IME MODULE 4 NOTES

1.Enumerate the differences between ferrous and non-ferrous materials

Ans; Ferrous metals Ferrous metals contain iron. Examples are cast iron, mild steel, medium
carbon steel, high carbon steel, stainless steel, and high speed steel.
Composition, properties and uses of some common ferrous metals

Sl. Name of
No Composition Properties Application
Material
s
Very Strong and Brittle, Low Manufacture
Iron > 90%, Carbon 2-4.5%, of
melting
Silicon 1-3%, Small
amount of Sulphur, point, Wear resistant, Resistant machine
1. Cast Iron
Phosphorus, Manganese to deformation, Good fluidity frames,
Flywheels,
Soft and Ductile, Good weldability, Engine
Chains, block,
Low Carbon Bolts, Keys,
Good machinability, Good
2. Steel (Mild formability, Good toughness Washers,
Steel) Channels and
Carbon 0.05-0.3%
Beams, Shafts,
Gears
Kitchen
3. Stainless Steel Equipment,
Stainless, Resistant to rusting, Surgical
Chromium 18%, Nickel Resistant to corrosion Equipment,
8%, Carbon 0.03% Shaving blades
Tool Steel Ex: Higher Hardness, Wear Drill bits,
High speed steel Carbon 0.7-0.8%, Vanadium Lathe tools,
(HSS) resistance, Abrasion resistance
4. 1-2%, Chromium 3-5%, Milling cutters,
Cobalt Reamers

Non-Ferrous Metals
Non-ferrous metals do not contain iron. Some common non-ferrous
metals are aluminum, copper, zinc, tin, brass (copper + zinc), and bronze
(copper + tin).
Composition, properties and uses of some common non-ferrous metals
Sl. No Non-ferrous metal Propertie Application
Light Weight,s Resistance s Conductors,
Induction motors,
to Windings and cables, Aircraft
1. Aluminium corrosion, High ductile, parts, Engine
High electrical conductor
Good electrical Refrigerator and Air conditioner
conductivity, tubes,
2. Copper
Good corrosion Electrical wires, Alloying of
Brass (Alloy of Copper) Good machinability,
resistance, brass parts,
Light weight,High Pump and bronze, Statues,
Cartridge cases, Fuses,
As
3. Copper+Zinc, Copper 51- resistance to corrosion, Good
castability brazing solder, clock parts
81%, Zinc 19-49%
 Bronze(Alloy of Copper), Very good strength, Good Bells, Kitchen utensils,
corrosion resistance, Gears, Saxophone
Copper+Tin, Copper 90%, Tin
4. Improved hardness, Easy
5-10%
machinability
2. Write short notes on following materials a) ceramicsb) glass c) Shape memory alloys.
(a)ceramics; Ceramics is an Inorganic non-metalic solid manufactured by baking naturally
occurring clays at high temperatures. Properties are Brittle, hard, wear resistant,chemically
stable, electrically and thermally insulator and high melting point. Examples: Glass, Optical
fiber glass, cermets Applications: Knives, high voltage
insulators, cutting tool tips, dies, engine parts, pottery,tiles etc.
(b)glass; A type of ceramic, glass is an inorganic, non- metallic compound that cools to a rigid
condition without crystalizing. Glass is a ceramic material produced by conversion of glass into
polycrystalline structure through heat treatment. Window glass,cookware, fibre optic cable,
fibre glass insulation
(C)shape Memory Alloys
A shape memory alloy (SMA, smart metal, memory metal, memory alloy, muscle wire, smart
alloy) is an alloy that "remembers" its original, cold forged shape: returning the pre deformed
shape by heating. This material is a lightweight, solid state alternative to conventional
actuators such as hydraulic, pneumatic, and motor based systems. Shape memory alloys have
applications in industries including medical and aerospace
Example: The three main types of shape memory alloys are the copper-zinc aluminium-
nickel, copper-aluminium-nickel, and nickel-titanium (NiTi) alloys but SMA's can also be
created by alloying zinc, copper, gold, and iron. Some of the application includes Aircraft,
Robotics and Medicine related industries

3. Define and explain, with neat sketches, the soldering process

Ans; Soldering is a method of joining similar or dissimilar metals by the application of heat
and using a filler metal or alloy called solder, whose liquidus temperature is below 4500 C.
Soldering is used for obtaining a leak proof joint or a low resistance electrical joint. The
soldered joints are not suitable for high temperature applications because of the low melting
temperatures of the filler metals used.

Soft soldering is used extensively in sheet metal work, plumbing work and electrical junctions
for joining parts that are not exposed to the action of high temperatures and are not
subjected to excessive loads and forces or vibrations.

 Soft solder is an alloy of lead and tin.

 The melting temperature of soft solder will be 150 to 3500C.

 In soft soldering, Zinc chloride and ammonium chloride are the most common soldering
fluxes used which are quick acting and produce efficient joints.

