ME3392 -ENGINEERING

MATERIALS AND
METALLURGY
REGULATION : 2021
YEAR / SEM : II / III

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 COURSE OBJECTIVES

1. To learn the constructing the phase diagram and using of

iron-iron carbide phase diagram for microstructure formation.

2. To learn selecting and applying various heat treatment

processes and its microstructure formation.

3. To illustrate the different types of ferrous and non-ferrous

alloys and their uses in engineering field.

4. To illustrate the different polymer, ceramics and composites

and their uses in engineering field.

5. To learn the various testing procedures and failure

mechanism in engineering field.

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 OUTCOMES

At the end of the course the students would be able to

1. Explain alloys and phase diagram, Iron-Iron carbon diagram
and steel classification.
2. Explain isothermal transformation, continuous cooling
diagrams and different heat treatment processes.
3. Clarify the effect of alloying elements on ferrous and non-
ferrous metals.
4. Summarize the properties and applications of non-metallic
materials.
5. Explain the testing of mechanical properties.
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TEXT BOOKS:
1.Kenneth G.Budinski and Michael K. Budinski, “Engineering Materials”, Prentice Hall of
India Private Limited, 9th edition ,2018.

2. Sydney H.Avner, “Introduction to Physical Metallurgy”, McGraw Hill Book Company,

1994
 
REFERENCES:
2.A. Alavudeen, N. Venkateshwaran, and J. T.WinowlinJappes, A Textbook of Engineering
Materials and Metallurgy, Laxmi Publications, 2006.

2. Amandeep Singh Wadhwa, and Harvinder Singh Dhaliwal, A Textbook of Engineering

Material and Metallurgy, University Sciences Press, 2008.

3. G.S. Upadhyay and Anish Upadhyay, “Materials Science and Engineering”, Viva Books
Pvt.Ltd, New Delhi, 2020.

4. Raghavan.V, “Materials Science and Engineering”, Prentice Hall of India Pvt.Ltd. 6th
edition, 2019.

5. Williams D Callister, “Material Science and Engineering” Wiley India Pvt Ltd, 2nd
edition Re print 2019
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 UNITS TO BE COVERED

UNIT I CONSTITUTION OF ALLOYS AND

PHASE DIAGRAMS

UNIT II HEAT TREATMENT

UNIT III FERROUS AND NON-FERROUS

METALS

UNIT IV NON-METALLIC MATERIALS

UNIT V MECHANICAL PROPERTIES AND

DEFORMATION MECHANISMS
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 INTRODUCTION
MATERIAL:
The elements, substance, or parts of which something is made or
can be made .

In Physics, Materials are classified into Solids, liquids and gases.

In Chemistry, Materials are classified into organic and inorganic.

In Engineering, Material means structural material that is used to

produce various engineering products.
Engineering Materials are classified into Metals and Non-metallic.

METALLURGY:
The technique or science of working or heating metals so as to
give them certain desired shapes or properties. the technique or
science of making and compounding alloys. the technique or science of
separating metals from their ores.
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Metallic Materials or Metals:
– Materials composed of one or more elements such as
a) iron,
b) copper,
c) aluminium,
d) nickel,
e) titanium,
f) lead,
g) tin and
h) zinc
are known as metallic.
Characteristics:
 High Thermal conductivity,
 High Electrical conductivity,
 Deformable,
 Opaque,
 Polished etc.
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Metals are defined as minerals or substances that are found naturally below the surface of the earth.
Classification of Metals
–A) Classification by Iron Content
–B) Classification by Atomic Structure
–C) Classification by Magnetic and Non-Magnetic Metals
Types of Metals:
A) Ferrous Metals - Metals with considerably scarce amounts of iron in their composition aren’t classed as ferrous metal.
1. Steel:
A) Stainless Steel
B) Tool Steel
2. Carbon Steel:
A) Low Carbon Steel
B) Medium Carbon Steel
C) High Carbon Steel
3. Alloy Steel
4. Cast Iron
5. Wrought Iron
B) Non-Ferrous Metals - Non-ferrous metals don’t contain a major quantity of iron 
1. Aluminium
2. Copper
3. Lead
4. Zinc
5. Tin
6. Brass
7. Bronze
8. Titanium
9. Cobalt
10. Nickel
11. Tungsten

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Non Metallic materials:
Non-metallic materials are any materials, both synthetic and natural,
which do not contain metal. These materials are able to retain their unique
chemical properties during the machining process.
Types:
i. Polymers:
Polymers are commonly called plastics consists of long molecular chains
containing many repeated units of “monomers”.
Ex: Polyethylene, Nylon, PVC etc.
Characteristics:
 Poor conductors of heat and electricity,
 Poor reflectors of light,
 Low density, strength and stiffness.

