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Metallurgy

Metallurgy Basic Course

Multimedia Course on METALLURGY

	DETAILED CONTENTS: Metallurgy (see Contents )


1. BASIC PRINCIPLES 1.1 Chemical Systems Homogeneous and heterogeneous systems Chemical-physics of metallurgical processes 1.2 Physics of Metal Materials Structure of matter Solidification metals and alloys Crystal lattices Solid solutions Deformations of the crystal lattice Solid state transformations 1.3 Phase Diagram Cooling curve of a pure metal Solubility in the liquid state Insolubility in the solid state 1.4 Phase Diagram of Binary Metal Alloys General rules of interpretation Iron-Carbon Diagram - Hypoeutectoid steel - Hypereutectoid steel - Eutectoid steel - Hypoeutectic cast iron - Hypereutectic cast iron - Structural transformations - Critical points Addition of Elements 1.5 Process Metallurgy Metallurgical processes Production of Carbon Steels - Production of Cast Iron - Refining - Casting and Solidification - Rolling 1.6 Heat Treatments Introduction - Heat treatment steps - Critical points - Thermal transformations - Cooling rate - TTT and CCT Curve (or Bain curve) - Steel hardenability Kinetics transformation of the steel structure - Austenite - Ferrite - Perlite - Cementite - Bainite - Martensite Type of thermal treatments Heat treatments at temperatures above critical points - Full Annealing - Isothermal annealing - Coalescence annealing - Normalisation - Quenching Treatments without phase variations - Tempering - Softening annealing - Relaxation Quench and tempering Surface heat treatments - Induction hardening - Thermochemical diffusion treatments - Cementation - Nitriding - Comparison Cementation-Nitriding 2. PROPERTIES OF METAL MATERIALS 2.1 Physical and mechanical characterization Mechanical properties Tensile strength Hardness - Brinell Hardness - Vickers Hardness - Rockwell Hardness - Microhardness Resiliency - Test equipment - Transition ductile-brittle - Transition temperature - Resilience test - Test parameters - Izod impact strength test Creep (Cold flow) Fatigue resistance - Fatigue failures - Typical aspect of a fatigue fracture - Fatigue tests - Wohler's curve - Fatigue limit Surface roughness - Roughness parameters - Roughness measurement 2.2 Sample preparation Sampling for mechanical tests - Definitions - Preparation and identification of the samples Location and preparation of samples - Flat products - Long products - Tubes 2.3 Test procedures and reference standards Test procedures and standards Test standards Measurement uncertainty - Possible factors of uncertainty - Types of measurement uncertainty - Expression of measurement uncertainty 2.4 Test results and suitability for use Use of test results Design mechanical parts - Mechanical tests - Tensile strength - Traction stiffness - Compressive strength - Hardness measurement - Resistance to torsion, bending - Resistance to shear stresses - Resistance to crack propagation - Resistance to fatigue - Resistance to creep Environmental effects on mechanical properties - Stress Corrosion Cracking - Hydrogen Induced Cracking - Corrosion Fatigue - Resistance to shock Manufacturing process - Criticality of the transformation - Mechanical properties and transformation - Controls and Testing Failure Analysis and Life Assessment - Life assessment - Failure analysis Evaluation of test results 3. METAL ALLOYS 3.1 Introduction 3.2 Ferrous Alloys Steel grades Classification based on alloy elements Classification according to applications Structural steels - General purpose steel - Weldable steels Special steels - Quenched and tempered steels - Nitriding steels - Cement steels - Self tempering steels - Tool steels - Steels for rolling bearings - Spring steels - Molding steels Stainless steels Casting steels Cast Irons 3.3 Non-Ferrous Alloys Aluminum Alloys - Characteristic structures - Alloy elements and features - Influence of alloying elements - Aluminum Industrial Alloys Magnesium Alloys Titanium Alloys Copper Alloys Nickel Alloys Cobalt Alloys 4. METALLOGRAPHY 4.1 Metallographic Techniques Introduction 4.2 Sample Preparation Metallographic sample Basic operations - Sectioning or cutting - Resin encapsulation - Grinding - Polishing - Chemical etching Metallographic replicas 4.3 Preparation Techniques Ferrous alloys Anti-friction alloys Aluminum alloys Copper alloys Magnesium alloys Nickel alloys Titanium alloys Zinc alloys 4.4 Micrographic Examinations Optical microscopy Scanning Electron Microscopy - Components - Operation principle - Related technique - Metallurgical application - Evolution of microscopy techniques - Evolution of microanalysis techniques 4.5 Characteristic Structures of Ferrous Materials Austenite Ferrite Cementite Perlite Martensite Bainite Graphite 4.6 Test procedures and reference standards Test procedures and standards Standardization levels 4.7 Test results and suitability for Use of Materials Use of the test results Microstructural examinations - Band structure classification in laminates - Determining average grain size - Determination of inclusions in steel - Estimating the depth of decarburization 4.8 Non-destructive Testing Introduction RT - Radiographic Testing UT - Ultrasonic Testing MT - Magnetic Testing PT - Penetrant Testing ET - Eddy current Testing VT - Visual Testing IT - Infrared Thermography CT - Computerized Tomography Thermal Stress Analysis