Physical Metallurgy :362 Syllabus September 2006 Ver. 1.0

Transcription

1 Physical Metallurgy :362 Syllabus September 2006 Ver. 1.0 Instructor: Victor A Greenhut McLarenCCR greenhut@alumina.rutgers.edu COURSE OBJECTIVES: The objectives of this course are to provide students with the following competencies: a. understanding the relationships between processing, structure, properties and performance { SP 3 } for metals Junior elective course: assumes students possess general materials engineering competence b. practical understanding of principles and theories of physical metallurgy c. knowledge of processing, structure, properties and performance for commercially important metal and alloys with practical engineering constraints. d. ability to select a metal system and/or an alloy based upon advantages/disadvantages of different technologies including costs (economics), performance, environmental concerns, manufacturability, and sustainability with consideration of health and safety and to a lesser extent social and political issues. e. ability to select casting vs. mechanical forming based upon advantages/disadvantages of differen technologies including costs (economics), performance, environmental concerns, manufacturability, and sustainability with consideration of health and safety and to a lesser extent social and political issues. f. ability to select a forming method and production path based upon advantages/disadvantages of different technologies including costs (economics), performance, environmental concerns, manufacturability, and sustainability with consideration of health and safety and to a lesser extent social and political issues. g. understanding how properly engineered metals and alloys can take effective advantage of the relative properties and costs of commonly used classes of metals and alloys. h. understand the relationship between processing and properties as they relate to manufacturing and end use. i. understand issues of long term performance under load and/or in an environment. j. Understand the relationships to and comparative properties of other materials types (ceramics, plastics, composites). without the expressed, signature permission of V.A. Greenhut. except for review purposes. 1

2 COURSE FORMAT: The course is provided in a highly interactive lecture/recitation format. Lectures, readings, exercises and homework deal with the technology of Physical Metallurgy with a strong emphasis on practical, common engineering backed by scientific understanding. Students are furnished a full paper version of lectures consisting of an extended outline (first step in text development) and visuals to follow every presented visual image-by-image (metallograph, schematic, graph, equations, table...). This material is derived, with major revision and update, from a week-long intensive course initiated and taught by the instructor and Prof. John Wood (Lehigh University). This short course was taught internationally, publicly and in-plant to many thousands of engineers and technologists for over two decades. It has been imitated by several professional materials societies. In the past, about half the material was taught successfully in :423, Ceramic-Metal Systems to furnish Ceramic Engineers with some basics of practical Physical Metallurgy. Required texts provide both a tutorial background, academic text (Physical Metallurgy tent.) and practical engineering reference (Metals Handbook: Desk Edition, 2 nd Ed.). Texts and supplementary text material (chiefly the full Metals Handbook online ) will be available at SERC and/or the Undergraduate Computer Room. Some will also be made available short-term by the instructor. PowerPoint visuals are used for all presentations, preceded in the paper, hand-out version by an extended written outline providing all major concepts for learning reinforcement in writing.* Students are furnished a full paper version of the extended outline and visuals to follow every presentation. And take notes lecture provides practical Physical Metallurgy (not provided in prior course work). For the ceramic-metal systems content, an overview article is provided, reading materials (print and CD) are available in the SERC Reading Room and are also available from the instructor for personal, legally compliant copying (most valuable sources are out of print). Viewgraph visuals are used and available to students for copying. The metallurgy segment is provided with slides. Copies of these notes and visuals are provided at copying cost. Students are encouraged to purchase through a special instructor-organized arrangement with ASM International the Metals Handbook: Desk Edition (at ½ price or better) as a course and life-long learning aid. Samples, examples of actual engineering problems, open-ended problem solving and application choices are incorporated both to extend knowledge to application and to provide engineering experience. Students will complete exercises as part of independent study both individually and in small groups. These realistic problems in materials selection and processing will be based chiefly on use of the complete Metals Handbook as a resource. Extra, voluntary workshops, seminars, and plant trips classes will be provided by the instructor and/or visiting scientists in topic areas related to course materials. This will include: Review of the Lever Law for phase diagram calculation (prior coursework) Enrichment workshops in failure analysis, corrosion analysis, materials selection, process selection, specific metal/alloy systems, etc. Plant trips (mini-mill, casting shop, forging shop...) without the expressed, signature permission of V.A. Greenhut. except for review purposes 2

