001- Engineering Skills Principles-1. Chapter - 03 Material

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1 001- Engineering Skills Principles-1 Chapter - 03 Material 1

2 Objective of Chapter 3.0 (Material) The aim of this section is to enable the candidate to: 1. Identify metals and compare their properties. 2. Understand the effect that material shape, and the position of force, has on deflection. 3. Be aware of the causes of rusting, and effects of cold working and heat treating plain carbon steels. 2

3 TOPIC 3.1 Introduction to Material Science Materials Basic Properties Of Materials 3

4 Introduction to Material Science Defined as the study of the properties of solid materials and how those properties are determined by a material s composition and structure. 4

5 Introduction to Material Science What are Materials? That s easy! Look around. Our clothes are made of materials, our homes are made of materials - mostly manufactured. Glass windows, vinyl siding, metal silverware, ceramic dishes Most things are made from many different kinds of materials. 5

6 Introduction to Material Science Kinds of Materials 1. Metals 2. Ceramics 3. Plastic 4. Semiconductor 5. Composites material 6

7 Introduction to Material Science Kinds of Materials Metals: are materials that are normally combinations of "metallic elements". Metals usually are good conductors of heat and electricity. Also, they are quite strong but malleable and tend to have a lustrous look when polished. Metals 7

8 Introduction to Material Science Kinds of Materials Ceramics: are generally compounds between metallic and nonmetallic elements. Typically they are insulating and resistant to high temperatures and harsh environments. Ceramics 8

9 Introduction to Material Science Plastics: are generally organic compounds based upon carbon and hydrogen. They are very large molecular structures. Usually they are low density and are not stable at high temperatures. Plastic 9

10 Introduction to Material Science Semiconductors: A semiconductor is a material with electrical conductivity due to electron flow (as opposed to ionic conductivity) intermediate in magnitude between that of a conductor and an insulator. Semiconductor materials are the foundation of modern electronics, including radio, computers, telephones, and many other devices. Such devices include transistors, solar cells, many kinds of diodes. 10

11 Introduction to Material Science Composites: Composite materials, often shortened to composites, are engineered or naturally occurring materials made from two or more constituent materials with significantly different physical or chemical properties which remain separate and distinct at the macroscopic or microscopic scale within the finished structure. 11

12 Material History of Materials Our history has been defined by the materials we use The stone age The copper age The bronze age The Iron age 12

13 Material IRON AND STEEL Iron Ore: Iron taken from a mine looks like clay. It is found combined with oxygen. The ore generally contain small amount of sulphur, Phosphorus, silicon manganese, copper etc. Types of Iron Ore 1. Black Magnetite 2. Red Hematite 3. Brown siderite 4. Brown Limonite 5. Iron pyrite 13

14 Material STEEL Steel is an alloy that consists mostly of iron and has a carbon content between 0.2% and 2.1% by weight, depending on the grade. Carbon is the most common alloying material for iron, but various other alloying elements are used, such as manganese, chromium, vanadium, and tungsten 14

15 Material CARBON STEEL Also called plain-carbon steel, is steel where the main alloying constituent is carbon. The American Iron and Steel Institute (AISI) defines carbon steel as: "Steel is considered to be carbon steel when no minimum content is specified or required for chromium, cobalt, columbium, molybdenum, nickel, titanium, tungsten, vanadium or zirconium. 15

16 Types of Carbon Steel Material Sr.NO. Name Percentage of Carbon 1 Dead mild steel 0.05% % 2 Mild steel 0.15% % 3 Medium Carbon Steel 0.3 % % 4 High Carbon Steel 0.5 % % 16

17 Material CAST IRON Cast iron is considered an alloy of iron, silicon and carbon. the carbon contents are usually adjusted in the rang of 1.7 to 4.5%,most of which is present in insoluble form (e.g graphite flakes) APPLICATION Cast iron tends to be brittle, except for malleable cast irons. With its relatively low melting point, good fluidity, castability, excellent machinability, resistance to deformation and wear resistance, cast irons have become an engineering material with a wide range of applications and are used in pipes, machines and automotive industry parts. 17

