TITLE:

INTRODUCTION TO
METALLOGRAPHY

METALLURGICAL ENGINEERING
&
WELDING AND FABRICATION
DEPARTMENTS

SCHOOL OF ENGINEERING

ADEWALE. S.T
ENGR. RAJI. N.K
AMACHI. K

YABA COLLEGE OF TECHNOLOGY

YABA LAGOS
 TABLE OF CONTENT

 Caution and Instruction

 Experiment 1 : Study of microscope: Identification of metallurgical microscope

 experiment 2: Samples preparation for microscopic examination

 Experiment 3: Macroscopic examination of metals (sulphur printing)

 Experiment 4: Macroscopic examination of metals (welded sections)

 Experiment 5: Preparation of mounted samples.

 Experiment 6: Microstructure of metal (steel and cast iron)

 Experiment 7: Heat treatment 1 (annealing and normalizing)

 Experiment 8: Heat treatment 2(carburizing of steel/mild steel samples)

 Experiment 9: Heat treatment 3: Hardening (Quenching and Tempering).

Page 1
 CAUTION
(i) Do not play with electricity.

(ii) Carelessness not only destroys the valuable equipment in the lab but also costs your life.

(iii)Mere conductivity of the experiment without a clear knowledge of the theory is of no value.

(iv) Before you turn on a switch, think of the consequences.

(v) Do not start the experiment until the experimental setup is verified.

LABORATORY INSTRUCTIONS

 Student should put on their safety wears on or before entry the Laboratory.
 Students should come with thorough preparation for the experiment to be conducted.

 Students will not be permitted to attend the laboratory unless they bring the practical
record fully completed in all respects pertaining to the experiment conducted in the
previous class.

 Experiment should be started only after the staff-in-charge has checked the
experimental setup.

 All the calculations should be made in the observation book. Specimen calculations for
one set of readings have to be shown in the practical record.

 Wherever graphs are to be drawn, A-4 size graphs only should be used and the same
should be firmly attached to the practical record.

 Practical record should be neatly maintained.

 They should obtain the signature of the staff-in-charge in the observation book after
completing each experiment.

 Theory regarding each experiment should be written in the practical record before
procedure in your own words.
 Practical record should be submitted at most two after each practical class for marking
and recording.

ISBN: - 978-978-974-320-4

Page 2
EXPERIMENT NO. 1
TITLE: STUDY OF MICROSCOPE: IDENTIFICATION OF PART AND
FUNCTION OF METALLURGICAL MICROSCOPE
OBJECTIVE: To study a metallurgical microscope, its operation and identify the
function of each part.
EQUIPMENT USED: A metallurgical microscope, a sample, pencil and ruler.
PROCEDURE:
i. Identify a metallurgical microscope.
ii. Draw out the metallurgical microscope in the metallography laboratory.
iii. Label each part of the microscope drawn above.
iv. State or write out the function of each part of the microscope.
DIAGRAM:

Fig 1: Non-inverted Metallurgical Microscope.

CONCLUSION:
i. What is the function of a plane glass reflector?
ii. What are the important part of an objective?

Page 3
EXPERIMENT NO:
DATE:
TITLE OF THE EXPERIMENT:
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AIM AND OBJECTIVES:
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EQUIPMENT USED
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THEORY OF THE EXPERIMENT:
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PROCEDURE:
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PRINCIPLE OF OPERATION:
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DIAGRAM:

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IDENTIFY PARTS AND WRITE OUT FUNCTIONS OF A TABLE TYPE
MICROSCOPES
S/N PARTS FUNCTIONS
1 Stage

2 Tubes

3 Rough and Fine

Focus Adjustments

4 Objective

OBSERVATION:
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PRECAUTION:
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CONCLUSION:
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___________________________________________________________________________
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 EVALUTION SHEET

NAME:
MATRIC NUMBER:
DATE:
TITLE:
AIM
PERFORMANCE OBJECTIVE
PERFORMANCE CRITERIA
MATERIAL/ TOOLS REQUIRED
OBSERVATION
GRAPH
DIAGRAM
TOTAL

Page 8
EXPERIMENT NO. 2
TITLE: SAMPLES PREPARATION FOR MICROSCOPIC EXAMINATION

Objectives:
 Familiarization with the procedure for preparation of a material specimen surface for
microscopic examination.
 Familiarization with compound optical microscopes and metallography.
 Examination of surface characteristics of engineering materials.

