11 Engineering Materials

Engineering Materials
Ceramics
Metals
Polymers
Composites
Department of Mechanical and Manufacturing Engineering 1

General classification of Materials
Materials
Metals Composites Non-metals
Ferrous metals Non-ferrous metals and Ceramics Polymeric

and alloys - irons, alloys - aluminum, copper, Glasses Thermoplastics plastics
carbon steels, alloy magnesium, nickel, titanium, Glass ceramics Thermoset plastics
steels, stainless steels, precious metals, refractory Graphite, Diamond Elastomers
tool and die steels metals, superalloys


Ferrous and Non-ferrous Metals
 Metal – an element, compound or alloy that is a good
conductor of both electricity and heat.
 Ferrous metals – contain mainly iron and small amounts of
other elements.
 Non-ferrous metals – that do not contain iron.
Ferrous Metal Non-Ferrous Metal
 Cast Iron  Aluminum
 Mild Steel  Copper
 Stainless Steel  Zinc, Tin & Lead
 High Speed Steel  Silver
 High Carbon Steel  Gold
Ferrous Metals -Types
Mild Steel – alloy of iron and carbon where carbon % is < 2%.
Apps. – Bolts and nuts, Building girders, Car bodies, Gates etc.
Cast Iron – is very strong and brittle having carbon between 2 - 6%.
Applications – Car cylinders & brake disc, Man hole covers, Vices for
metalworking etc.
Cast Iron
Mild steel
Ferrous Metals -Types
High Speed Steel (HSS) – an alloy of iron which contains high
content of tungsten, Cr & Va
Applications – Drill bits, cutting tools, high temp. applications etc.
Stainless Steel – an alloy of iron with Cr, Ni and magnesium.

 is very resistant to wear, water corrosion and rust.
Applications – Kitchen sinks, cutlery, teapots, cookware and surgical
instruments.
HSS
Stainless Steel

Non-ferrous Metals - Types
Aluminium – Light weight, good malleability and formability, high corrosion
resistance, high electrical and thermal conductivity.
Applications – Saucepans, cooking foil, window frames, ladders, bicycles
Copper – Very good conductor of heat and electricity.

Applications – Electrical components, cookware, plumbing and roof covers
Department of Mechanical and Manufacturing Engineering

7
Zinc – Resistant to corrosion, used mainly as coating material.
Applications – Used as a coating on screws, steel buckets etc.
Zinc
Tin – Ductile and very malleable metal

and resistant to corrosion
Applications – Used as a coating on Tin
food cans, beer cans, whistles, tin foil

and soldering.
Lead – Soft, malleable, and one of the heavy metals.

- has a bluish-white colour after being freshly cut, but it soon
tarnishes to a dull grayish colour when exposed to air.
Applications – Used for batteries, roof flashing and X-ray
protection etc.

Silver – Soft, white metal, has the highest electrical conductivity

 Highest thermal conductivity of any metal.
 Occurs naturally in its pure, free form.
Applications – Used for jewelry, currency coins sports trophies,
mirrors as a reflective metal etc.

Gold – dense, soft, shiny, malleable and ductile metal.
 Traditionally considered attractive.
 Pure gold has a bright yellow color and luster which it
maintains without oxidizing in air or water.
Applications – Used mainly for jewelry and in computers as a
conductor. Used for its reflective powers to protect satellites.

Magnesium – is a fairly strong, silvery white, light-weight metal

that slightly tarnishes when exposed to air.
– In powder form, it gets heat and ignites when
exposed to moisture and burns with a white flame.
Applications – Used in fireworks.

– It is alloyed with other metals to make them
lighter and more easily welded.

Heat Treatment
Process of heating and cooling of a metal / alloy in the solid
state so as to obtain a particular microstructure and hence the
desired properties.
Objectives
To improve the mechanical properties like tensile strength, impact
strength, ductility etc.
To improve Machinability.
To improve Hardness.
To modify Magnetic and Electrical properties.
To refine the grains.
To produce hard surfaces and soft interiors.
To relieve internal stresses and residual stress.

