UPM-CALC/SEM2/2020-21/CEL2106/PORTFOLION/TASK1 UNIVERSITI PUTRA MALAYSIA Oe Semester 2, 2022-2023 Mehcanical engeering lab Coruse Code : Lab3453 MATERIALS SCIENCE LABORATORY Name : Muhamad Ali Waleed Matric No. 24647ER43 Group No. 223 Instructor's Name : DR.Nurzihan Rhaman1.0 TITLE: METALLOGRAPHIC STUDY OF STEEL AND CAST IRON 2.0 OBJECTIVE: To study the metallographic of various heat treated carbon steel and cast iron. 3.0 THEORY 3.1 Introduction Metallographic is the microscopic study of structural characteristics on a metal and its alloy. Metallographic or microscopic study is an important area in order to study and examine the microstructure of metal and its alloy. Generally, the microstructure of a metal was formed due to the chemical composition, heat treatment and deformation processes. The metallographic study involves macro and micro examination. Macro examination can be done by observation through naked eyes or through magnification of 10X of microscope for the metal which have coarse microstructure while micro examination can be done by using higher magnification for fine microstructure of metal. This examination can be done by using optical microscopy (maximum magnification of 2000X) and electron microscopy (magnification of more than 2000X). 3.2 Carbon Steel Carbon steel is ferrous metal consist of iron and carbon (up to 2.0%), is widely used in engineering application because its variety of mechanical properties. The mechanical properties of steel such as ductility, hardness, toughness, and strong generally depends on the composition and heat treatment. The microstructures of carbon steel are as follows: (1) Austenite (Y) — solid solution of carbon in the iron with face centre cubic (F.C.C) crystal structure. The maximum solid solubility of carbon in austenite is 2% at 1130 °C. (2) Ferrite — solid solution of carbon in the iron which has a body centre cubic (B.C.C) crystal structure. The maximum solid solubility of carbon in austenite is 0.025% at 723 °C. (3) Cementite — is a chemical compound of carbon and iron and the weight percentage of carbon is 6.67%. It is also known as iron carbide and its chemical formula is FesC.(4) Pearlite — is a eutectoid structure, a mixture of ferrite and cementite microstructure. The lamella structure forms when austenite with 0.8% carbon is slowly cooled below 271 °C. The iron-carbon phase diagram(refer to appendix) shows the location of phases due to temperature changes and percentage of carbon in steel. 3.3 Heat Treatment Heat treatment is a heating and cooling process of solid metals or alloys to obtain a certain properties. Through heat treatment process, the mechanical properties of steel can change due to the changes of grain size and its microstructure. Heating beyond the critical temperature of A3 and Acm will produce austenite microstructure. If slow cooling is conducted, equilibrium structure will be obtained whereas non-equilibrium structure will be obtained if the cooling rate is fast. Equilibrium structure is a structure that can be predicted by using Fe- C equilibrium phase diagram, but not for non-equilibrium structure. Most common heat treatment for steel is: (a) Heat treatment which produce equilibrium microstructure (i) Annealing The main purpose of annealing process is to release the residual stress in order to increase ductility and machinability properties. Annealing was conducted by heating the steel to austenite temperature which depends on its carbon content, soaking at this temperature until it is completely transform to austenite, and cooling slowly in the furnace. The final microstructure is ferrite + pearlite for hypo eutectoid steel, pearlite for eutectoid steel and cementite + pearlite for hypereutectoid steel. (ii) Normalizing The heat treatment process and microstructure obtained are similar to annealing process, but the cooling process was conducted in static air. Therefore, the microstructure is slightly finer and uniform as well as better mechanical properties. (b) Heat treatment which produce non-equilibrium microstructure (i) Quenching The heat treatment is conducted by heating the steel until it is completely transform to austenite phase and followed by fast cooling (for instance in a water or oil medium). The microstructure obtained is called martensite which is hard and brittle. This heat treatment is also known as HARDENING process of steel. (ii) Tempering Tempering process is carried out after quenching process. The steel is heated at the temperature below lower critical temperature to improve the ductility and toughness. The microstructure that will be obtained tempered martensite.3.4 Cast iron Cast irons are a class of ferrous alloys with carbon