APPARATUS: Metal samples (e.g. brass, steel, aluminium etc.) manual hacksaw/power
saw/abrasive cut of wheels, A soluble water, flat smooth file, belt sander,
emery paper (Si-c) of different grades, mesh, diamond or alumina paste, sylvet
cloths, suitable etchants, cotton wool, air blower or dryer.
PROCEDURE:
A. SAMPLING
(i) Choose a sample as close as possible to the area of the fracture of the material
(ii) Choose another sample from the normal section of the material or metal
(iii)Make sure the specimen you are to cut out should be of a size and shape that is
convenient to handle (round shapes).
(iv) Use manual hacksaw or power saw to cut out soft material e.g. non-ferrous
materials (aluminium etc.) or alloy and non-heat treated steels.
(v) Use abrasive cut off wheel to cut out hard material e.g. heat treated steels, iron
etc.
(vi) While cutting, keep specimen cool by application of soluble oil or coolant
during the cutting operation.
B. ROUGH GRINDING: Since the sample is of a convenient size and shape to handle;
(i) FOR SOFT SAMPLE, make flat the surface of sample by slowly moving it up
and back or front and back the surface of a flat file.
(ii) FOR HARD SAMPLE, use the above procedure or use a belt sander to ground
the specimen.
(iii) While grinding, keep cool frequently by dipping in water during the operation.
(iv) Make sure the specimen is moved perpendicular to the existing scratches.
(v) Continue the process until the surface is flat and free from wire brushes and
scratches due to hacksaw or cut off wheel are no longer visible.
C. INTERMEDIATE POLISHING:
(i) Use different sizes of emery paper with finer abrasive (Si – C) for polishing.
(ii) Use from 180o mesh, 240o, 400o, stop with 600o mesh.
(iii) Carry out the operation using a dry emery paper.
(iv) When polishing a soft material, use lubricant to prevent overshooting of the
sample.
(v) Minimize the shearing of soft metals.
(vi) Provide a rising action to flush away surface removal product on the paper.
D. FINE POLISHING:
(i) Make a choice of cloth depending on the material you want to polish and the
purpose of metallurgical study.

Page 9
 (ii) (a) Dual disc polisher using alumna only (Alumna powder) 600 mesh or 2000
mesh + water or
(b) Use a wet rotary wheel (diamond cut compound or paste) covered with a
special cloth that is charged by carefully sized abrasive particles
(iii) When using wet rotary wheel covered with a special cloth, apply abrasive based
on the material you are polishing e.g. (a) gamma form of aluminium – oxides
(Al2O3), for ferrous and copper based materials, (b) cerium oxide for aluminium,
magnesium and their alloys, other abrasive chromium oxide, magnesium oxide
and diamond.
(iv) Draw out the diagram of the sample.
DIAGRAM:

Fig 2: A table polishing Machine

Fig 3: A Grinding Machine

QUESTIONS
1. Prepare a metallographic brass, steel or aluminum specimen going through the course
grinding, fine grinding, polishing and etching stages of specimen preparation. Clearly
label your specimen and submit it with the lab report.
2. Describe the steps involved in the preparation of your sample including the following:
a. Sectioning b. Mounting c. Course Grinding d. Fine Grinding e. Polishing f. Etching
3. Why must metallographic samples be washed and carefully dried before proceeding
from one grinding or polishing operation to the next?