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ii. Ceramics:
A ceramic is an inorganic non-metallic solid made up of either metal or non-
metal compounds that have been shaped and then hardened by heating to
high temperatures. 
Ex: Alumina, Silicon carbide, Silicon nitride.
Characteristics:
 High temperature strength,
 Low thermal conductivity,
 Corrosion resistance etc.

iii. Composites:
Composite materials are formed by combining two or more materials with
different properties, without dissolving or blending them into each other.
Ex: Fibre glass, Window frames etc.
Characteristics:
 High strength,
 High stiffness,
 High temperature performance,
 Corrosion resistance,
 Hardness etc.
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MATERIAL PROPERTIES

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Chemical property:
A chemical property is a characteristic of a particular substance
that can be observed in a chemical reaction. 

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Physical Property:
• Physical properties are things that are measurable. Those are things
like density, melting point, conductivity, coefficient of expansion,
etc.

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Mechanical property:
It is a property that involves a relationship between stress and
strain or a reaction to an applied force.

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Strength:
When an external load is applied on a material, then the capacity of
the material to withstand that load without destruction is called
strength of a material.
Elasticity:
The ability of a material to return to its original position after
deformation when the external load acting on it is removed is called
elasticity.
Stiffness:
The resistance of a material to elastic deformation or deflection is
called stiffness or rigidity.
Flexibility:
It is defined as the ability of the material to bend easily. This
mechanical properties of materials allow it to form in any shape.
Plasticity:
Plasticity is defined as the ability of a material to undergo some
degree of permanent deformation without rupture or failure.

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Ductility:
It is the property of a material by which it can be drawn into thin
wires.
Malleability:
Malleability is the ability of a material to be hammered into thin
sheets. Aluminium, copper, silver, tin, steel etc are malleable metals.
Toughness:
Toughness is defined as the ability of a material to withstand both
the plastic and elastic deformation. In other word, it is the measure of
the amount of energy a material can absorb before actual fracture or
failure takes place.
Resilience:
It is the capacity or ability of a material to absorb energy elastically.
And on the removal of the load this absorbed energy is given off same
as spring does.
Hardness:
The ability of a material by which it is able to resist scratching,
cutting, abrasion, indentation or penetration. It is closely related to
strength.
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Brittleness:
It is defined as the property of breaking of materials without much
permanent distortion.
Machinability:
It is the ability of the material to be cut easily by a sharp tool.
Creep:
The creep is defined as the slow and progressive deformation of a
material with the passage of time when it is subjected to constant
stress. 
Fatigue:
The phenomena of weakening of material when it is subjected to
repeated or fluctuating stress is called fatigue.

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 Mechanical
S.no Definition of the Mechanical Property
Property

1. Strength The capacity of a material to withstand load without destruction.

The ability of the material to return to its original condition after deformation on the
2. Elasticity
removal of external load.

3. Stiffness Resistance to elastic deformation or deflection

4. Flexibility The ability of the material to be bend.

The ability of a material to undergo some degree of permanent

5. Plasticity
deformation without rupture or failure.

6. Ductility The ability of the material to be drawn into thin wires.

7. Malleability The ability of the material to be hammered into thin sheets.

8. Toughness The ability of a material to withstand both the elastic and plastic deformation.

9. Resilience The capacity or ability of a material to absorb energy elastically.

The ability of a material to resist scratching, cutting, abrasion, indentation or

10. Hardness
penetration.
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S.no Mechanical Property Definition of the Mechanical Property

11. Brittleness The property of breaking of materials without much permanent distortion.

12. Machinability It is the ability of the material to be cut easily

The slow and progressive deformation of a material with the passage of time when
13. Creep
it is subjected to constant stress.

