2017 Me6403 Emm

A Course Material on
Engineering Materials and Metallurgy
By
DEPARTMENT OF MECHANICAL ENGINEERING
DHANALAKSHMI SRINIVASAN COLLEGE OF ENGINEERING
COIMBATORE
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Subject Code : ME6403
Subject : Engineering materials and metallurgy
Class : II Year MECHANICAL ENGINEERING
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CONTENTS
S.NO TOPIC PAGE NO
UNIT 1 CONSTITUTION OF ALLOYS AND PHASE DIAGRAMS
1.1 Classification of materials 4

1.2 Type of bonding 4
1.3 Crystal structures 5
1.4 Imperfection in solids 5
1.5 Introduction to phase diagram 6
1.6 Solid solution 6
1.7 Iron Carbon Diagram 7
1.8 Metal types 13
1.8.1 Ferrous metals 13
1.8.2 Alloy steels 16
1.8.3 Non ferrous metals 17
UNIT 2 HEAT TREATMENT PROCESS

2.1 Basic principles of heat treatment 20
2.2 Hardening 20
2.3 Annealing 22
2.4 Normalizing 25
2.5 Hardening process 25
2.6 Thermo chemical process 26
2.7 Tempering 27
2.8 Martempering and Austempering 27
UNIT 3 FERROUS AND NON FERROUS METALS

3.1 Effect of alloying elements on steel properties 29
3.2 Characteristics of alloying elements 30
3.3 Maraging steels 30
3.4 Heat treatment cycle 31
3.5 Classificaion of copper and its alloys 32
3.5.1 Brasses 33
3.5.2 Bronze 33
3.5.3 Tool and die steel 34
3.6 Effects of alloying elements on steel 35
UNIT 4 NON METALLIC MATERIALS

4.1 Polymers 36
4.2 Historical development 37
4.3 Polymer synthesis 40
4.4 Modification of Natural polymer 41
4.5 Polymer Architecture 42
4.6 Polymer morphology 43
4.7 Mechanical properties 45
4.8 Phase behavior 46
4.9 Polymer materials 52
4.9.1 Elstomer 52
4.9.2 Thermoplastics 52
4.9.3 Thermoets 52
4.10 Polmer structure 53
4.11 Polyisoperene 56
4.12 Isobutene-isoperene 56
4.13 Ethylene propylene 57
4.14 Silicone 58
4.15 Thermoplasts 59
4.16 Fundamentals of ceramics 61
4.17 Effect of microstructure on tribological properties of 67
ceramics
UNIT V MECHANICAL PROPERTIES AND DEFORMATION
MECHANISM
5.1 Plastic deformation 71
5.2 Brinell hardness est 72
5.3 Vickers hardness test 73
5.4 Rockwell hardness test 74
5.5 Charpy impact test 75
5.6 Fatigue test 79
5.7 Creep test 82
Question bank 86
University questions 91
ME6403 ENGINEERING MATERIALS AND METALLURGY LTPC
3003
OBJECTIVES:
• To impart knowledge on the structure, properties, treatment, testing and applications of
metals and non-metallic materials so as to identify and select suitable materials for various
engineering applications.
UNIT I ALLOYS AND PHASE DIAGRAMS 9
Constitution of alloys – Solid solutions, substitutional and interstitial – phase
diagrams,Isomorphous, eutectic, eutectoid, peritectic, and peritectoid reactions, Iron –
carbon equilibrium diagram.
Classification of steel and cast Iron microstructure, properties and application.
UNIT II HEAT TREATMENT 10
Definition – Full annealing, stress relief, recrystallisation and spheroidising – normalising,
hardening and Tempering of steel. Isothermal transformation diagrams – cooling curves
superimposed on I.T. diagram CCR – Hardenability, Jominy end quench test -
Austempering, martempering – case hardening, carburizing, Nitriding, cyaniding,
carbonitriding – Flame and Induction hardening – Vacuum and Plasma hardening.
UNIT III FERROUS AND NON-FERROUS METALS 9
Effect of alloying additions on steel- α and β stabilisers– stainless and tool steels – HSLA,
Maraging steels – Cast Iron - Grey, white, malleable, spheroidal – alloy cast irons, Copper
and copper alloys – Brass, Bronze and Cupronickel – Aluminium and Al-Cu – precipitation
strengthening treatment – Bearing alloys, Mg-alloys, Ni-based super alloys and Titanium
alloys.
UNIT IV NON-METALLIC MATERIALS 9
Polymers – types of polymer, commodity and engineering polymers – Properties and
applications of various thermosetting and thermoplastic polymers (PP, PS, PVC, PMMA,
PET,PC, PA, ABS, PI, PAI, PPO, PPS, PEEK, PTFE, Polymers – Urea and Phenol
formaldehydes)- Engineering Ceramics – Properties and applications of Al2O3, SiC, Si3N4,
PSZ and SIALON –Composites-Classifications- Metal Matrix and FRP - Applications of
Composites.
UNIT V MECHANICAL PROPERTIES AND DEFORMATION MECHANISMS 8
Mechanisms of plastic deformation, slip and twinning – Types of fracture – Testing of
materials under tension, compression and shear loads – Hardness tests (Brinell, Vickers and
Rockwell), hardness tests, Impact test lzod and charpy, fatigue and creep failure
mechanisms.
TOTAL : 45 PERIODS
OUTCOMES:
• Upon completion of this course, the students can able to apply the different materials, their
processing, heat treatments in suitable application in mechanical engineering fields.
TEXT BOOKS:
1. Avner,, S.H., “Introduction to Physical Metallurgy”, McGraw Hill Book Company,1994.
2. Williams D Callister, “Material Science and Engineering” Wiley India Pvt Ltd, Revised
Indian Edition 2007
REFERENCES:
1. Raghavan.V, “Materials Science and Engineering”, Prentice Hall of India Pvt. Ltd., 1999.
2. Kenneth G.Budinski and Michael K. Budinski, “Engineering Materials”, Prentice Hall of
India Private Limited, 4th Indian Reprint 2002.
3. Upadhyay. G.S. and Anish Upadhyay, “Materials Science and Engineering”, Viva Books
Pvt. Ltd., New Delhi, 2006.
4. U.C.Jindal : Material Science and Metallurgy, "Engineering Materials and Mettalurgy",
First Edition, Dorling Kindersley, 2012
ME 6403 ENGINEERING MATERIALS AND METALLURGY
COURSE OBJECTIVE
➢ Primary objective is to present the basic fundamentals of materials science and

engineering.
➢ Expose the students to different classes of materials, their properties, structures and
imperfections present in them.
➢ Help understand the subject with ease by presenting the content in a simplified and
logical sequence at a level appropriate for students.
➢ Aid the teaching learning process through relevant illustrations, animations and web
content and practical examples.
➢ Highlight important concepts for each topic covered in the subject
➢ Provide opportunity of self-evaluation on the understanding of the subject matter.
Historical Perspective:
Materials are so important in the development of civilization that
we associate Ages with them. In the origin of human life on Earth, the Stone
Age, people used only natural materials, like stone, clay, skins, and wood. When
people found copper and how to make it harder by alloying, the Bronze
Age started about 3000 BC. The use of iron and steel, a stronger material that
gave advantage in wars started at about 1200 BC. The next big step was the
discovery of a cheap process to make steel around 1850, which enabled the
railroads and the building of the modern infrastructure of the industrial world.
DSCE 1 Department of Mechanical Engineering

Quest for newer materials:

The driving force for the progress- Stone Age to IT age
Quest for more advanced materials to meet the growing needs as the civilization
progressed.A look at the history of materials chronologically clearly reveals this
300000 BC - Stone age People living in caves and hunting with stone-made weapons
200,000 BC Discovery of fire – Said to be the most significant discovery in human

civilization. However, till the time the fire was controlled
to contain and utilize the heat, it was not significant.
Containing the fire – Was not possible without materials. Started with
clay (a ceramic material) pots and now we have all kinds of means to control and contain
fire.
Introduction of metals
5500 BC First metals to be discovered – Copper and Gold
5000 BC Material processing - Annealing and Shaping. Throwing copper into camp fire
and hammering in early days
4000 BC Melting and casting of metals. Melting of Gold to give it different
shapes 3500 BC Reduction of copper from its ore – Nile Valley The dawn of
metallurgy. Perhaps discovered by chance much before by early potters
Discovery of Alloy - Metal Combinations

3000 BC The discovery of alloy – combination of metals
Mixing of Tin with Copper – Bronze Copper ore invariably contains some Tin
– Mixing of different ores having different Tin content produced the first Bronzes.
Iron and Steel – Building blocks of human civilization

1450 BC Iron wheels – discovery of iron making. Revolution
in warfare and cultivation
1500 BC Invention of Blast furnace – Production of pig iron from ores

1855 AD Sir Henry Bessemer (1813-1898) Bessemer steel making patent

20TH CENTURY Many other steel making processes – LD, Electric Arc, VAR for
making high quality steels
Early 20th Century – The golden era
1886 AD Hall process- Electrochemical process forextraction of Aluminium from
Alumina (Al2O3)
1890-1910AD Revolution in Transportation – Discovery of automobiles and Aero
plane
1939 AD Process for making Nylon – Introduction of plastics
AND SO ON…..
Materials Science and Engineering:

The combination of physics, chemistry, and the focus on the relationship between the
properties of a material and its microstructure is the domain of Materials Science. The
development of this science allowed designing materials and provided a knowledge base for
the engineering applications (Materials Engineering).
Advantages of Studying Materials Science and Engineering

➢ To be able to select a material for a given use based on considerations of cost and
performance.
➢ To understand the limits of materials
➢ To change the material properties based on the use.
➢ To be able to create a new material that will have some desirable properties

UNIT 1.CONSTITUTION OF ALLOYS AND PHASE DIAGRAMS
1.1 CLASSIFICATION OF MATERIALS

1.1.1Metals
Valence electrons are detached from atoms, and spread in an 'electron sea' that "glues" the
ions together. Metals are usually strong, conduct electricity and heat well and are opaque to
light (shiny if polished). Examples: aluminum, steel, brass, gold.
1.1.2 Semiconductors
The bonding is covalent (electrons are shared between atoms). Their electrical properties
depend extremely strongly on minute proportions of contaminants. They are opaque to visible
light but transparent to the infrared. Examples: Si, Ge, GaAs.
1.1.3Ceramics
Atoms behave mostly like either positive or negative ions, and are bound by Coulomb
forces between them. They are usually combinations of metals or semiconductors with oxygen,
nitrogen or carbon (oxides, nitrides, and carbides). Examples: glass, porcelain, many minerals.
1.1.4.Polymers
Are bound by covalent forces and also by weak van der Waals forces, and usually
based on H, C and other non-metallic elements. They decompose at moderate temperatures
(100 - 400 C), and are lightweight. Other properties vary greatly. Examples: plastics (nylon,
Teflon, polyester) and rubber.
1.2. TYPES OF BONDING

1.2.1 Ionic Bonding
This is the bond when one of the atoms is negative (has an extra electron) and another is
positive (has lost an electron). Then there is a strong, direct Coulomb attraction. An example is
NaCl. In the molecule, there are more electrons around Cl, forming Cl- and less around Na,
forming Na+. Ionic bonds are the strongest bonds.
1.2.2 Covalent Bonding
In covalent bonding, electrons are shared between the molecules, to
saturate the valency. The simplest example is the H2 molecule, where the
electrons spend more time in between the nuclei than outside, thus producing bonding.
1.2.3 Metallic Bonding

In the metallic bond encountered in pure metals and metallic alloys, the atoms contribute
their outer-shell electrons to a generally shared electron cloud for the whole block of

metal.
➢ Secondary Bonding (Van der Waals)
➢ Fluctuating Induced Dipole Bonds Polar
➢ Molecule-Induced Dipole Bonds
➢ Permanent Dipole Bonds
1.3.CRYSTAL STRUCTURES
Atoms self-organize in crystals, most of the time. The crystalline lattice is a periodic
array of the atoms. When the solid is not crystalline, it is called amorphous. Examples of
crystalline solids are metals, diamond and other precious stones, ice, graphite. Examples of
amorphous solids are glass, amorphous carbon (a-C), amorphous Si, most plastics
1.3.1.Unit Cells
The unit cell is the smallest structure that repeats itself by translation through the crystal. The
most common types of unit cells are the faced centered cubic (FCC), the
body-centered cubic (FCC) and the hexagonal close-packed (HCP). Other types exist,
particularly among minerals.
1.3.2.Polymorphism and Allotropy

Some materials may exist in more than one crystal structure, this is called polymorphism.
If the material is an elemental solid, it is called allotropy. An example of allotropy is carbon,
which can exist as diamond, graphite, and amorphous carbon.
1.3.3.Polycrystalline Materials
A solid can be composed of many crystalline grains, not aligned with each other. It is
called polycrystalline. The grains can be more or less aligned with respect to each other.
Where they meet is called a grain boundary.
1.4.IMPERFECTION IN SOLIDS
Materials are not stronger when they have defects.
The study of defects is divided according to their dimension:
0D (zero dimension) - point defects: vacancies and interstitials Impurities.
1D - linear defects: dislocations (edge, screw, mixed)
2D - grain boundaries, surfaces. 3D - extended defects: pores, cracks

1.5 Introduction to phase diagram

Component
Pure metal or compound (e.g., Cu, Zn in Cu-Zn alloy, sugar, water, in syrup.)
Solvent
Host or major component in solution.
Solute
Dissolved, minor component in solution.
System
Set of possible alloys from same component (e.g., iron-carbon system.)
Solubility Limit
Maximum solute concentration that can be dissolved at a given temperature.
Phase
Part with homogeneous physical and chemical characteristics
1.6.Solid Solutions
A solid solution occurs when we alloy two metals and they are completely soluble in
each other. If a solid solution alloy is viewed under a microscope only one type of crystal can be
seen just like a pure metal. Solid solution alloys have similar properties to pure metals but with
greater strength but are not as good as electrical conductors.
The common types of solid solutions are

1) Substitutional solid solution
2) Interstitial solid solutions
Substitution solid solution
The name of this solid solution tells you exactly what happens as atoms of the parent
metal ( or solvent metal) are replaced or substituted by atoms of the alloying metal (solute
metal) In this case, the atoms of the two metals in the alloy, are of similar size.
Interstitial solid solutions:
In interstitial solid solutions the atoms of the parent or solvent metal are bigger than the
atoms of the alloying or solute metal. In this case, the smaller atoms fit into interstices i.e
spaces between the larger atoms.
Phases
One-phase systems are homogeneous. Systems with two or more phases are
heterogeneous, or mixtures. This is the case of most metallic alloys, but also happens in
ceramics and polymers.
A two-component alloy is called binary. One with three components is called ternary.

Microstructure
The properties of an alloy do not depend only on concentration of the phases but how
they are arranged structurally at the microscopy level. Thus, the microstructure is specified by
the number of phases, their proportions, and their arrangement in space.
A binary alloy may be
➢A single solid solution
➢Two separated essentially pure components.
➢Two separated solid solutions.
➢A chemical compound, together with a solid solution.
Phase diagram:
A graph showing the phase or phases present for a given composition as a function of
temperature.
Poly phase material:

A material in which two or more phases are present.
Eutectoid:
Transforming from a solid phase to two other solid phases upon cooling.
Peritectoid:
Transforming from two solid phases to a third solid phase upon cooling.
Peritectoid reaction:
A reaction in which a solid goes to a new solid plus a liquid on heating, and reverse
occurs on cooling.
Iron-Iron Carbon diagram is essential to understand the basic differences among iron
alloys and control of properties.
Iron is allotropic; at room temperature pure iron exists in the Body Centered Cubic crystal
form but on heating transforms to a Face Centered Cubic crystal. The temperature that this first
transformation takes place is known as a critical point and it occurs at 910 degrees Celsius. This
change in crystal structure is accompanied by shrinkage in volume, sine the atoms in the face
centered crystal are more densely packed together than in the body centered cubic crystal. At
the second critical point the F.C.C crystal changes back to a B.C.C crystal and this change
occurs at 1390 degrees Celsius.
▪ Iron above 1390 degrees is known as delta iron
▪ Iron between 1390 and 910 degrees is known as gamma iron, Iron below 910 degrees is
known as alpha iron.
1.7.IRON CARBON DIAGRAM

Iron-carbon phase diagram
Iron-carbon phase diagram describes the iron-carbon system of

alloys containing up to 6.67% of carbon, discloses the phases compositions

and their transformations occurring with the alloys during their cooling c
or heating. Carbon content 6.67% corresponds to the fixed omposition of
the iron carbide Fe3C.
The diagram is presented in the p icture:
The following phases are involved in the transformation, occurring with iron-
carbon alloys:
L - Liquid solution of carbon in iron;
δ-ferrite - Solid solution of carbon in iron.
Maximum concentration of carbon in δ-ferrite is 0.09% at 2719 ºF

(1493ºC) - temperature of the peritectic transformation.
The crystal structure of δ-ferrite is BCC (cubic body centered). Austenite - interstitial solid
solution of carbon in γ-iron.
Austenite has FCC (cubic face centered) crystal structure, permitting high
solubility of carbon - up to 2.06% at 2097 ºF (1147 ºC).
Austenite does not exist below 1333 ºF (723ºC) and maximum carbo n concentration at
this temperature is 0.83%.
α-ferrite - solid solution o f carbon in α-iron. α-ferrite has BCC crystal structure and low
solubility of carbon - up to 0.25% at 1333 ºF (723ºC). α-ferrite exists at room temperature.
Cementite - iron carbide , intermetallic compound, having fixed com position Fe3C.
Cementite is a hard and brittle substance, influencing on the properties
of steels and cast irons.
The following phase transformations occur with iron-carbon alloys:
Alloys, containing up to 0.51% of carbon, start soli dification formation of with

crystals of δ-ferrite. Carbon content in δ-ferrite increases up to in course solidification, 0.09%
and at 2719 ºF (1493ºC) remaining liquid phase ferrite perform peritectic and δ-
transformation, resulting in formation of austenite.
Alloys, containing carbon more than 0.51%, but less than 2.06%, form primary austenite
crystals in the beginning of solidification and when the temperature reaches the curve ACM
primary cementite stars to form.
Iron-carbon alloys, containing up to 2.06% of carbon, are called steels.
Alloys, containing from 2.06 to 6.67% of carbon, experience eutectic

transformation at 2097 ºF (1147 ºC). The eutectic concentration of carbon is 4.3%.
In practice only hypoeutectic alloys are used. These alloys (carbon

content from 2.06% to 4.3%) are called cast irons. When temperature of an
alloy from this range reaches 2097 ºF (1147 ºC), it contains primary austenite
crystals and some amount of the liquid phase. The latter decomposes by eutectic
mechanism to a fine mixture of austenite and cementite, called ledeburite.
All iron-carbon alloys (steels and cast irons) experience eutectoid transformation at 1333
ºF (723ºC). The eutectoid concentration of carbon is 0.83%.
When the temperature of an alloy reaches 1333 ºF (733ºC), austenite transforms to

pearlite (fine ferrite-cementite structure, forming as a result of decomposition of
austenite at slow cooling conditions).
Critical temperatures
Upper critical temperature (point) A3 is the temperature, below which ferrite starts to
form as a result of ejection from austenite in the hypoeutectoid alloys.
Upper critical temperature (point) ACM is the temperature, below which cementite
starts to form as a result of ejection from austenite in the hypereutectoid alloys.
Lower critical temperature (point) A1 is the temperature of the austeniteto-pearlite
eutectoid transformation. Below this temperature austenite does not exist.
Magnetic transformation temperature A2 is the temperature below which α-ferrite is
ferromagnetic.
Phase compositions of the iron-carbon alloys at room temperature

o Hypoeutectoid steels (carbon content from 0 to 0.83%) consist of primary (proeutectoid)
ferrite (according to the curve A3) and pearlite.
o Eutectoid steel (carbon content 0.83%) entirely consists of pearlite.
o Hypereutectoid steels (carbon content from 0.83 to 2.06%) consist of primary
(proeutectoid) cementite (according to the curve ACM) and pearlite.
o Cast irons (carbon content from 2.06% to 4.3%) consist of proeutectoid
cementite C2 ejected from austenite according to the curve ACM , pearlite and transformed
ledeburite (ledeburite in which austenite transformed to pearlite).