4. What is the purpose of etching metallographic samples?

5. Why metallographic samples are sometimes mounted in plastic?

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MATRIC NO:
EXPERIMENT NO:
DATE:
TITLE OF EXPERIMENT:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
OBJECTIVES:
___________________________________________________________________________
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___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
EQUIPMENT USED:
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___________________________________________________________________________

THEORY OF THE EXPERIMENT:

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PROCEDURE:
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___________________________________________________________________________
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___________________________________________________________________________
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OBSERVATION:
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PRECAUTION:
___________________________________________________________________________
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___________________________________________________________________________

CONCLUSION:
___________________________________________________________________________
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___________________________________________________________________________
___________________________________________________________________________

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 EVALUTION SHEET

NAME:
MATRIC NUMBER:
DATE:
TITLE:
AIM
PERFORMANCE OBJECTIVE
PERFORMANCE CRITERIA
MATERIAL/ TOOLS REQUIRED
OBSERVATION
GRAPH
DIAGRAM
TOTAL

Page 14
EXPERIMENT NO. 3

TITLE: MACROSCOPIC EXAMINATION OF METALS (SULPHUR PRINTING)

Objective:
 To examine the nature of in homogeneities and flow lines in a metal by unaided eye
or with the aid of a low-powered microscope or magnifying glass
 To detect and permanently records the distribution of Sulphur in steel
Equipment: Magnifying Glasses, enchants, beakers, measuring flasks, stirrer a low-
powered microscope,
Specimen: A piece of rail material, Carbon Steel

THEORY OF EXPERIMENT:
Impurities may exist in steel products. It is desirable that their amounts should be minimal
and homogeneously distributed within the product. These impurities degrade the mechanical
properties of the steel, especially sulphur content in steel makes it brittle. Sulphur may exist
chemically in steel in one of two forms, either as manganese sulphide (MnS) or as iron
sulphide (FeS). Sulphur printing detects and permanently records the distribution of sulphur
in steel. The reaction of the sulphuric acid with the sulphide regions of the steel produces
hydrogen sulphide gas, which reacts with the silver bromide in the paper emulsion, forming a
characteristic brown to gray-black deposit of silver sulphide.

PROCEDURE:
i. Make sure the surface of metal or object to be tested is smooth and free from foreign
matter e.g. grease and dirt.
ii. Use emery paper of size or numbers 400 to 1200 for surface preparation as done in
experiment 2. Ensure thorough washing is done to produce a surface satisfactory for
the purpose.
iii. Pick photographic bromide paper. Soak the paper in a 2% aqueous solution of
sulphuric acid for about 3 or 4 min.
iv. Remove paper from the acid solution and allow to drain free from excess solution.
v. Then place the emulsion side of the paper in direct contact with the prepared
specimen surface and allow to remain in contact under moderately applied pressure
for 1 or 2 min.
vi. Make sure that all entrap air bubbles between the paper and the specimen surface are
remove.
Note: The sulphur in the steel (sulphide) react with sulphuric acid (H2SO4) produces
hydrogen sulphide gas (H2S), which reacts with the silver bromide (AgBr) in the paper
emulsion, forming a characteristic brown to gray-black deposit of silver sulphide.

Reaction equation: FeS +H2SO4  FeSO4 + H2S

Note: H2S stains on Bromide paper

vii. Wash the bromide paper by water up to three (3) minutes

Page 15
viii. Place in a photographic fixing solution (Sodium/ammonium thiosulfate) Na2S2O3 for
about 15minutes or in 20% hypo solution for about 5 minute
ix. Take it out of the solutions and wash with water up to 30minute or 15-20 minute and
dry.
Note: The intensity of brown colour on bromide paper indicate the degree of sulphur content
present in the steel.

QUESTIONS
1. Draw schematically sulphur inclusions in the rail material (Specimen 1).
2. Are the sulphur inclusions distributed homogeneously or as segregated points in the
material? Discuss their effects on the mechanical properties of the material.

