Professional Documents
Culture Documents
2
• To explain the influence of the crystalline
structure and the grains in the final properties.
• To analyze the most common alloys used in
engineering.
• To familiarize with the classification of steels
and its nomenclature according to AISI , SAE
and European codes.
• Hand on training on Metallography &
Microscopic examination of some familiar
metals
Performance
Materials Engineering
Designing the structure to achieve
specific properties of materials.
Structure Processing
• Processing
Properties • Structure
Materials Science • Properties
Investigating the relationship between
structure and properties of materials. • Performance
4
• Properties depend on structure Annealing T (F)
• Processing for structural changes
Ductility (%EL)
and strength and ductility?
Annealing T (C)
5
The COMET: first jet passenger plane - 1954
In 1949, the COMET aircraft was a newly designed, modern jet aircraft
for passenger travel. It had bright cabins due to large, square windows
at most seats. It was composed of light-weight aluminum.
In early 1950's, the planes began falling out of the sky.
These tragedies changed the way aircraft were designed and the materials
that were used.
6
• As noted, alloying can lead to new or enhanced properties, such as
advanced precipitation hardened 767 aircraft skin.
• Controlling the size and type of precipitates requires knowledge T vs. c
phase diagrams andT-T-T diagrams to know treatment.
Grain Boundaries
7
Pure Metals and their Alloys
Ferrous, is an adjective used to indicate the presence of iron. The word is derived from the Latin word ferrum (iron). Ferrous metals
include steel, cast iron (Alloys Fe+C) and alloys of iron with other metals (such as stainless steel).
Non-ferrous is used to indicate metals other than iron and alloys that do not contain an appreciable amount of iron.
Alloy: The mix of two or more substances where at least one of them is a metal. For example Steels, Cast Iron, Silumin, Duralumin, Brass,
Bronze, etc. Pure metals have not practical use in industrial applications due the low properties.
Ferrous Alloys (Base Fe) Non Ferrous Alloys
(Base Al, Cu, etc.)
Magnetic (Because the Iron • Non Magnetic
presence) • Light
Heavy (Density=7.85g/cm3) • No Superficial Rust
Superficial Rust • Color (Gray, Silver, Yellow,
Color Dark Brown Orange)
9
Crystalline: Atoms, ions or molecules are ordered in well defined arraignments
External morphology: Flat surfaces or faces that make definite angles with one another
Quartz, Diamond etc.
Amorphous: Atoms, ions or molecules have no orderly relationship to one another
12
1. Nucleation: It begins at 2. Crystal growth: Crystals
foreign particles in melt. begin to grow from each.
4. Polycrystalline structure:
3. Grain Formation: Interface Grain growth is limited by
develops. another grain, creating a
13
boundary between them
Mechanical Technological Physical
Properties Properties Properties
14
Steels = Fe + C where (C ≤ 2%)
Mild Steel: Non Alloy and low carbon steel with C from 0.16 to 0.29%, which is used in 85% of all steel applications in the world.
1. A steel with the following chemical composition:
C=0.15%; P<0.002%, S<0.001%
Will be classified as Low Carbon Non Alloy (LCNA) Steel .
Notes:
16
2. A steel with the following chemical composition:
17
3. An steel with the following chemical composition:
18
According to the American Iron and Steel Institute (AISI) and the Society of
Automotive Engineering (SAE) Steels are identified as follows:
• A Four Digits code for Non Alloy, Low Alloy and Medium Alloy Steels. In
this case the last two digits represents the carbon content in percentage
while the first two digits the subgroup of steels according to the alloy
system and application.
• A three digit code for High Alloy Steels (AISI) or five digits (SAE) where the
last two of the five represents the carbon content.
Notes:
In the most of the European countries to identify high alloy steels the
chemical element is specified and after the amount except when is 1%
for example:
22
Type of
Grade Criteria of use Type of supply Examples
alloy
Structures;
Good Weldability Bars, Flats, Sheet
LCNA Elements of machines were
Good Malleability Metal, Beams,
(C<0.3%) hardness is not an issue.
