Departmelt of Mechanical Engineering

Military-,Insiituf8ii5.i.nce and Technotog$

,. ,"

Me-29{ Metatiic Materiats Sessionat

;Subject Outline
Code Number ME-292t
. f "
Name Mqtal I ic Matffials Sessional

Course name

Stage

Duration
for a term (14 week)
Prerequisites

Credit Points

Contact FIr

Subject Introduction 1 ,.,

,,k
(i
.

ME-292 (Introduction to
ryetallicMaterials Sessional) course is designed to provide basic
concept to the students about the Metallic Materials.
Introduction to Metallogiaphic and
Metallographic sample Specimen preparation. Introduction
to study of phase diagrams. To
pro'ride initial rraining in thi: Metallurgical
Miuoscope, Grinder/ polisher machine and
mounting press. !
Aims&Objectives: . .i

l)To develop an understanding among the students

about the basic concepts of Metallic Materials.
To provide practice in the Techniques of raicro
specimen selection, polishing and Etching.
2) to provide initial Training in theMetallurgical
Microscope.
course aims to develop the basic concepts
on study of phase diagrams and microstudy
ii'"Itt of cast

4) Microstudy of heat Treatment(Steels)

Teaching methodsi ,
Lectuies 21 hrs at a term within 07 weeks.

Class Schedule:

D"y Time Class Room

ll,3A-14:20 Material & production proiesi Lib
 -t:
.1

Assessment: '-1rI
"it
.r! t. l''
ir
Continuous Assessment ' 30Ya
,.
I
Observation 5%
b
Attendance 'n 5%

AssigntlCl Test ,: 20%

Written Examination 70%

:
' ..-'t",
1 ::, f, i "'i,::'

Name of the Equipments for the Experiment:

1) Metallurgical Microscope with Fhoiograph! attachment.

2) Grinder/ Polisher machine

3) Mounting Press

4) Ultrasonic Crack Tester

5) T.V Monitor

Text and Reference books:

Introduction to Physical Metallurgy ( 2.d edition) UrOn", H Avener, publisher-Tata
Mc Graw- Hill
Edition-

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 t
Metallic M terials Sessional
Military Institute of, $6,i&ce & Technology (MIST)
Department of l$echanical Engineering

\48 294
Metallic,Materi'als Sessional
Level-2, Term-II
Contact Hr: 3/2 Credit: 0.75

Xame of the Experiments:

l ' Introduction to Metallographi$ and Meta[ographic Sample Specimen preparation.

2. Study of phaie Diagrams.
3. MicrostuCy steelsof 'u

-4. Heat treatment of steels-l i

'51 Heat treetment of steels-2
!
6. l\ficrostudy of cast irons-l ,
7. Nlicrostudy of cast irons-2
Experiment # 0l
lntroduction to Metallographic and Metallographic sample specimen
Preparation
*
Objeetives:
l. To provide practice in the techniques of nricro specimen selection, polishing,
and
etching. ^! \.a'
:

2. To provide initial training in the use of metallurgical microscope.

I. Take one sample from your inrt r.toi *nu identifu your sample by putting on an
identification number.
2. Polish the specimen manually by gtinding on a series of emery papers of
progressively finer grade. To polish at each paper, hold
the paper on top of a glass
sheet with one hand while rubding it e specimen with the other hand using
moderate pressure, back and forth across the abrasive surface in one direction
only. This creates a series of patallel scratches or grind marks
on the specimen.
3' It is naturally very important to avoid the transfer of loose abrasive particles
from
one paper to another. There before ptoceeding to the next
finer paper clean
thoroughly the loose abrasive par"tiqles from the specimen
and from the hands.
Clean each paper carefully before irse tg protect the quality
of the polishing job.
1' During grinding on the next finer paper, hold the specimen in
such a way that the
new, finer set of scratches will be approximately perpendicular
to the existing set
of scratches.
5' After completing the paper polishing, cldan the sample thoroughly
with soap water
and show it to the instructor. He will check its finish and indicate
whether you
may proceed to rhe final polishirrg step. .
6' Place some alumina powder or,r top of the wet polishing
cloth of the grinding
wheel' Hold the specimen fas$ down on the wheel under
a moderate pressure
slowly move in a direction opposite to the direction of the wheel.
Continue final
polishing until a mirror-finisfi i, obtuined. Hold the specimen
quite stationary
during most of the polishing operatioh. Before leaving the
wheel at the end of the
final fine polishing, rotate the specimen counterto the direction
of wheel rotation
to eliminate streaks caused by diaught of inclusions.