Page 16
EXPERIMENT NO:
TITLE:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
__________________________________________________________________________
OBJECTIVES:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
EQUIPMENT USED:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
PROCEDURES:
___________________________________________________________________________
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Page 17
DIAGRAM:

TABLE

S/N SAMPLE A SAMPLE B SAMPLE C

1 Name of material
or sample

2 Size of material

3 Duration of
mount

Page 18
OBSERVATIONS:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
PRECAUTION:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________

CONCLUSION:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________

EVALUTION SHEET

NAME:
MATRIC NUMBER:
DATE:
TITLE:
AIM
PERFORMANCE OBJECTIVE
PERFORMANCE CRITERIA
MATERIAL/ TOOLS REQUIRED
OBSERVATION
GRAPH
DIAGRAM
TOTAL

Page 19
EXPERIMENT NO. 4

TITLE: MACROSCOPIC EXAMINATION OF METALS (WELDED SECTIONS)

Objective:
 To examine the nature of in homogeneities and flow lines in a metal by unaided eye
or with the aid of a low-powered microscope or magnifying glass
Equipment: Magnifying Glasses. Enchants, beakers, measuring flasks, stirrer a low-powered
microscope,
Specimen: finding the location of weld section of a welded-material for carbon steel

THEORY OF EXPERIMENT:
It is often desirable, and frequently necessary, to determine the soundness of a welded joint
and to observe macroscopically over a cross section of the weldment the various zones where
in structural changes have occurred. This is accomplished by macro-etching the prepared
surface with the usual hydrochloric acid solution, or in some cases with a milder reagent such
as 2 or 3 % nital (ethyl alcohol + 2% HN03).

Procedure:
i. Using/ cutting out a welded section make sure the surface of metal or object to be
tested is smooth and free from foreign matter e.g. grease and dirt.
ii. Use emery paper of size or numbers 240 to 400 for surface preparation as done in
experiment 2. Ensure thorough washing is done to produce a surface satisfactory for
the purpose.
iii. Clean and dry the surface
iv. Then rub the specimen surface using a cotton tuft by using
9g FeCl3 + 6 cm3 HCL + 100 cm3 H2O solution until the weld section appears). OR
v. Pour milder reagent such as 2 or 3% natal (ethyl alcohol + 2% HNO3) or Ethanol and HNO3
mixed together is applied then Acetone OR
vi. Use cotton bod to apply naval jelly rust removal (it contains phosphoric Acid)
vii. Rinse in clean water properly and dry
viii. Examine by using magnifying glasses.

QUESTION
 Draw schematically welded-section of the specimen.

Page 20
EXPERIMENT NO:
TITLE:
___________________________________________________________________________
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___________________________________________________________________________
___________________________________________________________________________
__________________________________________________________________________
OBJECTIVES:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
EQUIPMENT USED:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
PROCEDURES:
___________________________________________________________________________
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DIAGRAM:

TABLE

S/N SAMPLE A SAMPLE B SAMPLE C

1 Name of material
or sample

2 Size of material

3 Duration of
mount

Page 22
OBSERVATIONS:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
PRECAUTION:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________

CONCLUSION:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________

EVALUTION SHEET

NAME:
MATRIC NUMBER:
DATE:
TITLE:
AIM
PERFORMANCE OBJECTIVE
PERFORMANCE CRITERIA
MATERIAL/ TOOLS REQUIRED
OBSERVATION
GRAPH
DIAGRAM
TOTAL

