ME-1201 ENGINEERING MATERIALS

Engr. Mansoor Idrees Dawson

Week 14
PROCESSING OF METALLIC
MATERIAL
 BY MANSOOR DAWSON

CLASSIFICATION OF METAL ALLOYS

 BY MANSOOR DAWSON

FABRICATION OF METALS
 BY MANSOOR DAWSON

FORMING TECHNIQUES

Forging Rolling

Extrusion Wire drawing

 BY MANSOOR DAWSON

ROLLING
 BY MANSOOR DAWSON

EXTRUSION
Chamber

product Ram

Indirect Extrusion

Direct Extrusion Chamber

Ram

product
 BY MANSOOR DAWSON

CASTING OF METALS

 Molten metal is poured into a mold and allowed to solidify

 Sand
 A disposable mold is made by packing special granular
materials and adhesives (“sand”) around a pattern. Liquid
metal is poured into the cavity left behind when the pattern
is removed
 Die or permanent mold
 A metallic mold which is reused
 Investment or lost wax process
 A mold cavity is formed by coating a “wax” pattern with
ceramic materials. When liquid metal is poured into the
mold, the wax melts away as the metal fills the cavity
 Continuous casting
 BY MANSOOR DAWSON

CASTING
 BY MANSOOR DAWSON

CONTINUOUS CASTING
 BY MANSOOR DAWSON

WELDING
 BY MANSOOR DAWSON

HARDNESS AND HARDENABILITY

 Hardness is a measure of the resistance of a

material to indentation or abrasion
 Hardenability is a measure of how easily a
material can be hardened
 Jominy End Quench Test
 A test sample of standard dimensions is
heated to above the eutectoid
temperature
 The sample is quickly transferred to the
test fixture and the water jet is turned on
 After the sample has cooled, the hardness
is measured at different distances from
the quenched end
 BY MANSOOR DAWSON

JOMINY END QUENCH TEST

 Cooling rate decreases with

increasing distance from the
quenched end
 The resultant microstructure along
the length can vary from all
martensite to all pearlite,
depending on TTT diagram and the
critical cooling rate for the
particular steel
 Hardness will therefore decrease
as distance from the quenched end
is increased
 BY MANSOOR DAWSON

HARDNESS AND HARDENABILITY

Effect of carbon content on hardenability

Effect of alloying on hardenability Hardness and hardenability increase with
carbon content
Last two digits in alloy designation indicate carbon content
 BY MANSOOR DAWSON

POWDER METALLURGY
 Compaction of powdered metal, followed by a heat treatment to produce
a more dense piece.
 Powder metallurgy makes it possible to produce a virtually nonporous
piece having properties almost equivalent to the fully dense parent
material.
 Diffusional processes during the heat treatment are central to the
development of these properties.

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 BY MANSOOR DAWSON

POWDER METALLURGY

 This method is especially suitable

for metals having low ductilities,
because only small plastic
deformation of the powder
particles need occur.
 Metals with high melting
temperatures are difficult to melt
and cast, and fabrication is
expedited using P/M.
 Parts that require very close
dimensional tolerances (e.g.,
bushings and gears) may be
economically produced using this
technique

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