3 DRAFT DRAFT DRAFT DRAFT DRAFT DRAFT DRAFT DRAF REQUIRED TEXTS (see Notes*) a. Metals Handbook : Desk Edition, 2 nd Ed., J.R. Davis ed. ASM International, Materials Park (1995) 1,300pages, ISBN: (book) ISBN: (CD) (see Note) b. Physical Metallurgy, Materials Engineering Series, Vol. 26, William F. Hosford, Taylor & Francis CRC Press, Boca Raton (2005) 520 pages, ISBN: (TENTATIVE) c. PowerPoint visuals used for recitations and the accompanying extended notes (derived from Metallurgy for Non-Metallurgists) will be furnished to students at the start of the semester for direct in-class note taking and out-of-class review of subject matter. Textual materials (print & electronic) will be available in the MS&E Undergraduate Computer Room and/or SERC Reading Room (and on short-term loan from the instructor). They might be copied for legally compliant personal use. SUPPLEMENTAL & REFERENCE TEXTS (see Notes*) Metals Handbook, 10th Edition, 21 Volume (26 Book) Set, ASM International, Materials Park ( ) 1,300pages, ISBN: (book) ISBN: (CD) (see Note) Textual materials (print and electronic) will be available in the SERC Reading Room and/or MS&E Undergraduate Computer Room (and on short-term loan from the instructor). They might be copied for legally compliant personal use. Notes: 1. The Metals Handbook : Desk Edition, 2nd Edition, and the complete Metals Handbook, 10 th Edition, are both available as a benefit to members of ASM International at: Most Junior & Senior MS&E majors now join Materials Advantage as student members Of the American Ceramic Society, ASM International, The Metallurgical Society). Materials Advantage membership is currently $25 per annum. 2. The Metals Handbook : Desk Edition, 2 nd Edition, will be furnished to students taking :362 at $120 (or less)* in book or CD version**- less than half the list cost of $244. This is a lifelong learning reference and intensive whose continued use will be encouraged by intensive use in instruction plus provision at an ultra-low price. 3. It is intended that the entire Metals Handbook : Desk Edition, 2 nd Edition, and the complete Metals Handbook,10 th Edition be available in print versions and directly (for access speed) on the computers in the MS&E Student Computer Room. * A special bulk minimum price has not yet been negotiated by the instructor. ** Both book and CD versions for $179 (or less) versus list cost of $362. Engineered Materials Handbook (Ceramics, Polymers, Composites) added at similar savings without the expressed, signature permission of V.A. Greenhut. except for review purposes 3

