Materials Engineering Lab Manual

MATERIALS ENGINEERING
LAB MANUAL
II Year B. Tech I- Semester
MECHANICAL ENGINEERING
MATERIALS ENGINEERING
LAB MANUAL
(R22A0382)
Prepared
by
Soma Vivekananda,
Assistant Professor.
MALLA REDDY COLLEGE OF ENGINEERING & TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING
(Autonomous Institution-UGC, Govt. of India)
Secunderabad-500100, Telangana State, India.
www.mrcet.ac.in
MATERIALS ENGINEERING LAB (R22) 2023-2024
MALLA REDDY COLLEGE OF ENGINEERING & TECHNOLOGY

II Year B. TECH - I- SEM L/T/P/C
-/-/2/1
(R22A0382) MATERIALS ENGINEERING LAB
COURSE OBJECTIVES:
1. Ability to function on multi-disciplinary teams in the area of materials testing.

2. Ability to use the techniques, skills and modern engineering tools necessary for
handling ferrous and non – ferrous metals engineering.
3. Understanding of professional and ethical responsibility in the areas of material testing.
4. Ability to communicate effectively the mechanical properties of materials
LIST OF EXPERIMENTS
To prepare the specimen by mounting powder.
1.The study of Microstructure of Low Carbon Steels.
2.The study of Microstructure of Medium Carbon Steels
3.Thestudy of Microstructure of High Carbon Steels
4.The study of Microstructure Cast Irons. (Grey cast Iron & White cast Iron).
5.The study of Microstructure Non – Ferrous pure metals. (Copper & Aluminum).
6.Thestudy of Microstructure Non-Ferrous alloys. (Brass & Bronze).
7.The study of Microstructure Heat treated steels.
8.To find out the hardenability of steels by Jominy End Quench Test.
9.Tofind out the hardness of various treated and untreated steels.
10.To Study of Microstructure of Composite Material subjected to tensile testing.
11.Tofind Tensile Strength of the Composite Material with the help of UTM.
NOTE: Minimum a total of 8 experiments are to be conducted.
COURSE OUTCOMES:
1. To provide the students’ knowledge in finding the microstructure of metals and alloys.
2. To know the characteristics of grain structure.
3. Get Exposure metallurgical microscope.
4. To provide students hands on experience to handle the etchants.
Malla Reddy College of Engineering & Technology 1

Experiment-1: To prepare the specimen by mounting powder
To prepare the given specimen for metallographic examination.
To Study the constructional details of Metallurgical Microscope and observe the micro structure
of the prepared specimen.
APPARATUS AND MATERIALS REQUIRED:
Metallurgical microscope, emery belt 1/0, 2/0, 3/0, 4/0 emery papers, lapping cloth, alumina
powder, etchants, sample of metal.
THEORY:
The microstructure of metal decides its properties. An optical microscope is used to study the
microstructure. A mirror polished surface of the metal is required for metallographic study.
PROCEDURE OF SPECIMEN PREPARATION:
Cut the specimen to the required size (small cylindrical pieces of 10 to 15mm diameter with
15mm height or 10mm cubes)
Mounting of Specimens:
The primary purpose of mounting is to make it convincement to handle specimens of
arbitrary shape and/or small sizes during various steps of metallographic sample preparation and
examination. A secondary purpose is to protect and preserve extreme edges or surface defects
during metallographic preparation. Specimens may also require mounting to accommodate various
types of automatic devices used in metallographic laboratories or to facilitate placement on the
microscope stage. An additional benefit of mounting is the identification of the sample (name,
alloy number or laboratory code number) without damaging the specimen.
Compression mounting:
It is most common mounting method, which involves molding around the metallographic specimen
by heat and pressure using the molding materials such as Bakelite, Diallyl Phthalate resins, and
acrylic resins. Bakelite and Diallyl phthalate are thermosetting, and acrylic resins are
thermoplastic. Not all materials or specimens can be mounted in thermosetting or thermoplastic
mounting. The heating cycle may cause changes in the microstructure, or the pressure may cause
delicate specimens to collapse or deform. The size of the selected specimen may be too large to be
accepted by the available mold sizes. These difficulties are usually overcome by cold mounting.
Cold Mounting requires no pressure and little heat, and is a mean of mounting large numbers of
specimens more rapidly than possible by compression mounting. Epoxy resins are most widely
used cold mounting materials. They are hard, and adhere tenaciously to most metallurgical, mineral
and ceramic specimens.

