Basics of

Basics of
Metallurgy
Metallurgy

Presented by
Touhidul Islam (17532)
Metallurgist, Refrigerator R&I
Metallurgy 1
Content
Topics Number of Slide
Metal Structure 10
Metal properties 15
Alloy 3
Steel & Cast iron 3
Aluminum alloys 4
Zinc base alloys 1
Heat treatment 5
Corrosion 9
Metal characterization 1
RoHS 1
Galvanizing 2
Q&A Session

Metallurgy 2
Metal parts Refrigerator
• MS tube • PPGI
• Aluminum tube • GI
• Copper tube • EGI
• MS sheet • PCM
• Aluminum Sheet • VCM
• SS sheet • Aluzinc/galvalume
• SS screw • Anodized aluminum
• MS screw • Tool steel (D2, DC53, M2)
• SS wire • Wrought alloy
• MS wire • Cast alloy
• Copper wire • aluminum foil
• SS spring • Copper capillary tube
• ZAM coating • Aluminum rod
• Zamac lock and hinge

Metallurgy 3
Engineering Materials

Major engineering purposes served by – Mg, Ti, Fe, Ni, Cu, Zn, Al, Pb

Metallurgy 4
Metal Structure
• Atomic structure- crystalline, amorphous, BCC, FCC
• Microstructure- Grain , Grain boundary

Metallurgy 5
Crystal structure

Metal Glass

Metallurgy 6
Crystal structure (SCC)

First layer Second layer directly over the 1st layer

Inefficient use of space.

Only 52% space is occupied by the atoms.
Rarely found in earth. Polonium.

Metallurgy 7
Crystal structure (BCC)

Second layer over the holes of 1st layer Third layer over the holes of 2nd layer

More efficient stacking.

Gives 68% space occupied by the atoms.
Ex- Many metals. Fe, Cr

Metallurgy 8
 Crystal structure (FCC)

First layer Second layer over the triangular space of 1st layer Third layer over the triangular space of 2nd layer

The most efficient stacking.

Gives 74% space occupied by the atoms.
Ex- Many metals. Cu, Al, Ag, Au
Diamond shaped space Triangular shaped space
Metallurgy 9
Crystal structure

Metals Crystal Packing Atomic Density Thermal

structure factor weight g/cc conductivity,
W/m.K
Fe BCC 0.68 56 7.87 80
Cr BCC 0.68 52 7.19 94
Ag FCC 0.74 108 10.5 420
Cu FCC 0.74 63 8.9 386
Au FCC 0.74 197 19.4 317
Al FCC 0.74 27 2.7 237

Metallurgy 10
Crystal defects

Vacancy defect Self interstitial defect

Interstitial defect Metallurgy Substitutional defect 11

Crystal defects (dislocation motion)

Line defect (edge dislocation) Atomic bonds Applying stress

Bond reform Bond break

When stress is applied the atomic bond break

and reform allowing the dislocation to glide
through the crystal lattice
Metallurgy 12
Microstructure
Liquid metal cooling down

Solid crystal forming Solid crystal growing Crystal meeting one another

solidification complete

Metallurgy 13
Microstructure

➢ Polycrystalline metal.
➢ The grains are separated by grain boundaries.
➢ The grain boundary impedes the dislocation motion.
➢ Polycrystalline metal is stronger than single crystal metal.
➢ The smaller the grain size the stronger the material will be.
Metallurgy 14
Metal properties
• Strength (YS, TS)
• Ductility (elongation)
• malleability
• Hardness
• Brittleness
• Toughness
• Fatigue
• Creep
• Elasticity
• Machinability
• Weldability
• Hardenability
• Castability
• Conductivity (electrical and thermal)

Metallurgy 15
Strength

ability to withstand an applied load without failure or plastic

deformation

Metallurgy 16
Strength

Metallurgy 17
 Strength

Normal condition Tensile loaded Load removed

For details you

can contact with
me personally
Metallurgy 18
Ductility and Brittleness
Ductility Brittleness

Degree to which a material can Breaks with little or no deformation

sustain plastic deformation under
tensile stress before failure

NOTE: Ductility can be measured by %elongation

Metallurgy 19
Ductility and Brittleness

(a) Brittle (b) moderate ductile (c) extreme ductile

Metallurgy 20
Ductility and Brittleness

Titanic disaster: 1912, in the North Atlantic Ocean, 1500 dead

Metallurgy 21
Hardness

Ability to resist permanent deformation,

either by scratching or indentation

Metallurgy 22
Hardness

Metallurgy 23
Hardness Test
Indenter

Hardness scale Unit Indenter Application

Brinell HB 10mm Hardened steel or tungsten carbide ball Al, Cu, MS, low carbon steel
Rockwell B HRB 1/16 inch steel ball Al, brass, soft steel
Rockwell C HRC Dimond cone H ≥HRB100,
steel
Vickers HV Diamond pyramid Thin sheet metal, small
specimen
Metallurgy 24
Toughness