4 Assessment of Outcomes: Student progress is assessed by a midterm and final examination. Progress is monitored by recitation questions, spot quizzes (verifying attention to readings) and real-world problem solving/applications via hand-in assignments. Course outcomes are assessed formally through the examinations, recitation interaction and student evaluation forms. Additional assessment questions for course modification are occasionally added to the form. Informal evaluation occurs through contacts with alumni, many of whom will find careers significantly incorporating the Physical Metallurgy course. About 5-10 contacts per year now occur from prior students who use the instructor as a resource for physical metallurgy questions. Students who took, :426, Ceramic-Metal Systems, report significant use of the metallurgy component and the utility of the Metals Handbook : Desk Edition, acquired as a recommended text. This includes recent graduates and graduates from prior decades. Relationship to Program & ABET Objectives & Proficiencies: Program Objectives The course provides contributions to program objectives 1-4. ABET General Proficiencies ( a. k. ) With respect to general ABET (Accreditation Board for Engineering and Technology) proficiencies it contributes significantly to items (a), (b), (c), (e), and (i) as they pertain to Materials Engineering and/or Metallurgy. Items (f), (g) and (h) are stressed through real world examples and examples in which other knowledge may contribute to solving engineering problems in Physical Metallurgy. The nature of multi-disciplinary teams (item d) in Physical Metallurgy, Materials Engineering, Plant Engineering, Engineering Design, etc. is discussed briefly. Several independent problems will be executed on a team basis with different teaming for each exercise in partial fulfillment of item d. ABET Program Specific Proficiencies As it is a vital part of Physical Metallurgy and application to various technological applications, the relationships between processing, structure, properties and performance { SP 3 } are stressed in identifying required physical and chemical properties, selecting materials, system approaches, optimizing production variables and metal components (microstructure and/or macrostructure). Stress on mesostructure, microstructure and nanostructure is somewhat greater than in traditional Physical Metallurgy courses. Most lecture/recitations begin with structure derived from processing metal and alloys. Structure is used as the rationale for properties and performance. The first major recitation is on Metallography. This satisfies the specialization requirements for { SP 3 } as set forth in both the requirements for Materials Engineering and in Metallurgy specializations in ABET requirements without the expressed, signature permission of V.A. Greenhut. except for review purposes WEEK-BY-WEEK SCHEDULE 4

5 Physical Metallurgy :362 Note: Text refers to chapter titles (in quotes) from Physical Metallurgy (above) unless otherwise noted. A new text developed by the instructor from the extended notes (Metallurgy Notes) and PowerPoint visuals is expected to be prepared for Spring Semester WEEK 1: A. Course Introduction Metallurgy Notes -- Sect. A Text -- Preface & INTRODUCTION Basic principles of Physical Metallurgy. Relationship of Extractive Metallurgy to Physical Metallurgy. Why metals are useful engineering materials. Fundamental overview of relationships between processing, structure, properties and performance { SP 3 }. Overview of course content and rules. B. Metallography Metallurgy Notes Sect. B Text Appendix A: MICROSTRUCTURAL ANALYSIS Microscope Methods: Macro-scale viewing, Optical Microscopy, SEM & TEM, Microanalysis Metallurgical Sample Preparation: Cutting, Grinding, Polishing, Etching Precautions in Preparing Samples. Microstructural Analysis and Correlations in SP 3 WEEK 2: A. Nature & Properties of Pure Metals Metallurgy Notes -- Sect. C Text -- Metals Handbook : Desk Edition, 2 nd Ed Metallic Bonding: Free and Nearly-Free Electron Models Metal Properties: Optical, Thermal, Electrical, Mechanical, Chemical Metal Structure: Bravais Lattices, FCC, HCP, BCC Relationship of Valence & Ion Size to Structure B. Imperfections in Metals Metallurgy Notes -- Sect. D Text DIFFUSION & DISLOCATIONS Vacancies: Entropy of Mixing, Number, Mobility, Diffusion Substitutional & Interstitial Solid Solution: Impurities and Alloying Dislocations: Edge and Screw, Crystal Growth Theoretical Strength, Plastic Deformation Multiplication & Strengthening Crystal Growth Mechanisms Twinning: Growth Twins, Mechanical Twins, Recrystallization Twins Martensite: Stress-Induced, Athermal, Type II Multiphase: Inter- and Intra- Granular without the expressed, signature permission of V.A. Greenhut, except for review purposes WEEK 3 5