Belt grinding: - One of the faces of the specimen is pressed against the emery belt of the belt
grinder so that all the scratches on the specimen are unidirectional. PRINCIPLE:
A Metallurgical microscope differs with a biological microscope in a manner by which specimen
of interest is illuminated. As metals are opaque their structural constituents Are studied under a
reflected light.
A horizontal beam of light from appropriate source is directed by means of plane glass reflects
downwards and through the microscope objective on to the specimen surface. A certain amount of
this light will be reflected from the specimen surface and that reflected light, which again passes
through the objective, will form an enlarged image of the illuminated area.
A microscope objective consists of a number of separate lens elements which are
compound group behave as positive and converging type of lens system of an illuminated object.
Specimen is placed just outside the equivalent front focus point of objective. A primary real image
of grater dimension than those of object field will be formed at some distance beyond the real lens
element. Objective size of primary image w.r.t. object field will depend on focal length of objective
and front focus point of objective. By appropriately positioning primary image w.r.t. a second
optical system, primary image be further enlarged by an amount related, to magnifying power of
eyepiece. As separation between objective and eye piece is fixed at same distance equivalent to
mechanical tube length of microscope, primary image may be properly positioned w.r.t eye piece.
By merely focusing microscope i.e. increase or decrease or the distance between object plane and
front lens of objective the image is formed by objective in conjunction with field of eyepiece and
microscope is so focused that primary image is located at focal point. Such precise positioning of
primary image is essential in order that final image can be formed and rendered visible to observe
when looking into eyepiece. If now entrance pupil of eye is made to coincide with exit pupil
eyepiece. Eyepiece lens in conjunction with cornea lens will form a second real image on retina.
This retrieval image will be erect, un reversed owing to the manner of response of human brain to
excitation of retina. The image since it has no real existence, known as virtual image and appears
to be inverted and reversed with respect to object field.
i. a) MAGNIFICATION:
The total magnification is the power of objective multiplied by power ofeyepiece (Power
of eye piece) (distance from eye piece to object)
Focal length of object
The magnification is marked on the side objective
Construction:
The micro scope consists of a body tube which carries an objective below, and an eyepiece above
with plane glass vertical illuminator above the objective. Incident light from a source strikes
illuminator at 450, part of which is reflected on to the specimen, Rays after reflection pass
through the eye again, working table is secured on heavy base. The microscope has compound
slide to give longitudinal and lateral movements by accurate screws having scale and verniers.
Vertical movement of specimen platform is made by a screw for proper focusing. For getting
perfect focusing fine adjustment of focusing can be made use of.
Light Filters: These are used in metallurgical microscope and essentially of three types
Gelatin sheets connected between two planes
Solid glass filters
Liquid dye solution
Solid glass filters are more preferable as they are more durable. Usually light filters are used
principally to render a quality of illumination. Hence filters improve degree of resolution.
A METZ-57 model microscope is used in the laboratory.
Optical compilation. Eye pieces and objectives of different magnifications are available. Huygens
eyepieces: 5x, 10x Achromatic objectives 5x, 10x, 45x.
PRECAUTIONS:
a. Ensure mirror polished surface of specimen before etching.
b. Fine focusing should be done only after correct focusing has beendone.
c. The glass lens should not be touched with fingers.
REVIEW QUESTIONS:
1. What is the use of micro structural study?
2. What is the difference among 1/0, 2/0, 3/0 and 4/0 emery papers?
3. What is lapping?
4. Why the specimen has to be etched before in lapping?
5. What are the different abrasives used in lapping?
6. Why the specimen has to be etched before micro structural study?
7. What is the etchant used for mild steel?
8. In a microstructure how the grain boundary area appears?
9. Why specimen is to be rotated through 90(between. Polishing on 1/0 and 2/0 emerypapers?
10. What is etching reagent used for duralumin?
11. Why should a specimen be prepared following the set procedure before its observation under a
microscope?
12. Is the specimen preparation necessary at all? If not why not?
13. What is the difference between Metallurgical microscope and Biological microscope?

