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Document 8

But explain

Uploaded by

kokulkokulan250
Copyright
© © All Rights Reserved
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Download as DOCX, PDF, TXT or read online on Scribd
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Question 1

a) Iron-Carbon Diagram and its Importance in Steel Manufacturing

The Iron-Carbon diagram, also known as the Phase Diagram of Iron-Iron


Carbide, is a graphical representation that illustrates the relationship
between the composition of iron-carbon alloys and their phase
transformations at different temperatures. It is a crucial tool in steel
manufacturing as it helps metallurgists understand and control the
properties of steel by manipulating its composition and heat treatment
processes.

Key features and their importance:

* Eutectic Point (E): At this point, liquid iron-carbon alloy solidifies into a
mixture of austenite (gamma phase) and cementite (Fe3C). This
transformation is essential for the production of cast iron.

* Eutectoid Point (C): Here, austenite transforms into a mixture of ferrite


(alpha phase) and cementite, forming pearlite. This transformation is crucial
for the production of mild steel.

* Austenite Region: This region is crucial for heat treatment processes like
annealing and quenching. By heating steel into this region, it can be
transformed into austenite, a single-phase solid solution. Subsequent cooling
at different rates results in various microstructures and properties.

* Ferrite Region: Ferrite is a soft, ductile phase that contributes to the


toughness and corrosion resistance of steel.

* Cementite Region: Cementite is a hard, brittle phase that enhances the


wear resistance of steel.

b) Important Points on the Iron-Carbon Diagram

* Eutectic point (E)

* Eutectoid point (C)

* Liquidus line

* Solidus line

* Austenite region

* Ferrite region

* Cementite region
c) Structure of Pure Iron

Pure iron has a body-centered cubic (BCC) crystal structure.

d) Pig Iron

Pig iron is a type of iron produced in a blast furnace. It contains a high


percentage of carbon (around 3-4%) and other impurities like silicon,
manganese, phosphorus, and sulfur. It is not suitable for direct use in most
applications and is further refined to produce steel or cast iron.

Question 2

a) Meaning of BCC, FCC, and CPH

* BCC (Body-Centered Cubic): A crystal structure where atoms are arranged


in a cubic lattice with an additional atom at the center of the cube.

* FCC (Face-Centered Cubic): A crystal structure where atoms are arranged


in a cubic lattice with an additional atom at the center of each face of the
cube.

* CPH (Close-Packed Hexagonal): A crystal structure where atoms are


arranged in a hexagonal lattice with two alternating layers of atoms.

b) Sketches

[Sketches of BCC, FCC, and CPH crystal structures]

c) Materials for Each Category

* BCC: Iron (alpha phase), Tungsten, Chromium

* FCC: Copper, Silver, Gold, Aluminum

* CPH: Zinc, Magnesium, Titanium

d) Creep of Material

Creep is the time-dependent deformation of a material under constant stress


at elevated temperatures. It is characterized by a gradual increase in strain
over time, even when the applied stress is below the material's yield
strength. Creep can lead to significant deformation and failure of
components in high-temperature applications.

e) Unique Property of Cast Iron


Cast iron is known for its excellent machinability. It can be easily machined
into complex shapes, making it ideal for various applications like engine
blocks, machine tool beds, and pipe fittings.

Question 3

a) Why Tensile Test is Done

Tensile tests are performed to determine the mechanical properties of


materials, including:

* Yield strength: The stress at which the material starts to deform plastically

* Ultimate tensile strength: The maximum stress the material can withstand
before fracture

* Ductility: The ability of the material to deform plastically before fracture

* Modulus of elasticity: The stiffness of the material

b) Type of Load in Tensile Testing

A uniaxial tensile load is applied to the specimen.

c) Factors Affecting Ultimate Tensile Strength

* Factors that affect:

* Composition of the material

* Heat treatment processes

* Presence of defects or impurities

* Factors that do not affect:

* Specimen size and shape (within certain limits)

d) UTM and Tests

UTM stands for Universal Testing Machine. It is a versatile machine used to


perform various mechanical tests on materials, including:

* Tensile tests

* Compression tests

* Flexural tests

* Shear tests
* Fatigue tests

e) Factors Affecting Compression and Tensile Tests

* Compression:

* Specimen geometry

* Loading rate

* Temperature

* Presence of defects or impurities

* Tensile:

* Specimen geometry

* Loading rate

* Temperature

* Presence of defects or impurities

* Surface finish

Question 4

a) Galvanizing

Galvanizing is a process of applying a protective zinc coating to steel or iron


to prevent rust. This is achieved by dipping the metal into a bath of molten
zinc or by applying zinc powder through a process called hot-dip galvanizing.

b) Glazing in Materials

Glazing refers to the process of coating a surface with a transparent or


translucent material, typically glass. In the context of materials, it can also
refer to the application of a glassy coating to a surface to improve its
properties, such as hardness, corrosion resistance, or optical properties.

c) Qualities of High-Temperature Alloys

High-temperature alloys are designed to withstand extreme temperatures


without compromising their mechanical properties. Key qualities include:

* High-temperature strength: The ability to retain strength and resist creep


at elevated temperatures.
* Oxidation resistance: The ability to resist oxidation and corrosion at high
temperatures.

* Thermal shock resistance: The ability to withstand rapid changes in


temperature without cracking or fracturing.

* Good creep resistance: The ability to resist time-dependent deformation


under stress at high temperatures.

d) Relationship between Temperature and Elasticity of Alloy Materials

Generally, the elasticity of alloy materials decreases with increasing


temperature. This is because the increased thermal energy causes the atoms
in the material to vibrate more vigorously, weakening the bonds between
them. As a result, the material becomes less stiff and more prone to
deformation under stress.

e) Materials Formed in Directional Solidification

Directional solidification is a technique used to produce single crystals or


highly oriented polycrystalline materials. It involves slowly cooling a molten
material from one end to the other, allowing the formation of large, well-
defined grains. Materials commonly produced through directional
solidification include:

* Single-crystal turbine blades for jet engines

* Highly oriented polycrystalline materials for electronic devices

Question 5

a) Five Most Usable Materials in the Modern Automotive Industry

* Steel: The most widely used material in the automotive industry due to its
strength, durability, and versatility. It is used in various components,
including body panels, frames, engine blocks, and suspension components.

* Aluminum: Lightweight and corrosion-resistant, aluminum is used


extensively in automotive components to reduce vehicle weight and improve
fuel efficiency. It is used in body panels, engine blocks, wheels, and
suspension components.

* Plastics: Lightweight and versatile, plastics are used in a wide range of


automotive components, including interior trim, exterior panels, and wiring
harnesses. They offer design flexibility and cost-effectiveness.
* Magnesium: Even lighter than aluminum, magnesium alloys are used in
specific components where weight reduction is critical, such as wheels and
transmission housings.

* Titanium: Although expensive, titanium alloys offer excellent strength-to-


weight ratio, high temperature resistance, and corrosion resistance. They are
used in high-performance applications like engine valves and exhaust
systems.

b) Malleability and Ductility of Materials

* Malleability: The ability of a material to be hammered or rolled into thin


sheets without breaking. Malleable materials can be easily shaped into
various forms. Examples of malleable materials include gold, silver, and
copper.

* Ductility: The ability of a material to be drawn into wires. Ductile materials


can be stretched and deformed without breaking. Examples of ductile
materials include copper, iron, and nickel.

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