18 CASTING Material A manufacturing process by which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. 18

19 ALUMINUM Is a silvery white member of the elements. It has the symbol Al. It is not soluble in water under normal circumstances. Aluminum is the third most abundant element, after oxygen and silicon. CHARACTERISTICS Material Aluminum is a soft, durable, lightweight, ductile and malleable metal with appearance ranging from silvery to dull gray, depending on the surface roughness. Aluminum is nonmagnetic and nonsparking and resistance to corrosion. Properties. Melting point K, C, F Boiling point 2792 K, 2519 C, 4566 F 19

20 Material COPPER Is a chemical element with the symbol Cu.. Pure copper is rather soft and malleable, and a freshly exposed surface has a reddishorange color. It is used as a thermal conductor, an electrical conductor, a building material, and a constituent of various metal alloys. CHARACTERISTICS It is a ductile metal, with very high thermal and electrical conductivity. Pure copper is rather soft and malleable. It is good resistance to corrosion Properties Melting point K, C, F Boiling point 2835 K, 2562 C,

21 BRASS Material Is an alloy of copper and zinc; the proportions of zinc and copper can be varied to create a range of brasses with varying properties. APPLICATION Is a substitutional alloy. It is used for decoration for its bright gold-like appearance; for applications where low friction is required such as locks, gears, bearings, doorknobs, ammunition, and valves; for plumbing and electrical applications; and extensively in musical instruments 21

22 Austenitic stainless steel. Material Steels have austenite as their primary phase (face centered cubic crystal). These are alloys containing chromium and nickel (sometimes manganese and nitrogen), structured around, 18% chromium, and 8% nickel. Austenitic steels are not hardenable by heat treatment. CHARACTERISTICS Austenitic stainless steels have high ductility, low yield stress and relatively high ultimate tensile strength, when compare to a typical carbon steel. 22

23 Ductility Basic Properties Of Materials Ductility is the property that enables a material to stretch, bend, or twist without cracking or breaking. This property makes it possible for a material to be drawn out into a thin wire. Malleability Malleability is the property that enables a material to deform by compressive forces without developing defects. A malleable material is one that can be stamped, hammered, forged, pressed, or rolled into thin sheets. 23

24 Hardness Basic Properties Of Materials Hardness refers to the ability of a metal to resist abrasion, penetration, cutting action, or permanent distortion. Hardness may be increased by working the metal and, in the case of steel and certain titanium and aluminum alloys, by heat treatment and cold-working Toughness A material that possesses toughness will withstand tearing or shearing and may be stretched or otherwise deformed without breaking. Toughness is a desirable property in aircraft metals. 24

25 Basic Properties Of Materials Elasticity Elasticity is that property that enables a metal to return to its original shape when the force that causes the change of shape is removed. This property is extremely valuable, because it would be highly undesirable to have a part permanently distorted after an applied load was removed. Each metal has a point known as the elastic limit, beyond which it cannot be loaded without causing permanent distortion. Brittleness Brittleness is the property of a metal that allows little bending or deformation without shattering. In other words, a brittle metal is apt to break or crack without change of shape. Because structural metals are often subjected to shock loads, brittleness is not a very desirable property. Cast iron, cast aluminum, and very hard steel are brittle metals. 25

26 Basic Properties Of Materials Conductivity Conductivity is the property that enables a metal to carry heat or electricity. Heat Conductivity The heat conductivity of a metal is especially important in welding, because it governs the amount of heat that will be required for proper fusion. Electrical conductivity Is the reciprocal quantity, and measures a material's ability to conduct an electric current. 26

27 Strength Basic Properties Of Materials Strength is the property that enables a metal to resist deformation under load. The ultimate strength is the maximum strain a material can withstand. Tensile strength is a measurement of the resistance to being pulled apart when placed in a tension load. The material must possess the strength required by the demands of dimensions, weight, and use. There are five basic stresses that metals may be required to withstand. These are tension, compression, shear, bending, and torsion. 27