Experiment-2: Study of Microstructures of Low Carbon Steels, Medium Carbon Steels And
High Carbon Steels
AIM: To Study the specimens of metals like mild steel, low carbon steel, medium carbon steel
and high carbon steel and observe the microstructure of the same.
APPARATUS:
Given Specimens
Belt Grinder
Emery Papers (80,120,240,400,600)
Alumina Paste (Grade-1, 2 & 3)
Disc Polishing Machines
Suitable Etching Agents
Air Blower
Metallurgical Microscope
THEORY:
Plain carbon steels are steels having carbon as the predominant alloying element and the other
alloying elements are either Nil or negligible though some amount of sulphur and phosphorous are
present. Normally the amounts are less than 0.05 percent and hence they are notconsidered. The plain
carbon steels are broadly classified in to
1. Low carbon steels with carbon content less than 0.3 percent.
2. Medium carbon steels contain Carbon between 0.3 to 0.7 percent.
3. The high carbon steels contain carbon from 0.7 to 1.5 percent.
LOW CARBON STEEL:
As the microstructure shows the structure of the mild steel, it contains 25% pearlite and 75%
ferrite. The dark region defines the pearlite and bright portion is of ferrite. The properties of low
carbon steels are:
 The material is soft and ductile.
 It is easily weldable.
 It is cold workable.
 The tensile strength varies between 390 to 550 N/ mm2.
 The Brinell hardness number varies from115 to 140.

 The application includes making steel wire, sheets, rivets, screws, pipe, chain and
Structural parts.
MEDIUM CARBON STEEL:
The microstructure reveals two phases are to be about 50% each. Hence the carbon content can
be accessed to be equal to it. The properties of medium carbon steels are invariably between low
and high carbon steels. The tensile strength varies between 75 to 800 N/ mm2 . The medium carbon
steels are used in manufacture of drop forging dies, die block plates, punches, screws and valve
springs etc.
HIGH CARBON STEEL:
Microstructure of high carbon steels consists of continuous network of cementite in matrix to
pearlite. This cementite structure is hard and brittle and hence has poor machinability. As carbon
content increases weldability and cold working decreases. They have high strength and hardness.
Its Tensile strength is up to 1400 N/mm2 hardness varies from 450 to 500 BHW. High carbon steels
are used in cutting machine tools, manufacturing cold dies and wheels for railways.
PROCEDURE:
1. Polish the specimen by using belt grinding machine.

2. Polish the specimen by using (80,120,240,400,600 & 1000) grade emery papers.
3. Polish the specimen by using (1/0, 2/0, 3/0, 4/0,) grade emery papers.
4. Subject the given specimen to mirror like finish by using disc polishing machine and with
suitable abrasive.
5. Clean the specimen with alcohol and wash it under the stream of flowing water.
6. After washing the specimen is dried.
7. After drying, apply the suitable etching agent for 30 to 60 sec.
8. After etching wash the specimen under the stream of flowing water.
9. Dry the specimen with the help of air blower.
10. Place the specimen under the microscope for metallurgical studies.
11. Draw the micro structure and identify the material for the given specimen.

PRECAUTIONS:
1) Polishing should be slow, smooth and flat.

2) Uniform pressure is applied throughout the polishing.
3) Proper Care should be Taken While Etching.
4) Wash Your Hands Thoroughly After Experiment.
RESULT:

Experiment-3: Study of Microstructure of the Cast Irons

AIM: To identify and draw the microstructures of Cast Iron specimens like Grey Cast Iron, White
Cast Iron, Malleable Cast iron, and S.G. Cast iron etc.
APPARATUS:
Given Specimens
Belt Grinder
Emery Papers (80,120,240,400,600 & 1000)
Air Blower
THEORY:
Cast irons contain 2 to 6.67 % of carbon. Since high carbon content tends to make the Cast ironvery brittle,
most commercially manufactured types are in the range of 2.5 to 4% of carbon. The ductility of Carbon
is very low and it cannot be rolled, drawn or worked at room temperature. However, they melt readily
and can be cast to complicated shapes which are usually machined tofinal dimensions. Since the casting
is only the suitable process applied to these alloys, they are known as cast irons.
Although the common cast irons are brittle and have lower strength properties than most steels,they are
cheap, can cast more readily than steel and have other useful properties. In addition, by proper alloying
good foundry control and appropriate heat treatment is possible. The properties ofany cast iron can be
varied over a wide range.
WHITE CAST IRON:

In white cast iron most of the carbon is present in the combed forms as cementite. This is obtained
by rapid cooling of the iron. White cast irons contains large amount of cementite as continuous inter
dendritic network. It makes the cast iron hard, wear resistance but extremely brittleand difficult to machine.
White cast irons are limited in engineering applications because of brittleness and lack of machinability.
They are used where resistant to wear is important and service does not require, suchas cement mixer, ball
mills certain types of drawing dies and extrusion nozzle. A large tonnage ofwhite cast iron is used as a
raw material for manufacture of malleable cast iron.
GREY CAST IRON:
In grey cast iron most or all of the carbon is uncombined form of graphite flakes. The tendencyof carbon
to form as graphite flakes is due to increased silicon and carbon content and thereby decreasing the
cooling rate.

