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Basic MetallurgyBy - K.Sevugarajan
Contact detailsMetz Lab Pvt.Ltd.First floor, Thangavel NagarWalajabad Main Road,Mannivakkam-600048
Cell: +91-8190810222 Mail: [email protected] www.metzlab.in
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1. Introduction2. Materials science3. Classification of materials4. Applications5. Advanced materials6. Metallurgy processes (Castings, Formings,
Powder Metallurgy, Welding etc,..)
Outline
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1. Introduction AgesBasic steps in metallurgy
Materials: Substances of which something is composed or made.Every segment of our everyday lives is influenced to one degree or another by materials.
Material Science: Investigating the relationship between the structure and properties of the materials
Metallurgy: The science and technology of extracting metals from their natural sources and preparing them for practical use
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1. Introduction AgesBasic steps in metallurgy
Age of Steel Petroleum Age Industrial Age Age of Flight Space Age -Sputnik Nuclear Age Computer Age Composite Material Age Nano Tech Age Green Age ?
Modern MetalAge consists ofmany overlappingTechnical Agesafter 1300
Basic ages of metals in the ancient world
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1. Introduction AgesBasic steps in metallurgy
The development of metallurgy was a long, and sometimes devious process that involved five basic steps.
1. Identifying and discovering its usefulness
2. Locating metals in quantity
3. Mining the ores.
4. Smelting the metal.
5. Shaping the metal into something useful.
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2. Material scienceStructurePropertyProcessingPerformance
Material science has four basic elements.
1. Structure
2. Property
3. Processing
4. Performance
Property
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2. Material scienceStructurePropertyProcessingPerformance
The structure of a material usually relates to the arrangement of its internal components.
subatomic atomic microscopic macroscopic
Electrons within individual atom and interaction
with nuclei
Organization of atoms or
molecules relatedto one another
Large groups of atoms, direct observation
by microscope
Structural elementsmay be viewed with naked eye
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2. Material scienceStructurePropertyProcessingPerformance
Property is a material trait in terms of the kind and magnitude of response to a specific imposed stimulus.
Mechanical(Strength, Hardness, Ductility, Stiffness)
Electrical(Electrical conductivity,
Dielectric constant)
Thermal(Heat capacity,
Thermal conductivity)
Magnetic(Magnetic moment,
Magnetic permeability)
Optical(Refraction index,
Reflectivity)
Deteriorative(Corrosion)
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2. Material scienceStructurePropertyProcessingPerformance
Processing: different ways for shaping materials into useful components or changing their properties.
Casting
Forming
Welding
Powder metallurgy
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2. Material scienceStructurePropertyProcessingPerformance
Performance: a function of a material’s properties.
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3. Classification of Materials
Metals and Alloys Ceramics, Glasses, and Glass-ceramics Polymers (plastics), Thermoplastics and Thermosets Composite Materials
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3. Classification of Materials
Materials
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• Principles• Types of failures• Failure modes• How to conduct failure analysis• Analyze data • Materials • Manufacturing process• Report preparation• Failures examples
Component Material
4. Applications
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Component Material
4. Applications
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Component Material
4. Applications
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4. Advanced Materials
Materials that are utilized in high-technology applications are sometimes termed advanced materials.
• Electronic materials
• Bio materials
• Nano materials
Electronic materialsBio materialsNano materials
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4. Advanced Materials
Electronic materials Semi conductor• Have electrical properties that are intermediate between the
electrical conductors and insulators.
Electrical characteristics are extremely sensitive to impurity concentration
Si, Ge, ZnOSuper conductor• A superconductor is a material that can conduct electricity or
transport electrons from one atom to another with no resistance.Tl7Sn2Ba2MnCu10O20+
Electronic materialsBio materialsNano materials
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4. Advanced Materials
Bio materials
Electronic materialsBio materialsNano materials
Employed in components implanted into the human body for replacement of diseased or damaged body parts.
not produce toxic substances be compatible with body tissues
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4. Advanced Materials
Nano materialsIt enables to carefully arrange atoms to develop mechanical, electrical, magnetic, and other properties. “Bottom-up” sciences called nanotechnology.
Nano = 10-9, nanotechnology < 100 nm equivalent 500 atom diameters
Electronic materialsBio materialsNano materials
Carbon based nanotubes Bucky Ball (C60)
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5.Metallurgy processCastingForming WeldingPowder metallurgy
Casting Casting A manufacturing process that pours a liquid material into a hollow mould until the material cools into a solidified shape
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5.Metallurgy processCastingForming WeldingPowder metallurgy
FormingForming operations change the geometry of the starting material without cutting it.
Rolling: Compressive deformation process in which the thickness of a plate is reduced by squeezing it through two rotating cylindrical rolls.
Forging: The work piece is compressed between two opposing dies so that the die shapes are imparted to the work.
Extrusion: The work material is forced to flow through a die opening taking its shape
Drawing: The diameter of a wire or bar is reduced by pulling it through a die opening (bar drawing) or a series of die openings (wire drawing)
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5.Metallurgy processCastingForming WeldingPowder metallurgy
ForgingA metal is shaped by compressive forces Oldest metal working process – 4000BC Can be performed with a hammer and anvil
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5.Metallurgy processCastingForming WeldingPowder metallurgy
WeldingCombining processes join two materials or deposit material onto the exterior surface of the starting material
BASE METAL
WELD
SOLIDIFIED SLAG
ARC POOL
WELDING ATMOSPHERE
CORE WIRE
ELECTRODE COATING
ARC STREAM
PENETRATION DEPTH
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5.Metallurgy processCastingForming WeldingPowder metallurgy
Powder MetallurgyPowder metallurgy is a process by which fine powdered materials are blended, pressed into a desired shape, and then heated to bond surfaces
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