6 A. Alloying (Phase Diagrams) Metallurgy Notes -- Sect. E. Text SOLID SOLUTIONS & PHASE DIAGRAMS Metals Handbook, 10 th Ed. Isomorphous Alloys: Cu-Ni Phase Diagram, Microstructure, Properties Eutectic Alloys: Pb-Sn Phase Diagram, Microstructure, Properties Cooling Rate Effects: Microstructure, Phase Distribution, Composition Change, Properties Other Phase Diagrams: Peritectic, Monotectic, Miscibility Gap, Solid Phase Changes- Fe-C Phase Diagram, Magnetism, Steel & Cast Iron Phase Fields B. Casting Technologies Metallurgy Notes, Sect. F. Text FREEZING, INTERMEDIATE PHASES Metals Handbook : Desk Edition, 2 nd Ed Casting Grain Structure: Ingot Structure, Dendritic Growth, Multiphase Structures Compositional Segregation: Micro- & Macro- Segregation, Impurities Porosity: Micro and Macro Residual Stresses: In Castings, Deformation on Material Removal Casting Technologies: Sand, Metal Mold, Investment, Die, Continuous, Metallic Glass WEEK 4 A. Strength & Deformation of Metals, Metallurgy Notes, Sect. G Text -- Metals Handbook : Desk Edition, 2 nd Ed Elastic Behavior: Stress Strain Relations, Directional Properties, Structure Sensitive and Insensitive Properties Plastic Behavior: Dislocation Slip, Theoretical Strength, Easy Glide, Yield Point Stress-Strain Curve: Engineering Yield Point, Engineering vs. True, Ultimate Stress Loading & Unloading, Work Strengthening Strength, Ductility, Energy Input, Hardness B. Strengthening by Work Hardening (Strengthening) Metallurgy Notes, Sect. H Text -- DISLOCATIONS Metals Handbook : Desk Edition, 2 nd Ed Mechanical Deformation: Tension, Shear, Bending Torsion Strain Hardening (Strengthening): Dislocation Multiplication, Forest Dislocations Other Mechanisms of Strain Hardening (Strengthening): Twins, Martensites, Single Crystal Strengthening Polycrystalline Deformation, Strengthening and Introduction of Texture Multiphase Microstructures Effect of Crystal Size and Texture: Structure Sensitive and Insensitive Properties Residual Stresses from Deformation without the expressed, signature permission of V.A. Greenhut. except for review purposes 6

7 WEEK 5 A. Annealing Metals Metallurgy Notes, Sect. I Text ANNEALING Effect of Cold Working: Percent Reduction Recovery & Recrystallization of Cold Worked Metal Grain Growth Grain Size Control, Cold Work and Properties Texture Recrystallization Temperature Effect of Degree of Cold Work Cold Working vs. Hot Working B. Mechanical Forming Technologies Metallurgy Notes, Sect. J Text Metals Handbook : Desk Edition, 2 nd Ed Forging: Open and Closed Die, Grain Texture and Mechanical Properties Rolling: Sheet, Rail, Die, Screw (rolled vs. cut thread) Extrusion: Conventional and Hydrostatic, Triaxial Stress Effects Drawing, Swaging Deep Drawing: Forming Limit Diagrams Embossing, Coining, Hobbing Spinning, Brake Forming, Hypervelocity Forming Spring-Back, Residual Stress, Finish, Tolerances WEEK 6 A. Principles of Alloy Strengthening (Non-Ferrous) Metallurgy Notes, Sect. K. 1 Text SOLID SOLUTIONS PHASE TRANSFORMATIONS Solution Strengthening: Substitutional & Interstitial, Dislocation Atmospheres, Effect of Misfit, Concentration, Multiple Additives, Relation to Other Strengthening Dispersions and Precipitates: Definitions and Mechanisms, Phase Diagrams, Reaction (ex. Carburizing, Nitriding) Dispersion Hardening (Strengthening): Heat Treatment, Ductility Effects Precipitation Hardening: Aging Heat Treatments, Thermo-Mechanical Treatments (TMT s) Forming and Heat Treatment B. Commercial Non-Ferrous Alloy Heat Treatment Metallurgy Notes, Sect. K. 2 Text ALLOYS : Al, Cu, Ni, Hexagonal, Pb-Sn, and Precious Alloy Designation Systems & Temper Designations Copper and Nickel: Cu-Ni, Cu & Ni Alloys Aluminum and Aluminum Alloys: Al 1100, Al 2024, Al 7075, Al-Si Titanium and Titanium Alloys Precious Metals Other Metals without the expressed, signature permission of V.A. Greenhut. except for review purposes 7

