Engineering Metallurgy

ME 2207
Credit Hour: 3.00
Department of Mechanical
Engineering
BAUST
 Reference Books

1. Avner S. H. (2014). Introduction to Physical

Metallurgy. 2nd Edition. New Delhi: Tata Mcgraw Hill.

2. Shackelford, J. F. (1996). Introduction to Materials

Science for Engineers. 6th Edition. Upper Saddle River,
N.J: Prentice Hall.
 Main Contents


Metals and Alloys

Crystal Structure of Metals

Iron-Iron Carbide Equilibrium Diagram

Heat Treatment

Composite Materials
 Detail Contents

 Metals and Alloys: Industrially Significant properties of metals;

Malleability, Ductility, Hardness, Toughness, Fatigue Resistance.
Destructive and Non-Destructive Tests applicable to metal.
 Crystal Structure of Metals: Types of crystal lattice, Solidification of metal
and alloys, Nucleation, Grain growth, cooling curves, Variables affecting
solidification.
 Iron-Iron Carbide Equilibrium Diagram: Plain carbon steels and their
microstructure; Crystal defeats, Dislocation theory.
 Heat Treatment: Methods and effects of Hardening, Annealing,
Normalizing, Quenching, Tempering, Austempering.
 Composite Materials: Introduction to composite materials,
importance of composite materials and uses, Latest developments in material
 Course Outcomes

CO1 Identify different properties of metals and alloys.

Draw various curves, equilibrium diagrams
CO2
related to metals and alloys.
Differentiate among different heat treatment
CO3
processes.
Enhance the knowledge of powder metallurgy and
CO4 composite materials in future with the basic
knowledge gathered from the course.
 Why Engineering Metallurgy is important for
mechanical engineering students?

1. Material Selection:
Mechanical engineers need to select appropriate materials for various
applications, considering factors such as strength, ductility, toughness, and
corrosion resistance.

2. Design and Analysis:

•Understanding Material Behavior: Knowledge of metallurgy helps
mechanical engineers predict how materials will behave under different loads,
temperatures, and environmental conditions. This is crucial for designing safe
and efficient mechanical components and systems.
•Failure Prevention: Metallurgy teaches students about the causes of material
failure, such as fatigue, creep, and corrosion, enabling them to design
components that can withstand long-term use without failing.
 Why Engineering Metallurgy is important for
mechanical engineering students?

3. Manufacturing Processes:

•Process Optimization: Many manufacturing processes, such as welding,

casting, forging, and heat treatment, are deeply rooted in metallurgical principles.
Mechanical engineers with a solid understanding of metallurgy can optimize
these processes to improve product quality and reduce costs.

•Material Processing: Knowledge of how different metals and alloys respond to

processing methods allows engineers to tailor materials to achieve desired
properties, such as hardness, toughness, or wear resistance.
 Why Engineering Metallurgy is important for
mechanical engineering students?

4. Innovation and Material Development:

•New Material Development: Mechanical engineers often work on developing

or applying new materials to create innovative products or improve existing ones.
A strong foundation in metallurgy is essential for understanding how to modify
material properties to meet specific engineering requirements.

•Composite Materials: With the growing use of composite materials in

engineering, understanding the metallurgical aspects of metal-matrix composites,
like the one you're studying in your journal paper, is vital.
 Why Engineering Metallurgy is important for
mechanical engineering students?

5. Cost and Sustainability Considerations:

•Economic Material Use: Metallurgical knowledge helps engineers select

materials that offer the best balance between cost and performance, which is
essential for creating economically viable products.

•Sustainable Practices: As sustainability becomes increasingly important,

understanding metallurgy allows engineers to design products that are more
recyclable, use less energy in production, and have a lower environmental
impact.
 Why Engineering Metallurgy is important for
mechanical engineering students?

6. Safety and Reliability:

•Critical Applications: In applications where safety is paramount, such as in
aerospace, automotive, and structural engineering, the choice of materials can
mean the difference between success and catastrophic failure. Metallurgical
knowledge ensures that materials will perform reliably under extreme conditions.

7. Interdisciplinary Knowledge:

•Collaboration with Material Scientists: Mechanical engineers often work
closely with material scientists. A background in metallurgy enables effective
communication and collaboration across disciplines, leading to better overall
product design and innovation.
 Why did The Mighty Titanic sunk?

 Material and Structural Issues:

Brittle Steel and Rivets: Some studies suggest that the steel used in
the Titanic’s construction was brittle in cold temperatures, which
could have caused the hull plates to fracture more easily upon
impact.
 Metallurgy and Classification of
Metallurgy

Metallurgy is the art and science of making metals and alloys in

forms and with properties suitable for practical use (Sir Alan
Cottrell)

Classification of metallurgy
 Extractive Metallurgy
 Mechanical Metallurgy
 Physical Metallurgy
 Classification of Metallurgy

1. Extractive Metallurgy:

•Definition: Extractive metallurgy involves the processes used to
extract metals from their ores and refine them.
•Key Areas:
•Pyrometallurgy: The use of high temperatures to extract and
purify metals.
•Hydrometallurgy: The use of aqueous solutions to extract metals
from ores.
•Electrometallurgy: The use of electrical energy to refine or
extract metals.
 Classification of Metallurgy

2. Mechanical Metallurgy:

•Definition: Mechanical metallurgy deals with the behavior of
metals under mechanical forces and the methods of shaping metals
through mechanical processes.
•Key Areas:
• Deformation Processes: Such as rolling, forging, extrusion,
and drawing.
• Testing and Analysis: Understanding material properties
through hardness testing, tensile testing, and impact testing.
• Fracture Mechanics: The study of the propagation of cracks
in materials.
 Classification of Metallurgy

