SARDAR RAJA COLLEGE OF ENGINEERING, ALANGULAM

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1 SARDAR RAJA COLLEGE OF ENGINEERING, ALANGULAM DEPARTMENT OF MECHANICAL ENGINEERING MICRO LESSON PLAN SUBJECT : ENGINEERING MATERIALS & METALLURGY CODE : ME 2253 CLASS : II Year / IV SEM STAFF: Mr. S.GANAPATHY NELLAI NAYAGAM, Asst.Prof, DEPT. OF MECHANICAL ENGG.

2 ME 2253 ENGINEERING MATERIALS AND METALLURGY L T P C (Common to Mechanical & Automobile) Review (Not for Exam): Crystal structure BCC, FCC and HCP structure unit cell crystallographic planes and directions, miller indices crystal imperfections, point, line, planar and volume defects Grain size, ASTM grain size number. UNIT I CONSTITUTION OF ALLOYS AND PHASE DIAGRAMS 9 Constitution of alloys Solid solutions, substitutional and interstitial phase diagrams, Isomorphous, eutectoid, eutectic, peritectic, and peritectroid reactions, Iron Iron carbide equilibrium diagram. Classification of steel and cast Iron, microstructure, properties and applications. UNIT II HEAT TREATMENT 9 Definition Full annealing, stress relief, recrystallisation and spheroidizing 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 - carburising, nitriding, cyaniding, carbonitriding, flame and induction hardening. UNIT III MECHANICAL PROPERTIES AND TESTING 9 Mechanism of plastic deformation, slip and twinning Types of fracture Testing of materials under tension, compression and shear loads Hardness tests (Brinell, Vickers and Rockwell), Impact test - Izod and Charpy, Fatigue and creep tests, fracture toughness tests. UNIT-IV : FERROUS AND NON FERROUS METALS 9 Effect of alloying elements on steel (Mn, Si, Cr, Mo, V, Ti & W) - stainless and tool steels HSLA - maraging steels Cast Irons - Grey, White malleable, spheroidal Graphite, Alloy cast irons, Copper and Copper alloys - Brass, Bronze and Cupronickel Aluminum and Al-Cu alloy precipitation hardening Bearing alloys. UNITV NON-METALLIC MATERIALS 9 Polymers types of polymer, commodity and engineering polymers Properties and applications of PE, PP, PS, PVC, PMMA, PET, PC, PA, ABS, PI, PAI, PPO, PPS, PEEK, PTFE Polymers Urea and Phenol Formaldehydes Engineering Ceramics Introduction to Fibre reinforced plastics. TOTAL : 45 PERIODS

3 TEXT BOOKS 1. Kenneth G.Budinski and Michael K.Budinski Engineering Materials Prentice-Hall of India Private Limited, 4th Indian Reprint REFERENCE BOOKS 1. William D Callister Material Science and Engineering, John Wiley and Sons Raghavan.V Materials Science and Engineering, Prentice Hall of India Pvt., Ltd., Sydney H.Avner Introduction to Physical Metallurgy McGraw Hill Book Company, Dieter G. E., Mechanical Metallurgy, Mc Graw Hill Book Company, O.P. Khanna, A text book of Materials Science and Metallurgy, Khanna Publishers, Vijaya. M.S. and G. Rangarajan, Material Science, Tata McGraw-Hill, 2007

4 SUBJECT OBJECTIVES OBJECTIVE 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.

5 MICRO LESSON PLAN Hours LECTURE TOPICS READING UNIT I - CONSTITUTION OF ALLOYS AND PHASE DIAGRAMS 1 Constitution of alloys, Solid solutions 2 Substitutional and interstitial 3 Phase diagrams 4 Isomorphous, eutectoid 5 Eutectic, peritectic reactions 6 Peritectroid reactions 7 Iron-Iron carbide equilibrium diagram 8 Clasification of steel and cast iron 9 Microstructure 10 Properties and applications UNIT II HEAT TREATMENT 11 Definition, Full annealing, stress relief & T5 12 recrystallisation and spheroidizing & T5 13 normalising, hardening and tempering of steel & T5 14 Isothermal transformation diagrams & T5 15 cooling curves superimposed on I.T. diagram 16 CCR - Hardenability 17 Jominy end quench test 18 Austempering, martempering 19 case hardening - carburising, nitriding, 20 cyaniding, carbonitriding 21 flame and induction hardening.