The ability of a material to absorb energy

up to fracture

NOTE: Toughness can be measured by impact test

Metallurgy 25
 Fatigue

Repeating these actions result

Metallurgy 26
Fatigue
Spring
Exercise instrument
Fan blade
Bandsaw blade
Bicycle peddle
Bicycle crank arm
Screw
Compressor Connecting rod
Railway Bridge
Aircraft

Cracking of materials and structural components due to cyclic (or fluctuating) stress.
Fatigue cracks can be initiated and propagated at stresses well below the yield strength of the material
Fatigue stages: Crack initiation, Crack propagation, Failure
Metallurgy 27
Fatigue
Ferrous (steel)

Non-ferrous (Cu, Al)

Figure 3. Typical fatigue stress cycles

Metallurgy 28
Fatigue simulation

Metallurgy 29
Creep

❑ The tendency of a solid material to

deform permanently under the
influence of constant static load at
elevated temperature .
❑ The load can below the yield strength.
❑ The material can creep when the
≥ 0.5 ( A
melting temperature)

Metallurgy 30
Alloy
• Mild Steel (MS)- Fe, C
• Cast iron- Fe, C
• Brass – Cu, Zn
• Bronze- Cu, Sn
• Stainless steel- Fe, C, Cr, Ni, Mn
• Tool steel- Fe, C, Cr, V, Mo

Metallurgy 31
Alloy

Strength Ductility Hardness

Metallurgy 32
Effect of alloying element
Element Positive Attributes Negative Attributes
Carbon Hardness, strength, hardenability Ductility, Weldability
Manganese Strength, hardenability Weldability, Machinability
Phosphorus Machinability Ductility, Toughness
Sulfur Machinability Impact Resistance
Chromium Corrosion and abrasion resistance Machinability
Molybdenum High Temperature Strength, pitting Machinability, Weldability
Copper Strength Forgeability
Vanadium Wear Resistance Ductility
Silicon Fluidity, elasticity, strength Decarburization, Machinability

Metallurgy 33
Steel and Cast iron
1400 C to 1538 C

912 to 1400 C

Below 912 C

Metallurgy Fig: Iron – Carbon phase Diagram 34

Steel Common Class

Metallurgy 35
Steel Designation System
Table-1: Alloy steel Table-2: stainless steel

SAE Type Example

designation

3XX Austenitic SS SS 304, SS 316

4XX Ferritic and martensitic SS SS 430

Table-3: Tool steel

Example:
Grade: SAE 1018 SAE Type Example
designation
A plain carbon steel contains
0.18% carbon. W Water Hardening

O Oil Hardening
Suffixes Process A Air Hardening
HR Hot rolled
D High carbon; high chromium D2
CR Cold rolled
S Shock resisting
CDS Cold drawn seamless
P Plastic mold P20
Q&T Quenched and tempered
H Hot working H13
TMT Thermo Mechanical Treatment

Metallurgy 36
Aluminum alloys

Metallurgy 37
Cast Aluminum Designation System
X XX .X
0 for castings (products)
1 for Ingots

Identity of the
specific alloy

Example:
Aluminum grade: 295.0

A Copper base aluminum

casting
Metallurgy 38
Wrought Aluminum Designation System
Designation
1XXX A
Major element
≥ 99.00%
X X XX Al percentage after decimal.
(Applicable only for 1XXX series)
2XXX Cu
3XXX Mn
4XXX Si
Impurity level/modification
5XXX Mg
6XXX Mg and Si
7XXX Zn
8XXX Other Example:
Aluminum grade: 1060
A wrought aluminum alloys
having 99.60% aluminum.
Metallurgy 39
Aluminum Temper Designation

Temper Description
Designation
F As fabricated
O Annealed
H Stain hardened ( hardened by cold work)
W Solution heat treated (unstable)
T Thermally treated (stable)

Metallurgy 40
Zinc base alloy
Two important alloy

ZAM- Zinc, Aluminum, Magnesium alloy. Galvanizing alloy.

ZAMAC- Zinc, Aluminum Magnesium and Copper alloy. Die casting alloy.

Role of alloying element in zinc

Cu- enhanced strength, hardness, wear resistance.

Mg- improves grain structure, prevents inter-granular corrosion.