At 4.3% carbon composition, on cooling Liquid phase is converted in to two solids

hence forming Eutectic reaction.
L ↔ γ + Fe3C
Eutectoid: 0.76 wt%C, 727 °C

γ(0.76 wt% C) ↔ α (0.022 wt% C) + Fe3C
Shown below is the steel part of the iron carbon diagram containing up to 2% Carbon. At the
eutectoid point 0.83% Carbon, Austenite which is in a solid solution changes directly into a solid
known as Pearlite which is a layered structure consisting of layers of Ferrite and Cementite

DSCE 11 Department of Mechanical E ngineering


1.8. METAL TYPES

The metals that Steelworkers work with are divided into two general classifications:
ferrous and nonferrous. Ferrous metals are those composed primarily of iron and iron alloys.
Nonferrous metals are those composed primarily of some element or elements other than iron.
Nonferrous metals or alloys sometimes contain a small amount of iron as an alloying element
or as an impurity.
1.8.1.FERROUS METALS
Ferrous metals include all forms of iron and steel alloys. A few examples include
wrought iron, cast iron, carbon steels, alloy steels, and tool steels. Ferrous metals are iron- base
alloys with small percentages of carbon and other elements added to achieve desirable
properties. Normally, ferrous metals are magnetic and nonferrous metals are nonmagnetic.
IRON
Pure iron rarely exists outside of the laboratory. Iron is produced by reducing iron ore to
pig iron through the use of a blast furnace. From pig iron many other types of iron and steel are
produced by the addition or deletion of carbon and alloys. The following paragraphs discuss
the different types of iron and steel that can be made from iron ore.

PIG IRON
Pig iron is composed of about 93% iron, from 3% to 5% carbon, and various amounts of
other elements. Pig iron is comparatively weak and brittle; therefore, it has a limited use and
approximately ninety percent produced is refined to produce steel. Cast-iron pipe and some
fittings and valves are manufactured from pig iron.
WROUGHT IRON
Wrought iron is made from pig iron with some slag mixed in during manufacture.
Almost pure iron; the presence of slag enables wrought iron to resist corrosion and oxidation.
The chemical analyses of wrought iron and mild steel are just about the same. The difference
comes from the properties controlled during the manufacturing process. Wrought iron can be
gas and arc welded, machined, plated, and easily formed; however, it has a low hardness and
low-fatigue strength.
CAST IRON
Cast iron is any iron containing greater than 2% carbon alloy. Cast iron has a high-
compressive strength and good wear resistance; however, it lacks ductility, malleability, and
impact strength. Alloying it with nickel, chromium, molybdenum, silicon, or vanadium
improves toughness, tensile strength, and hardness. A malleable cast iron is produced through a
easily as the low-carbon steels. They are used for crane prolonged annealing process. hooks,
axles, shafts, setscrews, and so on.
INGOT IRON
Ingot iron is a commercially pure iron (99.85% iron) that is easily formed and possesses
good ductility and corrosion resistance. The chemical analysis and properties of this iron and
the lowest carbon steel are practically the same. The lowest carbon steel, known as dead- soft,
has about 0.06% more carbon than ingot iron. In iron the carbon content is considered an
impurity and in steel it is considered an alloying element. The primary use for ingot iron is for
galvanized and enameled sheet.
STEEL
All the different metals and materials that we use in our trade, steel is by
far the most important. When steel was developed, it revolutionized the
American iron industry. With it came skyscrapers, stronger and longer
bridges, and railroad tracks that did not collapse. Steel is manufactured from
pig iron by decreasing the amount of carbon and other impurities and adding
specific amounts of alloying elements. Do not confuse steel with the two
general classes of iron: cast iron (greater than 2% carbon) and pure iron (less than 0.15%
carbon). In steel manufacturing, controlled amounts of alloying elements are
added during the molten stage to produce the desired composition. The
composition of a steel is determined by its application and the specifications
that were developed by the following: American Society for Testing and
Materials (ASTM), the American Society of Mechanical Engineers (ASME),
the Society of Automotive Engineers (SAE), and the American Iron and Steel
Institute (AISI).Carbon steel is a term applied to a broad range of steel that
DS
CE 14 Department of Mechanical Engineering
falls between the commercially pure ingot iron and the cast irons. This range of carbon steel
may be classified into four groups:
HIGH-CARBON STEEL/VERY HIGH-CARBON STEEL

Steel in these classes respond well to heat treatment and can be
welded. When welding, special electrodes must be used along with preheating and stress-
relieving procedures to prevent cracks in the weld areas. These steels are
used for dies, cutting tools, milltools, railroad car wheels, chisels, knives, and so
on.
LOW-ALLOY, HIGH-STRENGTH, TEMPERED STRUCTURAL STEEL

A special lowcarbon steel, containing specific small amounts of
alloying elements, that is quenched and tempered to get a yield strength of
greater than 50,000 psi and tensile strengths of 70,000 to 120,000 psi. Structural
members made from these high-strength steels may have smaller cross-
sectional areas than common structural steels and still have equal or greater
strength. Additionally, these steels are normally more corrosion- and abrasionresistant.
High-strength steels are covered by ASTM specifications. NOTE: This type
of steel is much tougher than low-carbon steels. Shearing machines for this type of
steel must have twice the capacity than that required for low-carbon
steels STAINLESS STEEL
This type of steel is classified by the American Iron and Steel Institute (AISI) into two
general series named the 200-300 series and 400 series. Each series includes several types of
steel with different characteristics. The 200-300 series of stainless steel is known as
AUSTENITIC.
This type of steel is very tough and ductile in the as-welded
condition; therefore, it is ideal for welding and requires no annealing under
normal atmospheric conditions. The most well-known types of steel in this series
are the 302 and 304. They are commonly called 18-8 because they are
composed of 18% chromium and 8% nickel.
The chromium nickel steels
Low-Carbon Steel . . . 0.05% to 0.30% carbon are the most widely used
and are normally nonmagnetic.
Medium-Carbon Steel . . . 0.30% to 0.45% carbon
High-Carbon Steel . . . 0.45% to0.75% carbon their crystalline structure
into two general groups.
One Very High-Carbon Steel . . . 0.75% to 1.70% carbon group is known as
FERRITIC CHROMIUM and the other group as MARTENSITIC CHROMIUM.

1.8.2.ALLOY STEELS
Steels that derive their properties primarily from the presence of alloying element other
than carbon are called ALLOYS or ALLOY STEELS. Note, however, that alloy steels always
contain traces of other elements. Among the more common alloying elements are nickel,
chromium, vanadium, silicon, and tungsten. One or more of these elements may be added to the
steel during the manufacturing process to produce the desired characteristics.
Alloy steels may be produced in structural sections, sheets, plates, and bars for use in the
as rolled condition. Better physical properties are obtained with these steels than are possible
with hot. These alloys are used in structures where the strength of material is especially
important. Bridge members, railroad cars, dump bodies, dozer blades, and crane booms are made
from alloy steel. Some of the common alloy steels are briefly described in the paragraphs below.
NICKEL STEELS
These steels contain from 3.5% nickel to 5% nickel. The nickel increases
the strength and toughness of these steels. Nickel steel containing more than 5% nickel has an
increased resistance to corrosion and scale. Nickel steel is used in the manufacture of aircraft
parts, such as propellers and airframe support members.
CHROMIUM STEELS
These steels have chromium added to improve hardening ability, wear resistance, and
strength. These steels contain between 0.20% to 0.75% chromium
and 0.45% carbon or more. Some of these steels are so highly resistant to wear that they are
used for the races and balls in antifriction bearings. Chromium steels are highly resistant to
corrosion and to scale.
CHROME VANADIUM STEEL

This steel has the maximum amount of strength with the least amount of weight. Steels
of this type contain from 0.15% to 0.25% vanadium, 0.6% to 1.5% chromium, and 0.1% to
0.6% carbon. Common uses are for crankshafts, gears, axles, and other items that require high
strength. This steel is also used in the manufacture of high-quality hand tools, such as wrenches
and sockets.
TUNGSTEN STEEL
This is a special alloy that has the property of red hardness. This is the ability to continue
to cut after it becomes red-hot. A good grade of this steel contains from 13% to 19% tungsten,
1% to 2% vanadium, 3% to 5% chromium, and 0.6% to 0.8% carbon. Because this alloy is
expensive to produce, its use is largely restricted to the manufacture of drills, lathe tools,
milling cutters, and similar cutting tools.
MOLYBDENUM
This is often used as an alloying agent for steel in combination with chromium and nickel.
The molybdenum adds toughness to the steel. It can be used in place of tungsten to make the
cheaper grades of high-speed steel and in carbon molybdenum high-pressure tubing.

MANGANESE STEELS
The amount of manganese used depends upon the properties desired in the finished
product. Small amounts of manganese produce strong, free-achgining steels. Larger amounts
(between 2% and 10%) produce a somewhat brittle steel, while still larger amounts (11% to
14%) produce a steel that is tough and very resistant to wear after proper heat treatment.
1.8.3. NONFERROUS METALS

Nonferrous metals contain either no iron or only insignificant amounts used as an
alloy.
Some of the more common nonferrous metals Steelworkers work with are as follows:
copper, brass, bronze, copper-nickel alloys, lead, zinc, tin, aluminum, and Duralumin. NOTE:
These metals are nonmagnetic. COPPER
This metal and its alloys have many desirable properties. Among
the commercial metals, it is one of the most popular. Copper is ductile,
malleable, hard, tough, strong, wear resistant, machinable, weld able, and
corrosion resistant. It also has high-tensile strength, fatigue strength, and
thermal and electrical conductivity. Copper is one of the easier metals to
work with but be careful because it easily becomes work-hardened;
however, this condition can be remedied by heating it to a cherry red and then letting it cool.
This process, called annealing, restores it to a softened condition. Annealing
and softening are the only heat-treating procedures that apply to copper.
Seams in copper are joined by riveting, silver brazing, bronze brazing, soft soldering,
gas welding, or electrical arc welding. Copper is frequently used to give a protective coating to
sheets and rods and to make ball floats, containers, and soldering coppers.
CARBON STEELS
Carbon steels are iron-carbon alloys containing up to 2.06% of carbon, up to1.65% of
manganese, up to 0.5% of silicon and sulfur and phosphorus as impurities.
Carbon content in carbon steel determines its strength and ductility. The
higher carbon content, the higher steel strength and the lower its ductility. According to the
steels classification there are following groups of carbon steels:
•
Low carbon steels (C < 0.25%)
• Medium carbon steels (C =0.25% to 0.55%)
• High carbon steels (C > 0.55%)
• Tool carbon steels (C>0.8%)
Designation system of carbon steels Chemical compositions of some carbon

steels Properties of some carbon steels
Low carbon steels (C < 0.25%)

Properties: good formability and weldability, low strength, low cost.
Applications: deep drawing parts, chain, pipe, wire, nails, some machine parts.

Medium carbon steels (C =0.25% to 0.55%)
Properties: good toughness and ductility, relatively good strength, may be hardened by
quenching
Applications: rolls, axles, screws, cylinders, crankshafts, heat treated machine parts.
High carbon steels (C > 0.55%)

Properties: high strength, hardness and wear resistance, moderate ductility.
Applications: rolling mills, rope wire, screw drivers, hammers, wrenches, band saws.
Tool carbon steels (C>0.8%) - subgroup of high carbon steels

Properties: very high strength, hardness and wear resistance, poor weldability, low ductility.
Applications: punches, shear blades, springs, milling cutters, knives, razors. Designation
system of carbon steels
American Iron and Steel Institute (AISI) together with Society of Automotive Engineers
(SAE) have established four-digit (with additional letter prefixes) designation system:
LOW-ALLOY, HIGH-STRENGTH, TEMPERED STRUCTURAL STEEL

A special lowcarbon steel, containing specific small amounts of
alloying elements, that is quenched and tempered to get a yield strength of
greater than 50,000 psi and tensile strengths of 70,000 to 120,000 psi. Structural
members made from these high-strength steels may have smaller cross-
sectional areas than common structural steels and still have equal or greater
strength. Additionally, these steels are normally more corrosion- and abrasionresistant.
High-strength steels are covered by ASTM specifications. NOTE: This type
of steel is much tougher than low-carbon steels. Shearing machines for this type of
steel must have twice the capacity than that
required for low-carbon steels
STAINLESS STEEL
This type of steel is classified by the American Iron and Steel Institute (AISI) into two
general series named the 200-300 series and 400 series. Each series includes several types of
steel with different characteristics. The 200-300 series of stainless steel is known as austenitic.
AUSTENITIC
This type of steel is very tough and ductile in the as-welded
condition; therefore, it is ideal for welding and requires no annealing under
normal atmospheric conditions. The most well-known types of steel in this series
are the 302 and 304. They are commonly called 18-8 because they are
composed of 18% chromium and 8% nickel. The chromium nickel steels Low-Carbon

SAE 1XXX
First digit 1 indicates carbon steel (2-9 are used for alloy steels); Second
digit indicates modification of the steel.
0 - Plain carbon, non-modified
1 - Resulfurized
2 - Resulfurized and rephosphorized
5 - Non-resulfurized, Mn over 1.0%
Last two digits indicate carbon concentration in 0.01%.
Example: SAE 1030 means non modified carbon steel, containing 0.30% of carbon.
A letter prefix before the four-digit number indicates the steel making technology:
A - Alloy, basic open hearth

B - Carbon, acid Bessemer
C - Carbon, basic open hearth
D - Carbon, acid open hearth
E - Electric furnace
Example: AISI B1020 means non modified carbon steel, produced in acid Bessemer and
containing 0.20% of carbon.
Chemical compositions of some carbon steels
SAE/AISI grade C, % Mn,% P,% max S,% max
1006 0.08 max 0.35 max 0.04 0.05
1010 0.08-0.13 0.30-0.60 0.04 0.05
1020 0.17-0.23 0.30-0.60 0.04 0.05
1030 0.27-0.34 0.60-0.90 0.04 0.05
1045 0.42-0.50 0.60-0.90 0.04 0.05
1070 0.65-0.76 0.60-0.90 0.04 0.05
1090 0.85-0.98 0.60-0.90 0.04 0.05
1117 0.14-0.20 1.10-1.30 0.04 0.08-0.13
1547 0.43-0.51 1.35-1.65 0.04 0.05

UNIT II HEAT TREATMENT PROCESS
2.1.BASIC PRINCIPLES OF HEAT TREATMENT

Heat treatment of a metal or alloy is a technological procedure, including controlled
heating and cooling operations, conducted for the purpose of changing the alloy
microstructure and resulting in achieving required properties.
There are two general objectives of heat treatment: hardening and annealing.
2.2.HARDENING
Hardening is a process of increasing the metal hardness, strength, toughness, fatigue
resistance.
• Strain hardening (work hardening) – strengthening by cold work (cold deformation)
Cold plastic deformation causes increase of concentration of dislocations, which mutually

entangle one another, making further dislocation motion difficult and therefore resisting the
deformation or increasing the metal strength.
• Grain size strengthening (hardening) - strengthening by grain refining.
Grain boundaries serve as barriers to dislocations, raising the stress required to cause
plastic deformation.
• Solid solution hardening- strengthening by dissolving an alloying element.
Atoms of solute element distort the crystal lattice, resisting the

dislocations motion. Interstitial elements are more effective in solid solution
hardening, than substitution elements.
• Dispersion strengthening – strengthening by adding second phase into metal matrix.
The second phase boundaries resist the dislocations motions, increasing

the material strength. The strengthening effect may be significant if fine hard
particles are added to a soft ductile matrix (composite materials).
Hardening by result of Spinodal decomposition. Spinodal structure is characterized by

strains on the coherent boundaries between the Spinodal phases causing hardening of the alloy.

• Precipitation hardening (age hardening) - strengthening by precipitation of fine particles

of a second phase from a supersaturated solid solution.
The second phase boundaries resist the dislocations motions, increasing the material
strength. The age hardening mechanism in Al-Cu alloys may be illustrated by the phase
diagram of Al-Cu system. When an alloy Al-3%Cu is heated up to the temperature TM, all
CuAl2 particles are dissolved and the alloy exists in form of single phase solid solution (α-
phase). This operation is called solution treatment.
Slow cooling of the alloy will cause formation of relatively coarse particles of CuAl2
intermetallic phase, starting from the temperature TN.However if the the cooling rate is high
(quenching), solid solution will retain even at room temperature TF. Solid solution in this non-
equilibrium state is called supersaturated solid solution.
Obtaining of supersaturated solid solution is possible when cooling is considerably
faster, than diffusion processes. As the diffusion coefficient is strongly
dependent on the temperature, the precipitation of CuAl2 from supersaturated
solution is much faster at elevated temperatures (lower than TN).This process
is called artificial aging. It takes usually a time from several hours to one
day. When the aging is conducted at the room temperature, it is called natural
aging. Natural aging takes several days or more.

Precipitation from supersaturate d solid solution occurred in several steps:

• Segregation of Cu atoms into plane clusters. These clusters are called called
Guinier-Preston1 zones (G-P1 zones).
• Diffusion of Cu atoms to the G -P1 zones and formation larger clusters, called GP2
zones or θ” phase. This phase is coherent with the matrix .
• Formation of ‘θ’ phase which is partially coherent with the matrix. This phase
provides maximum hardening.
2.3.ANNEALING
Annealing is a heat treatment procedure involving heating the alloy and holding it at
a certain temperature (annealin g temperature), followed by controlled cooling.
Annealing results in relief of internal stresses, softening,
chemical homogenizing and transformation of the grain structure into more
stable state.
Annealing stages:
- a relatively low temperatu re process of
reducing internal mechanical stresses, caused by cold-work, casting or welding.
During this process atoms move to more stable positions in the
crystal lattice. Vacancies and interstitial defects are eliminated and
some dislocations are annihilate d.
Recovery heat treatment is used mainly for preventing stress-corrosion cracking
and decreasing distortions, caused by internal stresses.
-alteration of the grain structure of the metal.

If the alloy reaches a par ticular temperature (recrystallization or annealing temperature)
new grains start to grow from the nuclei formed in the cold worked metal. The new
grains absorb imperfections an d distortions caused by cold deformation. The grains are equi-
axed and independent to the ol d grain structure.
As a result of recrystallization mechanical properties (stre ngth, ductility)
of the alloy return to the pre-cold-work level. The annealing te mperature and
the new grains size are dependent on the degree of cold-wor k which has
been conducted. The more the cold-work degree, the lower the annealing
temperature and the fine recrystallization grain structure. Low d egrees of cold-
work (less than 5%) may cause formation of large grains.Usually the annealing
temperature of metals is between one-third to one-half of t he freezing point
measured in Kelvin (absolute) tem perature scale.
(ov er-annealing, secondary recrystallization) - growth of the new

grains at the expense of their neighbors, occurring at temperature, above the
recrystallization temperat ure.
This process results in coarsening grain structure and is undesirable.