Hard soldering is used to produce a joint which can withstand higher load and temperature
also. 1. Hard solder is an alloy of copper tin and silver.

2. Hard solder employs solder which melts at higher temperatures 600 to 9000 C is stronger
than used in soft soldering.
3. In Hard soldering, Zinc chloride and ammonium chloride are the most common soldering
fluxes.

4. Define brazing. With neat sketch, explain the brazing process.

Ans; Brazing is the method of joining two similar or dissimilar metals using a special
fusible alloy.Joints formed by brazing are stronger than that of soldering. During the
brazing, the base metal of the two pieces to be joined is not melted. The filler metal
must have ability to wet the surfaces of the base metal to which it is applied. Some
diffusion or alloying of the filler metal with base metal takes place even though the base
metal does not reach its melting temp. The materials used in brazing are copper base and
silver base alloy. These two can be classified under the name spelters.
Advantages of Brazing
1. It is easy to learn.
2. It is possible to join virtually any dissimilar metals.
3. The bond line is very neat aesthetically.
4. Joint strength is strong enough for most non-heavy-duty type of application.
Disadvantages of Brazing
1. Brazed joints can be damaged under high temp.
2. Brazed joint require a high degree of cleanliness.
3. The joint color is often different from that of the base metal.

5. Define welding. With a neat sketch, explain arc welding.

Ans; It is a metallurgical joining of two metal pieces together to produce a single piece of
metal with or without filler material using (i) only heat, or (ii) heat and pressure at plastic
state.
 The principle of electric arc welding is as follows, Here the source of heat is electric arc,
when two conductors are touched together momentarily an electric arc is formed. The
heat produced by the arc will be at a temperature
of about 5000 to 60000C.In arc welding, usually the parts to be joined are wired as one
pole of circuit and electrode held by the operator forms the other pole. When electrode
strikes the junction of the parts to be joined an electric arc is produced, the intense heat
of arc quickly melts the part thereby forming a small molten pool. At the same time the
tip of electrode at the arc also melts, and this molten metal of the electrode is carried
over by the arc to the molten metal pool of the workpiece(parts). A solid joint will be
formed when the molten metal cools and solidifies. The flux coating over the electrode
produces an inert gas shield surrounding the arc and protects the molten metal from
oxidizing by coming in contact with the atmosphere.

6.With a neat Sketch & labeled parts of the Gas welding system, explain its working
principle

Ans; Gas welding is a fusion type of welding in which a strong gas flame is used to raise
the temperature of the workpieces so as to melt them. The gasses that can be used for
heating are
(i) Oxygen and acetylene mixture
(ii) Oxygen and hydrogen mixture
Oxygen and acetylene gas mixture is most commonly used in gas welding.

A neutral flame shown in Fig A is obtained by supplying equal volumes of oxygen and

acetylene in the gas ratio 1:1.The neutral flame consists of an inner white cone surrounded by
a blue flame. Most of the oxy-acetylene welding is done with the use of the neutral flame.

A carburising flame shown in Fig B is obtained by supplying excess acetylene in the gas

ratio 0.95 to 1.It has three cones: an inner white cone, surrounded by an intermediate whitish
cone and a bluish envelope flame. This flame is used in welding alloy steels, cast iron and
aluminium to protect from the oxidizable elements.
The oxidizing flame shown in Fig C is obtained by supplying excess oxygen in the gas ratio

1.15 to 1.5.In appearance it resembles a neutral flame with the exception that the inner white
cone is somewhat shorter.This flame is used in oxy-acetylene cutting and is not suitable for
welding, since weld metal will be oxidized.

7. With neat sketches, explain different types of oxy-acetylene gas flames

Ans; Oxy-Acetylene gas welding is a fusion type of welding in which an Oxy-Acetylene gas
flame is used to raise the temperature of the workpieces so as to melt them to produce a strong
joint.
Construction: 1. Two large cylinders: one containing oxygen at high pressure, and the other
dissolved acetylene also at high pressure.
2. Pressure regulators: One for each cylinder. It regulates pressure of gas as per the
requirement.
3. Blow torch: used to mix both gasses and to burn the gas mixture at its tip.
4. Pressure gauges: Used to measure cylinder and delivery pressure separately.
Process: After the initial equipment preparation and set up, the respective gases from cylinders
are carried from the pressure regulator to the welding torch using rubber hose pipes. Upon
reaching the welding torch, these gases are allowed to mix and then are led out of the torch
through the orifice of the blow pipe. Then it is lighted up using a spark lighter, thereby start
burning at the tip of nozzle and resultant flame will be at 32000C is used to melt the work
pieces. To fill up the gaps between the work pieces and to add strength to the joint, filler rod
are added to the molten metal pool. The molten metal pool that contains molten metal of the
filler rod and the work piece solidifies to form a strong weld joint.

8. Differentiate between the following Soft Soldering & Hard Soldering; Soldering &
Brazing ;Brazing & Welding