It is a low melting alloy, having good cast ability and machanibility. It has low tensile strength,high
compression strength and very low ductility. Grey cast iron has excellent damping capacityand is often
used as base for machinery or any equipment subject to vibration. It is also used for machine tool bodies,
pipes and agricultural implements. The presence of graphite flakes provideslubricating effect to sliding
bodies.
The composition of typical grey cast iron is as follows
 Carbon: 2.8 to 3.6%
 Silicon: 1 to 2.75%
 Manganese: 0.4 to 1%
 Phosphorous: 0.1 to 1%
 Sulphur: 0.06 to 0.12%.

PROCEDURE:
suitable abrasive.
6. After washing the specimen is dried. After drying apply the suitable etching agent for
30 to 50 sec.
7. After etching wash the specimen under stream of flowing water.
8. Dry the specimen with the help air drier.
9. Place the specimen for metallurgical studies.
10. Draw the microstructure and analyze the properties
APPLICATIONS:
Agricultural tractor and implement parts, automotive and diesel crank shafts, piston and
cylinder heads, electrical fittings, motor frames, hoist drums, flywheels and elevator buckets, steel
mill, furnace doors and bearings wrenches levers and handles.
RESULT:

Experiment-4:
To Study of Microstructure of Non-Ferrous Pure Metals Copper & Aluminum
AIM: To Study the given pure metal like COPPER & ALUMINUM and observe the microstructure of the
same
APPARATUS:
Mounting Press
Thermosetting Powder (Bakelite Powder)
Specimens
Belt Grinder
Emery Papers (80,120,240,400,600)
Air Blower
DESCRIPTION:
Iron is an allotropic material which means that exists in more than one type of lattice
structure depending upon temperature. The percentage of carbon in the iron is 0.8.pure iron is
soft and malleable. Depending upon the percentage of carbon it is classified as steels and cast
irons.
PROCEDURE:
1. The given specimen is mounted in a thermosetting material by using mounting press.

suitable abrasive i.e. Alumina paste.
7. After washing, the specimen is dried.
8. After drying apply the suitable etching agent for 30 to 60 sec.
8. After etching wash the specimen under the stream of flowing water.
9. Dry the specimen with the help of air blower.
10. Place the specimen under the microscope for metallurgical studies.

11. Draw the micro structure and identify the material for the given specimen.
PRECAUTIONS:
Pressure should be applied uniformly.

Polishing should be slow, smooth and flat.
Proper Care Should be Taken While Etching.
Wash Your Hands Thoroughly After Experiment.
RESULT:

Experiment- 5:
Study of Microstructure of Non-Ferrous Alloys Like Aluminum, Copper and Their
Alloys.
AIM: To study the microstructures of Nonferrous alloy specimens like Al, Cu alloys and bearing metal.
APPARATUS:
Given Specimens
Belt Grinder
Emery Papers (80,120,240,400,600 & 1000)
Air Blower
THEORY:
Nonferrous metals and alloys contain other than iron as a main constituent. They exhibit
different properties compared to ferrous metals and alloys. Hence their application also differs from
ferrous metals. We shall study the microstructures of Al, Cu, and alloys.
CU- ALLOYS
BRASS:
Brasses are the copper alloys containing zinc up to 30% they possess relatively good corrosion
resistance and good working properties. They also possess high ductility hence they are suitable for
drastic cold working. In common to relieve the stresses annealing is done. Most normally used brass
contains 30% zinc and 70% copper which is known as cartridge brass. This shows higher ductility
and malleability. The microstructure hows a typical equi axied grain structure with twins in annealed
structure. This brass is used for making cartridge cases. Other applications includes radiator cases,
head light reflectors, hardware, and plumbing accessories.
AL-ALLOYS:
Aluminum alloy contains silicon up to 12 %. Aluminum- silicon is also called as silumin.