THE SOFTENING PROCESSES

Heat Treatment is the controlled heating and cooling of metals to
alter their physical and mechanical properties without changing the
product shape. Heat treatment is sometimes done inadvertently due to
manufacturing processes that either heat or cool the metal such as welding
or forming. Heat Treatment is often associated with increasing the strength
of material, but it can also be used to alter certain manufacturability
objectives such as improve machining, improve formability, restore ductility
after a cold working operation. Thus it is a very enabling manufacturing
process that can not only help other manufacturing process, but can also
improve product performance by increasing strength or other desirable
characteristics. Steels are particularly suitable for heat treatment, since they
respond well to heat treatment and the commercial use of steels exceeds that
of any other material. Steels are heat treated for one of the following reasons:
Softening
Softening is done to reduce strength or hardness, remove residual stresses, improve
toughnesss, restore ductility, refine grain size or change the electromagnetic properties of
the steel.
Restoring ductility or removing residual stresses is a necessary operation when a large
amount of cold working is to be performed, such as in a cold- rolling operation or
wiredrawing.
Annealing — full Process, spheroidizing, normalizing and tempering— austempering,
martempering are the principal ways by which steel is softened.
Hardening:
Hardening of steels is done to increase the strength and wear
properties. One of the pre-requisites for hardening is sufficient carbon and
alloy content. If there is sufficient Carbon content then the steel can be
directly hardened. Otherwise the surface of the part has to be
Carbon enriched using some diffusion treatment hardening
techniques. Material Modification: Heat treatment is used to modify
properties of materials in addition to hardening and softening. These
processes modify the behavior of the steels in a beneficial manner to
maximize service life, e.g., stress relieving, or strength properties, e.g.,
cryogenic treatment, or some other desirable properties, e.g., spring aging.
Annealing
Used variously to soften, relieve internal stresses, improve
machinability and to develop particular mechanical and physical
properties.In special silicon steels used for transformer laminations
annealing develops the particular microstructure that confers the unique
electrical properties.Annealing requires heating to above the As temperature,
holding for sufficient time for temperature equalisation followed by slow cooling. See
Curve 2 in Figure.1

Figure 1. An idealised TTT curve for plain carbon steel.
Stress from the forming operations can affect both rimfire and
centerfire cartridge cases. For many cases, especially those with bottlenecks,
the stresses are so great that high-temperature annealing must be used.After
forming, a bottleneck case may appear perfectly serviceable. However,
massive stresses are likely to remain in these areas. If the ammunition is
loaded and stored without addressing these stresses, cracks can appear in the
bottleneck area.

Case bottlenecks are normally flame-annealed by the following process:
set of gas burners that rapidly heat the neck and shoulder area to glowing.
he heated area of the case is immediately tipped into a water bath

to quench the case, establishing the large grain size.
area. In commercial ammunition, this dark area may be polished

out for cosmetic reasons; in U.S. military ammunition, the
discoloration remains vi sible.
gradually, from small grains in the head area to large o nes at the
case mouth, determines c ase hardness.
All high pressure cases must have variable metallurgical properties depending on
the part of the case, as follows:
- must be t ough and relatively unyielding, small brass

grains contribute to the t oughness.
2.4.NORMALISING
Also used to soften and relieve internal stresses after cold work and to
refine the grain size and m etallurgical structure. It may be used t o break up
the dendritic (as cast) str ucture of castings to improve their m achinability
and future heat treatment response or to mitigate banding in rolled
steel. This requires heatin g to above the As temperature, holding for
sufficient time to allow tem perature equalization followed by air co oling. It is
therefore similar to annealing but with a faster cooling rate. Curve 3 in Figure I would
give a normalized structure.
2.5.THE HARDENING PROCESSES

Hardening
In this process steels which contain sufficient carbon, and perhaps other alloying elements,
are cooled (quenc hed) sufficiently rapidly from above the transformation temperature to
produce Martensite, the hard phase already described, s ee Curve 1 in Figure 1.There is a
range of quenching media of varying severity, water o r brine being the most severe, through
oil and synthetic products to air which is the least severe.
Tempering
After quenching the steel is hard, brittle and internally stre ssed. Before
use, it is usually necessar y to reduce these stresses and increa se toughness
by 'tempering'. There will als o be a reduction in hardness and the selection of
tempering temperature dictates the final properties. Tempering curves,

which are plots of hardness against tempering temperature. exist for all
commercial steels and are used to select the correct tempering temperature.
As a rule of thumb, within the tempering range for a particular steel, the
higher the tempering temperature the lower the final hardness but the greater
the toughness. It should be noted that not all steels will respond to all heat
treatment processes, Table 1 summaries the response, or otherwise, to the
different processes.
Boronised substrates will often require heat treatment to restore mechanical

properties. As borides degrade in atmospheres which contain oxygen, even when combined as
CO or C02, they must be heat treated in vacuum, nitrogen or nitrogen/hydrogen atmospheres.
PROCESSING METHODS
In the past the thermochemical processes were carried out by pack cementation or salt
bath processes. These are now largely replaced, on product quality and environmental
grounds, by gas and plasma techniques. The exception is boronising, for which a safe
production scale gaseous route has yet to be developed and pack cementation is likely to
remain the only viable route for the for some time to come.
The gas processes are usually carried out in the now almost universal seal quench
furnace, and any subsequent heat treatment is readily carried out immediately without taking
the work out of the furnace. This reduced handling is a cost and quality benefit.
TECHNIQUES AND PRACTICE

As we have already seen this requires heating to above the As temperature, holding to
equalise the temperature and then slow cooling. If this is done in air there is a real

risk of damage to the part by decarburisation and of course oxidation. It is increasingly

common to avoid this by ‗bright„ or ‗close„ annealing using protective atmospheres. The
particular atmosphere chosen will depend upon the type of steel.
NORMALISING
In common with annealing there is a risk of surface degradation but as air cooling is
common practice this process is most often used as an intermediate stage to be
followed by machining, acid pickling or cold working to restore surface integrity.
HARDENING
With many components, hardening is virtually the final process and great care must
taken to protect the surface from degradation and decarburisation. The ‗seal quench„ furnace
is now an industry standard tool for carbon, low and medium alloy steels. The work is
protected at each stage by a specially generated atmosphere.
Some tool steels benefit from vacuum hardening and tempering; salt baths were
widely used but are now losing favour on environmental grounds.
2.7.TEMPERING
Tempering is essential after most hardening operations to restore some toughness to
the structure. It is frequently performed as an integral part of the cycle in a seal quench
furnace, with the parts fully protected against oxidation and decarburisation throughout the
process. Generally tempering is conducted in the temperature range 150 to 700°C,
depending on the type of steel and is time dependent as the microstructural
changes occur relatively slowly.
Caution: Tempering can,in some circumstances, m a k e the steel brittle which is the
opposite of what it is intended to achieve.
There are two forms of this brittleness
Temper Brittleness which affects both carbon and low alloy steels
when either, they are cooled too slowly from above 575°C, or are held for excessive
times in the range 375 to 575°C. The embrittlement can be reversed by heating to
above 575°C and rapidly cooling.
Blue Brittleness affects carbon and some alloy steels after tempering in the range 230
to 370°C The effect is not reversible and suDSCEptible steels should not be employed in
applications in which they sustain shock loads. If there is any doubt consult with the heat
treater or in house metallurgical department about the suitability of the steel type and the
necessary heat treatment for any application.
2.8.MARTEMPERING AND AUSTEMPERING
It will be readily appreciated that the quenching operation used in hardening
introduces internal stresses into the steel. These can be sufficiently large to distort or even
crack the steel.
Martempering is applied to steels of sufficient hardenability and involves an
isothermal hold in the quenching operation. This allows temperature equalisation across the
section of the part and more uniform cooling and structure, hence lower stresses. The steel

can then be tempered in the usual way.

Austempering also invo lves an isothermal hold in the quenching operation, but the
structure formed, whilst hard and tough, does not require further tempering. The process is
mostly applied to high carbon steels in relatively thin sections for springs o r similarparts .
These processes are shown schematically in the TTT Curves, (figures 2a and 2b). there is
sufficient heat sink in the part and an external quench is not needed. There is a much lower
risk of distortion associated with this practice, and it can be highly automated and it is very
reproducible
- the case walls must combine flexibility and strength to contribute to the
obturati on system.
- must be softer (larger brass grains) to prevent cracks from the strain of
holding a bullet.


3.1.EFFECT OF ALLOYING ELEMENTS ON STEEL PROPERTIES
Alloying is changing chemical composition of steel by adding elements
with purpose to improve its properties as compared to the plane carbon steel.
The properties, which may be improved
Stabilizing austenite - increasing the temperature range, in which austenite exists.

The elements, having the same crystal structure as that of austenite
(cubic face centered - FCC), raise the A4 point (the temperature of formation
of austenite from liquid phase) and decrease the A3 temperature.
These elements are nickel (Ni), manganese (Mn), cobalt (Co) and c opper
(Cu).
Examples of austenitic steels: austenitic stainless steels, Hadfield
steel (1%C, 13%Mn, 1.2%Cr).
Stabilizing ferrite - decreasing the temperature range, in which austenite
exists.
The elements, having the same crystal structure as that of ferrite (cubic
body centered - BCC), lower the A4 point and increase the A 3 temperature.
These elements lower the solubility of carbon in austenite, causing

increase of amount of carbides in the steel.
The following elements have ferrite stabilizing effect: chromium (Cr),
tungsten (W), Molybdenum (Mo), vanadium (V), aluminum (Al) and silicon
(Si).
Examples of ferritic steels:transformer sheets steel (3%Si), F-Cr alloy
Carbide forming - elements forming hard carbides in steels.

The elements like chromium (Cr), tungsten (W), molybdenum (Mo),vanadium (V),
titanium (Ti), niobium (Nb), tantalum (Ta),zirconium (Zr) form hard (often complex)
carbides, increasing steel hardness and strength.Examples of steels containing relatively high
concentration of carbides: hot work tool steels, high speed steels. Carbide forming elements
also form nitrides reacting with Nitrogen in steels.
Graphitizing - decreasing stability of carbides, promoting their breaking

and formation of free Graphite.
The following elements have graphitizing effect: silicon (Si), nickel (Ni), cobalt (Co),
aluminum (Al).
Decrease of the eutectoid concentration.

The following elements lower eutectoid concentration of carbon:
titanium (Ti), molybdenum (Mo), tungsten (W), silicon (Si), chromium (Cr),
nickel (Ni).

Increase of corrosion resistance.

Aluminum (Al), silicon (Si), and chromium (Cr) form thin an strong oxide film on the
steel surface, protecting it from chemical attacks.
3.2.CHARACTERISTICS OF ALLOYING ELEMENTS

Manganese (Mn) - improves hardenability, ductility and wear resistance.
Mn eliminates formation of harmful iron sulfides, increasing strength at high temperatures.
Nickel (Ni) - increases strength, impact strength and toughness, impart
corrosion resistance in combination with other elements.
Chromium (Cr) - improves hardenability, strength and wear resistance,
sharply increases corrosion resistance at high concentrations (> 12%).
Tungsten (W) - increases hardness particularly at elevated temperatures due to
stable carbides, refines grain size.
Vanadium (V) - increases strength, hardness, creep resistance and impact resistance due to
formation of hard vanadium carbides, limits grain size. Molybdenum (Mo) - increases
hardenability and strength particularly at high temperatures and under dynamic conditions.
Silicon (Si) - improves strength, elasticity, acid resistance and promotes

large grain sizes, which cause increasing magnetic permeability.
Titanium (Ti) - improves strength and corrosion resistance, limits austenite grain size.
Cobalt (Co) - improves strength at high temperatures and magnetic permeability.
Zirconium (Zr) - increases strength and limits grain sizes.
Boron (B) - highly effective hardenability agent, improves deformability and machinability.
Copper (Cu) - improves corrosion resistance.
Aluminum (Al) - deoxidizer, limits austenite grains growth.
3.3.MARAGING STEELS
Maraging steels (from martensitic and aging) are steels (iron alloys) which are known
for possessing superior strength and toughness without losing malleability,
although they cannot hold a good cutting edge. Aging refers to the extended
heat-treatment process. These steels are a special class of low- carbon ultra-
high-strength steels which derive their strength not from carbon, but
from precipitation of inter-metallic compounds. The principal alloying element
is 15 to 25% nick el. Secondary alloying elements are added to produce
intermetallic precipitates, which include cobalt, molybdenum, and
titanium. Original development was carried out on 20 and 25% Ni steels to which
small additions of Al, Ti, and Nb were made.
The common, non-stainless grades contain 17-19% nickel, 8-12%
cobalt,3-5% molybdenum, and 0.2-1.6% titanium. Addition of chromium
produces stainless grades resistant to corrosion. This also indirectly
increases hardenability as they require less nickel: high-chromium, high-nickel
steels are generally austenitic and unable to transform to martensite when
heat treated, while lower-nickel steels can transform to martensite.

Properties
Due to the low carbon content maraging steels have good
machinability. Prior t o aging, they may also be cold rolled to as much as 80-
90% without cracking. Maraging steels offer good weldability, but must
be aged afterward to restore the properties of heat affected
zone. When heat-treated the alloy has very little dimensional change, so it is
often machined to its final dimensions. Due to the high alloy content
maraging steels have a high hardenability. Since ductile FeNi martensites are
formed upon cooling, cracks are non-existent or negligible. The steels can
be nitrided to increase case hardness, and polished to a fine surface finish.
Non-stainless varieties of maraging steel are moderately corrosion-

resistant, and resist stress corrosion and hydrogen embrittlement. Corrosion-
resistance can be increased by cadmium plating or phosphating.
3.4.HEAT TREATMENT CYCLE

The steel is first annealed at approximately 820 °C (1,510 °F) for 15-
30 minutes for thin sections and for 1 hour per 25 mm thickness for heavy
sections, to ensure formation of a fully austenitized structure. This is
followed by air cooling to room temperature to form a soft, heavily-
dislocated iron-nickel lath (untwinned) martensite. Subsequent aging (precipitation
hardening) of the more common alloys for approximately 3 hours at a
temperature of 480 to 500 °C produces a fine dispersion of Ni3(X,Y)
intermetallic phases along dislocations left by martensitic transformation,
where X and Y are solute elements added for such precipitation.
Overaging leads to a reduction in stability of the primary, metastable,
coherent precipitates, leading to their dissolution and replacement with
semi-coherent Laves phases such as Fe2Ni/Fe2Mo. Further excessive heat-
treatment brings about the decomposition of the martensite and reversion to austenite.
Newer compositions of maraging steels have revealed other intermetallic
stoichiometries and crystallographic relationships with the parent martensite, including
rhombohedral and massive complex Ni50(X,Y,Z)50 (Ni50M50 in simplified notation).
Uses
Maraging steel's strength and malleability in the pre-aged stage allows it
to be formed into thinner rocket and missile skins than other steels, reducing
weight for a given strength. Maraging steels have very stable properties, and, even
after overaging due to excessive temperature, only soften slightly. These
alloys retain their properties at mildly elevated operating temperatures and have
maximum service temperatures of over 400 °C (752 °F)
They are suitable for engine components, such as crankshafts and gears,
and the firing pins of automatic weapons that cycle from hot to cool repeatedly
while under substantial load. Their uniform expansion and easy
machinability before aging make maraging steel useful in high-wear

components of assembly lines and dies. Other ultra-high-strength steels,

such as Aermet alloys, are not as machinable because of their carbide
content.
In the sport of fencing, blades used in competitions run under the auspices
of the Fédération Internationale d'Escrime are often made with maraging steel.
Maraging blades are required in foil and épée because crack propagation in
maraging steel is 10 times slower than in carbon steel, resulting in less blade
breakage and fewer injuries. The notion that such blades break flat is a
fencing urban legend: testing has shown that the blade-breakage patterns in
carbon steel and maraging steel blades are identical.
Stainless maraging steel is used in bicycle frames and golf club heads. It
is also used in surgical components and hypodermic syringes, but is not
suitable for scalpel blades because the lack of carbon prevents it from holding
a good cutting edge.
Maraging steel production, import, and export by certain states, such as the
United States, is closely monitored by international authorities because it is
particularly suited for use in gas centrifuges for uranium enrichment; lack of maraging
steel significantly hampers this process. Older centrifuges used aluminum tubes; modern ones,
carbon fiber composite.
Copper alloys are metal alloys that have copper as their principal component. They have
high resistance against corrosion. The best known traditional types are bronze,
where tin is a significant addition, and brass, using zinc instead. Both these
are imprecise terms, and today the term copper alloy tends to be substituted, especially
by museums.
Compositions
The similarity in external appearance of the various alloys, along with
the different combinations of elements used when making each alloy, can
lead to confusion when categorizing the different compositions. There are as
many as 400 different copper and copper-alloy compositions loosely
grouped into the categories: copper, high copper alloy, brasses, bronzes,
copper nickels, copper-nickel-zinc (nickel silver), leaded copper, and
special alloys. The following table lists the principal alloying element for
four of the more common types used in modern industry, along with the name
for each type. Historical types, such as those that characterize the Bronze Age, are
vaguer as the mixtures were generally variable.
3.5.CLASSIFICATION OF COPPER AND ITS ALLOYS

Family Principal alloying element UNS numbers
Copper alloys, brass Zinc (Zn) C1xxxx-C4xxxx,C66400-
C69800
Phosphor bronze Tin (Sn) C5xxxx
Aluminium bronzes Aluminium (Al) C60600-C64200
Silicon bronzes Silicon (Si) C64700-C66100
DSC
E 32 Department of Mechanical Engineering
Copper nickel, Nickel (Ni) C7xxxx

nickel silvers
3.5.1.BRASSES
A brass is an alloy of copper with zinc. Brasses are usu ally yellow in
color. The zinc content can vary between few % to about 40%; as long as it is
kept under 15%, it does not markedly decrease corrosion resistance of
copper. Brasses can be se nsitive to selective leaching corrosion under certain
conditions, when zinc is leached from the alloy (dezincification), leaving behind a spongy
copper structure.
3.5.2.BRONZES
A bronze is an alloy of copper and other metals, most often tin, but also aluminium and
silicon.
Aluminium bronzes are alloys of copper and aluminium. The content of
aluminium ranges mostly between 5-11%. Iron, nickel, manganes e and silicon
are sometimes added. Th ey have higher strength and corrosion resistance than
other bronzes, especially in m arine environment, and have low reactivity to
sulfur compounds. Aluminium forms a thin passivation layer on the surface of the metal.
CARBON STEELS
Carbon steels are iron-carbon alloys containing up to 2.06% of carbon, up to 1.65% of
manganese, up to 0.5% of silicon and sulfur and phosphorus as impurities.
Carbon content in carbon steel determines its strength and ductility. The
higher carbon content, the higher steel strength and the lower its ductility.
ALLOY STEELS
Alloy steels are ir on-carbon alloys, to which alloying elements are
added with a purpose to improve the steels properties as com pared to the
Carbon steels. Due to effect of alloying elements, properties of alloy steels
exceed those of plane carbon steels. AISI/SAE classification divide alloy steels
⇐
onto groups according to the maj or alloying elements: 8%);
According to the four-digit classification SAE/AISI system:
First digit indicates the class of the alloy steel:
2- Nickel steels;
3-Nickel-chromiu m steels;
4- Molybdenum steels;
5- Chromium steels;
6-Chromium-vanadium steels;
7-Tungsten-chrom ium steels;
9- Silicon-manganese steels.
Second digit indicates concentration of the major element in percents (1 means 1%).

Last two digits indicate carbon concentration in 0,01%.

Example: SAE 5130 means alloy chromium steel, containing 1% of chromium and 0.30% of
carbon.
3.5.3.TOOL AND DIE STEELS

Tool and die steels are high carbon steels (either carbon or alloy)
possessing high hardness, strength and wear resistance. Tool steels are heat
treatable. In order to increase hardness and wear resistance of tool steels,
alloying elements forming hard and stable carbides (chromium, tungsten,
vanadium, manganes e, molybd enum) are added to the composition.
Designation system of one-letter in combination with a number is accepted
for tool steels. The letter means:W - Water hardened plain carbon tool steels
Applications: chisels, forging dies, hummers, drills, cutters, shear blades, cutters, drills,
razors.
Properties: low cost, very hard, brittle, relatively low harden ability, suitable for small parts
working at not elevated temperatures.
O, A, D - Cold work tool steels

Applications: drawing and forging dies, shear blades, highly effective cutters.
Properties: strong, hard and tough crack resistant.
O -Oil hardening cold work alloy steels;
A -Air hardening cold work alloy steels;
D -Diffused hardening cold work alloy steels;
S - Shock resistant low carbon tool steels

Applications: tools experiencing hot or cold impact.
Properties: combine high toughness with good wear resistance.
T,M – High speed tool steels (T-tungsten, M-molybdenum)

Applications: cutting tools. Properties: high wear heat and shock resistance.
H – Hot work tool steels

Applications: parts working at elevated temperatures, like extrusion, casting and forging dies.
Properties: strong and hard at elevated temperatures.
P - Plastic mold tool steels

Applications: molds for injection molding of plastics.
Properties: good machinability.