Good Machinability Pipes
Devices
For manufacturing Elements of machine.
For Machining + Heat Treatment to change
MCNA Elements of Machines where
superficial hardness. Bars
0.3≤C<0.5% hardness is important.
Regular Weldability (Not for manufacturing
welding)
HCNA To withstand deformation and wearing. Tools
Bars
C≤0.5% Bad Weldability (Not for welding at all) Springs
LCLA Bars, Flats, Sheet
Similar to LCNA but more Tensile strength, Structures.
C<0.3%; Metal, Beams,
Resistant to marine corrosion.
Steels ∑AE<5% Pipes
Thermal Resistance and Thermal stability (Cr,
LCMA Pipes Pipelines
Mo)
C<0.3%
Pipelines
5%≤∑AE<10% Low temperature Applications Pipes, plates
Special equipment.
MCLA
Similar to MCNA but more hardness after heat Tools
and Bars
treatment. Elements of machines
MCMA
Rust Free Food containers
LCHA Pipes, Flats, Sheet
Luxury Chemical industry equipment.
(Stainless) metal
Antibacterial Medical equipment
24
Introduction
25
What is a phase?
A homogeneous portion of the system that has a
uniform chemical and physical characteristics.
Every pure material is a phase : elements, compounds.
Example
solid sugar is a “solid phase” and sugar-syrup solution
is a “liquid phase”
Both have different chemical composition: one is pure
sugar (C12H22O11) and the other is a solution of sugar
and water (H2O)
Every teaspoon of the sugar-syrup is always of same
composition
26
A map of the temperature at which different phase
changes occur on very slow heating and cooling in
relation to Carbon, is called Iron- Carbon Diagram.
The Fe-C phase diagram is a fairly complex one, but we
will only consider the steel and cast iron part of the
diagram, up to 6.67% Carbon.
It is used to tailor properties of steel and to heat treat
them.
Iron- Carbon diagram shows
The type of alloys formed under very slow cooling,
Proper heat-treatment temperature and
How the properties of steels and cast irons can be
radically changed by heat-treatment.
27
28
1. Ferrite
Ferrite is the interstitial solid solution of carbon in alpha iron. It has B.C.C.
Structure. It has very limited solubility for carbon (maximum 0.022% at 727°C and
0.008% at room temperature). Ferrite is soft and ductile.
2. Austenite
Austenite is the interstitial solid solution of carbon in gamma (γ) iron. It has FCC
structure. Austenite can have maximum 2.14% carbon at 1143°C. Austenite is
normally not stable at room temperature. Austenite is non-magnetic and soft.
3. Cementite
Cementite or iron carbide (Fe3C) is an intermetallic compound of iron and carbon.
It contains 6.67% carbon. It is very hard and brittle. This intermetallic compound is
a metastable phase and it remains as a compound indefinitely at room temperature.
4. δ-ferrite
It is a solid solution of carbon in δ-iron. It is stable at high temperatures. It has BCC
Structure. It has no engineering importance
29
1. Pearlite
The pearlite consists of alternate layers of ferrite and
cementite. It has properties somewhere between ferrite
and cementite. The average carbon content in pearlite is
0.76%
2. Ledeburite
Ledeburite is an eutetcic mixture of austenite and
cementite in the form of alternate layers. The average
carbon content in ledeburite is 4.3%. Found in Cast iron
30
31
Phases
1. Ferrite
2. Austenite
3. Cementite
Ferrite Austenite
4. δ-ferrite
1. Pearlite
2. Ledeburite
Pearlite
32
The diagram shows Three horizontal lines which indicate
isothermal reactions (on cooling / heating). Always
indicates an invariant reaction in binary phase
diagrams:
First horizontal line is at 1493°C, where peritectic
reaction takes place:
Liquid + ↔ austenite (almost no engineering importance)
Liquid+Cementite
Austenite
Pro-eutectic Austenite
Cementite + Ledeburite
+ Ledeburite
Ferrite
Pearlite+
Pro-eutectoid
Ferrite+Pearlite
34
Peritectic: 0.16% C, 14930 C
δ(0.11% C) + L(0.51)%C ↔ γ (0.16%C)
35
Eutectic reaction: at 4.30 % C and 1147 °C
L (4.30% C) ↔ γ (2.14% C) + Fe3C
In eutectic reaction, the liquid solidifies as a phase mixture of austenite (containing 2.14% C)
and cementite. This phase mixture is known as ledeburite.