Page 23
EXPERIMENT NO. 5
TITLE: MICROSTRUCTURE OF METAL (STEEL AND CAST IRON)
AIM AND OBJECTIVE: Studying and drawing of microstructure of steels.
RESOURCES: Different ranges of steel; from 0.2% carbon – 0.8% carbon, steel, diagram
samples and different forms of cast iron, microscope, Rotary Pre-grinders. Polishing
Machine. Abrasive cut-off machine
PROCEDURE:
1) SAMPLING
 Choose a sample as close as possible to the area of the fracture of the material
 Choose another sample from the normal section of the material or metal
 Make sure the specimen you are to cut out should be of a size and shape that is
convenient to handle (round shapes).
 Use manual hacksaw or power saw to cut out soft material e.g. non-ferrous materials
(aluminium etc.) or alloy and non-heat treated steels.
 Use abrasive cut off wheel to cut out hard material e.g. heat treated steels, iron etc.
 While cutting, keep specimen cool by application of soluble oil or coolant during the
cutting operation.
2) ROUGH GRINDING: Since the sample is of a convenient size and shape to handle;
 FOR SOFT SAMPLE, make flat the surface of sample by slowly moving it up and
back or front and back the surface of a flat file.
 FOR HARD SAMPLE, use the above procedure or use a belt sander to ground the
specimen.
 While grinding, keep cool frequently by dipping in water during the operation.
 Make sure the specimen is moved perpendicular to the existing scratches.
 Continue the process until the surface is flat and free from wire brushes and scratches
due to hacksaw or cut off wheel are no longer visible.
3) INTERMEDIATE POLISHING:
 Use different sizes of emery paper with finer abrasive (Si – C) for polishing.
 Use from 180o mesh, 240o, 400o, stop with 600o mesh.
 Carry out the operation using a dry emery paper.
 When polishing a soft material, use lubricant to prevent overshooting of the sample.
 Minimize the shearing of soft metals.
 Provide a rising action to flush away surface removal product on the paper.
4) FINE POLISHING:
 Make a choice of cloth depending on the material you want to polish and the purpose
of metallurgical study.
(a) Dual disc polisher using alumna only (Alumna powder) 600 mesh or 2000
mesh + water or
(b) Use a wet rotary wheel (diamond cut compound or paste) covered with a
special cloth that is charged by carefully sized abrasive particles
 When using wet rotary wheel covered with a special cloth, apply abrasive based on
the material you are polishing e.g. (a) gamma form of aluminium – oxides (Al2O3),

Page 24
 for ferrous and copper based materials, (b) cerium oxide for aluminium, magnesium
and their alloys, other abrasive chromium oxide, magnesium oxide and diamond.
5) MICROSCOPE EXAMINATION

 After preparing each samples of steel or cast iron to be examined in a microscope.

 Examine the structure of each steel and cast iron.
 Draw what it looks like.
 Discuss the shape and structure of each.
 Compare the structure of each sample.
 State how each structural look may affect the properties of the metal.

TABLE
STEEL
Range _________________ to ________________________% carbon.
S/N NAME PERCENTAGE MICROSTRUCTURAL
COMPOSITION DRAWING
OF CARBON
(%C)

Page 25
2

3.

CAST IRON
S/N NAME PERCENTAGE MICROSTRUCTURAL
COMPOSITION DRAWING
OF CARBON
(%C)

Page 26
1

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 EVALUTION SHEET

NAME:
MATRIC NUMBER:
DATE:
TITLE:
AIM
PERFORMANCE OBJECTIVE
PERFORMANCE CRITERIA
MATERIAL/ TOOLS REQUIRED
OBSERVATION
GRAPH
DIAGRAM
TOTAL

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EXPERIMENT NO. 6

TITLE: PREPARATION AND STUDY OF MICROSTRUCTURES OF MILD

STEELS, LOW CARBON STEELS, AND HIGH CARBON STEELS

AIM:
To prepare the specimens of pure metals like mild steels, low carbon steel and
High carbon steels and observes the microstructure of the same

RESOURCE:
a. Given specimen
b. Specially designed files
c. Belt grinder
d. Emery papers (80,120,240,400,600)
e. Disc polishing machine
f. Metallurgical Microscope
g. Etchants

THEORY
Plain carbon steels are steels having carbon as the predominant alloying element and the
other alloying elements are either Nil or negligible though some amount of sulphur and
phosphorous are present. Normally the amounts are less than 0.05 percent and hence they are
not considered. The plain carbon steels are broadly classified in to low carbon steels with
carbon content less than 0.3 percent and medium carbon steels contain Carbon between 0.3 to
0.7. The high carbon steels contain carbon from 0.7 to 1.5 percent.