28 Basic Properties Of Materials Machinability The term machinability refers to the ease with which a metal can be machined to an acceptable surface finish. Materials with good machinability require little power to cut, can be cut quickly, easily obtain a good finish, and do not wear the tooling much; such materials are said to be free machining. The factors that typically improve a material's performance often degrade its machinability. Therefore, to manufacture components economically, engineers are challenged to find ways to improve machinability without harming performance. 28

29 001- Engineering Skills Principles-1 Chapter - 03 Material 29

30 Objective of Chapter 3.0 (Material) The aim of this section is to enable the candidate to: 1. Identify metals and compare their properties. 2. Understand the effect that material shape, and the position of force, has on deflection. 3. Be aware of the causes of rusting, and effects of cold working and heat treating plain carbon steels. 30

31 TOPIC 3.2 Identification Methods Identify Metals In

32 IDENTIFICATION METHODS Because of the widespread use and necessity for metals in Manufacturing it is important for the worker to have a basic understanding of metals and metallurgy when fabricating and making repairs on metals. 32

33 IDENTIFICATION METHODS Many methods are used to identify a piece of metal. Identification is necessary when selecting a metal for use in fabrication or in determining its behavior. 33

34 IDENTIFICATION METHODS Some basic methods used for Metal identification are: Color Use of magnet Basic methods Of Identification Density 34

35 Copper Color IDENTIFY METALS IN 3.1 Some metals can be easily identified by Color test Reddish Brown 35

36 Copper Density test 3 D =8.94 g/cm Formula D = M / V A M=8.94* M= g If put all value in equation-a D= / D=8.94 g/cm3 Ans. IDENTIFY METALS IN 3.1 DENSITY CHART Elements Volume(cm ) Mass(gm) Density Copper 25x25x75mm -? 3 36

37 IDENTIFY METALS IN 3.1 Copper Density test Copper piece Reference weight Copper piece Reference weight 37

38 IDENTIFY METALS IN 3.1 Aluminum Color Whitish 38

39 Aluminum Density test IDENTIFY METALS IN 3.1 Formula D = M / V DENSITY CHART Elements Volume Mass(weight) Density Aluminum 25x25x75mm -? 39

40 Aluminum Density test IDENTIFY METALS IN 3.1 Aluminum piece Reference weight Aluminum piece Reference weight 40

41 IDENTIFY METALS IN 3.1 Brass Color Yellow if high zinc content 41

42 Brass Density test IDENTIFY METALS IN 3.1 Formula D = M / V DENSITY CHART Alloy Volume Mass(weight) Density Brass 25x25x75mm -? 42

43 Brass Density test IDENTIFY METALS IN 3.1 Aluminum piece Reference weight Aluminum piece Reference weight 43

44 Austenitic Stainless Steel Color Bright silvery smooth IDENTIFY METALS IN

45 Austenitic Stainless Steel Density test IDENTIFY METALS IN 3.1 Formula D = M / V DENSITY CHART Alloy Volume Mass(weight) Density Aus. Stainless Steel 25x25x75mm -? 45

46 Austenitic Stainless Steel Density test IDENTIFY METALS IN 3.1 Aus. Stainless steel piece Reference weight Aus. Stainless steel piece Reference weight 46

47 IDENTIFY METALS IN 3.1 Cast Iron Color Test Dull gray 47

48 Cast Iron Density test IDENTIFY METALS IN 3.1 Formula D = M / V DENSITY CHART Alloy Volume Mass(weight) Density Cast Iron 25x25x75mm -? 48

49 Cast Iron Density test IDENTIFY METALS IN 3.1 Cast Iron piece Reference weight Cast Iron piece Reference weight 49

50 Carbon Steel Color Test IDENTIFY METALS IN 3.1 Dark gray 50

51 Carbon Steel Density test IDENTIFY METALS IN 3.1 Formula D = M / V DENSITY CHART Alloy Volume Mass(weight) Density Carbon steel 25x25x75mm -? 51