contents above 2.14 wt%; in practice, however, most cast irons contain between 3.0 and 4.5 wt% C and, in addition, other alloying elements. Steel alloys within this composition range become completely liquid at temperatures between approximately 1150 and 1300°C, which is considerably lower than for steels. Thus, they are easily melted and amenable to casting. Furthermore, some cast irons are very brittle, and casting is the most convenient fabrication technique. The most common cast iron types are: 3.4.1 White cast iron Low-silicon cast irons (containing less than 1.0 wt% Si) and rapid cooling rates, most of the carbon exists as cementite instead of graphite. White iron is very hard but brittle, high wear and abrasion resistance and extremely difficult to machine. Typical applications are rollers in rolling mills, brake shoes, extrusion nozzles. 3.4.2 Malleable cast Iron Heating white iron at temperatures between 800 and 900°C for a prolonged time period and in a neutral atmosphere causes a decomposition of the cementite, forming graphite, which exists in the form of clusters or rosettes surrounded by a ferrite or pearlite matrix, depending on cooling rate. Typical applications includes casting mold, railroad, pipe fittings and bridges, connecting rods 3.4.3 Gray cast Iron Gray Iron is the least expensive and the most common variety. Typical carbon ranges are 2.5% to 4% with 1% to 3% silicon. The graphite exists in the form of flakes (similar to corn flakes), which are normally surrounded by ferrite or pearlite matrix. Because of these graphite flakes, a fractured surface takes on a gray appearance, hence its name. Mechanically, gray iron is comparatively weak and brittle in tension as a consequence of its microstructure; the tips of the graphite flakes are sharp and pointed, and may serve as points of stress concentration when an external tensile stress is applied. Strength and ductility are much higher under compressive loads. Applications include large machinery parts with intricate shapes, general purpose cast iron, sewer pipes (due to better corrosion resistance than most steels) 3.4.4 Ductile cast Iron Adding a small amount of magnesium and/or cerium to the gray iron before casting produces a distinctly different microstructure and set of mechanical properties. Graphite still forms, but as nodules or sphere-like particles instead of flakes. Castings are stronger and much more ductile than gray iron Applications include structural (load carrying) parts, valves, pump bodies, crankshafts, gears.4.0 5.0 6.0 7.0 APPARATUS The specimens of carbon steel that will be examined are: (a) Specimen A: 0.35wt% carbon steel which is furnace cooled from 870°C (b) Specimen B: 0.8 wt% carbon steel which is furnace cooled from 870 ° C (c) Specimen C: 0.35 wt% carbon steel which is water quenched from 870°C and tempered at 600° C for 2 hours (d) Specimen D: White cast iron heated at 1000°C for 60 hours then slowly cooled to room temperature (e) Specimen E: Gray cast iron added with magnesium and/or cerium EXPERIMENTAL PROCEDURE Microstructure examination under the microscope Examine every prepared specimen under the optical microscope and sketch the microstructure of the specimen. Student must be careful during operate the microscope especially during the adjustment of the magnification lenses to make sure the lens does not touch the surface ofthe specimen. Start the examination of specimen by using low magnification lens. RESULTS 6.1 Sketch and label the microstructure of all samples observed under optical microscope. State the magnification of the lens used.(35 marks) 6.2 Indicate the location of all specimens on the Fe-C equilibrium phase diagram based on the carbon content. What is your conclusion regarding to that specimen? (10marks) DISCUSSIONS 7.1 Explain the purpose of mounting, grinding, polishing and etching and suggest the machine or materials use for each step of specimen preparation. (8 marks) 7.2 Give your opinion and suggest how to get the best result for polishing. (4 marks)8.0 9.0 7.3 Give your opinion regarding to mechanical properties and the example of industrial application for the specimen A and C. (8 marks) 7.4 Briefly explain the differences of the microstructure between specimen D and E.(10 marks) CONCLUSIONS Conclude your results and discussions from the experiment not more than 120 words.(20marks) TEAM WORKING Collects and presents to the team a great deal of information related to the group purpose.(Smarks)OO Specimen A Specimen B Microtructure : Microtucture : Magnification : Magnification : Specimen C Microtructure : Magnification : Specimen D Specimen E Microtructure : Microtructure : Magnification : Magnification :