LOW CARBON STEEL:

As the microstructure shows the structure of the mild steel, it contains 25% pearlite
and 75% ferrite. The dark region defines the pearlite and bright portion is of ferrite. The
Properties of low carbon steels are:
i. The material is soft and ductile
ii. It is easily weldable
iii. It is cold workable
iv. The tensile strength varies between 390 to 550 N/ mm2
v. The Brinell hardness number varies from115 to 140.
Note: The application includes making steel wire, sheets, rivets, screws, pipe chain and
structural parts.
MEDIUM CARBON STEEL:

The microstructure reveals two phases are to be about 50% each. Hence the carbon content
can be accessed to be equal to it. The properties of medium carbon steels are invariably
between low and high carbon steels. The tensile strength varies between 75 to
800 N/ mm2
The medium carbon steels are used in manufacture of drop forging dies, die block plates,
punches, screws and valve springs etc.

HIGH CARBON STEEL:

Page 29
Microstructure of high carbon steels consists of continuous network of cementite in matrix to
pearlite. This cementite structure is hard and brittle and hence has poor machinability. As
carbon content increases weldability and cold working decreases. They have high strength
and hardness. Its Tensile strength is up to 1400 N/mm2 hardness varies from 450 to 500
BHW.
High carbon steels are used in cutting machine tools, manufacturing cold dies and wheels for
railways.

PROCEDURE:

 The specimens of pure metals like Mild steel, Low carbon steel and high carbon steels
are mounted in a thermosetting material as explained in the experiment no. 2.
 Polish the specimen by using (80,120,240,400and 600) grade emery papers.
 Subject the given specimen to mirror like finish by using disc polishing machine and
with suitable abrasive.
 Clean the specimen with alcohol and wash it under the stream of flowing water.
 After washing the specimen is dried.
 After drying apply the suitable etching agent for 30 to 60 sec.
 After etching wash the specimen under the stream of flowing water.
 Dry the specimen with the help of air blower.
 Place the specimen under the microscope for metallurgical studies.

QUESTIONS
1. Draw the micro structure and identify the material for the given specimen.
2. State the features of the following ferrite, pearlite and cementite

Page 30
MATRIC NO:
EXPERIMENT NO :
DATE:
TITLE OF EXPERIMENT:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
OBJECTIVES:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
EQUIPMENT USED:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________

THEORY OF THE EXPERIMENT:

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PROCEDURE:
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___________________________________________________________________________
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DIAGRAM:

OBSERVATION:
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___________________________________________________________________________
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PRECAUTION:
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CONCLUSION:
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___________________________________________________________________________
___________________________________________________________________________
EVALUTION SHEET

NAME:
MATRIC NUMBER:
DATE:
TITLE:
AIM
PERFORMANCE OBJECTIVE
PERFORMANCE CRITERIA
MATERIAL/ TOOLS REQUIRED
OBSERVATION
GRAPH
DIAGRAM
TOTAL

Page 34
EXPERIMENT NO. 7
TITLE: HEAT TREATMENT 1 (ANNEALING AND NORMALIZING)
OBJECTIVE: To study the effect of annealing and normalizing on the properties of
steel.
RESOURCES USED: Electric Arc furnace, tong, bucket, shovel, Steel sample.

PROCEDURE FOR ANNEALING:

(i) Choose the material to be used
(ii) Measure the initial size and final size of the specimens before and after the experiment
(iii) Note the shape of the object before and after experiment
(iv) Plug electric furnace and heat for a little while
(v) Wear your hand gloves pick your specimen and place it in a container
(vi) After placing the specimen in a container, use the tong to place or carry the container
then place in the electric furnace.
(vii) Heat the furnace to the required temperature.
(viii) Note the operation time
(ix) Keep the specimen at that temperature (holding).
(x) Note the holding time
(xi) Off the furnace
(xii) Carefully open up the furnace and pick up the container
(xiii) Finally cool at a very slow rate.