Metallurgy 41
Metal process
• Heat treatment • Welding
• Anodizing • Soldering
• Brazing
• Galvanizing
• Forming
• Casting • Forging
• Pickling • Rolling
• Sintering • Extrusion
• Drawing
• Etching
• Machining
• Hard chrome • Electroplating
plating

Metallurgy 42
Heat treatment

• Heating to a certain temp below melting point

• Holding for a certain period
• Cooling down at a certain rate

Purpose: To give desired mechanical properties

Metallurgy 43
Heat treatment
Purpose Treatment
To soften Annealing
To strengthen Normalizing
To harden Hardening
To relief stress Stress relief annealing

Metallurgy 44
Annealing and Normalizing

As the grain size decreases the

yield strength increases

Metallurgy 45
Hardening Fe structure- BCC (at room temp)
FCC ( above 912 C)
BCC (above 1400 C)

Hardening transformation:

BCC FCC BCT

Metallurgy 46
Case hardening
Case hardening
methods:
1. Carburizing
2. Nitriding
3. Carbo-nitriding
4. Cyaniding
5. Induction
hardening
6. Flame
Gear
hardening
➢ Used to increase the hardness of
the outer surface of a metal.
➢ Wear resistant hard surfaces +
high core toughness

Metallurgy Crankshaft Fasteners 47

Corrosion

Degradation of metal, that

results from a chemical or
electrochemical reaction with
its environment

Metallurgy 48
Corrosion
Thermodynamically
unstable
Why do metals corrode??

Metastable
Metal extraction:
Corrosion: Metal
Reduction in
oxidation.
melting furnace.
Bond formation
Bond breaking
releases energy,
needs energy,
exothermic
endothermic
Energy level

process
process.

Stable
Corrosion products: Metal Every material tends to
Ore: Metal oxides,
oxides, sulfides etc. release energy to be stable
sulfides etc.

Metallurgy 49
Corrosion
Four essential Conditions
i. Anode
ii. Cathode
iii. Anode cathode contact
iv. electrolyte

Anode reaction:
M(s) = M+n (aq) + ne- (metal oxidation)

Cathode reaction:
• Hydrogen evolution, 2H+ (aq) + 2e-→ H2( )
• Oxygen reduction (acidic media), O2(g) + 4H+(aq) + 4 - → H2O
• Oxygen reduction (neutral/basic media), O2(g) + 4e- + 2 H2O→ 4OH- ( q)
• Metal ion reduction, M+3(aq) + - → +2 (aq)
• Metal deposition, M+ (aq) + - → ( )

Metallurgy 50
Forms of corrosion

➢ Uniform Attack
➢ Galvanic or Bimetallic Corrosion
➢ Crevice Corrosion
➢ Pitting
➢ Intergranular Corrosion
➢ Selective leaching
➢ Erosion Corrosion
➢ Stress-corrosion cracking

Metallurgy 51
Galvanic corrosion

➢ Occurs when two different metals

are in electrical contact in an
electrolyte.
➢ More noble metal is protected and
the more active metal tends to
corrode.
➢ The driving force for corrosion is a
potential difference between the
different materials.

Metallurgy 52
Galvanic corrosion

More active or
anodic

Example:
Bimetallic System Anode (corrodes) Cathode

Zinc and MS Zinc MS

Copper and MS MS Copper

Monel and Cast Which one will corrode?
iron

Metallurgy 53
Uniform attack

➢ Occurs uniformly over the

entire surface of the metal
component.
➢ General thinning takes place
until failure.
➢ Oxygen and moisture are the
main culprits for this
corrosion.

Metallurgy 54
Pitting

➢ Localized corrosion of a metal surface confined to a point or small

area, that takes the form of cavities.
➢ Most dangerous form of corrosion.
➢ Chloride, sulphate or bromide ions accelerate the reaction rate.

Metallurgy 55
Corrosion test (SST, SWAAT)

➢ Salt Spray Test (SST)

➢ To check the corrosion resistance
of coatings and materials.
➢ Measurement unit SST hours
➢ Sodium chloride salt solution

➢ Acidified Synthetic Sea Water

Testing (SWAAT).
➢ Synthetic sea salt solution
➢ Acetic acid

Metallurgy 56
Metal characterization

Method Properties
Optical emission spectroscopy (OES) Composition

Hardness tester Hardness

Universal Testing Machine (UTM) YS,TS, %E

Impact tester Toughness

Optical microscope Microstructure

Scanning Electron Microscopy (SEM) Topography of materials (resolution of ∼2 nm)

Energy dispersive Spectroscopy (EDS) Elemental identification and composition

X-ray Diffraction (XRD) Crystal structure, size

Metallurgy 57
RoHS
➢ RoHS- Restriction of Hazardous Substances
➢ European Union (EU) restricts the use of ten
hazardous materials.
➢ All applicable products in the EU market must pass
RoHS compliance.

•Cadmium (Cd): < 100 ppm

•Lead (Pb): < 1000 ppm
•Mercury (Hg): < 1000 ppm
•Hexavalent Chromium: (Cr VI) < 1000 ppm

Metallurgy 58
Galvanizing
Which one will corrode last?

Coating gap Coating gap

Copper coated MS tube

Zinc coated MS tube ED coated MS tube

Metallurgy 59
Galvanizing
Hot-dip Galvanizing Electrolytic Galvanizing

Product:
Product:
1. Screws
1. MS tube
2. EGI sheet
2. GI sheet
3. Aluzinc/Galvalume sheet
(55%Al)
Metallurgy 60
Q&A Session

Metallurgy 61
Metallurgy