal of distortion
at the atomic scale. This severely impedes the motion of dislocations in the structure.
Remembering that motion of dislocations is the mechanism of plastic flow in metal, stopping
their motion makes the steel hard and brittle.
In martensite the high level of carbon in the ferrite steel structure (which makes the ferrite
strained and very unhappy) can come out of the ferrite (and form very small particles of
Fe3C) if it is given enough thermal energy to diffuse. This is done by raising the temperature
of the steel (although it must not become austenite again – normally temper temperatures are
lower than 700oC to avoid this). This may look like annealing, but its given a special name,
tempering. During tempering of martensite, the carbon comes out of the ferrite and so the
ferrite structure is less strained and dislocations find it easier to move in it. The hardness goes
down, but so does the brittleness. In fact, it can now become quite tough.

There is no point just tempering a steel – it needs to be quenched from the austenite
temperatures first. Thus, you will often hear people refer to quenched and tempered steels
(Q&T). These steels can have very exciting combinations of mechanical properties, with a
good balance between strength and toughness.
Whilst in the previous section it was explained that if a steel was quenched from austenite,
martensite will form, martensite will only form if the quench rate is high enough. If the
quench rate is too low, then the soft mixture of ferrite and Fe3C will form.
But how fast does the quench rate need to be to form martensite? It depends upon the steel. If
the steel has a high alloy content (such as high carbon, high manganese etc), then the rate at
which it has to be quenched to form martensite is quite low – it is easy for form martensite
even with a low quench rate, and we say that such a steel has a high hardenability (not the
same as it having a high hardness). Conversely, if the steel has low levels of alloying, we
need a very high quench rate to form martensite – the steel is said to have a low
hardenability.  

3.3 Heat treatment Experiments

Annealing cold worked Aluminium
Take a number (see demonstrator for how many to use) of the tensile test samples (dogbones)
which have been punched out of the aluminium alloy at its greatest reduction in thickness.
Anneal the sample in a furnace at 400oC for 15 minutes (well above the recrystallisation
temperature), then take it out and air cool.
Quenching and tempering of steels
You will be provided with a number of tensile and Charpy impact specimens in 0.4wt% and
0.1wt% carbon steel. Charpy specimens allow the toughness of a material to be measured
(more of this in the lab on materials testing).
Following instruction from the demonstrator take the 0.4%C tensile samples and place them
in a furnace at 840oC, also put the 0.4%C Charpy samples and the 0.1%C tensile samples in a
furnace at 900oC. This will make the samples austenite, with all the carbon dissolved. Again
following instruction from the demonstrator take the samples from the furnaces with tongs,
quenching some 0.4wt%C samples in oil. The quenching process will form martensite in the
steel. Again following instruction from the demonstrator, take some of the martensitic
samples and put them in a furnace for 10 minutes to temper them. Place the samples in the
labelled boxes for testing in one of the later sessions. Samples that have been allowed to cool
slowly in a furnace (normalised) will be provided for you.
Hardenability of steels
To examine the hardenability of two steels, the Jominy end quench method will be employed.
 Figure 8 Schematic diagram of Jominy bar with end water quench.

Take the Jominy bar and heat it to 875oC for 30 minutes to bring it into the austenite regime.
Drop the sample into the quench rig and turn the water on to generate the end quench (see
Figure Figure ). The quench rate will vary along the bar, with the highest quench rate at the
quench end (around 225oC s-1), and lower quench rates as the distance from the quench end
increases (around 2oC s-1 at the end furthest from the quench). You will investigate the
change in hardness in the samples with position in a later laboratory.
The compositions of the two types of Jominy bar are given in the following table.
Sample Composition / wt%

reference C Mn Ni Cr Mo Fe

3 0.4 0.8 - - - balance

14 0.4 0.6 1.5 1.0 0.3 Balance

For further information on the Jominy end quench, see:

http://www.doitpoms.ac.uk/tlplib/jominy/index.php

Note: ML3 and ML4 will be uploaded in the spring semester.

 Plagiarism (copying, cheating)
Plagiarism is a form of cheating where someone copies another person’s work and submits it with
the intention that it should be taken as their own work. You must not do this in any form of
individual coursework. In particular, you must not copy portions of text, figures, designs,
1
CAD drawings, computer programs, etc. from any source without reference. This includes
the internet, other students’ work, books, journal articles, etc.

Some assignments are done as group activities and a single report, compiled by the whole group,
is requested. However, in most cases, you are asked for an individual submission. While we would
encourage you to discuss the work with others, it is essential that what you put in your report is
your own work, written by you, in your own style. As a guide, any help you receive from others
must be no more than you would reasonably expect to obtain from the module convener. For
example, you could reasonably expect him or her to tell you in broad terms how to tackle a
problem or help you to understand a difficult point and we have no objection to you receiving that
kind of help from other students. However, you would not expect the module convener to give you
his own part-completed or fully-completed model answer.

Module conveners will normally provide further specific guidance about their
coursework assignments. If you have any doubts about what is and is not allowed in
any particular case, ask the convener.

In much of what you do, you are expected and encouraged to refer to the work of other people.
We want you to read text books, to get information from the internet and to discuss assignments
with your fellow students. However, if you use other people’s work you MUST make it clear that
you are doing this and give a reference to the original (see below for referencing other people’s
work).

In order to protect honest students from those who try to cheat and gain marks they haven’t
earned, the School uses special software that detects when text has been copied from the internet
or from other students’ work. Other software detects computer programs that have been copied
from someone else. We will take action whenever we suspect that cheating has been attempted.

Any student found guilty of plagiarism may be subject to any or all of the following sanctions:
• award of a mark of zero for the piece of work, or for the assessment of the whole module

• issue a written warning

• request the Vice-Chancellor to suspend or exclude the student
• request the Council to expel the student or to revoke any degree awarded.
Any of these can obviously have very serious consequences for a student’s studies.

The University policy on Academic offences can be found in the Quality Manuel at:
http://www.nottingham.ac.uk/quality-manual/assessment/offences.htm. The procedure normally
involves a hearing of the Academic Offences Committee and, until this reaches a decision, the
examiners will not consider the student’s performance in the module and no mark will be released.
This can delay decisions on progression or even the award of the degree.

Referring to other people's work

If you need to use information from published work, it is essential that you make this clear by
providing the reference to the source. If you quote material directly, you must put it in quotation
marks ("......") and again indicate the source. Even if you summarise the material in your own
words, you must indicate the source. Information about standard referencing methods can be
found at: http://www.nottingham.ac.uk/schoolm3/local/School-Intranet/Support/Refer.htm