Chemical compositions of some tool and die steels

AISI No C% Mn % W% Si% Cr% Mo % V% Co %
W1 1.0 o.35 0.3 - - - - -
O1 0.95 1.1 0.5 0.30 0.5 - - -
A2 1.0 0.3 - 0.3 5.0 1.0 - -
D2 1.55 0.30 - 0.3 12.0 1.0 - -
S1 0.5 0.30 2.5 0.30 1.5 - - -
T15 1.6 0.30 12.0 0.3 4.0 - 5.0 5.0
M2 0.9 0.30 6.0 0.30 4.0 5.0 2.0 -
H13 0.35 0.40 - 1.0 5.0 1.5 1.0 -
P20 0.4 1.5 - 0.4 1.9 0.2 - -
3.6.EFFECTS OF ALLOYING ELEMENTS IN STEEL
Steel is basically iron alloyed to carbon with certain additional elements to give the
required properties to the finished melt. Listed below is a summary of the effects various
alloying elements in steel.
Carbon
The basic metal, iron, is alloyed with carbon to make steel and has the effect of
increasing the hardness and strength by heat treatment but the addition of carbon enables a
wide range of hardness and strength.
Manganese
Manganese is added to steel to improve hot working properties and
increase strength, toughness and hardenability. Manganese, like nickel, is an
austenite forming element and has been used as a substitute for nickel in the
A.I.S.I 200 Series of Austenitic stainless steels (e.g. A.I.S.I 202 as a substitute for A.I.S.I 304)
Chromium
Chromium is added to the steel to increase resistance to oxidation.
This resistance increases as more chromium is added. 'Stainless Steel' has approximately
11% chromium and a very marked degree of general corrosion resistance
when compared with steels with a lower percentage of chromium. When added
to low alloy steels, chromium can increase the response to heat treatment, thus
improving hardenability and strength.
Nickel
Nickel is added in large amounts, over about 8%, to high chromium
stainless steel to form the most important class of corrosion and heat resistant
steels. These are the austenitic stainless steels, typified by 18-8, where the
tendency of nickel to form austenite is responsible for a great toughness and high strength
at both high and low temperatures. Nickel also improves resistance to oxidation and corrosion.
It increases toughness at low temperatures when added in smaller amounts to alloy steels.
Molybdenum
Molybdenum, when added to chromium-nickel austenitic steels, improves resistance to
pitting corrosion especially by chlorides and sulphur chemicals. When added to low alloy

steels, molybdenum improves high temperature strengths and hardness. When added to
chromium steels it greatly diminishes the tendency of steels to decay in service or in heat
treatment.
Titanium
The main use of titanium as an alloying element in steel is for
carbide stabilisation. It combines with carbon to for titanium carbides, which
are quite stable and hard to dissolve in steel, this tends to minimise the
occurrence of inter-granular corrosion, as with A.I.S.I 321, when adding approximately
0.25%/0.60% titanium, the carbon combines with the titanium in
preference to chromium, preventing a tie -up of corrosion resisting
chromium as inter-granular carbides and the accompanying loss of corrosion resistance at the
grain boundaries.
Phosphorus
Phosphorus is usually added with sulphur to improve machinability in
low alloy steels, phosphorus, in small amounts, aids strength and corrosion
resistance. Experimental work shows that phosphorus present in austenitic
stainless steels increases strength. Phosphorus additions are known to increase the
tendency to cracking during welding.
Sulphur
When added in small amounts sulphur improves machinability but does not cause hot
shortness. Hot shortness is reduced by the addition of manganese, which combines with the
sulphur to form manganese sulphide. As manganese sulphide has a higher melting point than
iron sulphide, which would form if manganese were not present, the weak spots at the grain
boundaries are greatly reduced during hot working.
Selenium
Selenium is added to improve machinability.
Niobium (Columbium)
Niobium is added to steel in order to stabilise carbon, and as such performs in the same
way as described for titanium. Niobium also has the effect of strengthening steels and alloys
for high temperature service.
Nitrogen
Nitrogen has the effect of increasing the austenitic stability of stainless
steels and is, as in the case of nickel, an austenite forming element. Yield
strength is greatly improved when nitrogen is added to austenitic stainless steels.
Silicon
Silicon is used as a deoxidising (killing) agent in the melting of steel, as a result, most
steels contain a small percentage of silicon. Silicon contributes to hardening of the ferritic
phase in steels and for this reason silicon killed steels are somewhat harder and stiffer than
aluminium killed steels.

Cobalt
Cobalt becomes highly radioactive when exposed to the intense radiation of nuclear
reactors, and as a result, any stainless steel that is in nuclear service will have a cobalt
restriction, usually aproximately 0.2% maximum. This problem is emphasised because there is
residual cobalt content in the nickel used in producing these steels.
Tantalum
Chemically similar to niobium and has similar effects.
Copper
Copper is normally present in stainless steels as a residual element. However it is added
to a few alloys to produce precipitation hardening properties

UNIT 4 NON-METALLIC MATERIALS

4.1.Polymer
Appearance of real linear polymer chains as recorded using an atomic force microscope
on surface under liquid medium. Chain contour length for this polymer is ~204 nm; thickness
is ~0.4 nm.
A polymer is a large molecule (macromolecule) composed of repeating structural units.

These subunits are typically connected by covalent chemical bonds. Although the term polymer
is sometimes taken to refer to plastics, it actually encompasses a large class of natural and
synthetic materials with a wide variety of properties.
Because of the extraordinary range of properties of polymeric materials, they play an

essential and ubiquitous role in everyday life. This role ranges from familiar synthetic plastics
and elastomers to natural biopolymers such as nucleic acids and proteins that are essential for
life.
Natural polymeric materials such as shellac, amber, and natural rubber have been used
for centuries. A variety of other natural polymers exist, such as cellulose, which is the main
constituent of wood and paper. The list of synthetic polymers includes synthetic rubber,
Bakelite, neoprene, nylon, PVC, polystyrene, polyethylene, polypropylene, polyacrylonitrile,
PVB, silicone, and many more.
Most commonly, the continuously linked backbone of a polymer used for the
preparation of plastics consists mainly of carbon atoms. A simple example is polyethylene,
whose repeating unit is based on ethylene monomer. However, other structures do exist; for
example, elements such as silicon form familiar materials such as silicones, examples being
silly putty and waterproof plumbing sealant. Oxygen is also commonly present in polymer
backbones, such as those of polyethylene glycol, polysaccharides (in glycosidic bonds), and
DNA (in phosphodiester bonds).
Polymers are studied in the fields of polymer chemistry, polymer physics, and polymer
science
Etymology

The word polymer is derived from the Greek words πολύ- - poly- meaning "many"; and
μέρος - meros meaning "part". The term was coined in 1833 by Jöns Jacob Berzelius, although
his definition of a polymer was quite different from the modern definition.
4.2.Historical development
Starting in 1811, Henri Braconnot did pioneering work in derivative cellulose
compounds, perhaps the earliest important work in polymer science. The development of
vulcanization later in the nineteenth century improved the durability of the natural polymer
rubber, signifying the first popularized semi-synthetic polymer. In 1907, Leo Baekeland
created the first completely synthetic polymer, Bakelite, by reacting phenol and formaldehyde
at precisely controlled temperature and pressure. Bakelite was then publicly introduced in
1909.
Despite significant advances in synthesis and characterization of polymers, a correct

understanding of polymer molecular structure did not emerge until the 1920s. Before then,
scientists believed that polymers were clusters of small molecules (called colloids), without
definite molecular weights, held together by an unknown force, a concept known as association
theory. In 1922, Hermann Staudinger proposed that polymers consisted of long chains of atoms
held together by covalent bonds, an idea which did not gain wide acceptance for over a decade
and for which Staudinger was ultimately awarded the Nobel Prize. Work by Wallace Carothers
in the 1920s also demonstrated that polymers could be synthesized rationally from their
constituent monomers. An important contribution to synthetic polymer science was made by
the Italian chemist Giulio Natta and the German chemist Karl Ziegler, who won the Nobel
Prize in Chemistry in 1963 for the development of the Ziegler-Natta catalyst. Further
recognition of the importance of polymers came with the award of the Nobel Prize in
Chemistry in 1974 to Paul Flory, whose extensive
work on polymers included the kinetics of step-growth polymerization and of addition

polymerization, chain transfer, excluded volume, the Flory-Huggins solution theory, and the
Flory convention.
Synthetic polymer materials such as nylon, polyethylene, Teflon, and silicone have
formed the basis for a burgeoning polymer industry. These years have also shown significant
developments in rational polymer synthesis. Most commercially important polymers today are
entirely synthetic and produced in high volume on appropriately scaled organic synthetic
techniques. Synthetic polymers today find application in nearly every industry and area of life.
Polymers are widely used as adhesives and lubricants, as well as structural components for
products ranging from children's toys to aircraft. They have been employed in a variety of
biomedical applications ranging from implantable devices to controlled drug delivery.
Polymers such as poly(methyl methacrylate) find application as photoresist materials used in
semiconductor manufacturing and low-k dielectrics for use in high-performance
microprocessors. Recently, polymers have also been employed as flexible substrates in the
development of organic light-emitting diodes for electronic display.
4.3.Polymer synthesis

The repeating unit of the polymer polypropylene
Polymerization is the process of combining many small molecules known as

monomers into a covalently bonded chain. During the polymerization process, some
chemical groups may be lost from each monomer. This is the case, for example, in
the polymerization of PET polyester. The monomers are terephthalic acid (HOOC-C6H4-
COOH) and ethylene glycol (HO-CH2-CH2-OH) but the repeating unit is -OC-C6H4-
COO-CH2-CH2-O-, which corresponds to the combination of the two monomers with the loss
of two water molecules. The distinct piece of each monomer that is incorporated into the
polymer is known as a repeat unit or monomer residue.
Laboratory synthesis
Laboratory synthetic methods are generally divided into two categories, step-growth
polymerization and chain-growth polymerization. The essential difference between the two is
that in chain growth polymerization, monomers are added to the chain one at a time
only,whereas in step-growth polymerization chains of monomers may combine with one
another directly. However, some newer methods such as plasma polymerization do not fit
neatly into either category. Synthetic polymerization reactions may be carried out with or
without a catalyst. Laboratory synthesis of biopolymers, especially of proteins, is an area of
intensive research.
Biological synthesis

There are three main classes of biopolymers: polysaccharides, polypeptides, and

polynucleotides. In living cells, they may be synthesized by enzyme-mediated processes,
such as the formation of DNA catalyzed by DNA polymerase. The synthesis of proteins
involves multiple enzyme-mediated processes to transcribe genetic information from the
DNA to RNA and subsequently translate that information to synthesize the specified protein
from amino acids. The protein may be modified further following translation in order to
provide appropriate structure and functioning.
4.4.MODIFICATION OF NATURAL POLYMERS

Many commercially important polymers are synthesized by chemical modification of
naturally occurring polymers. Prominent examples include the reaction of nitric acid and
cellulose to form nitrocellulose and the formation of vulcanized rubber by heating natural
rubber in the presence of sulfur.
Polymer properties
Polymer properties are broadly divided into several classes based on the scale at
which the property is defined as well as upon its physical basis. The most basic property of
a polymer is the identity of its constituent monomers. A second set of properties, known as
microstructure, essentially describe the arrangement of these monomers within the polymer
at the scale of a single chain. These basic structural properties play a major role in
determining bulk physical properties of the polymer, which describe how the polymer
behaves as a continuous macroscopic material. Chemical properties, at the nano-scale,
describe how the chains interact through various physical forces. At the macro-scale, they
describe how the bulk polymer interacts with other chemicals and solvents.
Monomers and repeat units

The identity of the monomer residues (repeat units) comprising a polymer is its first
and most important attribute. Polymer nomenclature is generally based upon the type of
monomer residues comprising the polymer. Polymers that contain only a single type of
repeat unit are known as homopolymers, while polymers containing a mixture of repeat units
are known as copolymers. Poly(styrene), for example, is composed only of styrene monomer
residues, and is therefore classified as a homopolymer. Ethylene-vinyl acetate, on the other
hand, contains more than one variety of repeat unit and is thus a copolymer. Some biological
polymers are composed of a variety of different but structurally related monomer residues;
for example, polynucleotides such as DNA are composed of a variety of nucleotide subunits.
A polymer molecule containing ionizable subunits is known as a polyelectrolyte or

ionomer.
Microstructure
The microstructure of a polymer (sometimes called configuration) relates to the

physical arrangement of monomer residues along the backbone of the chain. These are the
elements of polymer structure that require the breaking of a covalent bond in order to
change. Structure has a strong influence on the other properties of a polymer. For

example, two samples of natural rubber may exhibit different durability, even though their
molecules comprise the same monomers.
4.5.POLYMER ARCHITECTURE
••••••••
•• • •• • ••• •
• • •
Branch point in a polymer
An important microstructural feature determining polymer properties is the polymer
architecture.The simplest polymer architecture is a linear chain: a single backbone with no
branches. A related unbranching architecture is a ring polymer. A branched polymer
molecule is composed of a main chain with one or more substituent side chains or branches.
Special types of branched polymers include star polymers, comb polymers, brush polymers,
dendronized polymers, ladders, and dendrimers.
Branching of polymer chains affects the ability of chains to slide past one another by
altering intermolecular forces, in turn affecting bulk physical polymer properties. Long chain
branches may increase polymer strength, toughness, and the glass transition temperature
(Tg) due to an increase in the number of entanglements per chain. The effect of such long-
chain branches on the size of the polymer in solution is characterized by the branching
index. Random length and atactic short chains, on the other hand, may reduce polymer
strength due to disruption of organization and may likewise reduce the crystallinity of the
polymer.
A good example of this effect is related to the range of physical attributes of

polyethylene. High-density polyethylene (HDPE) has a very low degree of branching, is
quite stiff, and is used in applications such as milk jugs. Low -density polyethylene (LDPE),
on the other hand, has significant numbers of both long and short branc hes, is quite flexible,
and is used in applications such as plastic films.
Dendrimers are a special case of polymer where every monomer unit is branched.
This tends to reduce intermolecular chain entanglement and crystallization.
Alternativel y, dendritic polymers are not perfectly branched but share similar properties
to dendrimers due to their high degree of branching.
The architecture of the polymer is often physically determined by the functionality of

the monomers from which it is formed. This property of a monomer is defined as the number
of reaction sites at which may form chemical covalent bonds. The basic functionality
required for forming even a linear chain is two bonding sites. Higher functionality yields
branched or even crosslinked or networked polymer chains.
An effect related to branching is chemical crosslinking - the formation of covalent

bonds between chains. Crosslinking tends to increase Tg and increase strength and
toughness. Among other applications, this process is used to strengthen rubbers in a process
known as vulcanization, which is based on crosslinking by sulfur. Car tires, for ex ample, are
highly crosslinked in order to reduce the leaking of air out of the tire and to toughen their
durability. Eraser rubber, on the other hand, is not crosslinked to allow flaking of the rubber
and prevent damage to the paper.
A cross-link suggests a branch point from which four or more distinct chains emanate.
A polymer molecule with a high degree of crosslinking is referred to as a polymer network.
Sufficiently high crosslink concentrations may lead to the formation of an infinite network,
also known as a gel, in which networks of chains are of unlimited extent—essentially all
chains have linked into one molecule.
Chain length
The physical properties of a polymer are strongly dependent on the size or length of
the polymer chain. For example, as chain length is increased, melting and boiling
temperatures increase quickly. Impact resistance also tends to increase with chain length, as
does the viscosity, or resistance to flow, of the polymer in its melt state.
3.2
Chain length is related to melt viscosity roughly as 1:10 , so that a tenfold increase
in polymer chain length results in a viscosity increase of over 1000 times. Increasing chain
length furthermore tends to decrease chain mobility, increase strength and toughness, and
increase the glass transition temperature (Tg).This is a result of the increase in chain
interactions such as Van der Waals attractions and entanglements that come with increased
chain length. These interactions tend to fix the individual chains more strongly in position
and resist deformations and matrix breakup, both at higher stresses and higher temperatures.
A common means of expressing the length of a chain is the degree of polymerization,

which quantifies the number of monomers incorporated into the chain . As with other
molecules, a polymer's size may also be expressed in terms of molecular weight. Since
synthetic polymerization techniques typically yield a polymer product including a range of
molecular weights, the weight is often expressed statistically to describe the distribution of
chain lengths present in the same. Common examples are the number average molecular
weight and weight average molecular weight. The ratio of these two values is the
polydispersity index, commonly used to express the "width" of the molecular weight
distribution. A final measurement is contour length, which can

be understood as the length of the chain backbone in its fully extended state.
The flexibility of an unbranched chain polymer is characterized by its persistence

length.
Monomer arrangement in copolymers
Monomers within a copolymer may be organized along the backbone in a variety of ways.
• Alternating copolymers
[AB...]n (2).
possess regularly alternating monomer residues:
II Periodic copolymers have monomer residue types arranged in a repeating

sequence: [AnBm...] m being different from n .
Statistical copolymers have monomer residues arranged according to a known
• statistical rule. A statistical copolymer in which the probability of finding a particular

type of monomer residue at an particular point in the chain is independent of the types of
surrounding monomer residue may be referred to as a truly random copolymer (3).
• Block copolymers have two or more homopolymer subunits linked by covalent bonds
(4).
Polymers with two or three blocks of two distinct chemical species (e.g., A and B)
are called diblock copolymers and triblock copolymers, respectively. Polymers with
three blocks, each of a different chemical species (e.g., A, B, and C) are termed
triblock terpolymers.
• Graft or grafted copolymers contain side chains that have a different composition or
configuration than the main chain.(5)
Tacticity
Tacticity describes the relative stereochemistry of chiral centers in neighboring
structural units within a macromolecule. There are three types: isotactic (all
substituents on the same side), atactic (random placement of substituents), and
syndiotactic (alternating placement of substituents).
4.6.Polymer morphology
Polymer morphology generally describes the arrangement and microscale
ordering of polymer chains in space.
DSC
Crystallinity
When applied to polymers, the term crystalline has a somewhat ambiguous usage. In
some cases, the term crystalline finds identical usage to that used in conventional
crystallography. For example, the structure of a crystalline protein or polynucleotide, such as
a sample prepared for x-ray crystallography, may be defined in terms of a conventional unit
cell composed of one or more polymer molecules with cell dimensions of hundreds of
angstroms or more.
A synthetic polymer may be lightly described as crystalline if it contains regions of

threedimensional ordering on atomic (rather than macromolecular) length scales,
usually arising from intramolecular folding and/or stacking of adjacent chains.
Synthetic polymers may consist of both crystalline and amorphous regions; the
degree of crystallinity may be expressed in terms of a weight fraction or volume
fraction of crystalline material. Few synthetic polymers are entirely crystalline.
The crystallinity of polymers is characterized by their degree of crystallinity, ranging

from zero for a completely non-crystalline polymer to one for a theoretical completely
crystalline polymer. Polymers with microcrystalline regions are generally tougher (can be
bent more without breaking) and more impact-resistant than totally amorphous polymers.
Polymers with a degree of crystallinity approaching zero or one will tend to be

transparent, while polymers with intermediate degrees of crystallinity will tend to be opaque
due to light scattering by crystalline or glassy regions. Thus for many polymers, reduced
crystallinity may also be associated with increased transparency.
Chain conformation
The space occupied by a polymer molecule is generally expressed in terms of radius

of gyration, which is an average distance from the center of mass of the chain to the chain
itself. Alternatively, it may be expressed in terms of pervaded volume, which is the volume
of solution spanned by the polymer chain and scales with the cube of the radius of gyration.
4.7.Mechanical properties
The bulk properties of a polymer are those most often of end-use interest. These are
the properties that dictate how the polymer actually behaves on a macroscopic scale.
Tensile strength
The tensile strength of a material quantifies how much stress the material will endure
before suffering permanent deformation. This is very important in applications that rely upon
a polymer's physical strength or durability. For example, a rubber band with a higher tensile
strength will hold a greater weight before snapping. In general, tensile strength increases with
polymer chain length and crosslinking of polymer chains.
Young's modulus of elasticity

Young's Modulus quantifies the elasticity of the polymer. It is defined, for small

strains, as the ratio of rate of change of stress to strain. Like tensile strength, this is highly
relevant in polymer applications involving the physical properties of polymers, such as rubber
bands. The modulus is strongly dependent on temperature.
Transport properties
Transport properties such as diffusivity relate to how rapidly molecules move through
the polymer matrix. These are very important in many applications of polymers for films and
membranes.
4.8.Phase behavior
Melting point
The term melting point, when applied to polymers, suggests not a solid-liquid phase
transition but a transition from a crystalline or semi-crystalline phase to a solid amorphous
phase. Though abbreviated as simply Tm, the property in question is more properly called the
crystalline melting temperature. Among synthetic polymers, crystalline melting is only
discussed with regards to thermoplastics, as thermosetting polymers will decompose at high
temperatures rather than melt.
Glass transition temperature

A parameter of particular interest in synthetic polymer manufacturing is the glass
transition temperature (Tg), which describes the temperature at which amorphous polymers
undergo a transition from a rubbery, viscous amorphous solid, to a brittle, glassy
amorphous solid. The glass transition temperature may be engineered by altering the degree
of branching or crosslinking in the polymer or by the addition of plasticizer.
Mixing behavior
In general, polymeric mixtures are far less miscible than mixtures of small molecule
materials. This effect results from the fact that the driving force for mixing is usually
entropy, not interaction energy. In other words, miscible materials usually form a solution
not because their interaction with each other is more favorable than their self-interaction, but
because of an increase in entropy and hence free energy associated with increasing the
amount of volume available to each component. This increase in entropy scales with the
number of particles (or moles) being mixed. Since polymeric molecules are much larger and
hence generally have much higher specific volumes than small molecules, the number of
molecules involved in a polymeric mixture is far smaller than the number in a small
molecule mixture of equal volume. The energetics of mixing, on the other hand, is
comparable on a per volume basis for polymeric and small molecule mixtures. This tends to
increase the free energy of mixing for polymer solutions and thus make solvation less
favorable. Thus, concentrated solutions of polymers are far rarer than those of small
molecules.
Furthermore, the phase behavior of polymer solutions and mixtures is more complex
than that of small molecule mixtures. Whereas most small molecule solutions exhibit only
an upper critical solution temperature phase transition, at which phase separation occurs with
cooling, polymer mixtures commonly exhibit a lower critical solution temperature phase
transition, at which phase separation occurs with heating.