6 UNIT III MECHANICAL PROPERTIES & TESTING 22 Mechanism of plastic deformation 23 slip and twinning Types of fracture 24 Testing of materials under tension 25 compression and shear loads 26 Hardness tests (Brinell, Vickers) 27 Hardness tests(rockwell) 28 Impact test - Izod and Charpy 29 Fatigue and creep tests 30 fracture toughness tests. UNIT IV - FERROUS AND NON FERROUS METALS 31 Effect of alloying elements on steel (Mn, Si, Cr, Mo, V, Ti & W) 32 Effect of alloying elements on steel (Mn, Si, Cr, Mo, V, Ti & W) 33 stainless and tool steels 34 HSLA - maraging steels Cast Irons 35 Grey, White malleable, spheroidal Graphite 36 Alloy cast irons, Copper and Copper alloys 37 Brass, Bronze and Cupronickel 38 Aluminum and Al-Cu alloy 39 precipitation hardening 40 Bearing alloys.

7 Hours LECTURE TOPICS READING UNIT V - NON-METALLIC MATERIALS 41 Polymers types of polymer 42 commodity and engineering polymers 43 Properties and applications of PE 44 PP, PS, PVC, PMMA, PET 45 PC, PA, ABS, PI, PAI 46 PPO, PPS, PEEK, PTFE Polymers 47 Urea and Phenol Formaldehydes 48 Engineering Ceramics 49 Introduction to Fibre reinforced plastics PREPARED BY, S.GANAPATHY NELLAI NAYAGAM & P.SETHU RAMALINGAM ASST. PROFESSOR/MECHANICAL

8 SARDAR RAJA COLLEGE OF ENGINEERING ALANGULAM DEPARTMENT OF MECHANICAL ENGINEERING MAXIMUM POSSIBLE QUESTIONS SUB CODE / NAME : ME44 ENGINEERING MATERIALS AND YEAR / SEM : II / IV METALLURGY UNIT-I (Constitution of alloys and phase diagrams) 1. Define Peritectic and Eutectoid reactions. PART-A 2. State the conditions under which two metallic elements will exhibit unlimited solid solubility. 3. Define the terms "ferrite" and "austenite" in iron-carbon alloy system. 4. Define solute and solvent. 5. What are the different types of solid solutions? 6. What is phase diagram? and its importance. 7. Define ferrite and austenite. 8. Define cementite, pearlite. 9. What is meant by hypo eutectoid, hypereutectoid steel? 10. What are cooling curves? UNIT-I (Constitution of alloys and phase diagrams) PART-B 1. Discuss the similarities and differences between substitutional and interstitial solid solution? (16)

9 2. What is cooling curve? How does the time temperature cooling curve of an alloy of eutectic composition different from that of a pure metal? (16) 3. Explain: 1. Eutectic reaction (4) 2. Eutectoid reaction (4) 3. Peritectic reaction (4) 4. Peritectoid reaction (4) 4. Draw Iron -Carbide equilibrium diagram and mark on it all salient temperature and composition fields. (16) 5. (1) Elements A & B melt at 7000 C and C respectively. Draw a typical isomorphous phase diagram between the elements A & B. (2) Elements A & B melt at 7000 C & C respectively. They form a eutectic at 35%A at temperature 5000 C. Draw a typical phase diagram between A & B. (16) 6. Metal A has melting point at C. Metal B has melting point of 5000 C. Draw one phase diagram (between the elements A & B) for each of the following conditions. (i)the two elements exhibit unlimited solid solubility. (ii)the alloy systems show formation of two terminal solid solution and a eutectic point at 50%A and at7000 C. (16) 7. (i)give the classification of steel. (2) (ii)desirable properties and application of low, medium and high carbon steel. (6) (iii)what is an alloy steel? How are alloy steel classified? Explain them. (8) 8. (i) Explain the classification of steel. (4)

10 (ii)desirable properties and application of GrayC.I, NodularC.I, WhiteC.I, MalleableC.I. (12) UNIT-II (Heat treatment methods) PART- A 1. A low carbon steel in tile normalised condition is stronger than tile same steel ill tile annealed condition. Why? 2. Case carburizing heat treatment is not generally carried out for medium carbon steels. Why? 3. What is "critical cooling rate" in hardening of steels? 4. What is meant by "heat treatment"? and its purpose. 5. What are the factors affecting the CCR? 6. What is meant by normalizing? and its purpose. 7. What is quenching? List some of the quenching medium. 8. What are the factors affecting the hardness? 9. What is meant by hardnability? What are the factors affecting it? 10. What is induction hardening? UNIT-II (Heat treatment methods) PART-B 1. Define hardenability of steel.explain the jominy end quench test used to determine hardenability of steel. How will you draw hardenability curves this sheet? (16) 2 Explain: 1. Annealing (4) 2. Spheroidising (4) 3. Normalizing (4)