3. Physical Metallurgy:

•Definition: Physical metallurgy is concerned with the physical
properties and structure of metals and alloys, and how these
properties are affected by composition, processing, and
environmental conditions.
•Key Areas:
• Phase Diagrams: Understanding the phases present in alloys
at different temperatures and compositions.
• Heat Treatment: Processes like annealing, quenching, and
tempering to alter material properties.
• Microstructure: Studying the grain structure, dislocations,
and other features at the microscopic level.
 Classification of Materials

Classification of Materials
• Metals • Composites
• Ceramics • Semiconductors
• Polymers • Biomaterials

Metals
Metals are composed of elements which readily give up
electrons to provide a metallic bond and electrical
conductivity.
Characteristics of Metals

• Crystal form in solid state

• Metallic lustre
• Good electrical conductivity
• High strength
• High hardness
• Good thermal conductivity
• High melting point
• Malleability etc.
Properties of Metals (materials)

 Mechanical properties
 Thermal properties (melting point, specific heat, thermal conductivity etc.)
 Electrical properties
 Magnetic properties
 Chemical properties (corrosion resistance)
 Optical properties
 Physical properties (appearance, color, density etc.)
 Technological properties (castability, weldability, machinability etc.)
 Mechanical Properties of Metals

 It include those characteristics that describe the behavior under

the action of external forces.
Importance
• The knowledge is essential in order to construct a mechanically
sound and safe structure
• These can be determined experimentally
• Determine the behavior of metals under applied forces and
loads
 Mechanical Properties

 It include those characteristics that describe the behavior under

the action of external forces.

Types
i) Elasticity viii) Ductility
ii) Plasticity ix) Malleability
iii) Toughness x) Brittleness
iv) Resilience xi) Hardness
v) Tensile strength xii) Fatigue
vi) Yield strength xiii) Wear resistance
vii) Impact strength
 Mechanical Properties

1. Elasticity
• Definition: The ability of a material to return to its original shape
and size after the removal of the force that caused the deformation.
• Explanation: When a material is subjected to a load, it deforms. If
it returns to its original shape once the load is removed, it is said to
be elastic. The most common example is a rubber band.
2. Plasticity
• Definition: The ability of a material to undergo permanent
deformation without breaking when subjected to a force.
• Explanation: Unlike elastic materials, plastic materials do not
return to their original shape after the load is removed. Plastic
deformation is essential in processes like molding and shaping
materials.
 Mechanical Properties

3. Toughness
• Definition: The ability of a material to absorb energy and plastically
deform without fracturing.
• Explanation: Toughness measures how much energy a material can
absorb before it breaks. It is a combination of strength and ductility.
A tough material is both strong and ductile, such as steel.
4. Resilience
• Definition: The ability of a material to absorb energy when
deformed elastically and release that energy upon unloading.
• Explanation: Resilience is the capacity of a material to store energy
when it is deformed elastically. The material's ability to recover
energy is crucial in applications like springs.
 Mechanical Properties

5. Tensile Strength
• Definition: The maximum amount of tensile (pulling or stretching)
stress that a material can withstand before failure.
• Explanation: Tensile strength is a critical property for materials that
are used in tension applications, such as ropes, cables, and structural
components. It indicates how much load a material can handle before
it breaks.
6. Yield Strength
• Definition: The stress at which a material begins to deform
plastically.
• Explanation: Yield strength represents the point beyond which the
material will not return to its original shape. It is an important
property for designing structures and components that can withstand
 Mechanical Properties

7. Impact Strength
• Definition: The ability of a material to resist sudden and forceful
impacts without fracturing.
• Explanation: Impact strength is crucial for materials that are
subjected to shocks or impacts, such as car bumpers and helmets. It
indicates the toughness of the material under dynamic loading.
8. Ductility
• Definition: The ability of a material to be stretched into a wire
without breaking.
• Explanation: Ductility is important in applications where the material
needs to be drawn or stretched, such as in the production of wires.
Metals like copper and aluminum exhibit high ductility.
 Mechanical Properties

9. Malleability
• Definition: The ability of a material to be deformed under
compressive stress, such as being hammered or rolled into thin sheets.
• Explanation: Malleability is crucial for forming materials into
various shapes without cracking. Gold is an example of a highly
malleable material.
10. Brittleness
• Definition: The tendency of a material to break or shatter without
significant deformation when subjected to stress.
• Explanation: Brittle materials, like glass and ceramics, have low
toughness and can fracture easily. They exhibit little or no plastic
deformation before breaking.
 Mechanical Properties

11. Hardness
• Definition: Hardness is a measure of the resistance to localized plastic
deformation induced by either mechanical indentation or abrasion.
• Explanation: Hardness is an important property for materials that
must resist wear and abrasion. Hard materials, like diamonds, are used
in cutting and grinding tools.
12. Fatigue
• Definition: The weakening of a material caused by repeatedly applied
loads, leading to the formation of cracks and eventual failure.
• Explanation: Fatigue is a critical consideration in components
subjected to cyclic loads, such as airplane wings and bridges. It can
lead to failure even if the stress is below the material's yield strength.
 Mechanical Properties

13. Wear Resistance

• Definition: The ability of a material to resist wear, abrasion,
or erosion when subjected to mechanical action.

• Explanation: Wear resistance is essential for materials that

are in contact with other surfaces and are subjected to
friction, such as gears and bearings. Materials with high
wear resistance have longer service lives in such
applications.