52 Carbon Steel Density test IDENTIFY METALS IN 3.1 Carbon Steel piece Reference weight Carbon Steel piece Reference weight 52

53 001- Engineering Skills Principles-1 Chapter - 03 Material 53

54 Objective of Chapter 3.0 (Material) The aim of this section is to enable the candidate to: 1. Identify metals and compare their properties. 2. Understand the effect that material shape, and the position of force, has on deflection. 3. Be aware of the causes of rusting, and effects of cold working and heat treating plain carbon steels. 54

55 TOPIC 3.3 Identify Metals In 3.1 As Non Ferrous or Ferrous Metal 55

56 Ferrous Metal & Non ferrous Metal Ferrous Metal ferrous metals are those which contain iron as a principle ingredient. Cast iron Non ferrous Metal Non ferrous metals are those which do not contain iron. Aluminium 56

57 Ferrous Metal & Non ferrous Metal Ferrous Carbon Steel Cast Iron Metal Copper Non-ferrous Brass Aluminum Austenitic stainless Steel 57

58 Copper Magnetic test IDENTIFY METALS IN 3.1 The use of a magnet is another method used to help in the general identification Of metals. Remember that ferrous metals, being iron-based alloys, normally are magnetic, and nonferrous metals are nonmagnetic. After magnetic test no attraction or repulsion were taken place. Copper is Non magnetic metal. 58

59 Aluminum Magnetic test IDENTIFY METALS IN 3.1 After magnetic test no attraction or repulsion were taken place. Aluminum is Non magnetic metal. 59

60 Brass Magnetic test IDENTIFY METALS IN 3.1 After magnetic test no attraction or repulsion were taken place. Brass is Non magnetic alloy. 60

61 Austenitic Stainless Steel Magnetic test IDENTIFY METALS IN 3.1 After magnetic test no attraction or repulsion were taken place.(it may be magnetic but in case of exact analysis ) Stainless steel is Non magnetic alloy. 61

62 Cast Iron Magnetic test IDENTIFY METALS IN 3.1 After magnetic test attraction were taken place. Cast Iron is Strongly magnetic alloy. 62

63 Carbon Steel Magnetic test IDENTIFY METALS IN 3.1 After magnetic test attraction were taken place. Cast Iron is Strongly magnetic alloy. 63

64 001- Engineering Skills Principles-1 Chapter - 03 Material 64

65 Objective of Chapter 3.0 (Material) The aim of this section is to enable the candidate to: 1. Identify metals and compare their properties. 2. Understand the effect that material shape, and the position of force, has on deflection. 3. Be aware of the causes of rusting, and effects of cold working and heat treating plain carbon steels. 65

66 TOPIC 3.4 Carry out simple comparativedeflection testsbetween specimens of equal length and cross-sectional area, centrally loaded and simply supported at each end. a) Flat bar face down b) Flat bar edge down c) I Section vertical d) I Section horizontal e) Tube 66

67 Definition: DEFLECTION The amount of deviation from a straight line or plane when a force is applied. May be permanent or temporary deformation. Sometimes called: Deformation, buckling, bending Practical Examples; 67

68 SIMPLY SUPPORTED BAR Bar Support Load Compression Tension 68

69 SPECIMEN Equal length Equal thickness Flat Bar I Section Tube 69

70 Flat Bar Face Down Bar Load Support Support Load Compression Tension 70

71 Flat Bar Edge Down Load Load Bar Support Support 71

72 Flat Bar Edge Down Load Compression A B Support Support Tension 72

73 I Section Vertical 73

74 I Section Horizontal Load 74

75 Tube Load 75

76 001- Engineering Skills Principles-1 Chapter - 03 Material 76

77 Objective of Chapter 3.0 (Material) The aim of this section is to enable the candidate to: 1. Identify metals and compare their properties. 2. Understand the effect that material shape, and the position of force, has on deflection. 3. Be aware of the causes of rusting, and effects of cold working and heat treating plain carbon steels. 77