t
i
 7' After a'firirror-finish is attained, wash the specimen and the hands
and dry the
specimen surface.
8' Never touch the polished ,ora"*1,,ffih'fingers at any time belause
skin oil and
salt will deposit a film or cause tarnlit, 'either of which will
hide the structure to
be observed :,
9' Etch the specimen with 2 ffi..nt niial. evoid over etching. Under etching is
preferable to over etching. Re-polish till the cloudy film has been removed and
surface is again showing a mirror finjsh Re-etch carefully.
Ask the instructor the
check your etched specimen a1d ad.vile you whether to proceed
to examine it on
the microscope or whether you need$ and etch again.
lolish
10' Examine the optical features of a metallurgical microscope. Draw on it a broken
line to show the path of rays of light from the light source
to the observer,s eye.
I l' Examine the microscope' I.ocate each of its components. Complete
the following
table by listing the magnifiing power of each objective rens
and each eye-piece.
Indicate the total magnifications available on your microscope.

Total mdgnification availaUle *ith eact tens

12. study the structure by focusing it by ,going away, from the lens. using the
mechanical stage movements, explore the etched surface,
adjusting the focus, if
necessary, as you go. Practice using both the stage
control knobs simultaneously
to move the specimen in various directions. Locate a good area
to sketoh. If your
specimen does not show a good, clear structure, ask the
instructor to advise you
whether you should re-polish and re-etch.
13. Complete the data sheet.
DATA SHEET

Material: f,

Magnification: Etchant:
Structure:
la

Before etching

After etching
 Experiment#02
Study of Phase Diagrams.

Phase Diagrams

It can be defined u, ifiugru* which contains a good number of information about

the metal or its alloy.
It is also known as a equilibrium diagrams or constitutional diagram.

Some basic concepts

. Phase

' A phase of a substance is a form of matter that is uniform throughout in

chemical composition and physical state
. A homogeneous region with distinct structure and physical properties
. "State matter which is uniform throughout not anly in chemical

composition but also in physical state" J. Willard Gibbs

. In principle, can be isolated
. Can be solid, liquid or gas
a A phase transition occurs at a characteristic temperafure for a given presswe
I Two phases are at equilibrium when their chemical potentials are equal.

I
a Phase transformation
. Change from one phase to another
. S -*Dtc.
I
E.g.L
' -+S,
. occurs because energy change is negative/goes from high to row energy

state

T Phase boundary
. Boundarybetween phases inaphase diagram

T
I
 i:1@ryinisri.*fl 1.41:: 1+ir!+nFqJii.r91sf!tr21q1

Gibb's Phase Rule

When Temperature, Pressure and Composition of are independent variables in the

equation of state.
* F:C-g+2
Where, F- number of degrees of freedom
C= number of chemical components.
P= number ofphases.

' Modified Gibbs Phase Rule (for ineompressible systems). Phase diagram usually
constructed for a fixed pressure of 1 atmosphere.

F:C-P+I

Limitations of Phase Diagram

l. It's gives information only on the constitution of alloys and not on the structural
distribution of the phases.
) The diagram shows only the equilibrium state, whereas alloys in practical use are
rarely in equilibrium.

Solidifi cation (cooling) curves

Tm

Real
-_ Time
 il
Micro-structural changes during solidification

Pure metal

w
Solidification (cooling) curves
$
L SoHification

Micro*structu ral chan ges durin g solidification

Tte Line

*
. Tie line can be defined as ths horizontal temperature line parallel to the x-axis
connecting two difference phase region.
l
. It is used to deterinine the comBosition of alloy for a particular temperature.

