Mettalurgy 11/9/2020

Metallurgy
Course Code-ME205
By
Dr. Biranchi Narayan Sahoo
Assistant Professor

Department of Mechanical Engineering

SVNIT Surat-359007
09-11-2020

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Details Syllabus
INTRODUCTION AND SCOPE (04 Hours)
Various fields of metallurgical engineering, Status of metallurgical industry in
India, Sources of metals, Basic outline of the principles of production of iron
and steel, copper, aluminum. Basic concepts of metallography.
STRUCTURE-PROPERTY CORRELATIONSHIP IN METALS (06 Hours)
Ferrous: Allotropic forms of Iron, Wrought Iron, Cast Irons - Grey, White,
Malleable and Spheroidal Graphite, Steel - Plain carbon steel, Alloying of steels,
Stainless steels, Tool steels, Maraging steels. Non-ferrous: Copper & Copper
alloys - Brass, Bronze, Cupro-Nickel; Aluminum and Aluminum alloys, Titanium
alloys, Nickel based super alloys.
SOLIDIFICATION OF METALS (04 Hours)
Solidification of pure metals, Nucleation, Growth, Applications of controlled
Nucleation & controlled growth.
DEFORMATION OF METALS (06 Hours)
Elastic & plastic deformation of metals, Strengthening mechanisms,
Importance of grain size, directional properties, Recovery, Recrystallization and
grain growth.
09-11-2020

Details Syllabus
EQUILIBRIUM PHASE DIAGRAMS (08 Hours)
Objectives & classification, Basic terms - system, phases & structural
constituent, Phase systems - Isomorphous, Eutectic. Eutectoid, Peritectic.
Interpretation of phase diagrams- s phase rule, Equilibrium phase diagram of
Fe-Fe3C system, Equilibrium phase diagrams of non-ferrous alloys.
HEAT TREATMENT (08 Hours)
Purpose, Definition and Classification of heat-treatment processes for steels,
Heat treatments for bulk materials - Annealing, Normalizing, Hardening,
Tempering, Isothermal cooling transformation diagram (ICT/TTT) and
Continuous cooling transformation (CCT) diagrams for steels, Various surface
hardening heat-treatment of steels; Heat-treatment of Al alloys - Solution
treatment, Solution quenching & Precipitation hardening.
NON-DESTRUCTIVE TESTING TECHNIQUES (06 Hours)
Importance, principle, procedure, equipments, advantages & limitations of
various non-destructive techniques - visual inspection, radiography, ultrasonic
testing, magnetic particle inspection, liquid penetrant inspection, eddy current
testing
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NON-DESTRUCTIVE TESTING TECHNIQUES

 Importance,
 principle, procedure, equipments,
 advantages & limitations of various non-destructive techniques -
visual inspection,
 radiography,
 ultrasonic testing,
 magnetic particle inspection,
 liquid penetrant inspection,
 eddy current testing

NON-DESTRUCTIVE TESTING TECHNIQUES

Mechanical testing of materials Non destructive testing
 Nondestructive testing (NDT) is a wide group of analysis techniques
used in science and technology industry to evaluate the properties of
a material, component or system without causing damage.
 The terms nondestructive examination (NDE), nondestructive
inspection (NDI), and nondestructive evaluation (NDE) are also
commonly used to describe this technology.
 Because NDT does not permanently alter the article being inspected,
it is a highly valuable technique that can save both money and time
in product evaluation, troubleshooting, and research.
 The six most frequently used NDT methods are
 Eddy-current,  Radiographic,
 Magnetic-particle,  Ultrasonic,
 Dye/liquid penetrant,  and Visual testing

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NON-DESTRUCTIVE TESTING TECHNIQUES

Mechanical testing of materials Non destructive testing
 NDT does not directly measure mechanical properties but they are
used to locate defects or flaws in the component.
 Flaws reduce useful life of component resulting in premature failure
even with a sound design and proper selection of materials.
 To obtain high level of reliability , defect should be absent or at
minimum level.
 NDT is carried out periodically.
 Replacement of component before its premature failure to avoid
dangerous results.