The average carbon content in ledeburite is 4.30%.
The eutectic reaction occurs at a constant temperature. This is known as eutectic temperature
and is 1147 °C.
In the micrograph,
the dark areas are
Fe3C layers, the light
phase is α- ferrite
Pearlite Formation
38
T(°C)
• 2 important points 1600
Adapted from Fig. 10.28,
Callister & Rethwisch 3e.
1. Eutectic (A): L
1400
L + Fe3C +L
1200
AA
2. Eutectoid (B): 1148°C L+Fe3C
Fe3C (cementite)
(austenite)
a + Fe3C 1000 +Fe3C
a
800 B 727°C = Teutectoid
600
a+Fe3C
400
0 1 2 3 4 5 6 6.7
(Fe) 0.76 4.30 C, wt% C
120 m
Result: Pearlite is Fe3C (cementite-hard)
alternating layers of a and Fe3C phases
a (ferrite-soft)
39
When alloy of eutectoid
composition (0.76 wt % C)
is cooled slowly it forms
pearlite, a lamellar or
layered structure of two
phases: α-ferrite and
cementite (Fe3C).
The layers of alternating
phases in pearlite are
formed for the same reason
as layered structure of
eutectic structures:
redistribution of C atoms
between ferrite (0.022 wt%)
and cementite (6.7 wt%) by
atomic diffusion.
Mechanically, pearlite has
properties intermediate to
soft, ductile ferrite and
hard, brittle cementite.
40
Compositions to the left of eutectoid
(0.022 - 0.76 wt % C) is hypoeutectoid
(less than eutectoid) alloys.
Microstructure change is
γ→α+γ→α+P
1. First ferrite is formed when
temperature comes down below Ae3
temperature.
γ→α+γ
2. The amount of ferrite increases with
decrease in temperature till eutectoid
temperature.
3. Remaining austenite changes to
pearlite at eutectoid temperature.
α+γ→α+P
41
T(°C)
1600
1400 L
(Fe-C System)
+L
1200 1148°C L+Fe3C
Fe3C (cementite)
(austenite)
1000
+ Fe3C
a
a 800 727°C
a a
600
a + Fe3C
400
a 0 1 2 3 4 5 6 6.7
(Fe)C0 C, wt% C
0.76
pearlite
pearlite
proeutectoid ferrite
42
Hypoeutectoid steels contain proeutectoid ferrite (formed
above the eutectoid temperature) plus the pearlite that
contains eutectoid ferrite and cementite.
43
Strength Prediction of hypo-eutectoid steels
Tensile strength of annealed hypo-eutectoid steels can be
Determined by the proportion of ferrite and pearlite
present:
App Tensile Strength= 40,000(percent ferrite) + 1 20,000(percent pearlite)
100
44
Compositions to the right of eutectoid
(0.76 - 2.14 wt % C) is hypereutectoid
(more than eutectoid) alloys.
γ → γ + Fe3C → P + Fe3C
1. First cementite is formed when
temperature comes down below Acm
temperature.
γ → γ + Fe3C
2. The amount of cementite increases with
decrease in temperature till eutectoid
temperature.
3. Remaining austenite changes to pearlite
at eutectoid temperature.
γ + Fe3C → P + Fe3C
45
T(°C)
1600
1400 L
+L
1200 1148°C L+Fe3C
Fe3C (cementite)
(austenite)
1000
+Fe3C
Fe3C
800
a
600
a +Fe3C
400
0 1 C0 2 3 4 5 6 6.7
0.76
(Fe) C, wt%C
pearlite
Pearlite
Dark area proeutectoid Fe3C
Light area 46
47
The Austenite to ferrite / cementite transformation in relation to Fe-Fe3C diagram
48
Effect of Alloying Elements
Of the four common alloying elements(Shaded ones), chromium and molybdenum are carbide-forming
elements and, in general, will prefer to segregate into the cementite constituents of steel. Nickel is not a carbide-
forming element and will prefer to segregate into the ferrite. Manganese tends to be in between these groups.
