SCOPE OF MATERIALS SCIENCE AND ENGINEERING

Performance

Material science is the investigation of the relationship

among processing, structure, properties, and
performance of materials.
DESIGNING MATERIALS

1. Composition,
2. Bonding,
3. Crystal Structure
4. Microstructure

ALL TOGETHER DEFINE MATERIAL PROPERTIES

which CAN BE CONTROLLED by PROCESSING.
 MACROEXAMINATION
Fast evaluation of heterogeneities in a metal by examining the surface with
the “naked eye” or a “magnifying glass”
By macro-examination we can distinguish the following:
• method of manufacture (as cast, rolled…)
• defects (sulphur segregation in steel)
• solidification structure (ingot casting)
• weld defects (porosity, cracks)
 SPECIMEN PREPARATION
1. SAMPLING AND SECTIONING
2. MOUNTING
3. GRINDING
4. POLISHING
5. ETCHING
6. OPTICAL MICROSCOPY
 SAMPLING AND SECTIONING
To remove a conveniently sized, representative specimen from a larger sample.

Fracturing, shearing, sawing, abrasive cutting, electric discharge machining

Abrasive Cutting Device Precision Cutting Device

Specimen orientation and directionality should be noted !!
 MOUNTING
Small or oddly shaped specimens should be mounted for easy handling and preparation.

Mounting materials:
• fusable metal alloys with low melting points
• thermoplastic or thermosetting plastics which require pressure and heat during
molding
• polyester resins mixed with hardener which do not require heat or pressure.
 GRINDING
In order to obtain a flat surface and to remove the distorted metal layer which
does not reveal the true microstructure.

Emery papers are used in succession from the coarsest to the finest. Number of
the emery paper indicates the number of abrasive particles in a unit area of
paper, and thus the coarseness or fineness of the abrasives.
220 → 320 → 400 → 500 → 600 → 800 → 1200

Carried out under flowing

water to prevent heating and
to carry away the material
from the specimen surface and
the abrasive paper.
TYPICAL SURFACES AFTER GRINDING
 POLISHING
In order to obtain a mirror like scratch free surface.

In Mechanical Polishing, the specimen is polished on a rotating disc covered with very
hard abrasive particles like Al2O3, Fe2O3, MgO or diamond paste as required.
 ETCHING
As-polished specimens do not exhibit
their microstructure, simply because light
is reflected uniformly. Etching is carried
out in order to create image contrast, by
creating level differences on the
specimen surface.

Level differences are created by a

controlled acid attack on the specimen
surface. This is achieved by dipping the
specimen in a suitable dilute acid
solution, called etchant.
 EXAMPLE ETCHED MICROSTRUCTURES
When the specimen is under etched, the image will not be clear enough. In such a
case, the specimen should be further etched.
When the specimen is over etched, the surface of the specimen is ‘burnt’ and
image will be dark such a specimen should be repolished.
IRON-CARBON (Fe-C) PHASE DIAGRAM

STEELS
TYPICAL MICROSTRUCTURES OF STEEL
Hypoeutectoid Steel
TYPICAL MICROSTRUCTURES OF STEEL
Eutectoid Steel
TYPICAL MICROSTRUCTURES OF STEEL
Hypereutectoid Steel
 INFORMATION OBTAINED from a TTT DIAGRAM

• Transformation temperature TTT Diagram of the Eutectoid Steel

dictates the final microstructure.
• Transformation involves both
Nucleation and Growth.
• TTT diagrams are given for a
specific composition (alloy).
• For every different composition
the curves have a different
configuration and orientation
with respect to both the
temperature axis and the time
axis.
Possible Transformations by the Decomposition of Austenite
Austenite

Slower Rapid
(Water or Oil Quenching)
Cooling Quench
(Furnace Cooling or Air Cooling)

Moderate cooling
Furnace C. Air C.

Coarse Fine Bainite

Pearlite Martensite
  - Brasses
• The most common copper alloys in which
Zinc is the main alloying element.

• As may be observed from Cu-Zn phase

diagram, up to nearly 35 wt% Zn, single 
phase is stable.

• -brasses are relatively soft and ductile

due to their FCC crystal structure. They
can be easily cold worked.
Cold Rolling Operation
Experiment III. MICROSTRUCTURE OF MATERIALS

SPECIMEN NO STEEL GRADE PROCESSING ROUTE

1 AISI 1060 Furnace Cooling

2 AISI 1060 Air Cooling

3 AISI 1060 Water Quenching

4 AISI 1060 Oil Quenching

5 AISI 1020 Furnace Cooling

6 Brass Cold Worked + Annealed

7 Steel Cold deformed

 Images Taken by Optical Microscope (magnification: 50x)
#1 #2

#5 #7
 Images Taken by Optical Microscope (magnification: 50x)
#4 #3

#6
 Images Taken by Optical Microscope (magnification: 100x)

#1 #2

#5 #7
 Images Taken by Optical Microscope (magnification: 100x)
#4 #3

#6
 Images Taken by Optical Microscope (magnification: 200x)
#1 #2

#5 #7
 Images Taken by Optical Microscope (magnification: 200x)
#4 #3

#6
 Information about the Experiment Report
OBJECTIVE
To observe the effect of
• cooling rate
• carbon content
• plastic deformation
on microstructure of several ferrous alloys. The microstructures of some
nonferrous alloys will also be examined.
APPARATUS
1. An optical microscope
2. Etching Reagent (2 % Nital)
SPECIMENS
1. AISI 1060 steel specimens, 4 pieces. Furnace cooled, air cooled,
quenched in water and quenched in oil.
2. AISI 1020 steel specimens. 1 piece. Furnace-cooled.
3. Brass specimen (α-brass). 1 piece.
4. Plastically deformed steel specimen. 1 piece.
 In the report you need to draw microstructures in the empty spheres by hand. You should explain the microstructures
(amount of phases, details of the microstructural features etc.) in accordance with the related diagrams (such as eqm
phase diagrams, TTT, CCT). In case of comparison questions drawings should be comparable with each other (For
example, when carbon content increases the amount of pearlite also increases).

Example Specimen Microstructure Presentation Style to Answer the Questions in the Report

1) Schematic Drawing of a Microstructure and Its Explanation

Explanation:
Hand Drawing

2) Schematic Drawing of 2 Microstructures and Their Comparison

Explanation and Comparison:

Hand Drawing Hand Drawing
 Questions
( You need to answer these questions in the discussion section of your report, NOT the ones at the end of the manual!)
1. Why etching is necessary to observe the microstructure under optical microstructure? Which etchants are used for
single-phase brasses? Indicate the names of the etchants and content of the etchants.
2. What are the mandatory specimen preparation steps, and why some of the steps are optional?
3. What are the phases present in furnace cooled 1060, air cooled 1060 and water quenched 1060 specimens? Draw the
microstructures schematically using the example format provided earlier. Explain the differences in these 3 microstructures.
4. Compare the microstructures of furnace cooled 1020 and furnace cooled 1060 specimens. Please be careful to make
your drawing consistent with the real system in terms of compositions. (You can use lever rule to compare.)
5. Compare the microstructures of water quenched 1060 and oil
1060 water quenched 1060 oil quenched
quenched 1060 specimens. Can you differentiate them by only
looking with naked eye or just by looking the optical images that
are given to you in the previous pages? What can be the problem
of the water quenching, and how can it be solved? (Hint:
6. Schematically draw the microstructures of specimen #2
and #7 at 100x magnification? Explain the differences you
see in the two microstructures.
7. Even though α- brass is single FCC phase, we see color
difference in the optical image of α- brass. Explain the reason
of this color difference seen in the microstructure?