8 WEEK 7 A. Steel Metallurgy I Microstructures & Properties Metallurgy Notes, Sect. L.1 Text STEELS Eutectoid (1080) Steel: Cooling Rate, Structure & Properties, Austenite, Ferrite and Cementite, Pearlite, Martensite, Bainite Hypoeutectoid (1040) Steel: Cooling Rate Structure & Properties B. Steel Metallurgy II CCT & TTT Diagrams Metallurgy Notes, Sect L. 2 Text HARDENING OF STEELS LOW CARBON STEELS TTT Diagrams: Microstructures and Properties CCT Diagrams: Conventional CCT Constant Rate CCT Diagrams, Effects of C Content and Alloying Jominy End Bar Quench Tests and Cooling Rate Curves Shape-Dimension Cooling Plots: Predicting Microstructure and Properties MIDTERM (Date- TBD) - Covers Material through Week 7 - (Date- TBD) MIDTERM WEEK 8 A. Steel Metallurgy III - Heat Treatment and Selection Metallurgy Notes, Sect. L.3 Text TEMPERING AND SURFACE HARDENING SPECIAL STEELS Quenching Media Normalizing, Spheroidization, Quench and Temper, Martempering, Austempering... Retained Austenite Surface Hardening: Flame and Induction Hardening, Carburizing, Nitriding, Carbonitriding High Strength Low Alloy (HSLA) Steels, Maraging Steels, Trip Steels Tool Steels, Silicon Steels Selecting Steels SEMESTER BREAK SEMESTER BREAK B. Cast Iron Metallurgy Notes, Sect. M Text CAST IRONS Eutectic Phase Diagram, Casting Additions, Eutectoid Reactions White Cast Iron Grey Cast Iron Ductile Cast Iron Malleable Iron, Wrought Iron (Then and Now) without the expressed, signature permission of V.A. Greenhut. except for review purposes 8

9 WEEK 9 A. Stainless Steel Metallurgy Notes, Sect. N Text SPECIAL STEELS - Stainless Steel Austenitic Stainless Steel: Phase Diagrams, Transformation, Sigma Phase Ferritic Stainless Steel Martensitic Stainless Steel PH Stainless Steels Trip Steels B. Toughness and Fracture Metallurgy Notes, Sect. O Text Metal Handbook, 10 Ed. -- Vol. 11 Griffith Criterion, General Fracture Toughness Formulation, K 1c, Irwin Criterion Ductile-Brittle Transition, NDT, Liberty Ships, R 1c Toughness Testing: Charpy & Izod Tests, Other Toughness Tests Material Selection: Toughness/Strength Trade-offs WEEK 10 A. Long Term Performance Under Load Fatigue Metallurgy Notes, Sect. P Text -- Metals Handbook, 10 th Ed. Vol. 19 General Fatigue Behavior Mechanisms of Low Amplitude, High Cycle Fatigue Persistent Slip Lines, Dislocation/Vacancy Mechanisms Fatigue Curves: Endurance & Fatigue Limit, Non-Zero Mean Stress Environmental Factors Fatigue Laws : Relationship to Fracture Toughness, Cumulative Damage, Predicting Fatigue Failure, Fatigue Crack Inspection, High Amplitude Fatigue Failure Prevention: Stop Drilling, Environmental Control, Ultrasonic Treatments B. Long Term Performance Under Load Creep Metallurgy Notes, Sect. Q Text Metals Handbook, 10 th Ed. Vol. 11 Creep, Stress Relaxation, and Stress Rupture High Temperature Creep Behavior Creep Laws and Failure Prediction Metallurgical Change and Failure Prevention Preventing Creep Failure: Materials Selection, Creep Resistant Microstructure, W Alloys WEEK 11 A. Failure Analysis & Prevention - Principles Metallurgy Notes, Sect. R Text Metals Handbook, 10 th Ed. Vol. 11 Failure Analysis Protocols and Reports Brittle and Quasi-Brittle Failure: River Patterns, Hackle, Rib Marks, Chevron Marks, Identifying Failure Origins, Microstructure Effects Intergranular and Transgranular Failure Ductile Failure: Cup-Cone, Tensile, Tearing and Shear Failures Fatigue: Fatigue Striations, Fatigue Marks, Identifying Failure Origins in Fatigue without the expressed, signature permission of V.A. Greenhut. except for review purposes 9