Phase Diagrams; Two metals completely soluble in the liquid & solid states

l0 30 40 50 60 7A 80 100
A oB . B

Composition
Phase Diagrams: Two metals completely soluble in the liquid state & completely
insoluble in the solid state

Ta la

Tie line
Tg
Liquid (L)
m n

TB
T
Solid (S) Eiectic T

A B
(100%)
Composition (weightpercentage) (100%)
Phase Diagrams: Two metals completely soluble in the liquid state but only pargy
soluble in the solid state

Wt%B -----------)

B particles
I
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t
T
I
I

I
I
I
I
I
!

wt%B
-=-.+
 L
I
l.+
l^!
I
lt
I
I
I
I
I
I

a
Phase Diagrams: Alloy at various composition

Liquid (L)

Eutectic point

L*ArnB,

A*A,BN
A*Bn+(A*Bn+B)
a B+(AmB,+B)

A I

Composition (weight percentage) B

(100%)
(100%)
The Iron-Carbon Diagram

ff*mpssiti$l{nt$6 ff}

lffi?

,d*
() rt&uuknitd
s
tld
4,I tt{t}& $
tt
L. A,l wts' fr
q
d

$lffi
$
B
r y + ffraphik
,1t

0,$$ wffif,
a {Fenite}

1i
_i
f34 1fl(

f;rmp*iti*n {ffim fi} $rafil

General Properties:

l
' 6 - fercile,(present only at extreme temperatures)
Austenite, (FCC, high formability, high solubility of C, over 2%C can be
dissolved in it, r$rst of heat treatments begin with this single phase). FCC Iron
with much Carbon.Ductile.Ferrite, BCC, stable form of iron below 912 deg.C,
only up to 0.02 wtyo C in solid solution and leads to two phase mixture in most
of steels. It id Iron with a little Carbon. Fairly Soft.
Cementite (iron-carbide), stoichiomotric intermetalic compound, hard, brittle,
exact melting point unknolvn. Hard ceramic material.Currie point Q7A deg. C),

atomic level nonmaguetic-to'magnetic transition

Peritectic, at 1495 deg.C, with low wt% Calloys (almost no engineering
importance).
Eutectic, at 1148 deg.C, with 4.3wt%o C, hapends to all alloys of more than
2.llwtoh C and they are called cast irons.
a
Eutectoid at727 deg.C with eutectoid composition of 0.77wt% C, alloys
bellow Z.llo/oC miss the eutectic reaction to create two-phase mixture. They
are steels.
 r300 | + FelC
p 1 200
o} 1 100
Austenite
te
Ij.
1000
rt,
$. $00 .y
ts
+ Fe3C
ID
l.* 800
Hypo 700
P HYPer Eutectoid
Eutectoid 600
500 Fe

4$0 t6.7 u
a + Fe3C
300
effi
1SO
oL
d 3{
Fe Weight % C
Ferrite - u
Austenite -}
Cementite - Fe:(
Medium-carbon steals
Low-c*rbon {*rnild" } steels
 . }dL
a

\Iicrostructures in Eutectic Systems

T("C)
!, C o wt%Sn
400

(Pb.Sn

System)
 Y"
.'t '

t 20 30
co Ic o , wt%Sn
iC. limitatT ) re-s
(sol- limitatT E)
\It'

Pb-Sn
t
llicrographof pb-sn
system eutectic microstructurc
200
TE
 T('c)
3

2Ot
lE (Pb€nSystem)

10(

60I
80 Co, wt% Sn
eutecuc
ltflrtM{emffi€: c 61-9

eutectic m icro-constituenl

: - Forms before eutectoid

a ;lnr t lt
F-.J(lti

{g}
 i r-c t Phase Diagram
rfc)
16fi)
6
c., i:It_d- r

14(x)

tu sc t( s

T+Fe 3 C !o
l=
T eutectoid IE
l( S
c,+Fe 3C l:
or2\r41.so566.
'l I-
.7
FL
.. _: b) o'77 \ c q, uilyolc
qffitutuUr' :":,_ j= Fe g C (cementite-hard)
r$lffim-;s: ; ;-,nr= cf
o
o
(, cr (fiarrite*d)
ultilir -" r l::rases. o
=
o
o
: irBl

(Fe-C System)

l* ltl
:
ff, .,
o
hm =c
o
E
,mffil o
()

hffi ()
(O
(,
IL

i coFl 6 6.7
'"4d--:--€
C; Co, wt%C
* ;c-;',1g = w9

nh HYPo eutectoid
iOO
steel
Erpoeutectoid Steel

(F+C .