In dilute solution, the properties of the polymer are characterized by the interaction
between the solvent and the polymer. In a good solvent, the polymer appears swollen and
occupies a large volume. In this DSCEnario, intermolecular forces between the solvent and
monomer subunits dominate over intramolecular interactions. In a bad solvent or poor
solvent, intramolecular forces dominate and the chain contracts. In the theta solvent, or the
state of the polymer solution where the value of the second virial coefficient becomes 0, the
intermolecular polymer-solvent repulsion balances exactly the intramolecular monomer-
monomer attraction. Under the theta condition (also called the Flory condition), the polymer
behaves like an ideal random coil. The transition between the states is known as a coil-
globule transition.
Inclusion of plasticizers
Inclusion of plasticizers tends to lower Tg and increase polymer flexibility.
Plasticizers are generally small molecules that are chemically similar to the polymer and
create gaps between polymer chains for greater mobility and reduced interchain interactions.
A good example of the action of plasticizers is related to polyvinylchlorides or PVCs. A
uPVC, or unplasticized polyvinylchloride, is used for things such as pipes. A pipe has no
plasticizers in it, because it needs to remain strong and heat-resistant. Plasticized PVC is
used for clothing for a flexible quality. Plasticizers are also put in some types of cling film to
make the polymer more flexible.
Chemical properties
The attractive forces between polymer chains play a large part in determining a
polymer's properties. Because polymer chains are so long, these interchain forces are
amplified far beyond the attractions between conventional molecules. Different side groups
on the polymer can lend the polymer to ionic bonding or hydrogen bonding between its own
chains. These stronger forces typically result in higher tensile strength and higher crystalline
melting points.
The intermolecular forces in polymers can be affected by dipoles in the monomer

units. Polymers containing amide or carbonyl groups can form hydrogen bonds between
adjacent chains; the partially positively charged hydrogen atoms in N-H groups of one chain
are strongly attracted to the partially negatively charged oxygen atoms in C=O groups on
another. These strong hydrogen bonds, for example, result in the high tensile strength and
melting point of polymers containing urethane or urea linkages. Polyesters have dipole-
dipole bonding between the oxygen atoms in C=O groups and the hydrogen atoms in H-C
groups. Dipole bonding is not as strong as hydrogen bonding, so a polyester's melting point
and strength are lower than Kevlar's (Twaron), but polyesters have greater flexibility.
Ethene, however, has no permanent dipole. The attractive forces between

polyethylene chains arise from weak van der Waals forces. Molecules can be thought of as
being surrounded by a cloud of negative electrons. As two polymer chains approach, their
electron clouds repel one another. This has the effect of lowering the electron density on one
side of a polymer chain, creating a slight positive dipole on this side. This charge is enough
to attract the second polymer chain. Van der Waals forces

are quite weak, however, so polyethylene can have a lower melting temperature compared to
other polymers.
Standardized polymer nomenclature

There are multiple conventions for naming polymer substances. Many commonly
used polymers, such as those found in consumer products, are referred to by a common or
trivial name. The trivial name is assigned based on historical precedent or popular usage
rather than a standardized naming convention. Both the American Chemical Society (ACS)
and IUPAC have proposed standardized naming conventions; the ACS and UPAC
conventions are similar but not identical. Examples of the differences between the various
naming conventions are given in the table below:
In both standardized conventions, the polymers' names are intended to reflect the
monomer(s) from which they are synthesized rather than the precise nature of the repeating
subunit. For example, the polymer synthesized from the simple alkene ethene is called
polyethylene, retaining the -ene suffix even though the double bond is removed during the
polymerization process:

Fig 1: The polymerisalion of elhene in 10 poly(elhene)
Polymer characterization
The characterization of a polymer requires several parameters which need to be
specified. This is because a polymer actually consists of a statistical distribution of chains of
varying lengths, and each chain consists of monomer residues which affect its properties.
A variety of lab techniques are used to determine the properties of polymers. Techniques
such as wide angle X-ray scattering, small angle X-ray scattering, and small angle neutron
scattering are used to determine the crystalline structure of polymers. Gel permeation
chromatography is used to determine the number average molecular weight, weight average
molecular weight, and polydispersity. FTIR, Raman and NMR can be used to determine
composition. Thermal properties such as the glass transition temperature and melting point
can be determined by differential scanning calorimetry and dynamic mechanical analysis.
Pyrolysis followed by analysis of the fragments is one more technique for determining the
possible structure of the polymer. Thermogravimetry is a useful technique to evaluate the
thermal stability of the polymer. Detailed analyses of TG curves also allow us to know a bit
of the phase segregation in polymers. Rheological properties are also commonly used to
help determine molecular architecture (molecular weight, molecular weight distribution and
branching)as well as to understand how the polymer will process, through measurements of
the polymer in the melt phase. Another polymer characterization technique is Automatic
Continuous Online Monitoring of Polymerization Reactions (ACOMP) which provides
real-time characterization of polymerization reactions. It can be used as an analytical
method in R&D, as a tool for reaction optimization at the bench and pilot plant level and,
eventually, for feedback control of full-scale reactors. ACOMP measures in a model-
independent fashion the evolution of average molar mass and intrinsic viscosity, monomer
conversion kinetics and, in the case of copolymers, also the average composition drift and
distribution. It is applicable in the areas of free radical and controlled radical homo- and
copolymerization, polyelectrolyte synthesis, heterogeneous phase reactions, including
emulsion polymerization, adaptation to batch and continuous reactors, and modifications of
polymers.

Polymer degradation
A plastic item with thirty years of exposure to heat and cold, brake fluid, and sunlight.
Notice the discoloration, swollen dimensions, and tiny splits running through the material
Polymer degradation is a change in the properties—tensile strength, color, shape, or

molecular weight—of a polymer or polymer-based product under the influence of one or
more environmental factors, such as heat, light, chemicals and, in some cases, galvanic
action. It is often due to the scission of polymer chain bonds via hydrolysis, leading to a
decrease in the molecular mass of the polymer.
Although such changes are frequently undesirable, in some cases, such as
biodegradation and recycling, they may be intended to prevent environmental pollution.
Degradation can also be useful in biomedical settings. For example, a copolymer of polylactic
acid and polyglycolic acid is employed in hydrolysable stitches that slowly degrade after they
are applied to a wound.
The suDSCEptibility of a polymer to degradation depends on its structure. Epoxies

and chains containing aromatic functionalities are especially suDSCEptible to UV
degradation while polyesters are suDSCEptible to degradation by hydrolysis, while polymers
containing an unsaturated backbone are especially suDSCEptible to ozone cracking. Carbon
based polymers are more suDSCEptible to thermal degradation than inorganic polymers such
as polydimethylsiloxane and are therefore not ideal for most high-temperature applications.
High-temperature matrices S uch as bismaleimides (BMI), condensation polyimides

(with an O-C-N bond), triazines (with a nitrogen (N) containing ring), and blends thereof are
suDSCEptible to polymer degradation in the form of galvanic corrosion when bare carbon
fiber reinforced polymer CFRP is in contact with an active metal such as aluminum in salt
water environments.
The degradation of polymers to form smaller molecules may proceed by random

scission or specific scission. The degradation of polyethylene occurs by random scission —a
random breakage of the bonds that hold the atoms of the polymer together. When heated
above 450 °C, polyethylene degrades to form a mixture of hydrocarbons. Other polymers,
such as poly(alpha-methylstyrene), undergo specific chain scission with breakage occurring
only at the ends. They literally unzip or depolymerize back to the constituent monomer.

The sorting of polymer waste for recycling purposes may be facilitated by the use of
the Resin identification codes developed by the Society of the Plastics Industry to identify the
type of plastic.
Product failure
In a finished product, such a change is to be prevented or delayed. Failure of safety-

critical polymer components can cause serious accidents, such as fire in the case of cracked
and degraded polymer fuel lines. Chlorine-induced cracking of acetal resin plumbing joints
and polybutylene pipes has caused many serious floods in domesticproperties, especially in
the USA in the 1990s. Traces of chlorine in the water supply attacked vulnerable polymers
in the plastic plumbing, a problem which occurs faster if any of the parts have been poorly
extruded or injection molded. Attack of the acetal joint occurred because of faulty molding,
leading to cracking along the threads of the fitting which is a serious stress concentration.
Polymer oxidation has caused accidents involving medical devices. One of the oldest
known failure modes is ozone cracking caused by chain scission when ozone gas attacks
suDSCEptible elastomers, such as natural rubber and nitrile rubber. They possess double
bonds in their repeat units which are cleaved during ozonolysis. Cracks in fuel lines can
penetrate the bore of the tube and cause fuel leakage. If cracking occurs in the engine
compartment, electric sparks can ignite the gasoline and can cause a serious fire.
Fuel lines can also be attacked by another form of degradation: hydrolysis. Nylon 6,6
is suDSCEptible to acid hydrolysis, and in one accident, a fractured fuel line led to a spillage
of diesel into the road. If diesel fuel leaks onto the road, accidents to following cars can be
caused by the slippery nature of the deposit, which is like black ice

4.9.POLYMER MATERIALS
There are three general groups of polymer materials:
Elastomers
Thermoplastics
Thermosets
4.9.1.Elastomers
Elastomers are polymers possessing high elasticity - may be reversibly stretched at
high degree. Elastomers consists of long lightly cross-linked molecules.
Common elastomers are:
Polyisoprene (natural
rubber) Butyl
Nitrile
Neoprene
Ethylene-
Propylene Hypalon
Silicone
Elastomers may be strengthened by vulcanization process (heat treatment in presence of

chemical agents). Vulcanization results in increase of cross-linking of the molecules.
Vulcanized elastomers are elastic for small deformations.
4.9.2.Thermoplastics
Thermoplastics are polymers, which soften (becomes pliable and plastic) and melt
when heated. In the melted conditions thermoplastics may be formed by various methods
(injection molding, extrusion, Thermoforming). No new cross-links form (no chemical
curing) when a thermoplastic cools and harden. Thermoplastics may be reprocessed (remelt)
many times.
Common thermoplastics are:
Thermoplastic Low Density Polyethylene (LDPE)
Thermoplastic High Density Polyethylene (HDPE)
Polypropylene (PP)
Acrylonitrile-Butadiene-Styrene (ABS)
Polyvinyl Chloride (PVC)
Polymethylmethacrylate
(PMMA) Polytetrafluoroethylene
(PTFE) Polyethylene
Terephtalate (PET) Nylon 6 (N6)
Polyimide (PI)
Polycarbonate (PC)
Polysulfone (PSF)
4.9.3.Thermosets
Thermosets are polymers which do not melt when heated. Thermosets molecules are
cross-linked by strong covalent intermolecular bonds, forming one giant molecule. Cross-
linking is achieved in curing process initiated by heat, chemical agents or radiation.
Before curing processing thermoset materials are stored in partially

polymerized condition. Thermosets are stronger and stiffer than thermoplastics.
Common thermosets are:
Epoxies (EP)
Unsaturated Polyesters
(UP) Phenolics (PF)
Urea Formaldehyde (UF)
Melamine Formaldehyde
(MF) Alkyds (AMC)
4.10.POLYMER STRUCTURE
Polymer
Polymer is a substance (natural or synthetic), molecules of which consist of numerous
small repeated chemical units (monomers) linked to each other in a regular pattern.
Polymers usually combine crystalline and amorphous structures (semi-crystalline).
Degree of polymerization
Degree of polymerization is an average number of monomers (mers) in a polymer
molecule. Polymer molecules may combine up to million of monomers (mers) forming a one-
dimensional structure (chain), two-dimensional structure (planar molecules) or
threedimensional structure.
One-dimensional structure is common for organic polymers.
Organic polymer
Organic polymer is a polymer compound built of hydrocarbon base monomer units.
Besides carbon and Hydrogen the following atoms may be incorporated in polymer
molecules: Oxygen, Nitrogen, chorine, fluorine, silicon, phosphorous, and sulfur. Atoms of a
polymer molecule are held by covalent bonding.
Neighboring chains may form secondary bonds between them (cross-links)
which are less strong than covalent bonding between the atoms within the molecules.
Cross-links provide elasticity to the polymer, preventing sliding of the
neighboring chains when the material is stretched.
Branched polymer
Branched polymer consists of molecules having side chains (branches) attached to
the main chain.
Copolymer
Copolymer is a polymer molecule of which contains more than one kind of
monomers. Nylon is a common copolymer. Its molecules consist of two alternating
monomers: diacid and diamine.
Graft copolymer
Graft copolymer is a kind of branch polymer, side chains of which are made of
monomers differing from the monomer of the main chain.

Block copolymer
Block copolymer is a polymer molecules of which built from alternating
polymeric blocks of two or more different polymers.
Structure parameters affecting polymer properties:
Increase of the chain length.
Effect: increase of tensile strength and Modulus of Elasticity (stiffness).
Increase of number and length of side chains.

Effect: increase of tensile strength and stiffness.
Introduction of large monomers in molecules.

Effect: increase of stiffness.
Increase of number and strength of cross-links.

Effect: increase of tensile strength and stiffness.
Orientation of the molecules as a result of deformation during manufacturing.
Effect: Anisotropy of the material properties (properties along the deformation differ from
those in other directions). Every polymer is characterized by a temperature below of which
mobility of its molecules sharply decreases and the material becomes brittle and glassy.
This temperature is called Glass Transition Temperature.
Monomer molecular structures of different polymers are presented in the picture:

Elastomers
Elastomers are polymers possessing high elasticity - may be reversibly stretched at
high degree. Elastomers consists of long lightly cross-linked molecules.
Common elastomers are:
Polyisoprene (natural
rubber) Butyl
Nitrile
Neoprene
Ethylene-
Propylene Hypalon
Silicone
Elastomers may be strengthened by vulcanization process (heat treatment in presence

of chemical agents). Vulcanization results in increase of cross-linking of the molecules.
Vulcanized elastomers are elastic for small deformations.
Vulcanization produces cross-links which make impossible shaping material.

Therefore most of elastomers are shaped before cross-linking. However there are some
elastomer materials which are not cross-linked when heated. These astomers may be
reversibly remolded by heating many times (like Thermoplastics).
Such kind of elastomers is called Thermoplastic Elastomers.
Thermoplastic elastomers are manufactured by copolymerization of two or more monomers

forming block polymers or graft polymers.
Common thermoplastic elastomers are:
Polyurethanes
Polyester Copolymers
Styrene-Butadiene
Properties and applications of some elastomers

Elastomer Polyisoprene (natural
rubber) Elastomer Butyl (Isobutene-
Isoprene) Elastomer Nitrile
Elastomer Neoprene (Chloroprene)
Elastomer Ethylene-Propylene (EPDM)
Elastomer Hypalon (CSM, Chlor-Sulfonated Polyethylene)
Elastomer Silicone
Thermoplastic elastomer Polyurethane
Thermoplastic elastomer Styrene-Butadiene
Thermoplastic elastomer Polyester Copolymer

ELASTOMER
4.10.POLYISOPRENE (NATURAL RUBBER)
Property Value in metric unit Value in US unit
Density 0.93 *10³ kg/m³ 58.1 lb/ft³
Tensile strength 20 MPa 2900 psi
Elongation 800 % 800 %

Glass transition temperature -70 ºC -94 ºF
Maximum work temperature 80 ºC 176 ºF
7 9 9 11
Electric resistivity 10 -10 Ohm*m 10 -10 Ohm*cm
Dielectric constant 2.7 - 2.7 -
Excellent abrasion resistance;

Excellent tear strength;
Excellent resilinence;
Excellent low temperature flexibility;
Excellent dielectric strength;
Poor resistance to ozone and oxygen;
Poor resistance to sunlight and heat;
Poor resistance to solvents.
Applications: automobile tires, gaskets, hoses.
Elastomer
4.11.ELASTOMER BUTYL (ISOBUTENE-ISOPRENE)
Property Value in metricunit Value in US unit
Elongation 900 % 900 % Glass

transition temperature -79 ºC -110 ºF Maximum
work temperature 100 ºC 212 ºF
9 11
Electric resistivity 10 Ohm*m 10 Ohm*cm
Very low permeability to air;
Excellent resistance to acids and alkali;
Excellent heat resistance;
Poor resistance to solvents, fuel, oil.

Applications: inner lining of automobile tires, steam hoses and diaphragms.
ELASTOMER
4.12.NEOPRENE (CHLOROPRENE)

3 5
Electric resistivity 10 Ohm*m 10 Ohm*cm
Dielectric constant 9 - 9 -
Excellent abrasion resistance;

Good resistance to oil, fuel and petroleum based
solvents; Excellent resistance to ozone;
Very good resistance to sunlight;
Poor resistance to lacquer solvents.
Applications: oil and crude oil hoses, gaskets, diaphragms, lining of chemical vessels.

Elastomer
4.13.ELASTOMER ETHYLENE-PROPYLENE (EPDM)

8 10
Electric resistivity 10 Ohm*m 10
-
Dielectric constant 3.3 - 3.3
Excellent resistance to sunlight and

heat; Excellent resistance to ozone and
oxygen; Excellent resistance to water and
steam; Excellent low temperature
flexibility; Good dielectric strength;
Good abrasion resistance;
Poor resistance to fuel, oil, alcohol.
Applications: electrical insulation, shoe soles, hoses, conveyor belts.
4.14.ELASTOMER SILICONE

3 9 5 11
Electric resistivity 10 -10 Ohm*m 10 -10 Ohm*cm
Excellent resistance to ozone and

oxygen; Excellent resistance to heat and
sunlight; Excellent weather resistance;

Wide work temperature interval: -150ºF…600 ºF (-100ºC…315 ºC)

Poor resistance to fuel, oil, hydrocarbons;
Poor abrasion resistance
Poor tear resistance
Applications: high temperature sealant, adhesives, vibration damping components.

