Professional Documents
Culture Documents
Metals PDF
Metals PDF
CHAPTER 6
1
Metals
METALLIC MATERIAL
Metals and Alloys
Ferrous
Eg: Steel,
Cast Iron
Nonferrous
Eg:Copper
Aluminum
QUESTION 1
1.
b.
c.
Stainless steel
Brass
Cast iron
Casting Process
Casting mold
% Cold work =
x 100
EXTRUSION
Metal under high pressure is forced through opening in a
die.
Common Products are cylindrical bar, hollow
tubes from copper, aluminum etc.
Normally done at high temperature.
Indirect extrusion needs less power however has
limit on load applied
Direct
Extrusion
Die
Container
Metal
Indirect
Extrusion
Container
10
Metal
10
FORGING
Metal, usually hot, is hammered or pressed into desired
shape.
Types:
Open die:
Dies are flat and simple in shape.
(Example products: Steel shafts)
Closed die:
Dies have upper and lower impresion.
(Example products: Automobile engine connection rod)
Direct
Forging
Indirect
Forging
Metal
Die
12
DRAWING
% cold work =
X 100
Original area
13
14
14
15
STRESS
Elastic deformation:
Metal returns to its original dimension after tensile
force is removed.
Plastic deformation:
The metal is deformed to such an extent such
that it cannot return to its original dimension
16
F
Engineering stress ,
=
A0
17
Engineering strain , =
Change in length
Original length
0
0
18
= Shear stress =
S
A
Shear strain =
19
(Stress)
E=
(Strain)
Strain
E=
Stress
20
Examples:
Modulus of Elasticity of steel is 207 Gpa.
Modulus of elasticity of Aluminum is 76 Gpa
21
YIELD STRENGTH
22
Al 2024-Tempered
S
T
R
E
S
S
Mpa
Necking Point
Al 2024-Annealed
Strain
Stress strain curves of
Al 2024 With two different
heat treatments. Ductile
annealed sample necks more
23
24
PERCENT ELONGATION
% Elongation =
Initial Length
25
% Reduction
=
Area
26
27
28
True Stress = t =
F
Ai (instantaneous area)
True Strain = t =
Ln
li
l0
Ln
A0
Ai
29
QUESTION 2
1.
2.
3.
30
4.
5.
6.
7.
(Answer: 0.235)
31
8.
Compare the engineering stress and strain with the true test and
strain for the tensile test of low-carbon steel that has the following
test values.
Load applied to specimen = 69 000N
Initial specimen diameter = 1.27 cm
Diameter specimen under 69 200 N load = 1.2 cm
(Answer: 544.6 MPa, 610 Mpa, 0.12, 0.117)
9.
32
HARDNESS
Hardness is a measure of the resistance of a metal to
permanent (plastic) deformation.
General procedure:
Measure hardness by
measuring depth or
width of indentation.
33
34
FRACTURE
35
DUCTILE FRACTURE
Ductile fracture :
High plastic deformation & slow crack propagation (fracture
due to slow crack propagation).
Three steps :
Specimen forms neck and cavities within neck.
Cavities form crack and crack propagates towards
surface, perpendicular to stress.
Direction of crack changes to 450 resulting in cup-cone
fracture.
36
Ductile fracture
37
BRITTLE FRACTURE
Three stages:
Plastic deformation concentrates dislocation along slip
planes.
Microcracks nucleate due to shear stress where
dislocations are blocked.
Crack propagates to fracture.
38
Example:
HCP Zinc ingle crystal under high stress along {0001}
plane undergoes brittle fracture.
Brittle Fracture
40
TOUGHNESS
Toughness is a measure of energy absorbed before
failure.
Impact test measures the ability of metal to absorb
impact.
Toughness is measured using impact testing
machine
42
FRACTURE TOUGHNESS
K1 Y a
where
K1 = Stress intensity factor.
= Applied stress.
a = edge crack length
Y = geometric constant.
43
Example:
Al 2024 T851
26.2MPam1/2
4340 alloy steel 60.4MPam1/2
44
QUESTION 3
1.
45
FATIGUE
46
Final rupture
48
CREEP
Creep curve.
The slope of the linear part of the curve is the steady-state creep rate.
50
High temperature
or stress
Medium temperature
or stress
Low temperature
or stress
51
52
53
stress
54
REFERENCES
55