The elements on the left—titanium, zirconium, vanadium, niobium, tantalum, and tungsten—form very stable
carbides (tantalum carbide has the highest known melting point, 4000 °C, or 7200 °F).
The oxides, nitrides, and sulfides formed by all of the reactive elements in steel are generally present as small
particles called inclusions.
Effect of Alloying Elements on Grain growth
Dependence of Eutectoid Composition
Alloying Steel With More Elements
• Teutectoid changes: • Ceutectoid changes:
C eutectoid (wt% C)
Ti Si
T Eutectoid (°C)
Mo Ni
W
Cr
Cr Si
Mn
Mn W
Ti Mo
Ni
51
Strength Elongation
(MPa) (%)
30
1000
TS
(MPa)
TS
500 15 YS0.2
YS
0.2
% δ (%)
0
0 0.5 1 %C
Hardness
Impact
In industries Pure metals are not use, due to the low
properties. Alloys offer better properties due to the
involvement of foreign atoms in the crystalline
structure.
The chemical composition have influence in the
Mechanical, Technological and Physical properties.
The most common alloys in our environment will
be (Steels, Brasses, Bronzes, Aluminum and Cast
Iron).
54
NOT shown in Fe-Fe3C Diagram. . . . !!! WHY ???
3.No resultant shape change in the 3. Resultant shape change of the bulk
sample sample
57
58
Summary of Microstructures and Mechanical Properties for
Iron–Carbon Alloys
Possible transformations involving the decomposition of austenite.
Solid arrows, transformations involving diffusion;
dashed arrow, Diffusionless transformation.
59
Summary of Microstructures and Mechanical Properties for
Iron–Carbon Alloys
60
Microstructures and & their Appearances in an Optical Microscope
61
Plate Martensite Lath-Plate Martensite
Lath Martensite
Spherardize Structure[white
Bainite and pearlite]
globules are cementite] 62
Common Doubts
The Fe-Fe3C is just a part of the Fe-C phase diagram, the entire Fe-C phase
diagram extends to the right hand side upto 100 wt% C, which is pure Carbon
phase called Graphite. (Fe-C phase diagram has got not so significant use in
steel industry, that’s why its generally not shown).
Ferrite is a phase, Austenite is a phase, Cementite is a phase but pearlite is not
a phase, pearlite is just a colony of 2 phases-ferrite & Cementite in a grain.
We discussed the “solution” of Fe & C and definitely not a mixture. Solution
is homogenous in its composition and properties everywhere whereas a
mixture is not. (Sugar-Syrup is a solution and clay in water is a mixture).
The width of the precipitate at the grain boundary varies as a grain boundary
can be a high-angle grain boundary or a low-angle grain boundary, High angle
grain boundaries are highly preferential sites for nucleation of precipitates due
to their high incoherency.(Different orientation of grains)
Different “Heat-Treatment” processes changes the microstructure
differently for the same alloy composition. We discussed the phase diagram
and microstructures for a “Slow cooling” process. Quenching (Oil and water)
is a fast cooling process and it produces martensite (another phase of iron)
along with other phases depending on the processing parameters.
63
NED UNIVERESITY OF ENGINEERING & TECHNOLOGY
METALLURGICAL ENGINEERING DEPARTMENT
Quantitative Metallography
66
Sample preparation
67
Sectioning
Why sectioning?
1. Size limitation of specimen to be examined under optical microscope.
2. Locate area needs to be selected from a large sample.
Cutoff wheels with grit sizes from 60 to 120 are recommended for sectioning
metallographic specimens
Abrasive-wheel sectioning can produce damage to a depth of 1 mm (0.04 in.)