4.15.THERMOPLASTICS
Thermoplastics are polymers, which soften (becomes pliable and plastic) and melt when
heated. In the melted conditions thermoplastics may be formed by various methods (injection
molding, extrusion, Thermoforming). No new cross-links form (no chemical curing) when a
thermoplastic cools and harden. Thermoplastics may be reprocessed (re-melt) many times.
Molecules of most of thermoplastics combine long polymer chains alternating with

monomer units.
Thermoplastic materials may contain filler materials in form of powder or fibers,
providing improvement of specific material properties (strength, stiffness, lubricity, color
etc.).
Thermoplastic groups:
Polyolefines: Low Density Polyethylene (LDPE), High Density

Polyethylene (HDPE), Polypropylene (PP).
Styrenics: Polysterene (PS), Acrylonitrile-Butadiene-Styrene (ABS),

Styrene-Acrylonitrile (SAN), Styrene/Acrylic (S/A), Styrene-Maleic
Anhydride (SMA).
Vinyls: Polyvinyl Chloride (PVC), Chlorinated Polyvinyl Chloride (CPVC).
Acrylics: Polymethylmethacrylate (PMMA), Polyvinilchloride-Acrylic

Blend (PVC/MA).
Fluoropolymers: Polychlorotrifluoroethylene (CTFE), Polytetrafluoroethylene

(PTFE), Polyvinylidene Fluoride (PVDF).
Polyesters: Polyethylene Terephtalate (PET), Polyester PETG (PETG),

Polybutylene Terephtalate (PBT), Polyarilate (PAR), Liquid Crystal Polyester
(LCP).
Polyamides (Nylons): Nylon 6 (N6), Nylon 66 (N66), Nylon 11 (N11), Nylon

12 (N12), Polyphtalamide (PPA), Polyamidemide (PAI).
Polyimides: Polyimide (PI), Polyetherimide (PEI).
Polyethers: Polyacetal (POM), Polycarbonate (PC), Polyphenylene Oxide

Blend (PPO), Polyaryletherketone (PAEK), Polyetheretherketone.

Sulfur Containing Polymers: Polyphenylene Sulfide (PPS),

Polysulfone (PSF), Polyethersulfone (PES), Polyarylsulfone (PAS).
Properties and applications of some thermoplastics

Thermoplastic Low Density Polyethylene (LDPE)
Thermoplastic High Density Polyethylene (HDPE)
Thermoplastic Polypropylene (PP)
Thermoplastic Acrylonitrile-Butadiene-Styrene
(ABS) Thermoplastic Polyvinyl Chloride (PVC)
Thermoplastic Polymethylmethacrylate (PMMA)
Thermoplastic Polytetrafluoroethylene (PTFE)
Thermoplastic Polyethylene Terephtalate (PET)
Thermoplastic Polyamide (Nylon 6)
Thermoplastic Polyimide (PI)
Thermoplastic Polycarbonate (PC)
Thermoplastic Polysulfone (PSF)
4.16.FUNDAMENTALS OF CERAMICS
Ionicandcovalent bonding
Ceramics
Ceramics (ceramic materials) are non-metallic inorganic compounds formed from metallic
(Al, Mg, Na, Ti, W) or semi-metallic (Si, B) and non- metallic (O, N, C) elements.
Atoms of the elements are held together in a ceramic structure by one of the following
bonding mechanism: Ionic Bonding, Covalent Bonding, Mixed Bonding (Ionic-Covalent).
Most of ceramic materials have a mixed bonding structure with various ratios between
Ionic and Covalent components. This ratio is dependent on the difference in the
electronegativities of the elements and determines which of the bonding mechanisms is
dominating ionic or covalent.
Electro negativity
Ionic Bonding
Covalent Bonding
Ionic-Covalent (mixed) Bonding
Characterization of ceramics properties
Electro negativity
Electro negativity is an ability of atoms of the element to attract electrons of atoms of another
element. Electronegativity is measured in a relative dimensionless unit (Pauling scale) varying
in a range between 0.7 (francium) to
3.98 (fluorine).
Non-metallic elements are strongly electronegative. Metallic elements are characterized by

low electro negativity or high electro positivity - ability of the element to lose electrons.

Ionic Bonding
Ionic bonding occurs between two elements with a large difference in their electro
negativities (metallic and non-metallic), which become ions (negative and positive) as a
result of transfer of the valence electron from the element with low electro negativity to the
element with high electro negativity.
The typical example of a material with Ionic Bonding is sodium chloride (NaCl).
Electropositive sodium atom donates its valence electron to the electronegative

chlorine atom, completing its outer electron level (eight electrons):
As a result of the electron transfer the sodium atom becomes a positively charged ion
(cation) and the chlorine atom becomes a negatively charged ion (anion). The two ions
attract to each other by Coulomb force, forming a compound (sodium chloride) with ionic
bonding. Ionic bonding is non-directional.

Covalent Bonding
Covalent bonding occurs between two elements with low difference in their
electronegativities (usually non-metallics), outer electrons of which are shared between the four
neighboring atoms. Covalent Bonding is strongly directional.
Ionic-Covalent (mixed) Bonding

Ionic-covalent (mixed) bonding with various ratios of the two fractions (ionic and
covalent) occurs in most of ceramic materials.
Degree of Ionic Bonding can be estimated from the following formula:
I.F. = exp(-0.25*ΔE²)
Where
I.F. - fraction of ionic bonding;
ΔE - difference in the electro negativities of the elements.
Characterization of ceramics properties

In contrast to metallic bonding neither ionic nor covalent bonding form free electrons,
therefore ceramic materials have very low electric conductivity and thermal conductivity.
Since both ionic and covalent bonds are stronger than metallic bond, ceramic materials are
stronger and harder than metals.
Strength of ionic and covalent bonds also determines high melting point, modulus of elasticity
(rigidity), temperature and chemical stability of ceramic materials. Motion of dislocations
through a ceramic structure is impeded therefore ceramics are generally brittle that limits their
use as structural materials.
Ceramics may have either crystalline or amorphous structure. There are also ceramic
materials, consisting of two constituents: crystalline and amorphous.

Structure of ceramic materials

The following factors affect structure of ceramics:
Balance of electrical charges of anions and cations
Radius Ratio (rc/ra)

Where
rc - radius of cation;
ra - radius of anion.
Radius Ratio determines Coordination Number (CN)- the maximum number of anion
nearest neighbors for a cation.The anion neighbors do not touch each other.
rc/ra = 0.225…0.414(SiO2) CN = 4
rc/ra = 0.414…0.732(SnO2, PbO2) CN = 6
rc/ra = 0.732…1.0(ThO2) CN = 8
Covalent bonding component, which tends to form tetrahedral coordination, may affect the
Coordination Number.
• Ionsstructure.are packed with maximum density, providing minimum energy of the

Ceramic structures are classified and designated according to the pattern structures of
several natural minerals:

Tetrahedral silica block (SiO4-4) may form various silicate structures:

Island and DoubleIsland Silicates
Single or two silica blocks, containing other cations, form Island (olivine) or Double
Island Silicates (hemimorphite).
Ring and Chain Structures

Several (3,4,5,6) silica units join each other, forming a chain (orthopyroxenes,
clinopyroxenes, asbestos) or closed ring (beryl).
Sheet (layer) structure

Silica units connect to each other, forming infinite sheet (micas, serpentine, chlorite,
talc).
Framework silicate
Quartz, cristobalite, and tridymite minerals are based on the framework silicate structure.
Silicates exist in two forms: crystalline and amorphous (glasses).
General classification ofceramics

There are various classification systems of ceramic materials, which may be attributed to
one of two principal categories: application base system or composition base system.

Application base classification of ceramic

materials Tribology of ceramics
Characteristics of friction and wear of a ceramic material are determined by a
combination of its bulk microstructure parameters, surface conditions and environmental
factors (temperature, atmosphere pressure, etc.), lubrication conditions.
Effect of microstructure on tribological properties of ceramics

o Parameters of microstructure and their influence on friction and wear of
ceramics o Manufacturing processes forming microstructure of ceramics
Effect of surface characteristics on tribological properties of
ceramics o Surface characteristics
o Methods of modification of ceramic surfaces
Effect of lubrication on tribological properties of ceramics

4.17.EFFECT OF MICROSTRUCTURE ON TRIBOLOGICAL PROPERTIES OF

CERAMICS
Parameters of microstructure and their influence on friction and wear of ceramics
Grain size
The main disadvantage of Ceramics as compared to Metals and Polymers is their low
toughness. Toughness is a bulk mechanical property of a material however it correlates with
its wear resistance particularly when the wear is a result of abrasive action caused by
cracking. Finer grain structure results in increased toughness and better wear resistance.
Grain size also determines the surface finish quality, which may be achieved by grinding and
polishing operations. Fine grain structure allows decreasing the size of the surface micro
asperities after the surface finish operation resulting in lower coefficient of friction.
Critical flaw size (the size of a flaw that results in rapid fracture)
Effect of flaw size on the fracture strength of a ceramic material is expressed by the
Griffith equation:
σC =KIC /(Y(π a)½)
where:
KIC - stress-intensity factor, measured in MPa*m½;

a - the flaw size;
Y - geometry factor.
According to the equation flaws of lower size result in increased material toughness
and higher wear resistance.
Flaw size is generally proportional to the grain size.
Homogeneity
Homogeneous distribution of the matrix particles size and pores size, second phase
particles (toughening particles) incorporated between the matrix particles, aid phase (binders,
etc.) locating at the grains boundaries results in lowering the flaw size and consequently in
increase of the fracture strength (according to the Griffith equation).Higher fracture strength
causes higher wear resistance.Bulk homogeneity of the microstructure allows creating fine
and homogeneous surface finish with low content of surface flaws.High quality surface
possess low coefficient of friction.
Manufacturing processes forming microstructure of

ceramics Powder preparation
Powder characteristics such as particle shape (spherical, irregular), average particle
size, size distribution determine the ceramic grain size and the amount and size of the pores.
Compaction (shape forming)
The value of the applied pressure, the method of its application (Uniaxial (Die)

Pressing, Isostatic Pressing, Injection Molding, Extrusion, Slip Casting, etc.) and the amount
of binders and other additives (plasticizers, lubricants, deflocculants, water etc.) determine
the pores size and the residual internal stresses.
Sintering
Diffusion proceeding during sintering process causes the pores to diminish or even to
close up resulting in densification of the ceramic material. The bonding and other second
phases are distributed between the grains of the main ceramic phase. The matrix grains may
grow during the sintering process. Thus sintering process determines the final grains and
pores size and the physical and chemical homogeneity.
Effect of surface characteristics on tribological properties of ceramics

Surface characteristics
Surface topography
Friction characteristics (coefficient of friction, wear) are strongly dependent on
the type of the lubrication regime (boundary lubrication, mixed lubrication,
hydrodynamic lubrication).The lubrication regime is determined by the ratio of the
lubricant film thickness to the surface roughness Ra.Rough ceramic surface with
relatively large microasperities causes direct contact between the rubbing surfaces and
results in high coefficient of friction and increased wear.High surface finish quality allows
to improve the tribological characteristics of ceramics. Ceramics are brittle and they wear
by fracture mechanism, which is characterized by formation of cracks in the
subsurface regions surrounding the wear groove. The volume of the lost material is higher
than the volume of the wear track. Thus wear of brittle ceramics results
in roughening the surface. The effect of roughening during friction is lower in toughened
ceramics.
Surface defects
Sintering defects, surface machining, impacts during friction, embedded particles introduce
surface flaws, which lead to fracture cracking and increase wear.
Surface composition and tribochemical reactions

Ceramic surface may adsorb molecules of the environmental gases and liquids. Such
surfaces with modified composition may have different coefficient of friction. Coefficient of
friction of ceramics in vacuum is commonly higher than that in air. Hydration of Oxide
ceramics in a humid atmosphere also results in changing their coefficients of friction and
wear. Wear of hydrated silicon nitride and silicon carbide is decreased. Wear of hydrated
Alumina ceramics and Zirconia ceramics is increased due to chemisorption
embrittlement.Surface of Non-oxide ceramics oxidizes in the presence of Oxygen in the
environment. The oxidation is enhanced at increased temperatures. Oxide film on the
surface of a non-oxide ceramic decrease the coefficients of friction serving as a solid
lubricant.
Methods of modification of ceramic surfaces

Plasma oxidizing - a method of surface oxidation by elemental Oxygen supplied to the
ceramic surface by plasma.

Ion nitriding and carburizing - a method of introducing nitrogen (nitriding) or carbon

(carburizing) atoms into the ceramic surface by means of plasma (glow-discharge).
Ion implantation - a method of introducing a material into a ceramic surface by
electrostatically accelerated ions.
Laser densification - a method of heating the ceramic surface layer by a laser beam
resulting in closing the pores between the ceramic powder particles.
Electron beam densification - a method of heating the ceramic surface layer by an
electron beam resulting in closing the pores between the ceramic powder particles.
Chemical etching - cleaning the ceramic surface by acids.
Sputter etching - bombarding the ceramic surface by accelerated plasma ions,
which vaporize the surface molecules.
Effect of lubrication on tribological properties of ceramics

Lubricants decrease coefficient of friction and reduce wear of the rubbing Parts.
Lubricants remove the heat generated by friction.
This function is particularly important for ceramics since they have lower thermal
conductivity and usually produce more heat due to relatively high coefficient of
friction. Lubricants remove wear debris from the rubbing surfaces.
Lubricants also protect the ceramic surface from the environment.
Liquid lubricants
Liquid hydrocarbon lubricants are commonly used for relatively low temperatures
(up to 392ºF/200ºC). Silicone oils may be used up to 570ºF (300ºC).
Solid lubricants
Solid lubricants may be used for lubricating ceramics in various forms: suspensions in
liquid lubricants, dry powders, Dispersions in gases, coatings. Requirements to solid
lubricants properties: good adhesion to the ceramic surface, low shear strength in the
sliding direction and high compression strength in the direction of the load
(perpendicular to the sliding direction).Substances used as solid lubricants:
graphite, molybdenum disulfide, boron nitride, Poly tetra fluoro ethylene (PTFE), calcium
fluoride- barium fluoride eutectic. Maximum work temperature some of the solid
lubricants is low (PTFE:392ºF/200ºC). Other lubricants may withstand up to
1508ºF/820ºC (calcium fluoride-barium fluoride eutectic).
Gaseous lubricants
Vapors of some organic substances may serve as lubricants for ceramics. The
vaporized molecules of such lubricant reach the ceramic surface react with it and form on
its surface a film possessing low coefficient of friction.


UNIT 5 MECHANICAL PROPERTIES AND DEFORMATION MECHANISM

5.1.PLASTIC DEFORMATION
Plastic deformation is a change of the material dimensions remaining after removal of
the load caused the deformation. Plastic deformations in metals occur by “slip” mechanism,
illustrated in the picture:
When the yield stress is achieved one plane of atoms in crystal lattice
glides over another. Few parallel slip planes form a block, neighboring with
another block. Thus movement of the crystal planes is resulted in a series of
steps, forming slip bands - black lines viewed under optical microscope.
Slip occurs when the share resolved stress along the gliding planes reaches a critical
value. This critical resolved shear stress is a characteristic of the material.
Certain metals (Zn and Sn) deform by a process of twinning, differing from the normal
slip mechanism, where all atoms in a block move the
same distance. In the deformation by twinning atoms of each slip plane in a block move
different distance, causing half of the crystal lattice to become a mirror image of another half.
In polycrystalline material directions of slips are different in

different crystals. If a grain is oriented unfavorably to the stress
direction its deformation is impeded. In addition to this grain boundaries are
obstacles for the slip movement as the slip direction should be changed when
it crosses the boundary. As a result of the above strength of polycrystalline
materials is higher, than that of mono-crystals.
Slip and twinning processes, occurring during plastic deformation result

in formation of preferred orientation of the grains. If the stress value required
for a slip is higher than cohesion strength, metal fracture occurs. Stress-
DSC
strain relations are considered in Tensile test and Stress-Strain Diagram.
Microscopically, plastic deformation is a result of permanent distortion of lattice by

extensive rearrangement of atoms within it. There is an irreversible shear displacement of one
part of the crystal relative to another in a definite crystallographic direction. This process is
known as slip. Slip follows the path of least energy. It coincides to the direction in which atoms
are most closely packed.
In a lattice, crystalline array of atoms are having linear imperfection,

called dislocation. Slip is considered as step-by-step movement of
dislocation within a crystal. In well-annealed metals, density of dislocation is not high enough
to cause such macroscopic deformation. Therefore, there must be some mechanism that causes
dislocations to multiply to a large number. Slip is one of such mechanisms in which
dislocations reproduce themselves.
There are two types of dislocations: edge dislocation and screw dislocation. The edge
dislocation moves across the slip plane in the direction of applied shear force. The direction of
movement of screw dislocation is normal to the direction of slip step. When slip occurs by
combination of the two types of dislocations, it results in a curved dislocation.
Another mechanism of plastic deformation that occurs in certain

metals under certain circumstances is by twinning. In this process, atoms in
each successive plane within a block move different distances. As a result the
direction of the lattice is altered so that each half of the crystal becomes a
mirror image of the other half along a twinning plane. In case of BCC
structure, twinning occurs after some plastic deformation or when stress is applied
quickly.
5.2.THE BRINELL HARDNESS TEST

The Brinell hardness test method consists of indenting the test material
with a 10 mm diameter hardened steel or carbide ball subjected to a load of
3000 kg. For softer materials the load can be reduced to 1500 kg or 500 kg
to avoid excessive indentation. The full load is normally applied for 10 to 15
seconds in the case of iron and steel and for at least 30 seconds in the case of
other metals. The diameter of the indentation left in the test material is
measured with a low powered microscope. The Brinell harness number is
calculated by dividing the load applied by the surface area of the indentation.

The diameter of the impression is the average of two readings at right angles and
the use of a Brinell hardness number table can simplify the determination of the Brinell
hardness. A well structured Brinell hardness number reveals the test
conditions, and looks like this, "75 HB 10/500/30" which means that a
Brinell Hardness of 75 was obtained using a 10mm diameter hardened steel
with a 500 kilogram load applied for a period of 30 seconds. On tests of
extremely hard metals a tungsten carbide ball is substituted for the steel
ball. Compared to the other hardness test methods, the Brinell ball makes
the deepest and widest indentation, so the test averages the hardness over
a wider amount of material, which will more accurately account for multiple
grain structures and any irregularities in the uniformity o f the material. This
method is the best for achieving the bulk or macro-hardness of a material, particularly
those materials with heterogeneous structures.
5.3.VICKERS HARDNESS TEST

The Vickers hardness test method consists of indenting the test material
with a diamond indenter, in the form of a right pyramid with a square base and
an angle of 136 degrees between opposite faces subjected to a load of 1 to 100kgf. The full
load is normally applied for 10 to 15 seconds. The two diagonals of the indentation left in
the surface of the material after removal of the load are measured using a microscope and
their average calculated. The area of the sloping surface of the indentation is calculated. The
Vickers hardness is the quotient obtained by dividing the kgf load by the square mm area of
indentation.

F= Load in kgf
d = Arithmetic mean of the two diagonals, d1 and d2 in mm HV = Vickers hardness
When the mean diagonal of the indentation has been determined the Vickers hardness may
be calculated from the formula, but is more convenient to use conversion tables. The Vickers
hardness should be reported like 800 HV/10, which means a Vickers hardness of 800, was
obtained using a 10 kgf force. Several different loading settings give practically identical
hardness numbers on uniform material, which is much better than the arbitrary changing of
scale with the other hardness testing methods. The advantages of the Vickers hardness test
are that extremely accurate readings can be taken, and just one type of indenter is used for
all types of metals and surface treatments. Although thoroughly adaptable and very precise
for testing the softest and hardest of materials, under varying loads, the Vickers machine is a
floor standing unit that is more expensive than the Brinell or Rockwell machines.
5.4.ROCKWELL HARDNESS TEST

The Rockwell hardness test method consists of indenting the test material with a
diamond cone or hardened steel ball indenter. The indenter is forced into the test material
under a preliminary minor load F0 (Fig. 1A) usually 10 kgf. When equilibrium has been
reached, an indicating device, which follows the movements of the indenter and so responds
to changes in depth of penetration of the indenter is set to a datum position. While the
preliminary minor load is still applied an additional major load is applied with resulting
increase in penetration (Fig. 1B). When equilibrium has again been reach, the additional major
load is removed but the preliminary minor load is still maintained. Removal of the additional
major load allows a partial recovery, so reducing the depth of penetration (Fig. 1C). The
permanent increase in depth of penetration, resulting from the application and removal of the
additional major load is used to calculate the Rockwell hardness number.
HR = E - e
F0 = preliminary minor load in kgf
F1 = additional major load in kgf
F = total load in kgf

e = permanent increase in depth of penetration due to major load F1 measured in units of

0.002 mm
E = a constant depending on form of indenter: 100 units for diamond indenter, 130 units
for steel ball indenter
HR = Rockwell hardness number
D = diameter of steel ball

TYPICAL APPLICATION OF ROCKWELL HARDNESS SCALES HRA . . . .