78 TOPIC 3.6 Describe the properties of non-metallic materials (other than timber) and their usage. 78

79 Nonmetallic Materials Non-metallic Materials a substance such as wood, plastic or fabric that is not made of metal Plastic Rubber fabric Ceramics 79

80 Properties Non-lustrous Non-metallic Materials 80

81 Properties Brittle or Soft Non-metallic Materials Brittleness Softness Brittleness Softness 81

82 Properties Non-metallic Materials Poor Conductor of Heat and Electricity Plastic for example is a poor conductor because it is an insulator. Plastic is made up of a substance that dose not allow the flow of electrons. Poor conductor of Electricity Poor conductor of Heat 82

83 Non-metallic Materials Properties Shock Absorption A property has a ability to absorb shock or impact. No Fracture Was Found On Safety Helmet 83

84 Non-metallic Materials Properties Acoustic Quieting Noise absorption Sound isolation Acoustic damping To prevent it from transferring out of one area Sounds can be absorbed rather than reflected inside the place To prevent vibration from transferring beyond the device into another material Sound Proof Room 84

85 Non-metallic Materials Advantages from the use of plastic for Pipe Light in weight and tough They are rust resistant Good elastic properties Smooth internal surface of the pipes offer less friction Plastic pipe Resistant to chemical attack Reduces chances of leakage. Available in large lengths 85

86 Non-metallic Materials Advantages from the use of plastic for Conduit Flexibility used for protecting electrical wiring Continuous Coils Plastic Condui t Friction less Resistant to chemical attack Remains ductile at low temperatures 86

87 Non-metallic Materials Disadvantages from the use of plastic for Pipes They are easily cracked Raw Material Costs Plastic Pipes At higher temperature s, the strength of plastic pipes reduces Not environment Friendly plastic pipes are not installed in high temperature 87

88 Non-metallic Materials Disadvantages from the use of plastic for Conduit Not conveyance for liquid or gases Plastic Conduit High Raw Material Costs Not environment Friendly 88

89 001- Engineering Skills Principles-1 Chapter - 03 Material 89

90 Objective of Chapter 3.0 (Material) The aim of this section is to enable the candidate to: 1. Identify metals and compare their properties. 2. Understand the effect that material shape, and the position of force, has on deflection. 3. Be aware of the causes of rusting, and effects of cold working and heat treating plain carbon steels. 90

91 TOPIC 3.7 Explain the difference between thermoplastic and thermosetting plastics and state suitable applications. 91

92 Thermoplastic And Thermosetting Plastics Thermoplastic Thermoplastics can be shaped easily by being cooled and heated time and time again. These can be softened as often as they are reheated. They are not so rigid. Thermosetting Plastics Thermo set on the other hand cannot be repeatedly heated, cooled and shaped. If heat the thermosetting material gets hardened the first time and if we again heat it, just burns without deforming. They are so rigid. 92

93 Thermoplastic And Thermosetting Plastics Application of Thermoplastic Nylon Thread Polystyrene Car Prototype Polythene Bag 93

94 Thermoplastic And Thermosetting Plastics Application Of Thermosetting Plastic Car door Handle Socket Chair 94

95 001- Engineering Skills Principles-1 Chapter - 03 Material 95

96 Objective of Chapter 3.0 (Material) The aim of this section is to enable the candidate to: 1. Identify metals and compare their properties. 2. Understand the effect that material shape, and the position of force, has on deflection. 3. Be aware of the causes of rusting, and effects of cold working and heat treating plain carbon steels. 96

97 TOPIC 3.8 State The Changes In Physical And Mechanical Properties Of Steel Due To Cold Working. 97

98 Cold Working. Altering the shape or size of a metal by plastic deformation. The process is usually performed at room temperature, but slightly elevated temperatures may be used to provide increased ductility and reduced strength Material 98

99 Cold Working. 99

100 Changing effect in Steel due to Cold Working. Physical Properties Mechanical Properties Bright Surface Good surface finish accurate to size free from scale Strength And Rigidity become increase It becomes hard Ductility becomes low makes the steel more brittle 100