System)

vo
:E
co
E
|D
o
o
r Ferc= r{ r+5PQQ
rf {t- *r"sd

22-
{,:..

Eutectoid Steel

Pearlite

Ferrite (white)
Cementite (dark)
+,

At0.77%C bY cooling from

austenite (FCC) changes to

BCC-fenite (max 0.02%C)

and excess C forms
intermetalic cementite.
Chemical crystalline solid
separation gives fine mixture
of ferrite and cementite.
Perlite (right), 1000x.

trXr poeutectoid Steel

With less than0.77o/oC from

austenite by cooling

transformation leads to growth of

low-C ferrite growth. At727deg.C
austenite transforms in to pearlite.

Mixture of proeutectoid femite

(white) and regions of Pearlite
forms.
Magnification 500X.

Hr pereutectoid Steel

)q
 Proeutectoid Cementite (white)
Pearlite (striPed)

' With more than 0'77o/oC, from

austenite transformation leads to
proeutectoid primary cementite and
secondary ferrite' At727 deg'C
austenite changes to Pearlite'

' Structure of primary cementite and

pearlite forms.

' Magnification 500X'

,.i lrons
a Iron{arbon alloys of
}.1f96C
or more are cast irons. rr

I Typical composition; ir.0-4.0o/oc,0.5-3.0% Si, less than 1.0% Mn and less than 0.2%

. Si-substitutes partialfd6r C and promotes formation of graphite as the carbon rich

component instead Fe3C.
.

Grq Cast Iron

Composes of: 2.5-4.0%oC, 1.0-

3.0%Si and 0.4-1.0% Mn.
--- Microstructure: 3-D graphite
-''!T':l|;{i
+ +i;":'ffEi
q L i,,i
,. x.f-.--.;iltf
flakes formed during eutectic

ffi
;i =\-r't. ..iIlj reaction. They have pointed
edges to act as voids and crack

initiation sites.
u:"={i?ffi
'\r -:l*: Sold by class (class 20 has min.
* ;,.i::::i;-i;l i)';',1

.,,,1ti+St. tensile strength of 20,000 psi is

-. 7.: -1*, a high C-equivalent metal in
I'->-..t,
ferrite matrix ). Class 40 would
have pearlite mafiix.
. hoperties: excellent compressive strength, excellent machinability, good
resistance to adhesive wear (self lubrication due to graphite flakes), outstanding

damping capacity ( graphite flakes absorb transmitted energy), good corrosion

resistance and it has good fluidity needed for casting operations.
. It is widely used, especially for large equipment parts subjected to compressive
loads and vibrations.

'l*lite Cast Iron

il Composes of: 1.8-3.6%C, 0.5-l.gyoSi and 0.25-0.8%Mn.
All'of its carbon is in the'form of iron-carbide (Fe3C). tt is called white because of

il distinctive white fracture surface.

It is very hard and br$le (a lot of Fe3C).
4'
It is used where a high wear resistance is dominant requirement (coupled hard

+ martensite matrix and iron-carbide). Thin coatings over steel (mill rolls).

+ Malleable Cast Iron

+ Formed by extensive heat treatment

t around 900 degC, Fe3C will

dissociate and form irregular shaped

t graphite nodules. Rapid cooling

restricts production amount to up to

kg. Less voids and notches.
5

il Ferritic MCI: 10% EL,35 ksi yield

I strength, 50 ksi tensile strength.

Excellent impact strength, good

corrosion resistance and good

il machinability.

Ductile iron with ferrite matrix (top) and pearlite matrix (bottom) at 500X.
{ Spheroidal shape ofthe graphite nodule is achieved in each case.

il Pearlitic Malleable Cast Iron

t Pearlitic MCI: byrapid cooling through eutectic transformation of austenite to

pearlite or martensite matrix.
{ composition:1-4Yo EL, 45-85 ksi yield strength, 65-105 ksi tensile strength. Not
as machinable as feritic malleable cast iron.