PROCEDURES:
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___________________________________________________________________________
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PROCESS DATA
SPECIMEN:
MAXIMUM TEMPERATURE:
MINIMUM TEMPERATURE:
CHEMICAL COMPOSITION:
SIZE:
SHAPE:
OPERATION TIME:
FINAL PROPERTIES DESIRED:
STATE OUT THE PURPOSE OF THE EXPERIMENT:
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OBSERVATIONS:

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___________________________________________________________________________
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PRECAUTION:
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QUESTION:
1. List out 3 purpose for annealing
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2. List out 2 other process of annealing which is used in the above.
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CONCLUSION:
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Page 37
PROCEDURE FOR NORMALIZING:
(i) Choose the material to be used
(ii) Measure and Cut out the required size to be used
(iii) Measure the initial size and final size of the specimens before and after the
experiment
(iv) Note the shape of the object before and after experiment
(v) Wear your hand gloves pick your specimen and place it in a container
(vi) After placing the specimen in a container, use the tong to place or carry the
container then place in the electric furnace.
(vii) Switch on the furnace and regulate to a required temperature.
(viii) Heat the metal above the transformation temperature e.g. up to 9000C for steel.
(ix) Cool from the above temperature with the adopted rate of cooling e.g:
(a) Heating the metal to around 9000C so that the metal transforms completely into
austenite.
(b) Holding at that temperature for some time (about 3 minutes/mm of thickness).
(c) Cooling at a rate of 800C to 900C per hour up to 7000C.
(d) Then air-cooled from 7000C to room temperature.
EXPERIMENT PROCEDURES:
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___________________________________________________________________________
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PROCESS DATA
SPECIMEN:
MAXIMUM TEMPERATURE (before cooling):
TEMPERATURE AFTER COOLING:
CHEMICAL COMPOSITION:
SIZE:
SHAPE:
OPERATION TIME:
STATE OUT THE PURPOSE OF THE EXPERIMENT:
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OBSERVATIONS:
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PRECAUTION:
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___________________________________________________________________________
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QUESTION:
1. List out three (3) purposes of normalizing.
CONCLUSION:
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___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
EVALUTION SHEET

NAME:
MATRIC NUMBER:
DATE:
TITLE:
AIM
PERFORMANCE OBJECTIVE
PERFORMANCE CRITERIA
MATERIAL/ TOOLS REQUIRED
OBSERVATION
GRAPH
DIAGRAM
TOTAL

Page 40
EXPERIMENT NO.8
TITLE: HEAT TREATMENT (CARBURIZING OF STEEL/MILD
STEELSAMPLES)

OBJECTIVE: To study the effect of carbon on the properties of steel.

RESOURCES USED: Electric furnace, tong, shovel, carburising box.
I. Charcoal, Petroleum Coke (carburizing Medium)
II. Energizer : Barium-tri-Oxo-carbonate (Baco3) 10-15%
PROCEDURE FOR CARBURIZING:
(i) Pack the box with carburizing medium and place sample of steel or mild steel in the
box
(ii) Ensure the steel or mild steel part to be treated is not touching the base of the box and
that the carburizing material is covering the sample.
(iii)Cover the box by lids & lusted (sealed & airtight).
(iv) Place the sample box in the furnace and heat to a desired temperature 900-950oc for
Steel or 700-750oc for Mild Steel
(xiv) Keep or maintained the part at this temperature (holding) till desired degree of
penetration is achieved.
(xv) Cover sample part which need not to be hardened with asbestos & fire plate or copper
plating (0.003 inches).
Possible chemical reaction formula:
C + O2 = CO2 ---------------------- (I)
CO2+C = 2CO -------------------- (II)
Note: At the carburising temperature, reaction always goes to the right. Carbon monoxide is
free to combine with iron,

2CO + 3Fe = Fe3C + CO2 ------ (III)

ENERGIZER
BaCo3 = Ba O + CO2 ------------ (IV)
The decomposition of BaCO3 provides CO2 which react with CO used for carburising.