101 Changing effect in Steel due to Cold Working. Bright Surface Through Out Accurate Size Good Surface Finish Free From Scale 101

102 Changing effect in Steel due to Cold Working. Strength and Rigidity Ductility becomes low and brittleness increases 102

103 001- Engineering Skills Principles-1 Chapter - 03 Material 103

104 Objective of Chapter 3.0 (Material) The aim of this section is to enable the candidate to: 1. Identify metals and compare their properties. 2. Understand the effect that material shape, and the position of force, has on deflection. 3. Be aware of the causes of rusting, and effects of cold working and heat treating plain carbon steels. 104

105 TOPIC 3.9 State the changes in physical and mechanical properties of steel due to temperature changes. Effects of: hardening, tempering, annealing, normalizing, recrystallization, grain growth 105

106 Changes In Physical And Mechanical Properties Of Steel Due To Temperature Changes. Heat Treatment Process To Improve mechanical properties of a material heat treatment process is used 106

107 Changes In Physical And Mechanical Properties Of Steel Due To Temperature Changes. Mechanical Property Mechanical properties are defined as those material properties that measure a material's reaction to applied force. Hardness Toughness Tensile strength 107

108 Changes In Physical And Mechanical Properties Of Steel Due To Temperature Changes. Physical properties are properties other than mechanical properties that depend on the physics of the material. Physical Property Density Heat Magnetic conductivity 108

109 Changes In Physical Properties Thermal Expansion of Steel Is the tendency of steel to change in volume in response to Gap is given between track joint to avoid deformation a change in temperature.all materials have this tendency. Otherwise deformation can takes place 109

110 Changes In Physical Properties Magnetic Property At Room temperature magnet attract with steel work piece After the heating to steel s grains, no attraction took place with magnet. 110

111 Changes In Physical Properties Density At Room temperature Density of steel remains same Density of steel will Decrease after heating effect. 111

112 Changes In Mechanical Properties Hardening Hardening This is the process of heating a piece of steel to a temperature within or above its critical range and then cooling it rapidly Physical Changes Steel might be distorted or cracked or scratches free and we can get shiny surface Mechanical Changes Steel becomes hard 112

113 Changes In Mechanical Properties Tempering Quench-hardened steels are brittle as well as hard. To make them suitable for cutting tools they have to be reheated to a specified temperature between 200 and 300 C and again quenched. Physical Changes Tempering To make them suitable for cutting Mechanical Changes Steel becomes tough (ie resistance to shock or impact) 113

114 Changes In Mechanical Properties Annealing Metal cools down in the furnace itself or by burying it in ashes or lime. This annealing process makes the metal very soft and ductile. Physical Changes Annealing Steel can be bent or Formed easily Mechanical Changes Makes the metal very soft and ductile. 114

115 Changes In Mechanical Properties Normalizing Steel cools down in free air. Although the cooling is slow, it is not as slow as for annealing so the metal is less soft and ductile. This condition is not suitable for flow forming but more suitable for machining. Physical Changes Normalizing Steel can not be bent or formed easily but machined easily Mechanical Changes Steel becomes tough (ie resistance to shock or impact) 115

116 Changes In Mechanical Properties Recrystallisation Is the term used when the distorted grains reform when they are heated. During recrystallization, the badly deformed grains are replaced by new, strain-free grains. New orientations, new grain sizes. Physical Changes Recrystallisation Steel can be bent or formed easily. Mechanical Changes The strength reduces and the ductility increases 116

117 Changes In Mechanical Properties Grain Growth Grain growth is the growth of some recrystallized grains, and it can only happen at the expense of other recrystallized grains. Because fine grain size leads to the best combination of strength and ductility, in almost all cases, grain growth is an undesirable process. Recrystallisati on Physical Mechanical Changes Changes The strength Steel can be reduces and bent or formed the ductility easily. increases 117

118 THANK YOU 118

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