UNIT II

ENGINEERING MATERIALS AND POLYMERS

2.1. ABRASIVE

Definition: Abrasives are hard substances that can be employed to rub down other objects
and used for polishing, shaping, grinding operations. They are used in the form of powder,
paper or cloth and grinding wheels .eg., Dentist uses an abrasive powder to clean teeth.

2.2. Abrasive power: It is the capacity of particular abrasive to rub down other object.

2.2.1. Properties of abrasive

1. Hardness

It is the capacity of an abrasive to grind or scratch away other materials. The harder the
abrasive, quicker will be its abrading action. It is measured on Moh’s scale or Vicker’s
scale.

Measurement of hardness:

Common abrasives are arranged in the increasing order of hardness for measuring hardness
of other materials.

Name of the abrasives Moh’s number

or hardness

Talc 1

Gypsum 2

Calcite 3

Fluorite 4

Apatite 5

Feldspar 6

Quartz 7

Topaz 8

Corundum 9

Diamond 10
For materials having minimum hardness (talc), the value of hardness given is 1 and for
materials having the highest hardness, the value given is 10.The hardness of all other
materials are taken within this limit.

Abrasives having their hardness 1–4 in Mho’s scale are known as soft abrasives.

2.3. Classification of abrasives

Abrasives are classified into two types. They are natural and synthetic abrasives.

2.3.1. Natural abrasives

1. Diamond

1. It is pure crystalline carbon.

2. It is the hardest known substance and its Moh’s number is 10.
3. It can cut the surface of any other substance.
4. It is chemically inert and not affected by acids and alkalis
5. The off colour diamond is called as borts.
6. The black colour diamond is known as carbonado.

Uses:
1. It is used in drill points for cutting rocks, stones and grinding wheels.
2. It is used as tools for cutting hard rubber and fibre.

2.3.2. Synthetic abrasives

1. Carborundum or Silicon carbide (SiC)

Preparation: Carborundum is manufactured by heating a mixture containing sand(54%) and

coke(34%), saw dust(10%) and common salt(2%) in an electric furnace at about 1650-
2200○C for 36 hours.

SiO2 + 3C →SiC+2CO
 Common salt helps to remove the iron impurities. The saw dust increases the
porosity of the charge, facilitates the escape of carbon monoxide and other volatile
matters from the reaction mixture.

Properties:

1. It is bluish-black crystalline material.

2. Hardness is 9.3 Moh’s scale.
3. It is chemically inert and can withstand high temperatures.
4. High abrasion resistance.
5. Heat conductivity is in between metals and ceramics.
6. Electrical conductivity is in between conductors and insulators.

Uses:
1. It is used for making grinding wheels.
2. These grinding wheels are employed for grinding glass, granite, rubber and leather.
3. It is used as heating element in furnace,coke ovens, and muffle furnaces.
4. It is used for making crucibles.

2.4. REFRACTORIES

Definition: Refractories are inorganic materials that can withstand high temperatures
without softening or undergoing any deformation in shape.

Function: The essential function of a refractory is to serve as a structural material and

maintain its mechanical functions at high temperatures under the service conditions.
Uses:
1. Refractories are used for the construction of lining of the furnaces, kilns, crucibles etc.
2. They are employed for the manufacture of cement, glass, ceramics, paper, etc.
3. They are also used for the manufacture of rocket nozzles and launch pads.

2.5. Characteristics or requisites of a good refractory

1. It should be infusible at the operating temperature.
2. Its physical, chemical and mechanical properties should not undergo any changes at
high temperature.
3. It should not crack at the operating temperature.
4. It should be chemically inert towards the corrosive action of molten metals, slags and
gases.
5. It should be able to withstand charge load at the operating temperature.
6. It should expand and contract uniformly, with temperature rise and fall respectively.
7. It should posses low permeability.

2.6. Classification of refractories

Refractories are classified into three types:
(1) Acidic refractories (2) Basic refractories and (3) Neutral refractories.
1. Acidic refractories
They consist of acidic materials like alumina and silica and are not attacked by acidic
materials, but are easily attacked by basic materials.
Example: Silica, alumina, fire-clay refractories.

2. Basic refractories
They are made up of basic materials like calcium oxide and magnesium oxide. They are not
attacked by basic materials, but are easily attacked by acidic substances.
Example: Magnesite (Magnesia) and dolomite refractories.
3. Neutral refractories

They are made from weakly acidic and basic materials and are inert towards both acidic and
basic substances.

Example: Graphite, silicon carbide, chromite and zirconi are fractories.