EXPERIMENT PROCEDURES:
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PROCESS DATA
SPECIMEN:
MAXIMUM TEMPERATURE (before cooling):
CHEMICAL COMPOSITION:
SIZE:
SHAPE:
OPERATION TIME:
STATE OUT THE PURPOSE OF THE EXPERIMENT:
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OBSERVATIONS:
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PRECAUTION:
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___________________________________________________________________________
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QUESTION:
2. List out two advantage and disadvantage of the process
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CONCLUSION:
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___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
EVALUTION SHEET

NAME:
MATRIC NUMBER:
DATE:
TITLE:
AIM
PERFORMANCE OBJECTIVE
PERFORMANCE CRITERIA
MATERIAL/ TOOLS REQUIRED
OBSERVATION
GRAPH
DIAGRAM
TOTAL

Page 43
EXPERIMENT NO. 9

TITLE: HEAT TREATMENT: HARDENING (QUENCHING) AND TEMPERING.

SUB-TITLE: HARDENING
OBJECTIVE:
 To study the effect of quenching on the properties of steel.
 To obtain desired hardness and structure in metal.
EQUIPMENT USED: Electric Arc furnace, tong, bucket, shovel.
Material Used: steel sample, quenching medium (brine solution, water, oil etc.)
PROCEDURE FOR HARDENING:
 Choose the material to be used
 Measure and Cut out the required size to be used
 Measure the initial size and final size of the specimens before and after the
experiment
 Note the shape of the object before and after experiment
 Prepare your quenching media in a suitable container. Note material must be a metal
container, avoid the use of plastic material
 Wear your hand gloves pick your specimen and place it in a container
 Place the specimen in a container and then in the electric furnace.
 Heat the furnace to the required temperature (above Transformation temperature,
around 900oc).
 Keep the specimen at that temperature (holding) for about 15-30minute per 25mm of
the cross section?
 Quench the specimen in a suitable quenching medium (brine solution, Water, Oli etc.)

EXPERIMENT PROCEDURES:
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___________________________________________________________________________
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PROCESS DATA
QUENCHING MEDIUM:
SPECIMEN:
QUEUNCHING TEMPERATURE:
NATURE OF QUENCHING MEDIUM:
COMPOSITION OF SPECIMEN:
SIZE:
SHAPE:
OPERATION TIME:
FINAL PROPERTIES DESIRED:
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SUB-TITLE: TEMPERING
OBJECTIVE:
 To remove brittleness caused by hardening and improve ductility of material.
EQUIPMENT USED: Electric Arc furnace, tong, bucket, shovel.
RECOMMENDED PROCEDURE FOR TEMPERING:
 Choose the material to be used
 Measure and Cut out the required size to be used
 Measure the initial size and final size of the specimens before and after the
experiment
 Note the shape of the object before and after experiment

Page 45
  Prepare your quenching media in a suitable container. Note material must be a metal
container, avoid the use of plastic material
 Wear your hand gloves pick your specimen and place it in a container
 Place the specimen in a container and then in the electric furnace.
 Heat the furnace to the required temperature (above Martensite structure temperature
(50oc).
 Keep the specimen at that temperature (holding) for few minute about 15-35minute
 Cool the specimen either rapidly or slowly
PROCEDURES:
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Page 46
 PROCESS DATA
TEMPERING MEDIUM:
SPECIMEN:
TEMPERING TEMPERATURE:
NATURE OF SPECIMEN BEFORE TEMPERING:
COMPOSITION OF SPECIMEN:
SIZE:
SHAPE:
OPERATION TIME:
FINAL PROPERTIES DESIRED/OBTAINED:
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OBSERVATIONS:
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PRECAUTION:
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CONCLUSION:
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Page 47
 EVALUTION SHEET

NAME:
MATRIC NUMBER:
DATE:
TITLE:
AIM
PERFORMANCE OBJECTIVE
PERFORMANCE CRITERIA
MATERIAL/ TOOLS REQUIRED
OBSERVATION
GRAPH
DIAGRAM
TOTAL

Page 48