Programme: Mechanical Engineering

Module Title: Foundations of Materials Science and Engineering

Module Code: 19MECH60C
Module Leader: Prof I El-Mahallawi

Assignment Title: Coursework lab report based on attending four lab sessions
Type: 15% Group with 5% for individual performance.
Weight: 20%
Assessing ILOs:
5. prepare samples for metallography and mechanical tests and produce data and from
relevant laboratory tests;
6. use lab equipment and handle materials safely;
7. present and discuss data from a variety of sources (including laboratory work) to
explain materials properties and applications.
Lab Report (based on attendance)

Group Work

Weight 15%
Programme: Mechanical Engineering
Module Title: Foundations of Materials Science and Engineering
Module Code: 19MECH60C
Module Leader: Prof I El-Mahallawi

LAB (1): Micro-specimen preparation and use of the metallurgical microscope (20 marks)

1- Sketch and label the microstructure of each of the samples examined, indicating etchant
and total magnification. Identify on your sketches the micro-constituents present and
any significant features observed.
2- Define metallographic examination and state the steps followed in the lab to prepare the
sample.
3- Explain why grain boundaries are the first to be visualized on a specimen of properly
polished and etched metal under the optical microscope.

LAB (2): The Hardness Test (20 marks)

1- Produce a simple sketch for the hardness testing device in the lab indicating its main
parts and functions. What is the type of this hardness machine?

2- For the same sample you used for microstructure examination. Report the hardness value
with its proper designation, and hence answer the following:
a- Describe the shape of the indenter.
b- Describe the shape of the indentation.
c- According to the hardness reading is this material hard or soft?
d- Compare the hardness with the microstructure of the part.
Programme: Mechanical Engineering
Module Title: Foundations of Materials Science and Engineering
Module Code: 19MECH60C
Module Leader: Prof I El-Mahallawi

LAB (3): Impact Test (20 marks)

1. Study the machine in the lab, draw a schematic of the machine and add the function of
each of its parts. Write the machine model and specifications.

2. Draw the specimen with dimensions.

Specimen Material Dimensions Notch

no. Specifications
W H L

3. Note the rupture energy of each specimen.

Specimen Rupture Energy

4. Study the features and draw the texture of the fractured surface of each specimen.

Specimen Illustration Comments

5. Comment on the results.

6. Discuss the significance and advantages of impact tests in comparison with static tests.
Programme: Mechanical Engineering
Module Title: Foundations of Materials Science and Engineering
Module Code: 19MECH60C
Module Leader: Prof I El-Mahallawi

7. What physical property of a material is determined by means of an impact test?

8. Why are Charpy impact specimens notched?

9. Discuss the effect of the following factors upon the results of impact tests:
(i) Characteristics of the notch
(ii) Speed of the hammer
(iii) Temperature of the specimen
Programme: Mechanical Engineering
Module Title: Foundations of Materials Science and Engineering
Module Code: 19MECH60C
Module Leader: Prof I El-Mahallawi

LAB (4): Tension Test) (20 marks)

Complete the following table for the sample that your group tested in the laboratory:

Load (kg) Extension (ΔL) Stress (F/AInitial) Strain (ΔL/L)

0 0 0 0

Plot the stress-strain diagram for your specimen material, and indicate the

0.2 % yield stress, ultimate tensile strength, the % elongation, % reduction in area,
modulus of elasticity,. Use ordinary millimeter graph paper.

After finishing answer the following questions.

1. Calculate the values of % elongation and % reduction in area and indicate their
significance?
2. Calculate the elastic modulus using the slope of the linear portion of the curve.
3. Determine the 0.2 % yield stress.
4. What property does the area under the stress-strain define?
Programme: Mechanical Engineering
Module Title: Foundations of Materials Science and Engineering
Module Code: 19MECH60C
Module Leader: Prof I El-Mahallawi

5. Compare the stress-strain curves for the cold-rolled and annealed steel and the aluminum
specimens shown hereunder, your answer should include some discussion in addition to
describing the behavior.

Stress-strain diagram

Cold rolled steel

Annealed steel

Aluminum alloy
Programme: Mechanical Engineering
Module Title: Foundations of Materials Science and Engineering
Module Code: 19MECH60C
Module Leader: Prof I El-Mahallawi

Individual discussion (5%)

The group will agree on assigning each member to answer one of the below questions. This
question will be the individual work for each student.

QUESTION (1)

The following data were collected from a test specimen of cold-rolled and annealed brass. The
specimen had an initial gage length l0 of 35 mm and an initial cross-sectional area A0 of 10.5
mm2.