I Ductile Cast Iron

I 2.4
{l
 formation of smooth
treatment by addition
of ferrosilicon (MgFesi)
witt out a
|r:at
spheres (noArt'O of graphite is promoted'
a Properties:2-lSyoVL'40-g0ksiyieldstrength'60-t20ksitensilestrength'
Attractiveengineeringmaterialdueto:goodductility'highstrength'toughness'
and low melting point
castability'
wear resistance, machinability

Globular cast iron

t
I
t
I
t
T
;

I List of MetallograPhic SamPles:

t 13
i.:.. a

1. steel samples
a.' dead soft steels

b. mild steels
c. medium carbon6teels
d. File steels

Cast iron samples

a. Grey cast irons "

b. White cast irons

c. Malleable cast irons (Ferritic)
d. Malleable cast irons (Pearlitic)
e. Ductile cast irons (Ferritio)
f. Ductile cast irons (Pearlitic)

J. Heat treatment samples

a. mild steels (Annealed)
b. Mild steels (Normalized)
c. File steels (Annealed)
d. File steels (Normalized)
e. File steels (Quenched)
f. File steels (Tempered)

Total number of samples: 16

Please note

All samples are mounted, grinned and polished, and etched carefully to reveal

microstructures with optr,num clarity. The samples are packed and marked in neat.

2z
ot
- ,t.
1:

Experiment # 03
MicrostudY of Steels

Objective:
' microsffucture of low carbon steels'
To study the micro constilwnts present in'the

Procedure:
and etch the specimen
1. Obtain a specimert rof steel from the instructor' Polish
accordingtotheproeeduresasusedinthepreviousexperiment.
2. Examinethespecimenonthemicrosoope,usingamagnificationofx400.
Reproduce the frricrostructure, labeling all
microconstituents carefully and neatly'
amounts of the microconstituents present in
your
3. Estimate the approximate relative
content' what will be the
sample. Identify the steel by calculating the oarbon
approximate tensile strength of the steel sample?
questions:
4. Complete the report by answering the following

steel? what is the

a) which is the predominant constituent in the dead soft
steel you have observed?
estimated percentage of carbon in dead soft

b) The matril of the materials microstructure

often plays a major role in
In the case of deab soft
determining the properties that the material has.
contribute? Explain.
steel, what particular property does the matrix
predominant constituent of mild steel? How does
it affect the
c) what is the
properties of the steel?
carbon steels?
d) How does an increase in carbon affect the structure of plain
content?
e) Why ari high carbon steels less ductile than steels of lower carbon
For what purposes are high-carbon steels best suited?

L9
 :i.

!' i"'- '

DATA SHEET

a0
Microstructure of showing grains of. . .....
Etched in .. Magnification .......
and ..

of " of" " " '

showing grains
Microstructure
and.. Etchedin"""" """Magnification

Al
Experiment # 04
Heat treatment of steels-1
+

Objective
ways of doing it, and to studY the
To understand the reasonslfor'heat treating steels' the
the properties of heat-treated
nature and type of resultant microconstituents that influence
steels.

Procedure:
1. Obtain a specimen of Steel from the instructor for heat treatment'
temperature
Z. Observe the heat treating furnace, the method of heating and measuring
used.
producing the mixture that is to be
3. Study the ingredients and observe the method of
used to control the furnace atmosphere'

4. Observe the method of packing the sample in heat treatment box and then charging
into the furnace.
and time for heating' holding
5. Observe the programming or setting up the temperature
and cooling cycles of heat treatment'
heat treatment process'
6. observe the method of cooling of sample during each
7. Take the heat treated sample and grind and polish it as before to study its

microstructure.
steel and label it'
8. Draw the representative microstructure of the heat treated
questions:
9. complete the report by answering the following
process is important?
Why an accurate teinperature measurement in heat treatment
a.
temperature? Name three
b. which equipment is used in your experiment to measure
other temperature measure devices'
c. Describe the function of each ingredient used to prepare
the heat treatment

mixture.
found in heat treated steel
d. List the names of some common defects that you may
sample.

e. Indicate the purposes of annealing and normalizing'

of mild steel and a file
f. Indicate the proper annealing and normalizing temperatures
steel samples.
g. Discuss the difference in structures of annealed and normalized mild
steel'
Y:::::',::::.-::i::1f,:;$1i'*": ::::::: il;;il;;,i"* :::::::::::