Control of cutting speed, wheel pressure, and coolant application minimizes damage
69
Sectioning
Micra cut
Abrasive cutting
machine
70
Mounting
Small or oddly shaped specimens are mounted to facilitate easy handling
during preparation and examination
Standard mounts usually measure 25 mm (1 in.), 32 mm (1.25 in.), or 38 mm
(1.5 in.) in diameter
Bakelite and diallyl phthalate are thermosetting resins which are most
widely used as moulding material
Transparent methyl methacrylate, polystyrene, polyvinyl chloride (PVC)are
some of the thermoplastic resins used in moulding
Both requires heat and pressure during molding. Thermosetting molds can
be ejected from the mould at the moulding temperature, while
thermoplastic resins must be cooled to ambient temperature under
pressure
Hot
mounting
Mounted press
specimen machine
71
Grinding & Polishing
To prepare the cut surface suitably for metallographic examination as optically flat,
reflective, smooth and scratch free
Grinding and abrasion
uses abrasive particles whose projecting points act as the cutting tools
the abrasive particles are cemented together onto a cloth or paper backing,
creating coated abrasive products whose exposed surface is the working surface
Emery papers are typical example for this kind
Polishing
The paper or cloth is attached to the surface of a wheel that is rotated at a
comparatively low speed in a horizontal plane
The specimen is held against the working surface of a wheel and rotated slowly in a
direction opposite that of the wheel
Diamond, alumina (Al2O3), and magnesium oxide (MgO) are the abrasives most
commonly used for polishing
72
Grinding & Polishing
73
Electrolytic Polishing
used widely in the metallography of stainless steels, copper alloys, aluminum alloys,
magnesium, zirconium, and other metals that are difficult to polish by conventional mechanical
methods
Electrolytic polishing can completely remove all traces of worked metal remaining from
mechanical grinding and polishing operations used in specimen preparation
Rough surface is made the anode of a suitable electrolytic cell, and preferential solution of the
"hills" or ridges on a rough surface takes place
In molded sample, only the portion of the specimen to be polished should be in contact with
the electrolyte
High surface finish can be obtained
Principle Machine
1. Electrolyte
2. Cathode
3. Workpiece to polish
(Anode)
4. Particle moving from
the work piece to the
cathode
5. Surface before
polishing
6. Surface after
polishing
74
Etching
A dilute acid is react with the surface of the sample. This operation is called etching. After
etching, the grain boundaries are visible in microscope.
ETCHING is used in metallography primarily to reveal the microstructure of a specimen under
the optical microscope
it is a procedure for achieving contrast in the microstructure
75
Some commonly used etchants
76
Behavior of different etchants on microstructure
Etched with 2% Nital Etched with 4% Picral Etched with Beraha’s reagent
77
MICROSCOPIC EXAMINATION OF METALS
AND ALLOYS
ANATOMY OF MICROSCOPE
79
ANATOMY OF MICROSCOPE
The simplest optical microscope, which has
been in use since the early seventeenth
century, is a single convex lens or
'magnifying glass'. The image is magnified,
real and inverted if the object distance u
(between lens and object) is between f and
2f, as shown in Figure
The image is magnified, real and inverted if
the object distance u is b/w f & 2f, as shown
in Figure (a).
If an image is to be recorded on a
photographic plate or viewed on a screen
then it must be real, and therefore we will
not be concerned with optical arrangements
which give rise to virtual final images.
81
TOOLS FOR PHASE ANALYSIS
Point
counting
ASTM E562 - 99
method
Quantitative
Phase Metallography Grain size
proportions
ASTM E 112 – 96
Interlamellar
spacing
82
QUANTITATIVE ANALYSIS
83
Point Counting Method:
84
AISI 8620 as received
25μm
85
FOR EXAMPLE AISI 8620 as received
Pearlite
Ferrite
25μm
The phases present in the received sample showing ferrite and pearlite region
was confirmed from Atlas of Microstructures of Industrial Alloys.