Load, N Elongation, mm Load, N Elongation l, mm

0 0.0000 1350 5.55
66 0.0112 1720 8.15
177 0.0157 2220 13.07
327 0.0199 2690 (maximum load) 22.77
462 0.0240 2410 25.25 (fracture)
797 1.72

(a) Plot the engineering stress–strain curve and the true stress–strain curve. Use a software
graphing Package.

(b) Calculate the 0.2% offset yield strength; Calculate the tensile strength; Calculate the elastic
modulus using a linear fit to the appropriate data.

(c) Can you use the equations that calculate the true stresses and true strains beyond the ultimate
tensile strength? Why? If the true stress–strain data were known past the point of necking, what
might the curve look like?
Programme: Mechanical Engineering
Module Title: Foundations of Materials Science and Engineering
Module Code: 19MECH60C
Module Leader: Prof I El-Mahallawi

QUESTION (2)

The following data were obtained from a series of Charpy impact tests performed on four ductile
cast irons, each having a different silicon content. Plot the data and determine

(a) the transition temperature of each (defined by the mean of the absorbed energies in the ductile
and brittle regions) and

(b) the transition temperature of each (defined as the temperature that provides 10 J of absorbed
energy).
Plot the transition temperature versus silicon content and discuss the effect of silicon on the
toughness of the cast iron. What is the maximum silicon allowed in the cast iron if a part is to be
used at 25°C?

Test Temperature Impact Energy (J)

(°C)
2.55% Si 2.85% Si 3.25% Si 3.63% Si
-50 2.5 2.5 2 2
-5 3 2.5 2 2
0 6 5 3 2.5
25 13 10 7 4
50 17 14 12 8
75 19 16 16 13
100 19 16 16 16
125 19 16 16 16
Programme: Mechanical Engineering
Module Title: Foundations of Materials Science and Engineering
Module Code: 19MECH60C
Module Leader: Prof I El-Mahallawi

QUESTION (3)

(a) Describe a test that you would use and the data you expect to obtain if you wanted to measure
the toughness of welded steel samples under impact conditions at Room Temperature of 25C,
would you expect the results to be valid if the steel operates at -40C.

(b) If it is required to calculate the maximum load that may be applied to a piece of material
without causing plastic deformation, which of the following values would you use for your
calculations knowing that the material has an offset yield strength of 345 MPa, ultimate tensile
strength of 420 MPa, and Young’s Modulus E= 103 GPa. Define what is meant by each of
these values.

QUESTION (4)

(a) The grain size is often determined when the properties of a polycrystalline material are under
consideration. In this regard, there exist several techniques by which size is specified in terms
of average grain volume, diameter, or area. Probably the most common method, however, is
that devised by the American Society for Testing and Materials (ASTM). The ASTM has
prepared several standard comparison charts, all having different average grain sizes. To each
is assigned a number ranging from 1 to 10, which is termed the grain size number. A specimen
must be properly prepared to reveal the grain structure, which is photographed at a
magnification of 100X. Grain size is expressed as the grain size number of the chart that most
nearly matches the grains in the micrograph. Describe two causes for grain refining in
metallurgical industries (casting and forming).

(b) You are asked to 1) Determine the ASTM grain size number of a metal specimen if 45 grains
per square inch are measured at a magnification of 100X. 2) For this same specimen, how
many grains per square inch will there be at a magnification of 85X?
Programme: Mechanical Engineering
Module Title: Foundations of Materials Science and Engineering
Module Code: 19MECH60C
Module Leader: Prof I El-Mahallawi

QUESTION (5)

(a) A catalyst is a substance that speeds up the rate of a chemical reaction without participating
in the reaction itself (i.e., it is not consumed). One important use of catalysts is in catalytic
converters on automobiles, which reduce the emission of exhaust gas pollutants such as
carbon monoxide (CO), nitrogen oxides (NOx, where x is variable), and unburned
hydrocarbons. Search literature and use proper citation to explain the adsorption sites on a
catalyst and their relation to present surface defects of metallic parts.

(b) For the given four microstructures of steel samples select the most likely proper chemical
analysis and hardness from the given data.
Programme: Mechanical Engineering
Module Title: Foundations of Materials Science and Engineering
Module Code: 19MECH60C
Module Leader: Prof I El-Mahallawi

Microstructure C% Hardness

Hardness values, HV 400, 180, 220, 160

C% 0.85%, 0.15%, 0.35%, 0.76%