10 B. Failure Analysis Workshop Metallurgy Notes, Sect. S Text Metals Handbook, 10 th Ed. Vol. 11 Group Activity: Identifying Failures, Failure Origins, Failure Scenarios and Failure Prevention (Includes real-world examples of most major classes of metallurgical failure, with several taken from the SOE). Week 12 A. Corrosion I - Metallurgy Notes, Sect. T.1 Text CORROSION Corrosion Types Corrosion Mechanisms Galvanic Corrosion: Galvanic Series, Electrochemical Series, Effect of Corrosion Environment Corrosion Curves, Current Density, Polarization Corrosion Examples Concentration/Dilution Effects Pourbaix Diagrams B. Corrosion II - Corrosion Under Stress Metallurgy Notes, Sect. T.2 Text Supplemental (TBD) Stress Corrosion Cracking: Failure Prediction, Stainless Steel - Cl Attack, Control Fatigue Corrosion Cracking Fretting Corrosion Hydrogen Embrittlement Impingement and Cavitation WEEK 13 A. Corrosion Control Metallurgy Notes, Sect. U Text Metals Handbook : Desk Edition, 2 nd Ed. Electrical Isolation Environment Change Cathodic and Anodic Protection Passivation: Stainless Steel - Cl Attack, Mechanical Shock, Abrasion (particle & bubble) Protective Coatings- Metallic, Polymeric, Ceramic Vapor Phase Protection B. Powder Metallurgy Metallurgy Notes, Sect. V Text POWDER PROCESSING Sources of Metal Powders Pressing and Deformation Effects Sintering; Solid State, Liquid Phase, Activated Hot Pressing Properties: Cost, Strength & Ductility vs. Conventional Forming, Porosity, Self Lubrication, Dispersed Phases, Applications without the expressed, signature permission of V.A. Greenhut. except for review purposes 10

11 WEEK 14 A. Metal Joining Metallurgy Notes, Sect. W Text -- WELDING Brazing & Soldering; Techniques, Fluxes, Cooling Rate, Mechanical Strength, Sweating, Wiping, Pb-Free Compositions Welding Methods: Flame, Arc, Submerged Arc, Resistance, Inertial Joint Design Residual Stress & Distortion Weld Metal and Flux Selection Weld Structure and Heat Distribution: HAZ (Heat Affected Zone), Microstructure Strength and Corrosion Properties B. Frontiers in Physical Metallurgy Metallurgy Notes, Sect. X Text Supplemental Video = 1: Riddles Underlying Nano-Particles and Nano-Wire, The Takayanagi Particle/Surface Project New Alloys Specialty Metals Metal Matrix Composites Metals in Solid State Electronics Surface Modification: Ion Bombardment, Sputtering, Nano-Metals Optional, Voluntary Group Review Sessions (Dates: TBD): Lever Law - Phase Diagram Review - Week 3 Midterm Exam Review - Final Exam Review - Week 7 or 8 (before Midterm) Week 14 or 15 (before Final) FINAL EXAM (Full Semester Material) without the expressed, signature permission of V.A. Greenhut. except for review purposes 11