The average pearlite region = point counted / total count
Average pearlite region = 28.17~28%
The remaining ~72% is the matrix (Ferrite).
86
AISI 8620 Annealed Sample
Ferrite
Spheroidal
carbides
25μm
we can calculate the ASTM grain size number, G, using the following formula from
E 112-96:
88
Grain Size
Comparison
procedure
GRAIN SIZE
MEASUREMENT
Intercept Planimetric
procedure procedure
89
Determination of Grain size by Heyn/Intercept Method
Heyn Lineal Intercept Procedure
The number of grains intercepted by one or more straight lines sufficiently long
to yield at least 50 intercepts (N).
To calculate the number of interceptions per mm, “NL”, we divide “N” by the
true length (circumference = πD) of the circle
NL = N/LT
The true length “LT” in mm divided by the magnification M.
To calculate the grain size, we first determine the mean lineal intercept length
”l”, which is the reciprocal of NL [ l=1/NL]
G is calculated from an equation from E112-96:
G = {-6.644 (log10 l) – 3.288} for Intercept where l is in mm
90
Determination of Grain by Jeffries Method
ASTM recommends
using a test circle
with a diameter of
79.8 mm (5000 sq.
mm area)
91
Determination of Grain by Jeffries Method
92
AISI 8620 Grain Size of As Recieved sample
There are 23 grains within the circle (ninside)
and 21 grains intercepted by the circle
(nintercepted). The number of grains per mm2,
NA, is calculated from:
NA = f {ninside + 1/2(nintercepted)} eqn(1)
The multiplier f is calculated from
f = M2 / Circle Area
Where M is the linear magnification of the
image.
f = 4002/π(402) = 31.83
So eqn (1) becomes,
NA = 31.83{23+ 1/2(21)}
NA = 1098.135 grains per mm2
From NA, we calculate the ASTM grain size,
25μm G, using the following formula:
G = {3.322 (log10 NA) – 2.954}
G = {3.322 (log10 1098.135) – 2.954}
G = 7.14
93
AISI 8620 Grain Size of Annealed sample
There are 77 grains within the circle
(ninside) and 28 grains intercepted by the
circle (nintercepted). The number of grains
per mm2, NA, is calculated from:
NA = f {ninside +1/2 (nintercepted)}eqn(1).
The multiplier f is calculated from
f = M2 / Circle Area
Where M is the linear magnification of the
image.
f = 4002/π(402) = 31.83
So eqn (1) becomes,
NA = 31.83{77+ 1/2(28)}
NA =2896 grains per mm2
25μm
From NA, we calculate the ASTM grain size,
G, using the following formula:
G = {3.322 (log10 NA) – 2.954}
G = {3.322 (log102896) – 2.954}
G = 6.85 94
ASTM Grain Size
2D VS 3D
95
INCLUSION RATING IN STEELS AS PER
ASTM STANDARDS
96
INCLUSIONS
97
INCLUSION RATING
98
CLASSIFICATION OF INCLUSIONS
99
CLASSIFICATION OF INCLUSIONS
heavy
A-Sulfide
Type
thin
100
CLASSIFICATION OF INCLUSIONS
101
PROCEDURE
The minimum polished surface area of a specimen for the microscopic
determination of inclusion content is 160 mm2 (0.25 in.2)
Another option is to use a reticle made for the microscope, which will superimpose the
required square mask directly onto the field of view
102
PROCEDURE
103
COMPARISON CHART- A (Sulfide type)
104
COMPARISON CHART- B (Aluminate type)
105
COMPARISON CHART- C (Silicate type)
106
COMPARISON CHART- D (Globular type oxides)
107
PROCEDURE
108
REFERENCES
▪ R E SMALLMAN – Modern Physical Metallurgy and Materials Engineering
▪ ASTM E 45 – 05 - Standard Test Methods for Determining the Inclusion Content of Steel
▪ Abrams, H., “Grain Size Measurement by the Intercept Method,” Metallography , Vol 4,
1971, pp. 59–78.
▪ ASTM E 112 “Methods for determining the average grain size” PCN 12-501 120-10
109