Quantum Series- Materials Engineering

254 Pages·3.636 MB·English

by  Hareesh Kumar

1
QUANTUM SERIES
For
B.Tech Students of Second Year
of All Engineering Colleges Affiliated to
Dr. A.P.J. Abdul Kalam Technical University,
Uttar Pradesh, Lucknow
(Formerly Uttar Pradesh Technical University)
Materials Engineering
By
Hareesh Kumar
TM
QUANTUM PAGE PVT. LTD.
Ghaziabad New Delhi
2
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Materials Engineering (ME : Sem-3)
1st Edition : 2009-10 12th Edition : 2020-21
2nd Edition : 2010-11
3rd Edition : 2011-12
4th Edition : 2012-13
5th Edition : 2013-14
6th Edition : 2014-15
7th Edition : 2015-16
8th Edition : 2016-17
9th Edition : 2017-18
10th Edition : 2018-19
11th Edition : 2019-20 (Thoroughly Revised Edition)
Price: Rs. 80/- only
Printed Version : e-Book.
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CONTENTS
KME 303 : Materials Engineering
UNIT-1 : CRYSTAL STRUCTURE (1–1B to 1–35B)
Crystal Structure: Unit cells, Metallic crystal structures, Ceramics.
Imperfection in solids:Point, line, interfacial and volume defects; dislocation
strengthening mechanisms and slipsystems, critically resolved shear stress.
Mechanical Property measurement: Tensile, compression and torsion tests;
Young’smodulus, relations between true and engineering stress-strain
curves, generalized Hooke’slaw, yielding and yield strength, ductility,
resilience, toughness and elastic recovery; Hardness: Rockwell, Brinell
and Vickers and their relation to strength.
UNIT-2 : STATIC FAILURE THEORIES (2–1B to 2–22B)
Static failure theories: Ductile and brittle failure mechanisms, Tresca, Von
mises, Maximum normal stress, Mohr-Coulomb and Modified Mohr-
Coulomb; Fracture mechanics:Introduction to Stress intensity factor approach
and Griffith criterion. Fatigue failure: High cycle fatigue, Stress-life approach,
SN curve, endurance and fatigue limits, effects of meanstress using the
Modified Goodman diagram; Fracture with fatigue, Introduction to non-
destructive testing (NDT).
UNIT-3 : PHASE DIAGRAM (3–1B to 3–26B)
Alloys, substitutional and interstitial solid solutions- Phase diagrams: Interpretation
of binaryphase diagrams and microstructure development; eutectic, peritectic,
peritectoid and monotectic reactions. Iron Iron-carbide phase diagram and
microstructural aspects ofledeburite, austenite, ferrite and cementite, cast iron.
UNIT-4 : HEAT TREATMENT OF STEEL (4–1B to 4–26B)
Heat treatment of Steel: Annealing, tempering, normalising and
spheroidising, isothermal transformation diagrams for Fe-C alloys and
microstructure development. Continuouscooling curves and interpretation
of final microstructures and properties austempering, martempering, case
hardening, carburizing, nitriding, cyaniding, carbo-nitriding, flame and
induction hardening, vacuum and plasma hardening.
UNIT-5 : METALS AND THEIR ALLOYS (5–1B to 5–28B)
Alloying of steel, properties of stainless steel and tool steels, maraging
steels-cast irons; grey, white, malleable and spheroidal cast irons - copper
and copper alloys; brass, bronze andcupro-nickel; Aluminium and Al-Cu
–Mg alloys - Nickel based superalloys and Titanium alloys.
SHORT QUESTIONS (SQ-1B to SQ-21B)
SOLVED PAPERS (2014-15 TO 2019-20) (SP-1B to SP-19B)

MATERIALS ENGINEERING
L-T-P
3-0-0
Objectives:
(cid:120) Understanding of the correlation between the internal structure of materials, theirmechanical
properties and various methods to quantify their mechanical integrity andfailure criteria.
(cid:120) To provide a detailed interpretation of equilibrium phase diagrams.
(cid:120) Learning about different phases and heat treatment methods to tailor the properties of Fe-
Calloys.

UNIT-I
Crystal Structure: Unit cells, Metallic crystal structures, Ceramics. Imperfection in solids:Point, line,
interfacial and volume defects; dislocation strengthening mechanisms and slipsystems, critically
resolved shear stress.
Mechanical Property measurement: Tensile, compression and torsion tests; Young’smodulus, relations
between true and engineering stress-strain curves, generalized Hooke’slaw, yielding and yield strength,
ductility, resilience, toughness and elastic recovery;Hardness: Rockwell, Brinell and Vickers and their
relation to strength.

UNIT-II
Static failure theories: Ductile and brittle failure mechanisms, Tresca, Von-mises, Maximumnormal
stress, Mohr-Coulomb and Modified Mohr-Coulomb; Fracture mechanics:Introduction to Stress-
intensity factor approach and Griffith criterion. Fatigue failure: Highcycle fatigue, Stress-life approach,
SN curve, endurance and fatigue limits, effects of meanstress using the Modified Goodman diagram;
Fracture with fatigue, Introduction to non-destructive testing (NDT).