NON-DESTRUCTIVE TESTING TECHNIQUES

Mechanical testing of materials Non destructive testing
Dye Penetrant Inspection
 Invisible cracks, porosity and other defects on the surface of
components easily detected by this technique.
 Components may be ferrous, nonferrous, plastic, glass or ceramic
 Procedure:-
1. Cleaning of surface.(Grease, oil, any other material).
2. Drying of surface.
3. Applying dye-penetrant on clean and dry surface. It is allowed to
penetrate in surface flaws. i) Liquid Soluble Penetrant ii) Fluroscent
4. Removing excess penetrant by soft or clean cotton.
5. Applying developer on surface. This pulls out dye from flaws and
flaws are revealed by colour of dye. Instead of developer, fine
developing powder or talc powder can be sprinkled on the surface.

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NON-DESTRUCTIVE TESTING TECHNIQUES

Mechanical testing of materials Non destructive testing
Dye Penetrant Inspection

MECHANICAL BEHAVIOR OF METALS

Mechanical testing of materials Non destructive testing
Advantages of Dye Penetrant Inspection
 This test can be applied to almost any type of metals, nonmetals,
magnetic or non magnetic type.
 Simple to utilize and control.
 Results of test can be interpreted fastly.
 Cost of test is very less as it does not require any instrument or
electronic display units.
 Sensitivity is greater than that of magnetic particle testing.
Disadvantages of Dye Penetrant Inspection
 Cleaning of components is must before and after testing to avoid
rusting.
 Misleading results may be obtained in case of components with
surface films and coatings
 Only surface defects can be detected
 Test is not applicable for powder metallurgical components

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MECHANICAL BEHAVIOR OF METALS

Mechanical testing of materials Non destructive testing
Sonic Inspection
 Sound is created in the component and from quality of sound,
presence of defect is judged.
 e.g. C.I. piece gives a dull sound as compared to steel piece if
dropped from certain height on the floor.
 e.g. Cups, saucer, earthen pots ,coconuts.

MECHANICAL BEHAVIOR OF METALS

Mechanical testing of materials Non destructive testing
Ultrasonic Test/inspection
Principle-
1. Measure of time required by ultrasonic vibrations to penetrate
material of interest , reflect from opposite side or from internal
discontinuity and return to point from where first introduced.
2. Behaviour of waves through cycle with regard to time is recorded on
CRO screen.
3. By observing this presence of defect and their location can be
detected.
Two types of Ultrasonic testing method
i)Pulse –echo method
ii) Transmission Method

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MECHANICAL BEHAVIOR OF METALS

Mechanical testing of materials Non destructive testing
i)Pulse –Echo method:-

MECHANICAL BEHAVIOR OF METALS

Mechanical testing of materials Non destructive testing
ii) Transmission Method

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MECHANICAL BEHAVIOR OF METALS

Mechanical testing of materials Non destructive testing
Advantages of Ultrasonic Test
 Better detection of flaws situated deep in metal due to superior
penetrating power of ultrasonic waves
 High sensitivity, better accuracy and reliability
 The equipment is portable and easy to handle
 Output of test can be processed by computer which lead to improved
result reliability

Disadvantages of Ultrasonic Test

 Due to manual operation, careful attention and highly skilled
operators are required
 Irregular shaped and rough parts are very difficult to examine
 Subsurface discontinuities are more difficult to detect
 Couplants are needed for testing

MECHANICAL BEHAVIOR OF METALS

Mechanical testing of materials Non destructive testing
Magnetic Particle (Magnaflux) Inspection
 It is used to detect various kinds of flaws in ferromagnetic
components such as weldings, castings, forgings of iron and steel.
 Component to be inspected for flaws is magnetized.
 In dry method of inspection special fine ferromagnetic powder is
applied on surface .
 This test is a very fast method of inspection and often used to test
aerospace components and automobile parts.
 This test is generally used to detect internal cracks like shrinkage
cavities, hot tears, zones of corrosion and non-metallic inclusions