Heat Treatment Process
Step 1: Heating the metal or alloy to prescribed temperature.

Step 2: Holding the specimen at that temperature for a pre-
determined period of time. Holding time or soaking time
depends upon the maximum thickness of the specimen.
Step 3: Cooling at a rate necessary to obtain a specific
microstructure for desired properties.
Classification of Heat Treatment Process:

 Annealing
 Normalizing
 Hardening
 Tempering
Heat Treatment - Types
Annealing – the specimen is heated to a prescribed

elevated temperature for an extended period of time and
then slowly cooled.
Annealing is carried out to
Relieve internal residual stresses developed during
machining, forging welding etc.
Increase softness, ductility and toughness.
Produce specific microstructure.

Normalizing – is similar to annealing except that, the specimen

is heated to a prescribed elevated temperature for an extended
period of time and the cooling is done at a faster rate.
Normalizing is carried out to
Increase softness, ductility and toughness.
Produce specific microstructure.
To improve machinability of low carbon steel

Normalizing vs Annealing
Normalizing Annealing
Normalized steels are tougher
Less tougher and harder.
and harder.
Finer and uniform grain size. Less finer grains.
Less expensive hence More expensive because of
preferred in Industries. prolonged heat treatment
Cooling rates are not critical. Cooling rates are critical.
Improves machinability of low Improves machinability of
carbon Steels. medium carbon Steels.
Normalized steels are less
More ductile.
ductile.
Hardening – to increase hardness, wear resistance, tensile

strength and yield strength for steel components
Steel is heated to a sufficiently high temperature

Holding (soaking) at that temperature for certain duration.
Rapid cooling in different media (water / oil / ice bath) to get
hardest phase.
Hardening is generally followed by tempering to reduce

internal stresses, improve wear resistance and improve
toughness.

Tempering – Steel after hardening becomes brittle,

develops micro cracks (not visible) and is strained due to
internal residual stresses.
Tempering - to reduce these undesirable properties and to

improving elastic limit and toughness.
Process involves reheating the hardened steel to a certain

temperature (< 600°c), followed by a slow cooling rate.
Reheating permits partial transformation of microstructure
and relieving of the internal stresses.


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Engineering Materials

Department of Mechanical and Manufacturing Engineering 1

Metals Composites Non-metals

Ferrous metals Non-ferrous metals and Ceramics Polymeric

Department of Mechanical and Manufacturing Engineering 2

Department of Mechanical and Manufacturing Engineering 3

Stainless Steel – an alloy of iron with Cr, Ni and magnesium.

Department of Mechanical and Manufacturing Engineering 6

Copper – Very good conductor of heat and electricity.

Department of Mechanical and Manufacturing Engineering

Tin – Ductile and very malleable metal

food cans, beer cans, whistles, tin foil

Lead – Soft, malleable, and one of the heavy metals.

Department of Mechanical and Manufacturing Engineering 9

Silver – Soft, white metal, has the highest electrical conductivity

Department of Mechanical and Manufacturing Engineering 10

Department of Mechanical and Manufacturing Engineering 11

Magnesium – is a fairly strong, silvery white, light-weight metal

Applications – Used in fireworks.

Department of Mechanical and Manufacturing Engineering 12

Department of Mechanical and Manufacturing Engineering 13

Step 1: Heating the metal or alloy to prescribed temperature.

Classification of Heat Treatment Process:

Annealing – the specimen is heated to a prescribed

Department of Mechanical and Manufacturing Engineering 15

Normalizing – is similar to annealing except that, the specimen

Normalizing is carried out to

Increase softness, ductility and toughness.

Produce specific microstructure.

To improve machinability of low carbon steel

Department of Mechanical and Manufacturing Engineering 16

Hardening – to increase hardness, wear resistance, tensile

Steel is heated to a sufficiently high temperature

Hardening is generally followed by tempering to reduce

Department of Mechanical and Manufacturing Engineering 18

Tempering – Steel after hardening becomes brittle,

Tempering - to reduce these undesirable properties and to

Process involves reheating the hardened steel to a certain

Department of Mechanical and Manufacturing Engineering 19

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