UNIT-III
Alloys, substitutional and interstitial solid solutions- Phase diagrams: Interpretation of binaryphase
diagrams and microstructure development; eutectic, peritectic, peritectoid and monotectic reactions.
Iron Iron-carbide phase diagram and microstructural aspects ofledeburite, austenite, ferrite and
cementite, cast iron.

UNIT-IV
Heat treatment of Steel: Annealing, tempering, normalising and spheroidising,
isothermaltransformation diagrams for Fe-C alloys and microstructure development.
Continuouscooling curves and interpretation of final microstructures and properties-
austempering,martempering, case hardening, carburizing, nitriding, cyaniding, carbo-nitriding, flame
andinduction hardening, vacuum and plasma hardening.

UNIT-V
Alloying of steel, properties of stainless steel and tool steels, maraging steels- cast irons;grey, white,
malleable and spheroidal cast irons- copper and copper alloys; brass, bronze andcupro-nickel;
Aluminium and Al-Cu – Mg alloys- Nickel based superalloys and Titaniumalloys.

Course Outcomes:
(cid:120) Student will be able to identify crystal structures for various materials and understand
thedefects in such structures.
(cid:120) Understand how to tailor material properties of ferrous and non-ferrous alloys.
(cid:120) How to quantify mechanical integrity and failure in materials.
Books and References:
1. W. D. Callister, 2006, “Materials Science and Engineering-An Introduction”, 6th Edition,
Wiley India.
2. Kenneth G. Budinski and Michael K. Budinski, “Engineering Materials”, Prentice Hall of
India Private Limited, 4th Indian Reprint, 2002.
3. V. Raghavan, “Material Science and Engineering’, Prentice Hall of India Private Limited,
1999.
4. Mechanics of materials by James M.Gere.
5. Introduction to engineering materials by B.K. Agarwal.
6. Physical metallurgy and advanced materials by R.E. Smallman.
7. Engineering mechanics of composite materials by Isaac M. Daniel.
8. U. C. Jindal, “Engineering Materials and Metallurgy”, Pearson, 2011.
Materials Engineering 1–1 B (ME-Sem-3)
1
Crystal Structure and
Mechanical Property
Measurement
CONTENTS
Part-1 : Crystal Structures :................................... 1–2B to 1–8B
Unit Cells, Metallic
Crystal Structures
Part-2 : Ceramics.................................................... 1–8B to 1–13B
Part-3 : Imperfection in Solids :......................... 1–13B to 1–21B
Point, Line, Interfacial
and Volume Defects
Part-4 : Dislocation Strengthening................... 1–21B to 1–23B
Mechanisms and Slip Systems,
Critically Resolved Shear Stress
Part-5 : Mechanical Property ............................. 1–23B to 1–26B
Measurement : Tensile,
Compression and Torsion Tests
Part-6 : Young’s Modulus, Relations................ 1–26B to 1–28B
between True and
Engineering Stress-Strain
Curves, Generalized Hooke’s Law
Part-7 : Yielding and Yield Strength,............... 1–29B to 1–31B
Ductility, Resilience,
Toughness and Elastic Recovery
Part-8 : Hardness : Rockwell,............................. 1–31B to 1–34B
Brinell and Vickers and
their Relation to Strength
1–2 B (ME-Sem-3) Crystal Structure & Mechanical Property Measurement
Crystal Structures : Unit Cells, Metallic Crystal Structures.
CONCEPT OUTLINE
Unit Cell : A small 3D representative structural sub unit of lattice is
called unit cell.
Crystal Structure : The crystal structure is formed by associating
every lattice point with an assembly of atoms or molecules or ions,
which are identical in composition, arrangement and orientation.
Questions-Answers
Long Answer Type and Medium Answer Type Questions
Que 1.1. With the help of neat sketch explain different types of
crystal structure. AKTU 2016-17, Marks 10
Answer
Following are the different types of crystal structures :
a. Body Centred Cubic Structure (BCC) :
1. BCC structure has atoms at its each corner and one atom in its centre.
Fig. 1.1.1. BCC.
1
 Total atoms in BCC = × 8 + 1 = 2 atoms
8
2. The coordination number of BCC arrangement is 8 and packing factor
is0.68.
Materials Engineering 1–3 B (ME-Sem-3)
3. The BCC structure can be generally seen in Lithium, Potassium, Sodium
etc.
b. Face Centred Cubic Structure (FCC) :
1. It consists of atoms at its each corner and one atom at centre of each
face.
1 1
 Total atoms in FCC unit cell = × 8 + × 6 = 1 + 3 = 4 atoms
8 2
2. The coordination number is 12 and packing factor is 0.74 for FCC
arrangement.
3. The FCC structure can be generally seen in Copper, Gold, Silver and
Lead etc.
Fig. 1.1.2. FCC.
c. Hexagonal Close-Packed Structure (HCP) :
1. The unit cell is like a hexagonal prism in HCP.
2. There are twelve corners and each corner have an atom and one atom
at the centre of each of the two hexagonal faces and three atoms in the
body of the cell. In total, seventeen atoms take part in formation of a
HCP unit cell.
1 1
 Total atoms in HCP = 12 × + 3 + 2 × = 6 atoms
6 2
3. This is identical to FCC, having coordination number 12 and packing
factor 0.74.
4. This HCP structure is generally seen in Zinc, Magnesium and Beryllium
etc.
Fig. 1.1.3. HCP.