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MECHANICAL BEHAVIOR OF METALS

Mechanical testing of materials Non destructive testing
Magnaflux test procedure
1. Cleaning Surface
2. Magnetization
3. Application of ferromagnetic Powder
4. Observation and Inspection
5. Demagnetization

MECHANICAL BEHAVIOR OF METALS

Mechanical testing of materials Non destructive testing

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MECHANICAL BEHAVIOR OF METALS

Mechanical testing of materials Non destructive testing

MECHANICAL BEHAVIOR OF METALS

Mechanical testing of materials Non destructive testing
Advantages of Magnaflux test
 Sub-surface cracks can be easily detected
 Almost any shaped and sized component can be tested for defects
 Instruments are portable and easy to handle
 Highly sensitive method to detect small and shallow surface cracks
Disadvantages of Magnaflux test
 Method is applicable only to ferromagnetic materials
 Surface plating or thin paint coating affect the sensitivity of the test
 After testing, demagnetization is a must
 Local heating and sparking is possible during test hence proper care
must be taken

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MECHANICAL BEHAVIOR OF METALS

Mechanical testing of materials Non destructive testing
Radiography Test
 NDT method that utilizes x-rays or gamma radiation to detect
discontinuities in materials, and to present their images on recording
medium.
 This includes X-rays, gamma rays and radioisotopes.
 This method is used to check internal cracks, defects in materials
which are made by casting, welding, forging.
 Nowadays, radiography techniques are finding more extensive
applications in the field of physical metallurgy and in the treatment of
various diseases.
 Rays are absorbed by the materials through which they are passed in
the proportion of their density.
 The rays, after passing through the components, show a picture on a
fluorescent screen or on a photographic plate.

MECHANICAL BEHAVIOR OF METALS

Mechanical testing of materials Non destructive testing
Radiography Test
 The cracks, blow holes and cavities appear lighter, whereas inclusions
of impurities appear darker than the metal component.
 Developed photographic film show lighter and darker areas to
represent the radiograph of defects in the component.

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MECHANICAL BEHAVIOR OF METALS

Mechanical testing of materials Non destructive testing

MECHANICAL BEHAVIOR OF METALS

Mechanical testing of materials Non destructive testing
Advantages of Radiography Test
 X-ray radiography is highly sensitive, fast method of finding defects
 X-ray radiography is suitable for various applications due to its
adjustable energy levels
 Gamma ray radiography has high penetrating power hence can be
used for more denser and thicker materials
 A number of samples can be inspected at a time by gamma ray
radiography
Disadvantages of Radiography Test
 X-ray radiography can be applied for thinner components due to its
less penetrating power
 X-ray radiography allows only one component to be tested at a time
 X-ray radiography involves high initial cost
 X-ray and gamma ray radiography involve radiations which are
hazardous to living beings
 Trained operators are required

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MECHANICAL BEHAVIOR OF METALS

Mechanical testing of materials Non destructive testing
Eddy Current Testing
 Basic Principle:-
 When coil carrying alternating current is brought near metallic
specimen, eddy currents are developed in specimen due to
electromagnetic induction.
 Magnitude of induced EMI depend on –
i. Magnitude and frequency of alternating current flowing in coil.
ii. Electrical conductivity of specimen.
iii. Magnetic permeability of specimen.
iv. Shape of specimen.
v. Relative positions of coil and specimen.
vi. Microstructure and hardness of Specimen.
vii. Amount and type of defects in the specimen

MECHANICAL BEHAVIOR OF METALS

Mechanical testing of materials Non destructive testing
Eddy Current Testing

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MECHANICAL BEHAVIOR OF METALS

Mechanical testing of materials Non destructive testing
Advantages ECT
 Test is quick and less time consuming
 Test can be automated easily
 Permanent record of test results can be easily available
 Test is versatile and can be used for various applications
Disadvantages ECT
 The instrument standardization and calibration is necessary from
time to time
 Instruments and display units are costly
 Test can be applied to components of limited size and shape

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