Cemented carbides, thin steel and shallow case hardened steel
HRB . . . . Copper alloys, soft steels, aluminium alloys, malleable irons, etc.
HRC . . . . Steel, hard cast irons, case hardened steel and other materials harder than 100
HRB HRD . . . . Thin steel and medium case hardened steel and pearlitic malleable iron

HRE... . Cast iron, aluminium and magnesium alloys, bearing metals

HRF... . Annealed copper alloys, thin soft sheet metals
HRG... . Phosphor bronze, beryllium copper, malleable irons HRH . . . Aluminium,
zinc, lead
HRK... .}HRL... .}
HRM... .}... . Soft bearing metals, plastics and other very soft materials
HRP... .}
HRR... .}
HRS... .}
HRV... .}
Advantages of the Rockwell hardness method include the direct Rockwell
hardness number readout and rapid testing time.
Disadvantages include many arbitrary non-related scales and
possible effects from the specimen support anvil (try putting a cigarette
paper under a test block and take note of the effect on the hardness
reading! Vickers and Brinell methods don't suffer from this
effect).
5.5.CHARPY IMPACT TEST

The Charpy impact test, also known as the Charpy v-notch
test, is a standardized high strain-rate test which determines the
amount of energy absorbed by a material during fracture. This absorbed
energy is a measure of a given material's toughness and acts as a
tool to study temperature- dependent brittle-ductile transition. It is widely
applied in industry, since it is easy to prepare and conduct and results
can be obtained quickly and cheaply. But a major disadvantage is that all results
are only comparative.
The apparatus consists of a pendulum axe swinging at a notched

sample of material. The energy transferred to the material can
be inferred by comparing the difference in the height of the hammer
before and after a big fracture.
The notch in the sample affects the results of the impact tes t,
thus it is necessary for the notch to be of regular dimensions and
geometry. The size of the sample can also affect results, since the
dimensions determine whether or not the material is in plane strain.
This difference can greatly affect conclusions made.
where all the aspects of the test and equipment used are described in detail.

Quantitative results
The quantitative result of the impact tests the energy needed to fracture a
material and can be used to measure the toughness of the material and the yield
strength. Also, the strain rate may be studied and analyzed for its effect on fracture.
The ductile-brittle transition temperature (DBTT) may be derived

from the temperature where the energy needed to fracture the
material drastically changes. However, in practice there is no sharp
transition and so it is difficult to obtain a precise transition
temperature. An exact DBTT may be empirically derived in many
ways: a specific absorbed energy, change in aspect of fracture (such as 50%
of the area is cleavage), etc.
Qualitative results
The qualitative results of the impact test can be used to
determine the ductility of a material. If the material breaks on a flat
plane, the fracture was brittle, and if the material breaks with jagged
edges or shear lips, then the fracture was ductile. Usually a material does
DSC
not break in just one to way or the other, and thus comparing the jagged of the
flat surface areas ductile fracture will give an estimate of the percentage of
and brittle fracture.
Sample sizes
According to ASTM A370,the standard specimen size for Charpy impact
testing is 10mm×10mm×55mm. Subsize specimen sizes are:
10mm×7.5mm×55mm, 10mm×6.7mm×55mm, 10mm×5mm×55mm,
10mm×3.3mm×55mm, 10mm×2.5mm×55mm.
Details of specimens as per ASTM A370 (Standard Test Method and
Definitions for Mechanical Testing of Steel Products).
5.6.FATIGUE TEST
In materials science, fatigue is the progressive and localized structural damage
that occurs when a material is subjected to cyclic loading. The
nominal maximum stress values are less than the ultimate tensile stress
limit, and may be below the yield stress limit of the material.
Fatigue occurs when a material is subjected to repeated loading and unloading.
If the loads are above a certain threshold, microscopic cracks will begin to form at the
surface. Eventually a crack will reach a critical size, and the structure will suddenly
fracture. The shape of the structure will significantly affect the

ME 6403 ENGINEERING MATERIALS AND M ETALLURGY
fatigue life; square holes or sharp corners will lead to elevated local stresses where
fatigue cracks can initiate. Round holes and smooth transitions or fillets are therefore
important to increase the fatigue strength of the structure.
Characteristics of fatigue
Fracture of an aluminium crank arm. Dark area of striation s: slow crack

growth. Bright granular are a: sudden fracture.
• In metals and alloys, the process starts w ith dislocation movements,eventually

forming persistent slip bands that nucleate short cracks.
• Fatigue is a st ochastic process, often showing considerable scatter even in
controlled environments.
• The greate r the applied stress range, the shorter
the life. F atigue life scatter tends to increase for
longer fatigue lives. Damage is cumulative. Materials do
not recover when rested. Fatigue life is influence d by a variety
of factors, su ch as temperature, surface finish, microstructure,
presence of oxidizing or inert chemicals, residual stresses, contact
(fretting), etc.
• Some materials (e.g.,some steel and titanium alloys) exhibit a theoretical
fatigue limit below which continued loading does not lead to structural
failure.
• In recent years, researchers have found that failures o ccur below the
theoretical fatigue limit at very high fatigue lives (109 t o 1010 cycles). An
ultrasoni c resonance technique is used in these experiments w ith
frequencies around 10-20 kHz
• High cycle fatigue strength (about 103 to 108 cycles) can be described by
stress-basedpar ameters. A load-controlled servo-hydraulic test rig is
commonly us ed in these tests, with frequencies
of aro und 20-50 Hz. Other sorts o f machines like
resonant magnetic machines can also be used, achieving frequencies up to
250 Hz.
• Low cycle fatigue (typically less than 103 cycles) is associated with
wide spread plasticity in metals; thus, a strain-based param eter should be
used for fatig ue life prediction in metals and alloys . Testing is conducted
with constant strain amplitudes typically at 0.01 -5 Hz.
FACTORS THAT AFFECT FATIGUE-LIFE

Cyclic stress state: Depending on the compl exity of the
DSCE 80 Department of Mechani cal Engineering

geometry and the loading, one or more properties of the stress

state need t o be considered, such as stress am plitude, mean
stress, biaxial ity, in-
phase or out-of-phase shear stress, and load
sequence,
Geomet ry: Notches and variation in cross section
throughout a
part lead to stress concentrations where fatigue cracks
initiate.
Surface quality: Surface roughness cause micro scopic stress

concentrations that lower the fatigu e strength.
Compressive residual stresses can be introduced in the surface
by e.g. shot peening to increase fatigue life. Such
techniques for producing surface stress are often referred to
as peening, whatever the mechanism used to produce the
stress. Low Plasticity Burnishing, Laser peening, and
ultrasonic i mpact treatment can also produce this surface
compressive stress and can increase the fatigu e life of the
component. This improvement is normally observed only
for high-cycle f atigue.
aterial Type: Fatigue life, as well as the behavior during

cyclic loading, varies widely for different m aterials, e.g.
composites and
polymers differ markedly from metals.
Residual stresses: Welding, cutting, ca sting, and
other manufac turing processes involving heat or
deformation can produce high levels of tensile residual stress,
which decrea ses the fatigue strength.
Size and distribution of internal defects: Ca sting defects
such as gas porosity, non-metallic inclusions and shrinkage
voids can significantly reduce fatigue strength.
Direction of loading: For non-isotropic materials, fatigue
strength depe nds on the direction of the principal stress.
Grain size: For most metals, smaller grains yield longer
fatigue lives, however, the presence of surface defects or
scratches w ill have a greater influence th an in a
coarse grain ed alloy.
Environment: Environmental conditions can cause
erosion, corros ion, or gas-phase embrittlement, which all affect
fatigue life. Corrosion fatigue is a problem encountered in
many aggres sive
environments.
Temperature: Extreme high or low tempe ratures can

decrease fatigu e strength.
DESIGN AGAINST FAT IGUE

Dependable design against fatigue-failure requires thorough

education and supervised experience in structural engineering,

mechanical engineering, or materials science. There are three principal
approaches to life assurance for mechanical parts that display increasing degrees
of sophistication:
1. Design to keep stress below threshold of fatigue limit (infinite lifetime

concept);
2. Design (conservatively) for a fixed life after which the user
is instructed to replace the part with a new one (a so-called
lifed part, finite lifetime concept, or "safe-life" design practice);
3. Instruct the user to inspect the part periodically for cracks
and to replace the part once a crack exceeds a critical length.
This approach usually uses the technologies of nondestructive
testing and requires an accurate prediction of the rate of crack-growth
between inspections.
This is often referred to as damage tolerant design or
"retirement-for- cause".
STOPPING FATIGUE
Fatigue cracks that have begun to propagate can sometimes be
stopped by drilling holes, called drill stops, in the path of the fatigue
crac k This is not recommended as a general practice because the hole
represents a stress concentration factor which depends on the size of
the hole and geometry. There is thus the possibility of a new crack starting in
the side of the hole. It is always far better to replace the cracked part entirely.
MATERIAL CHANGE
Changes in the materials used in parts can also improve
fatigue life. For example, parts can be made from better fatigue
rated metals. Complete replacement and redesign of parts can also
reduce if not eliminate fatigue problems. Thus helicopter rotor blades
and propellers in metal are being replaced by composite equivalents.
They are not only lighter, but also much more resistant to fatigue.
They are more expensive, but the extra cost is amply repaid by their
greater integrity, since loss of a rotor blade usually leads to total loss
of the aircraft. A similar argument has been made for replacement of
metal fuselages, wings and tails of aircraft.
5.7.CREEP TEST
Method for determining creep or stress relaxation behavior. To determine creep
properties, material is subjected to prolonged constant tension or compression loading
at constant temperature. Deformation is recorded at specified time intervals and a
creep vs. time diagram is plotted. Slope of curve at any point is creep rate. If failure
occurs, it terminates test and time for rupture is recorded. If specimen does not
fracture within test period, creep recovery may be measured. To determine stress
relaxation of material, specimen is deformed a given amount and decrease in stress
over prolonged period of exposure at constant temperature is recorded
Viscoplasticity is a theory in continuum mechanics that describes the rate-
dependent inelastic behavior of solids. Rate-dependence in this context means that the
deformation of the material depends on the rate at which loads are applied. The
inelastic behavior that is the subject of viscoplasticity is plastic deformation which
means that the material undergoes unrecoverable deformations when a load level

is reached. Rate-dependent plasticity is important for transie nt plasticity

calculations. The main difference between rate- independ ent plastic and
viscoplastic material models is that the latter exhibit not only permanent
deformations after the application of loads but continue to undergo a creep flow
as a function of time under the influence of the applied load.
The elastic respon se of viscoplastic materials can be represented in one-
dimension by Hookean spring elements. Rate- dependence can be represented by
nonlinear dashpot elemen ts in a manner similar to viscoelasticity. Plasticity can be
accounted for by adding sliding frictional elements as shown in Figure 1.In the figure
E is the modulus of elasticity, λ is the viscosity parameter and N is a power-law type
parameter that represents non-linear dashpot σ(dε/dt)= σ = λ(dε/dt)(1/ N)]. The sliding
element can have a yield stress (σy) that is strain rate dependent, or e ven constant,
Viscoplasticity is usually modeled in three -dimensions using overstress models of the
Perzyna or Duvaut-Lions types. In these models, the stress is allo wed to increase
beyond the rate-independent yield surface upon application of a load and then allowed
to relax back to the yield surface over time. The yield surrface is usually assumed not
to be rate-dependent in such models. An alternativ e approach is to add a strain rate
depen dence to the yield stress and use the techhniques of rate independent plasticity
to calculate the response of a material For metals and alloys, viscoplasticity is the
macroscopic behavior caused by a mechanism linked to the movement of dislocation
s in grains, with superposed effects of inter-crystalline gliding. The mechanism
usually becomes dominant at temperatur es greater than approximately one third o f
the absolute melting temperature. However, certain alloys exhibit viscoplasticity at
room temperature (300K). For polymer s, wood, and bitumen, the theory of
viscoplasticity is required to describe beha vior beyond the limit of elasticity or
viscoelasticity.
In general, viscoplasticity theories are useful in areas such as the calculation of
permanent deformations, the prediction of the plastic collapse of structures, the
investigation of stability, crash simulations, systems exposed to hig h temperatures
such as turbines in engines, e.g. a power plant, dynamic problem s and systems
exposed to high strain rates. dels of rate-independent plasticity that have a rate-
dependent yield stress.
Figure 3a. Creep test Figure 3b. Strain as a function of time in a creep test.
Creep is the tendency of a solid material to slowly move or defor m permanently

under constant stresses. Creep tests measure the strain response due to a constant
stress as shown in Figure 3. The classical creep curve represents the evolution of
strain as a function of time in a material subjected to uniaxial stre ss at a constant
temperature. The creep test, for instance, is performed by apply ing a constant
force/stress and analyzing the strain response of the system. In gener al, as shown in
Figure 3b this curve usually shows three phases or periods of behavior

A primary creep stage, also known as transient creep, is the starti ng stage during
which hardening of the material leads to a decrease in the rate of flow which is
initially very high. .
The secondary creep stage, also known as the steady state, is where the strain rate is
constant. .
A tertiary creep phase in which there is an increase in the strain rate up to the fracture
strain. .
Figure 4. a) Applied strai n in a relaxation test and b) induced stress as functions of

time over a short period for a viscoplastic material.
As shown in Figure 4, th e relaxation test is defined as the stress res ponse due to a
constant strain for a p eriod of time. In viscoplastic materials, relaxation tests
demonstrate the stress rel axation in uniaxial loading at a constant strain. In fact, these
tests characterize the viscosity and can be used to determine the relation which exists
between the stress and th e rate of viscoplastic strain. The decomposit on of strain rate
is
The elastic part of the strain rate is given

by
For the flat region of th e strain-time curve, the total strain rate is zero. Hence we
have,
Therefore the relaxation curve can be used to determine rate of viscoplastic strain and
hence the viscosity of the dashpot in a one-dimensional viscoplastic material model.
The residual value that is reached when the stress has plateaued a t the end of a
relaxation test corresponds to the upper limit of elasticity. For some m aterials such as
rock salt such an upper limit of elasticity occurs at a very small val ue of stress and
relaxation tests can be co ntinued for more than a year without any ob servable
plateau in the stress.

It is important to note that relaxation tests are extremely difficult to perform because
maintaining the condition in a test requires considerable delic acy
Tensile testing, also known as tension testing, is a fundam ental materials science test
in which a sa mple is subjected to uniaxial tension until fail ure. The results from the
test are commo nly used to select a material for an application, for quality control, and
to predict how a material will react under other t ypes of forces. Properties that are
directly measured via a tensile test are ultimate t ensile strength, maximum elongation
and reduction in area. From these m easurements the following properties can also be
determined: Young's modulus, Poisson's ratio, yield strength, and strain-harde ning
characteristics.
Tensile specimens made from an aluminum alloy. The left two sp ecimens have a
round cross-section and threaded shoulders. The right two are flat specimen designed
to be used with s errated grips.
A tensile specimen is a standardized sample cross-section. It has two shoulders and a
gage section in between. The shoulders are large so they can be readily gripped,
where as the gage section has a smaller cross-section so that the deformation and
failure can occur in this area.
The shoulders of the test specimen can be manufactured in various ways to mate to
various grips in the tes ting machine (see the image below). Each system has
advantages and disadvantages; for example, shoulders designed for se rrated grips are
easy and cheap to manuufacture, but the alignment of the specim en is dependent
on the skill of the tech nician. On the other hand, a pinned gri p assures good
alignment. Threaded sh oulders and grips also assure good alig nment, but the
technician must know to thread each shoulder into the grip at least one diameter's
length, otherwise the threads can strip before the specimen fr actures.
In large castings and forgi ngs it is common to add extra material, which is designed
to be removed from the casting so that test specimens can be made from it. These
specimen not be exact representation of the whole workpiece be cause the grain
structure may be different throughout. In smaller workpieces or when critical parts of
the casting must be te sted, a workpiece may be sacrificed to make the test
specimens.For workpieces that are machined from bar stock, the test specimen can be
made from the same piece as the bar stock.
The repeatability of a testing machine can be found by using special test specimens
meticulously made to be a s similar as possible.

QUESTION BANK
UNIT-1 CONSTITUTION OF ALLOYS AND PHASE DIAGRMS

PART-A
1. Define alloy.
2. What is degree of freedom?
3. What is mean by base metal?
4. What are alloy elements?
5. What are electron components?
6. Define phase.
7. What is an equilibrium phase diagram?
8. State Gibb’s phase rule.
9. What are cooling curves?
10. What is liquidus line? A solidus line?A solvus line?
11.What is tie line ?
12.What is 3 phase reaction?
13.Discuss between eutectic and eutectoid reactions?
14.Discuss between pretectic and prectectoid reactions?
15.What is steel?
16.What do you understand by allotrophy of iron?
17.What are intermediate componenets?
18.State Hume Rothery’s rule.
PART –B
1) Discuss the similarities and difference between substitutional and interstical
solid solutions.
2) Explain the rules by which chemical composition and amount of phases can be
estimated from phase diagram.
3) Explain the Binary phase diagram?
4) Explain the Unitary phase diagram?
5) How can construct the phase diagram binary eutectic alloy system?
6) Draw the iron carbide equilibrium diagram?
7) State and explain the Hume Rothery’srule?
8) Explain the primary crystallization of eutectoid steels ,hypereutectoid steels?
9) Explain the primary crystallization of eutectoid cast iron ,hypereutectoid cast
irons?
10) Explain the following reactions with reference phase diagram
a) Eutectic reaction
b) Eutectoid reaction
c) Peritectoid reaction
d) Peritectic reaction

UNIT 2 HEAT TREATMENT

PART-A
1.Define the term heat treatment.
2. What are the purposes of the processing heat treatment?
3. List the various stages of a heat treatment process.
4.What is meant by annealing?
5. What is meant by normalizing?
6. Diffentiate between normalizing and annealing
7. Definequenching process.
8.What is meant by hardening?
9. What is tempering?
10.What is martempering and austempering?
11. What is a TTT diagram?
12.What is a CCT diagram?
13.What is significance of the critical cooling rate?
14. What is the significance of the TTT diagram?
15.What do you meant by the term case hardening?
16.What is meant by full annealing?
PART –B
1) What is heat treatment? And explain the various stages of heat treatment
process.
2) Describe Normalizing process of heat treatment.
3) a) What do you understand by the hardening of steel.
b) Discuss the reason why martensite is very hard.
4) Explain the process of martempering .Compare and constrast it with as
tempering.
5) Differentiate between hardness and hardenability.
6) Discuss the uses of hardenability curves.
7) What the effects of tempering temperature on mechanical properties of steel.
8) Brief various tempering process.
9) What are TTT diagrams? how its drawn?.
10) What is a CCT diagram? And write short notes on critical cooling rate.


PART A
1. What are metals ?
2. What are the characteristics of metals?
3. What are the types of metals?
4.What are medium carbon steels?
5.State three reasons why ferrous alloys are used extensively.
6.What are alloy steel how they are classified?
7.What makes a stainless steel “stainless”?
8.What is meant by 18-4-1 high speed steels?
9.What are HSLA steels? Where are they used?
10. How can you classify cast irons?
11. Where are the white cast irons used?
12. What are alloy cast irons?
13. List some bronzes alloys.
14. List atleast4types of brasses used.
15. What are gun metals? Give its composition.
16. What are cupronickels?
17. What is duralumin? Give its composition.
PART B
1) Give the classification of steels , and give the properties and application of high
carbon and low carbon steels.
2) What are alloy steel? how the alloy steel are classified explain them.
3) give the sub effects of the following
a) Manganese
b) Silicon
c) Vanadium
e) Tungsten
4) Give the main classification of stainless steels? And their applications .
5) Write an engineering brief about the following
a) Tool steels b)HSLA steels c) Maraging steels
6) Explain the principle and characteristics of cast iron and explain the factors
which affect the cast iron.
7) Describe the main structure of the cast irons and accounted for their continued
use as engineering materials.
8) Discuss the composition, properties of any four copper alloys.
9) Explain the composition, properties of some aluminium alloys.
10) What are the necessary metallurgical characteristics of good bearing materials
11) Explain the effects of ageing temperature and time on the properties of alloys.