The phenomena of weakening of material when it is subjected to repeated or

14. Fatigue
fluctuating stress.

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Dimensional property:
The available size, shape and tolerances on materials are important in
selecting a material. Other dimensional properties include surface roughness,
waviness and micro topography.
Other Properties:
Electrical property:
Electrical properties are their ability to conduct electrical current. Various
electrical properties are resistivity, Electrical conductivity, temperature
coefficient of resistance, dielectric strength and thermoelectricity.

Magnetic property:
The property of a material which under the influence of its magnetic field
can attract or repel other substances.

Thermal property:
Thermal properties are associated with a material-dependent response
when heat is supplied to a solid body, a liquid, or a gas. 

Optical property:
The optical properties of a material define how it interacts with light. The
optical properties of matter are studied in optical physics, a subfield of optics. 
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HISTORICAL DEVELOPMENT OF MATERIALS

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 CRYSTAL STRUCTURES

1. Simple Cubic (SC) structure

2. Body Centred Cubic (BCC) structure
3. Face Centred Cubic (FCC) structure
4. Hexagonal Close Packed (HCP) structure

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Crystal Position of Atoms in a Unit cell Diagram
structure
SC One atom at each corner.

Total 8 corner atoms

BCC One atom at each corner and one atom at the

centre of the body.

Total 8 corner atoms + one centre atom

FCC One atom at each corner and one atom at the

centre of the each face

Total 8 corner atoms + 6 face centred atoms

HCP One atom at each corner of the hexagonal prism

and one atom each at the centre of the
hexagonal faces and 3 more atoms within the
body

Total 12 + 2 + 2 = 16 atoms 25
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 Examples of Various Crystal structures

Sl.No Crystal structure Examples of metals

.
I SC Polonium

II BCC Tungsten,
Vanadium,
Molybdenum,
Chromium,
Barium
Alkali metals and α-Iron, δ-iron
III FCC Copper,
Silver,
Gold,
Aluminium,
Nickel,
Lead, Platinum, γ-iron
IV HCP Magnesium,
Zinc,
Titanium,
Zirconium,
Beryllium,
Cadmium
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 Basic Terms:
Coordination number:
The number of nearest atoms which are directly surrounding a given atom.

Atomic radius:
It is the half the distance between the nearest neighbours in a crystal of a
pure element.

Atomic Packing Factor (Relative density of packing or atomic packing

density)
It is the ratio of the volume of the atoms per unit cell to the total volume
occupied by the unit cell.

Lattice planes:
A crystal lattice may be considered as an aggregate of a set of parallel equi-
distant planes of high density of lattices points.

Miller Indices:
Miller Indices are a method of describing the orientation of a plane or set
of planes within a lattice in relation to the unit cell.
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Classification of Crystal imperfections or defects:

Crystal Defects

Surface or Volume or
Point Defects Line Defects
Planar Defects bulk Defects

Point Defects or zero Line Defects or Surface or Planar Volume or bulk

dimensional defects Dislocations or one Defects or two Defects or three
dimensional dimensional defects dimensional
defects defects
a.Vacancies : a.Edge dislocation a.Grain boundaries a.Cracks
i.Schottky defect
b.Interstitials : b.Screw dislocation b.Tilt or twist b.Void
i.Frenkel defect boundaries
c.Impurities or - c.Twin boundaries c.Inclusion
Compositional:
i.Substititutional
impurity
ii.Interstitial impurity
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d.Electronic defects - d.Stacking faults d.Precipitate
Point Defects or zero dimensional defects:
The defects which take place due to imperfect packing of atoms during
crystallization are known as point defects.

Line Defects or Dislocations:

The defects which takes place due to dislocation or distortion of atoms
along a line in some direction are called as line defects.

Surface or Planar Defects:

The defects which takes place on the surface of a material are known as
surface defects.

Volume or bulk Defects:

These defects may arise when there is only small electrostatic dissimilarity
between the stacking sequences of closed packed planes in metals.

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