11 4. Hardening (4) 3. (i) What are austempering and martempering?what are their purpose? (8) (ii)explain the steps in Case carburizing of steel. (8) 4. Write short notes on: 1. Carburizing (4) 2.Nitriding (4) 3.Cyaniding (4) 4.Carbonitriding.(4) 5. Write short notes on (a) Flame hardening (b) Induction hardening. 6. (i)draw the schematic isothermal transformation diagram corresponding to 0.8% of carbon steel. (ii)explain hardening and tempering process. 1. Define endurance limit in fatigue test. UNIT-III(Mechanical properties and testing) PART-A 2. What properties are determined from tension testing of metallic products? 3. In general, HCP metals are hard and brittle while FCC metals are soft and ductile. Why? 4. Define slip. 5. Define twinning. 6. What is a fracture? 7. Write types of fractures. 8. What is the use of S-N curve? 9. Define creep 10.Write down the various mechanical test.

12 UNIT-III (Mechanical properties and testing) PART-B 1. (a)what are slip and twinning? What are their characteristics? (8) (b )Discuss characteristics of ductile fracture and brittle fracture. (8) 2. Explain the testing procedure for determining the following properties. (i)brinell hardness number (8) (ii) Creep strength (8) 3. Explain the testing procedure of (i)vickers hardness test (8) (ii) lzod impact test (8) 4. Explain the testing procedure of (i) Rockwell hardness test (8) (ii) Charpy impact test (8) 5. (a) Explain the mechanism of plastic deformation of metals by slip and twinning.(8) (b )Explain testing procedure for Fatigue test.(8) 6. Explain the testing procedure of (i) Tensile test (8) (ii) Creep test (8) UNIT-IV (Ferrous and Non-ferrous metals) PART-A 1. Compare the martensite that is formed in maraging steels with the martensite that is formed in carbon steels. 2. What is the main strength mechanism in high strength aluminum alloys? 3. What are the effect of chromium and molybdenum in low alloy steels? 4. What is the purpose of magnesium treatment in producing S.G. iron? 6.What is stainless steel?

13 7.What are the typesof stainless steel? 8.What are HSLA steel? 9.What are the types of cast irion? 10.What are the important copper alloys? UNIT-IV (Ferrous and Non-ferrous metals) PART-B 1. Write short notes on: (i) Austinitic stainless steel (5) (ii) Ferritic stainless steel (5) (iii) Martensitic stainless steel(6) 2. Write short notes on: (i) High speed steel (4) (ii) HSLA steel c (4) (iii) Marageing steel (4) (iv) Tool steel (4) 3. (i) What are ALPHA brass and ALPHA/BETA brass? (8) (ii)discuss step involved in precipitation hardening treatment anyone aluminum alloy as example. (8) 4. How will you classify brasses based on the composition of zinc Explain the properties & application of the main type of brasses. (16) 5. Write short notes on: (i) Gray C.I (4) (ii) White C.I (4) (iii) Malleable C.I (4) (iv) Spheroidal graphite CI(4) 6. Discuss the composition, properties & typical application of any four copper alloys. (16)

14 7. Discuss the composition, properties & typical application of some aluminum alloys. (16) UNIT-V (Non-Metallic materials) PART-A 1. Name four ethenic polymers (polymers that have the basic monomer structure of ethylene). 2. What are the important of alumina and silicon nitride? 3. Give one example each for metal-matrix composites and ceramic-matrix composites. 4. What is polymerization? 5. Distinguish between thermoplastics and thermosetting plastics. 6. What are engineering ceramics? 7. What are the types of engineering ceramics? 8. What is composites? 9. List the advantage and limitations of composites materials. 10. List the applications composites materials. UNIT-V (Non-Metallic materials) PART-B 1. Describe the molecular structure, properties and application of the following polymers. (i)polyvinyl chloride (PVC) (4) (ii)polystyrene (PS) (4) (iii)polyethylene terephthalate (PET) (4) (iv )Poly carbonate (4) 2. Describe the molecular structure, properties and application of the following polymeric materials. (i)poly methyl methacrylate (PMMA) (4)

15 (ii)poly tetra f1uoro ethylene (PTFE) (4) (iii)polyethylene terephthalate (PET) (4) (iv)acryl nitride butadiene styrene. (4) 3. Describe the molecular structure, properties and application of the following polymers. (i)polypropylene (PP) (ii) Polyvinyl chloride (PVC) (iii) Poly tetra f1uoro ethylene (PTFE) (iv)poly ethylene perethalate. 4. Describe the properties and application of the following ceramics materials (i)alumina (4) (ii)silicon carbide (4) (iii)silicon nitride (4) (iv)sialon. (4) 5. Write short notes about the different types of matrix materials and reinforced materials used to make polymers matrix composites. (16)