Mettalurey 11/9/2020 METALLURGY Course Code-ME205 By Dr. Biranchi Narayan Sahoo Assistant Professor @ Department of Mechanical Engineering SVNIT Surat-359007 Dr. B.N.Sahoo 1Mettalurey Dr. B.N.Sahoo 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, 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 11/9/2020Mettalurey 11/9/2020 > 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 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 spection (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 Dr. B.N.Sahoo 3Mettalurey Dr. B.N.Sahoo 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. + NDTis carried out periodically. + Replacement of component before its premature failure to avoid dangerous results. 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). . Drying of surface. . Applying dye-penetrant on clean and dry surface. It is allowed to penetrate in surface flaws. i) Liquid Soluble Penetrant ii) Fluroscent Removing excess penetrant by soft or clean cotton, . 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. 11/9/2020Mettalurey Dr. B.N.Sahoo Mechanical testing of materials Non destructive testing Dye Penetrant Inspection 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 I~ 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 11/9/2020Mettalurey Dr. B.N.Sahoo 11/9/2020 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. ‘eg. Cl. 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 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Mettalurgy 11/9/2020 Mechanical testing of materials Non destructive testing i)Pulse Echo method:- Mechanical testing of materials Non destructive testing Transmission Method Dr. B.N.Sahoo 7Mettalurey 11/9/2020 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 isadvantages 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 testing of materials Non destructive testing Magnetic Particle (Magnaflux) Inspection ‘lt 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 Dr. B.N.Sahoo 8Mettalurey 11/9/2020 Mechanical testing of materials Non destructive testing Magnaflux test procedure . Cleaning Surface 2. Magnetization Application of ferromagnetic Powder |. Observation and Inspection . Demagnetization Mechanical testing of materials Non destructive testing Dr. B.N.SahooMettalurey 11/9/2020 Mechanical testing of materials Non destructive testing 43 Cedar metodo mogettn. 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 Dr. B.N.Sahoo 10Mettalurey 11/9/2020 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 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. Dr. B.N.Sahoo 44,Mettalurey 11/9/2020 Mechanical testing of materials Non destructive testing Mechanical testing of materials Non destructive testing ‘Advantages of Radiography Test 4 X-ray radiography is highly sensitive, fast method of finding defects 4 Xray 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 4A number of samples can be inspected at a time by gamma ray| radiography isadvantages of Radiography Test 4 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 4 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 Dr. B.N.Sahoo 42,Mettalurey Dr. B.N.Sahoo 11/9/2020 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 — Magnitude and frequency of alternating current flowing in coil. Electrical conductivity of specimen. ji, Magnetic permeability of specimen. Shape of specimen. Relative positions of coil and specimen. .. Microstructure and hardness of Specimen. |. Amount and type of defects in the specimen Mechanical testing of materials Non destructive testing Eddy Current Testing Principle of ECT 13Mechanical testing of materials Non destructive testing Advantages ECT ¢p 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 4 The instrument standardization and calibration is necessary from time to time 4 Instruments and display units are costly ¢ Test can be applied to components of limited size and shape