Y:::*T::T::iT;::1T:i::i::::: i,;;;il;; 111:,:,

Y::::T::::::::::H:;5HT::::::i1 :;;H;;;i;; . :I11

I

I
Experiment # 05
f Heat Treiffnent of Steels-2
I

and tempering operations

of steel the methods
I H';ff*o t'e princifis of hardening
ofdoingit,andtostudythenatureandtypeofresultantmicroconstituentsthatinfluence
I the properties of heat-treated
steels'

I Procedure:
l.obtainaspecimenofsteelfiomtheinstructgrforheattreatrnent.
I z.observetheprogrammingorsettingupthetemperatureandtimeforheating,
of hardening treatment'
holding and oooling oyoles

t J.
4. Take one hardened sampre
and temper it at the temperature
indioated'

I 5. Taketheheat-treatedsamplesandgrindandpolishthemasbeforetostudytheir
microstructures.
microstructures and label them'
6. Draw the representative
; answering the following
questions:
7. Complete the report by
of hardening a steel sample?
What is thp prinoiple reason
a)
; b) Indicate why low carbon
steels are not hardened?

of martensitic transformation'
c) List the salient features
; d) Why tempering is necessary
after heat treatment?
tempering?
hardened structure during
e) What happens to the
hardness' what should
be the ProPer
; f) If you want to retain a maximum
temPering temPerature?
;

;
.:

;
I

;
 -{F"1,

tf DATA SHEET

Y'::e'*:::::::*:i::#:',',:T:: ::::::: i,;;;il;;,;;; :::::::::::

Y::*::::::::T:i::;::11::::::l]]3 :: M;;ffi;;,;;; :::

Microstructure ofannealed steel sample showing .........and

......Etched in..... .....Magnification.
 6pr
C

Experiment#CI6'-
Microstudy of Cast Irons-l

Ohjective;
To study the microconstituent! present in the microstructure of grey cast irons and white
cast irons.

l. Obtain two specimens of cast iron from the instructor. Polish the specimen
according to the procedures as used in the first experiment.
2. Examine the specimens under the microscope, both etched and unetched
conditions, using a magnification of X400.'Reproduce the microstructure, labeling
all microconstituents carefully and neatly.
3, Complete the report by answering the following questions:
a) What is the ringe of carbon percentage in cast irons? Why ttrose materials
are named as cast irons?

b) How cast irons are usually classified?

c) Which is the predominant constituent in grey cast iron?
d) Why graphite flakes are observed in unetched conditions?
e) Which properties of grey cast irons are attributed respectively by the *ut i*,"
and graphife flakes?

0 why white cast irons are not used as structural materials? Name some
applications of white cast irons.
 c"pr
C

nt-

DATA SI{EET

Microstructure of .... . .. .

*a ....... .. - -:...' .: E;;i; ; :. :. : :: : :: :.. : :: :.:. :.::ififfi,flffi#i

Microstructure of ...
and . . .. . .. . .. . ... .. . ... ..: E;,il tu :: :. :.. :::::: :: ::::: :.::if,;ftfl"l#ili

Microstructure of ......:..,..... .. showing grains of

and ......... ........
...... Etched in ..Magnification .
 ael

?r
'!
Experiment * Oi
Microstudy of Cast Irons-2 (Microstudy
ofMalleable and Ductil" Cast Irons)

Objective:
To study the microconstituerrtl present
in the microstructures of malleable
cast irons and
ductile cast irons.

Procedure:
obtain two specimens of cast iron
, '' from the instructor. porish the specimen
according to the proce{ures as
used in the first experiment.
2. Examine the specimens under
the microscope, both etched and
unetched
a magnification of X400. Reproduce
the microsrructure,
::Ty^T: -::*,
arr mlcroconstituents carefully
labering
and neatly.
3. Complete the report by answering
the following questions:
a) Indicate the difference, silicon
and manganese contents between
malleable
and ductile cast irons.
b) why cast irons are used as raw
materiar for producing mareabre
irons?
c) Discuss what happens during
first, second and third *u**,
heat treatment. "t**""i**rry
d) Why bull,s eye structure is produced?
e) Indicate the functions ofmagnesium
in producing duct,e iron.
0 whv desulphurization treatment is necessary during ductile
iron production?
g) summarize a comparison
between malleable and ductile
irons about their
quality. d
 6pr
C

Microstructure of
.....
and . ...... .. ..........;;ffi
!... .... i;
.. .... Et.t rd in . showing grains
of

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