UNIT 4 NON METALLIC MATERIALS

PART A
1. What are polymers?
2. What are characteristics of polymers?
3. Classify polymers.
4. Define monomer,homo polymer,copolymer.
5. What is polymerization?
6. Define the term degree of polymerization.
7. Difference between addition polymerization and condensation polymerization.
8. Why are additives added to polymers?
9 Difference between thermo plastic and thermosetting plastics.
10. Write short notes on nylons.
11. What are bakelites& its application?
12. What is meant by PSZ?
13. What are sialons& its applications?
14. What are composites?
15. List the applications of composite materials.
PART –B
1 . Define polymerization? And explain the various process?
2 .Define monomer and polymer .write typical polymeric repeat unit structure for both
addition and condensation polymerization:
3 , Describe the difference between thermoplastics and thermo setting plastics
4. Define following terms
a) Poly ethylene ,
b) PVC
c) Acetal
d) polyamides
5 . Give the applications of followings
a) PTEF b) PMMA
c) PET d) PEEK
6. Tabulate the characteristics of (1)poly formaldehyde (2)Urea formaldehyde
7 , What are ceramics ? Explain the uses ,applications ,and properties.
8.Give the applications of following;
a)PSC b)SiC c)Sialons

UNIT-5 MECHANICAL PROPERTIES AND TESTING

PART-A
1,What is mean by properties of materials?
2,Distinguish b/w elasticity & plasticity?
3.Distinguish b/w ductility& malleability?
4.Define brittleness.
5. Define hardness.
6.What is meant by toughness andstiffness?
7.Define four properties of metals?
8. State the schmid’slaw?
9. What is brittle factor?
10. What is ductile factor?
11. How can prevent the brittle factor?
12. How can you prevent the fatigue fracture?
13. What the factors affecting in creep?
14. How can you prevent the creep fractures?
15. Define the term notch sensitivity?
PART –B
1.List and explain the most important mechanical and technical properties ?
2.what is the effect of the following on the mechanical properties of the materials
a)grain size b)Heat treatment c)atmospheric exposure
3.Explain the two modes of plastic deformation in metals with neat sketches?
4.what is brittle fracture? explain the griffth’s theory on brittle fracture and deduce the
expression for the critical stress required to the propagate a crack simultaneously in
brittle material.
5.what is ductile fracture? Explain it mechanism:
6. a)explain mechanism of fatigue facture?
b)discuss any two mechanism of creep facture?
7.descripe the tensile test to various tensile properties?
8.a)describe the brinnel hardness test to determine the hardness of the metal?
b)give some limitations of brinnel hardness test?
9.explain the procedure for rock well hardness?
10.write an engineering brief about the creep test?

Reg.
No. :
Question Paper Code: E3135
B.E./B.Tech. DEGREE EXAMINATION, APRIL/MAY

2010
Fourth
Semester
Mechanical
Engineering
ME2253 — ENGINEERING MATERIALS AND
METALLURGY (Common to Automobile Engineering)
(Regulation
2008)
Time: Three hours Maximum: 100

Marks
Answer ALL
Questions
PARTA—(10×2=20
Marks)
1. State peritectic and peritectoid reactions.
2. Distinguish between steel and cast iron. Also classify steel with respect to
carbon percentage.
3. Enumerate any two differences between annealing and normalizing.
4. Explain the term ‘induction hardening’.
5. List the parameters that can be determined from the tensile test.
6. Mention some of the disadvantages of Brinell hardness test.
7. What will be the effects, if the following elements alloyed with
steel? (a) Phosphorous
(b) Sulphur.
8. Write down the composition and any one application of the following
alloys. (a) Duralumin
(b) Brass.
9. Name any two polymers and state their applications.
10. Mention any four attractive properties of engineering ceramics.

PART B — (5 × 16 = 80 Marks)
11. (a) (i) Draw Iron-carbon equilibrium diagram and label all the phases. Also
enumerate the properties of the following phase. (1)
Ferrite
(2) Austenite
(3) Cementite. (12) (ii)

Define the following terms (2+2)
(1) Solid solution
(2) Polymorphism.
Or
(b) (i) Explain Hume-Rothery rules of solid solubility. (6) (ii)
Discuss the composition, properties and application of the following

cast Iron
(1) Malleable cast Iron
(2) Spheroidal cast Iron. (5+5)
12. (a) (i) Draw Time-Temperature-Transformation (T-T-T) diagram and label

all the phases. Also enumerate any four objectives of heat
treatment of steel. (8)
(ii) What is case hardening? Explain the following processes. (1)
Carburizing
(2) Nitriding. (8) Or
(b) (i) What is hardenability? Describe a test that is used for

determination of hardenability of steel. (8) (ii)
Explain the different types of tempering process. (4) (iii) State
any four reasons for the formation quenching cracks. (4)
2 E 3135
13.(a) (i) With neat sketches explain the mechanism of slip and twining. Also
state the differences between them. (10)
(ii) Draw creep curve and explain the different stages of creep damage.
(6)
Or
(b) (i) Draw S-N curve for ferrous and non-ferrous metals and explain how
endurance strength can be determined. Also discuss the factors that
affect the fatigue life. (10)
(ii) Define the term ‘hardness of metal’. With a neat sketch, explain the
hardness measurement by Rockwell method. (6)
14. (a) (i) Write down the composition and applications of the following metal
(1) Stainless steel
(2) Tool steel. (5+5)

(ii) What is precipitation hardening? Illustrate this with an example.(6)
Or
(b) (i) Enumerate the composition and applications of following alloys.
(1) Cupro nickel
(2) Bronze
(3) Bearing alloy. (9)

(ii) State the effects of the following alloying elements in steel
(1) Chromium
(2) Molybdenum. (4)
(iii) State any three objectives of adding alloying elements on steel. (3)
15. (a) (i) Explain the following terms with respect to polymers
(1) Mechanical behaviour
(2) Thermal behaviour
(3) Electrical behaviour. (12)

(ii) What are the special properties of plastics that make them suitable
for engineering applications? (4)
Or
(b) (i) Enumerate the properties of the following
(1) Thermoplastics
(2) Thermosetting plastic
(3) Elastomers. (12)
(ii) Describe the concept of ‘Co-polymerization’. (4)
———————————
3 E 3135
Reg. No. :
Question Paper Code : 64034
B.E./B.Tech. DEGREE EXAMINATION, NOVEMBER/DECEMBER 2010
Fourth Semester
Mechanical Engineering
ME 2253 — ENGINEERING MATERIALS AND METALLURGY
(Common to Automobile Engineering)
(Regulation 2008)
(Also common to B.E. (Part -Time) - Third Semester - Mechanical Engineering —

Regulation 2009)
Time : Three hours Maximum : 100 Marks
Answer ALL questions
PART A — (10 × 2 = 20 Marks)
1. Define substitutional and interstitial solid solution.
2. What is eutectoid reaction?
3. Define tempering.
4. Differentiate carburizing and nitriding.
5. Classify the different hardness testing methods.
6. Draw the testing sample diagram for impact testing.
7. What is inoculation?
8. What is precipitation hardening?
9. Distinguish polymer and ceramic with respect to mechanical and physical

properties.
10. What are PMMA and PTFE?

PART B — (5 × 16 = 80 Marks)
11. (a) Draw Fe-Fe3C phase diagram and label all the phases. Discuss the structural
transformation while cooling from liquid to solid.
Or
(b) What is solid solution? Explain the Hume Rothery rules governing
substitutional solid solution. Draw isomorphous phase diagram.
12. (a) What is Hardening? Discuss in detail on different hardening methods and
mechanism. Compare hardening and annealing.
Or
(b) What is case hardening? Discuss nitriding process and its importance for
industrial applications. Differentiate surface chemical treatment and
surface thermal treatment.
13. (a) Describe fatigue testing and methods for improving fatigue strength of the
components. Draw the S-N curve for aluminium and titanium.
Or
(b) Write a short note on Rockwell hardness testing and their significance.
What are the properties measured from tensile testing and write their
engineering significance? Draw the stress and strain curve for aluminium,
cast iron and low carbon steel.
14. (a) Classify the ferrous materials with respect to alloying elements,
microstructure and properties and write the effect of alloying additions in
steels.
Or
(b) Write a short note on light weight non-ferrous alloys and discuss the
aluminium and its alloys with respect to alloying and heat treatment.
15. (a) Write the properties and applications of the following polymers and discuss
anyone fabrication methods of polymers.
(i) PE, (ii) PEEK, (iii) ABS and (iv) PTFE
Or
(b) List the important engineering ceramics and its applications. Discuss the
properties and applications of Si3N4 and SiC.
–––––––––––––
2 64034
Reg. No. :
B.E./B.Tech. DEGREE EXAMINATION, APRIL/MAY 2011
Fourth Semester
ME 2253 — ENGINEERING MATERIALS AND METALLURGY
(Common to Automobile Engineering)
(Regulation 2008)
(Common to PTME 2253 Engineering Materials and Metallurgy for B.E. (Part-Time)
Mechanical Engineering Third Semester-Regulation 2009)
Time : Three hours Maximum : 100 marks
Answer ALL questions
PART A — (10 × 2 = 20 marks)
1. What are eutectic and peritectic reactions? Give equations.
2. Define ferrite and cementite in Fe-C alloys.
3. Draw a typical isomorphous diagram and draw the cooling curves of a pure metal
and a solid solution.
4. List any two factors that affect hardenability of steels.
5. With a simple sketch show the phenomenon of slip in metallic materials.
6. Define ‘Creep’ of metals.
7. What is the structure difference between white cast iron and grey cast iron?
8. Name any two precipitation hardenable alloys.
9. What is the structure of polyethylene? Suggest any two uses.
10. Distinguish polymer and ceramic with respect to mechanical and physical
properties.
11. PART B — (5 × 16 = 80 marks)
12. (a) (i) Draw Fe-C diagram and mark all the phases. (8)
(ii) What are the different types of cast irons? Draw the microstructure
of any four types of cast irons. Give one application for each. (8)
Or
(b) Discuss the classification, micro structure properties and application of

steel. (16)
13. (a) (i) Give the process details of full annealing and spheroidising
treatments for steels. Explain the microstructure and need for these
treatments. (8)
(ii) What are hardening and tempering of high carbon steels? Give the
process details. What are the advantages of hardened and tempered
steels? (8)
Or
(b) (i) Discuss the method of constructing isothermal diagrams. (8)

(ii) Define hardenability and explain Jominy End Quench test. How to
use this Jominy end quench test data? (2+3+3)
14. (a) (i) What are the different types of fractures in metallic materials? Give
the important features of these fractured surfaces. What is the use
of this study? (8)
(ii) Explain Brinell hardness testing and its applications. (8)
Or
(b) (i) Discuss fatigue test for a metallic material. What is S-N diagram?
(8)
(ii) Why impact tests are important? Explain any one impact test. (8)
15. (a) (i) What are the effects of Si, Ni, Mn and Cr in steel and also in Fe-C
diagram? (8)
(ii) What are maraging steels? How are they manufactured? What are
their applications? (8)
2 11409
Or
(b) (i) Discuss any two copper base, any two aluminium base alloys. Give
at least one application for each alloy. (8)
(ii) Discuss the steps and the mechanism of precipitation hardening. (8)
16. (a) Discuss the structure and applications of any four thermoplastic and any
four thermoset plastic materials. (4×2+4×2)
Or
(b) (i) Discuss the properties and applications of the following four ceramics.
(1) Silica
(2) Zirconia
(3) SiC
(4) Cubic boron nitride. (4×2)

(ii) What are fibre reinforced plastics? Name any four fibres and their
matrix material. (8)
—————————
3 11409
Reg. No. :
B.E./B.Tech. DEGREE EXAMINATION, NOVEMBER/DECEMBER 2011.
Fourth Semester
ME 2253 — ENGINEERING MATERIALS AND METALLURGY (Common to Automobile
Engineering)
(Regulation 2008)
(Common to PTME 2253 – Engineering Materials and Metallurgy for B.E. (Part- Time) Third Semester
Mechanical Engineering – Regulation 2009)
Time : Three hours Maximum : 100 marks
Answer ALL questions. PART A — (10 × 2 = 20 marks)
1. Define solid solution.
2. Differentiate between grey cast iron and malleable cast iron.
3. Define spheroidizing.
4. What changes in physical and mechanical properties occur due to annealing?
5. Define toughness.
6. What is creep?
7. Write the effect of ‘‘Cr’’ as alloying element on steel.
8. Give the composition of the following non ferrous alloys
(a) Gunmetal
(b) Babbit metal.
9. Name the plastics used for the following applications (a) tooth brush (b)gears.
10. What is polymerization?
2 55460
PART B — (5 × 16 = 80 marks)
11. (a) Explain with a neat phase diagram the eutectic reaction and
peritectic reaction. (8 + 8) Or
(b) Describe with the aid of a diagram the Substitutional and interstitial solid solution.
(8+8)
12. (a) Explain with a neat sketch various quenching techniques followed in hardening.
Or
(b) Explain the procedure involved in each of the following process and changes
taking place in physical properties
(i) Carburising
(ii) Nitriding
(iii) Flame hardening. (5+5+6)
13. (a) Explain the two mechanisms of plastic deformation with neat sketch. (8 + 8) Or
(b) Sketch and describe the following hardness tests

(i) Brinell
(ii) Vickers. (8+8)
14. (a) Write short notes on : (i)

Maraging steel (ii)
Stainless steel (iii)
Springs steel
(iv) TRIP steel. (4 × 4 = 16) Or
(b) List all the alloys of following non ferrous metals and state their composition and
uses
(i) Copper
2 55460
(ii) Aluminium. (8+8)
15. (a) Explain the following with reference to their properties and applications
(i) PS (3)
(ii) PMMA (3)
(iii) PVC (4)
(iv) PTFE. (6)
Or
(b) Write short notes on :

(i) Ceramics (6)
(ii) Urea Formaldehyde (5)
(iii) Phenol Formaldehyde. (5)
——————
3 55460
B.E/B.Tech degree examination,May/June
2012 Question Paper Code-10413
Engineering Materials and metallurgy
AUTOMOBILE ENGINEERING
(Common to mechanical engineering)
FOURTH SEMESTER -(regulation 2008)
Answer all questions
PART A-(10*2=20 MARKS)
1.Differentiate Isomorphousand Eutectic reactions.
2.Draw the microstructure eutectoid steel and white cast iron.
3.Write the importance of spheroidising annealing.
4.Define hardenability and case depth.
5.Differentiate between Izod and Charpy impact testing.
6.Draw the S-N curve for mild steel and aluminium.
7.what is the effect of alloying Nickel and Chromium in steels?
8.Differentiate between precipitation hardening and dispersionstrengthening.
9.Define degree of polymerisation.
10.what are PEEK and PMMA?
PARTB-(5*16=80)
11. (a)(i) Indicate the different invariant reactions in Fe-Fe3 phase Diagram and draw and label all the
phases. (8)
(ii) Discuss the different classifications of steels and cast irons. (8) (or)
(b )(i ) Draw the indicative eutectic phase diagram (partially soluble type) (8 )
(i i ) Explain the Hume Rothery rules governing substitional solId solution (4)
(i i i ) Write short notes on about SG Cast iron . (4)
1
1 2 . (a ) what is annealing? Dis cuss in detail on different types of annealing and co mpare with normalizing.
(16) (or)
(b) (i) what is tempering?Discuss the structural transformation during tempering. (8)
(ii) what is carburizing? Discus s nitriding process and its importance for industrial applications.
(4)
(iii) Describe the Jominy End Test in details for determination of hardenability. (4)
1 3 . (a ) (i ) Draw the enginee ring stress–strain curve for mild steel, aluminium an d cast iron. Discuss the
tensile test and different mec hanical properties obtained in tensile testing. (8)
(ii) Write a short note on com pression test. (8) (or)
(b ) (i ) List the various types of hardness testing . Write a sho rt note on Brine ll and Vickers hardness
and their significance. (8)
(ii) What do you mean by slip and twinning? (8)
14. (a) (i) Describe the stainle ss steels with respect to composition, properties a nd applications. (8)
(ii) What is maraging steels? Discuss the strengthening method of maraging stee ls.(8) (or)
(b) (i) Discuss different types of copper alloys and their properties and applicatio ns.(8)
(ii) Write short notes on bearing alloys. (8)
1 5 . (a ) write the properties and applications of the following polymers and disc uss any one fabrication
methods of polymers. (16)
(i)PMMA,(ii)PP,(iii)ABS and (iv)PTFE. (or)
(b )(i ) List the important engineering ceramic materials and discuss its general applications of ceramic
materials in various engineeri ng fields. (8)
(ii) What are the advantages and disadvantages of ceramics? (8)

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A Course Material on

Engineering Materials and Metallurgy

DEPARTMENT OF MECHANICAL ENGINEERING

DHANALAKSHMI SRINIVASAN COLLEGE OF ENGINEERING

This is to certify that the e-course material

Subject Code : ME6403

Subject : Engineering materials and metallurgy

Class : II Year MECHANICAL ENGINEERING

S.NO TOPIC PAGE NO

UNIT 1 CONSTITUTION OF ALLOYS AND PHASE DIAGRAMS

1.1 Classification of materials 4

UNIT 2 HEAT TREATMENT PROCESS

UNIT 3 FERROUS AND NON FERROUS METALS

UNIT 4 NON METALLIC MATERIALS

➢ Primary objective is to present the basic fundamentals of materials science and

➢ Highlight important concepts for each topic covered in the subject

➢ Provide opportunity of self-evaluation on the understanding of the subject matter.

DSCE 1 Department of Mechanical Engineering

Quest for newer materials:

200,000 BC Discovery of fire – Said to be the most significant discovery in human

Discovery of Alloy - Metal Combinations

Iron and Steel – Building blocks of human civilization

DSCE 2 Department of Mechanical Engineering

1855 AD Sir Henry Bessemer (1813-1898) Bessemer steel making patent

Materials Science and Engineering:

Advantages of Studying Materials Science and Engineering

DSCE 3 Department of Mechanical Engineering

UNIT 1.CONSTITUTION OF ALLOYS AND PHASE DIAGRAMS

1.1 CLASSIFICATION OF MATERIALS

1.2. TYPES OF BONDING

1.2.3 Metallic Bonding

DSCE 4 Department of Mechanical Engineering

1.3.2.Polymorphism and Allotropy

DSCE 5 Department of Mechanical Engineering

1.5 Introduction to phase diagram

The common types of solid solutions are

DSCE 6 Department of Mechanical Engineering

Poly phase material:

1.7.IRON CARBON DIAGRAM

Iron-carbon phase diagram describes the iron-carbon system of

DSCE 7 Department of Mechanical Engineering

Maximum concentration of carbon in δ-ferrite is 0.09% at 2719 ºF

Alloys, containing up to 0.51% of carbon, start soli dification formation of with

Iron-carbon alloys, containing up to 2.06% of carbon, are called steels.

Alloys, containing from 2.06 to 6.67% of carbon, experience eutectic

In practice only hypoeutectic alloys are used. These alloys (carbon

When the temperature of an alloy reaches 1333 ºF (733ºC), austenite transforms to

Phase compositions of the iron-carbon alloys at room temperature

DSCE 9 Department of Mechanical Engineering

At 4.3% carbon composition, on cooling Liquid phase is converted in to two solids

Eutectoid: 0.76 wt%C, 727 °C

DSCE 10 Department of Mechanical Engineering

DSCE 11 Department of Mechanical E ngineering

DSCE 12 Department of Mechanical E ngineering

1.8. METAL TYPES

DSCE 13 Department of Mechanical Engineering

HIGH-CARBON STEEL/VERY HIGH-CARBON STEEL

LOW-ALLOY, HIGH-STRENGTH, TEMPERED STRUCTURAL STEEL

steels STAINLESS STEEL