There are two types of aluminum silicon alloys, they are:
LM-6:
It contains above 12% silicon due to its higher corrosion resistance and fluidity. It is used in
water cooled marine tools for pump parts.
LM-13
It contains silicon up to 12.5%, Ni 2.5%, ca 1% and Mg 12%. This shows good forgability and
low coefficient of thermal expansion. It is used in automobile pistons.
BEARING METAL:
Bearing metal has high compressive strength and high wear resistance, high fatigue strength and
better thermal conductivity for heat dissipation, corrosion resistance and good machinability. They
have hard and soft phases. Most widely used bearing metal is a Babbitt metal. They are called as
low melting bearing alloy. Lead based ad tin based Babbitt contain Antimony as most popular this
group.
PROCEDURE:
suitable abrasive.
3. clean the specimen with alcohol and wash it under the stream of flowing water
4. After washing the specimen is dried. After drying apply the suitable etching agent for
30 to 50 sec.
PRECAUTIONS:
1) Polishing should be slow, smooth and flat

2) Uniform pressure is applied throughout the polishing
3) Proper Care should be Taken While Etching.

4) Wash Your Hands Thoroughly After Experiment.
RESULT:

Experiment- 6: Study Hardenability of Steels by Jominy End Quench Test
AIM: To evaluate the hardenability of the low carbon steel or medium carbon steel by Jominy end
quench test method.
APPARATUS:
Heat treatment furnace – Muffle furnace
Jominy end quench apparatus,
Test specimen,
Rockwell test setup
PROCEDURE:
The various steps involved in evaluating the hardenability test for a given specimen are
1) Determination of hardness no. by Rockwell hardness test
2) Heat treatment in the furnace
3) Quenching the specimen in Jominy end quench apparatus
1) DETERMINATION OF HARDNESS NO.BY ROCKWELL HARDNESS TEST
The method of determining the hardness consists of measuring the depth of a diamond cone
penetrant that was forced into a metal by applying primary and secondary loads. This method of
measuring hardness significant because errors due to mechanical defects on the system such as
backlash are eliminated ad as well as errors resulting from slight surface imperfections.
The specimen is placed on a suitable anvil on the upper end of the elevation screw. A minor load
of 10 kg is applied by raising the anvil by using elevation screw. Then apply the major load by using
the leaver. After applying the load for a period of 20 sec, remove the load by turning the lever. Note
down the reading on the Rockwell scale.
2) HEAT TREATMENT IN THE FURNACE
Heat treatment is a combination of heating and cooled operations timed and applied to a metal
or alloy so as to produce the desired properties. Heat treated steels amount to about 5 percent of
total steel production, but it is indispensable for tools, dies, ad a variety of special purpose steels.
SPECIMEN: Medium carbon (plain Carbon) steel. The percentage of composition is
Carbon - 0.35% to 0.45%
Silicon - 0.35 %( max)

Manganese - 0.60% to 0.8%
Sulphur - 0.05 %( max)
Phosphorus - 0.05 % (max)
Take the specimen, place it in the furnace and supply the power. Wait till the temperature
reaches to the austenising temperature. Heat the specimen at the austenising temperature until it is
completely transformed in to Austenite.
3) QUENCHING THE SPECIMENIN JOMINY END QUENCH APPARATUS
Remove the specimen from the furnace with the help of tongs and gloves and place it in the
Jomny end quench apparatus and allow the jet of water to strike one end of the specimen. When the
specimen reaches to the room temperature remove it from the apparatus and find the Rockwell
hardness at 0.5cms along the length of the specimen. Plot the graph between the hardness and
distance from the quenched end.
OBSERVATION & TABULAR COLUMN:
Distance from
Specimen Load Rockwell scale Rockwell scale
S.NO Indenter (kgf) quenched end of
material (Before Treatment) (After Treatment)
the specimen
PRECAUTIONS:
1. Don’t use the hard water while Quenching, as it leads to formation of scales in nozzles and
copper conduits.
2. Always use hand gloves, tongs while operating furnace.
RESULT:

Experiment- 7: Study of Microstructures of Heat-Treated Steels

AIM:
To identify, draw and to analyze the microstructures of heat-treated steel specimens likeStainless
steel, High speed steel, Tool steel etc.
APPARATUS:
Given Specimens
Belt Grinder
Emery Papers (80,120,240,400,600 & 1000)
Air Blower
THEORY:
Heat treatment is a process of heating the metal below its melting point and holding it at that
temperature for sufficient time and cooling at the desired rate to obtain the required properties. Thevarious
heat treatment processes are annealing, normalizing, tempering, hardening, mar tempering,austempering.
The final mechanical properties depend on the microstructure formed due to various heat treatment
processes (due to various cooling rates). An annealed specimen was cooled in the furnaceor any good heat
insulating material; it obtains the coarse grain structure of ferrite and pearlite in case of hypo eutectoid
steels and coarse grain structure of ferrite and cementite in case of hyper eutectoid steel. It possesses
high ductility.
A normalized specimen was cooled in the presence of air so cooling rate increases, it obtainsthe fine
grain structure of ferrite and pearlite in case of hypo eutectoid steels and fine grain structureof ferrite and
cementite in case of hyper eutectoid steel. It possesses high ductility.
A hardened specimen was quenched in oil (in case of alloy steels) or in water (in case of carbonsteel).
due to faster cooling rate martensite (hard steel) structure was formed.

PROCEDURE:
1. Take the given treated (annealed, normalized, hardened) specimens.

2. Polish the specimen by using (80,120,240,400,600) grade emery papers.
suitable abrasive.
5. clean the specimen with alcohol and wash it under the stream of flowing water
6. After washing the specimen is dried. After drying supply the suitable etching agent for
30 to 50 sec.
PRECAUTIONS:
1. Polishing should be slow, smooth and flat.
2. Uniform pressure is applied throughout the polishing.
3. Proper Care should be Taken While Etching.
4. Wash Your Hands Thoroughly After Experiment.
RESULT:

Experiment-8: To Find Out the Hardness of The Various Treated and Untreated Steels
AIM:
To find the hardness of the given treated and untreated steel specimens by conducting the
hardness test.
APPARATUS:
Given specimens
Hardness tester
Indenter
THEORY:
The method of testing introduced by J.A. Brinell in 1900 consisting of indenting the metal witha
"d" mm diameter and tempered steel ball subjected to a definite load. Ball of 10 mm, 5 mm, and mm are
generally used. The load is maintained for a definite period (usually 10 or 15 sec) afterwhich the load is
removed and the diameter of the impression or indentation is measured. The hardness of the material
expressed as number and represented by the symbol "HB".
h= depth of indentation
(D − √(D2 − d2)
2
Brinnel's hardness number, HB = Total load / surface area of indentation
2F
 D (D − √(D2 − d2)
PROCDEDURE:
1. The face of the specimen is lightly grind and rubbed with fine emery paper if required.
2. Select the proper test table based on the size and shape of the specimen and place it on main
screw or elevating screw.
3. Select the diameter of the indenter as 10mm or 5 mm based on the thickness of the specimen
and place it I the corresponding ball holder and fix the ball holder.
4. Place the required weights on the weight hanger based on the type of material of the
specimen and diameter of the indenter
5. Check and keep the operating level in horizontal position.
6. Place the specimen securely on testing table
7. Turn the hand wheel in clock wise direction so that the specimen touches the ball Indenter.

8. Lift the operating lever for the horizontal position upwards slightly, after which it rotates
automatically.
9. Wait for 10 to 15 sec after lever becomes stand still and bring the lever back to horizontal
position.
10. Turn back the hand wheel and remove the specimen.
11. Measure the diameter of impression of indentation by Brinnel microscope and find the
Brinnel hardness number.
15. Turn the hand wheel in clock wise direction so that the specimen touches the ball Indenter
automatically.
position.
23. Turn the hand wheel in clock wise direction so that the specimen touches the ball Indenter
automatically.
position.

PRECAUTIONS:
1. Apply the load slowly and gradually on the sample.

2. Distance between old impression and location for new impression should be
3D (three times the ball diameter)
3. After applying the specified load wait for 15 sec then remove the load.
4. The thickness of the test piece must not be less than 8 times the depth of impression.
5. The surface to which the brinnel impression is to be made should be sufficiently smooth and
clean.
RESULT:
The Brinnel hardness number of the given material is ---------------

Experiment- 9:
To Study of Microstructure of Composite Material Subjected to Tensile Test
AIM:
To identify the different phases and to draw the microstructures Composite materials.
Apparatus and specimens required:
Metallurgical microscope, Al6082 metal matrix composite.
Theory:
Aluminum3 (Al) is used as a key metal matrix constituent in the production of composite
materials. There is an increased petition for a low cost, lightweight material with excellent
mechanical and tribological properties in the aerospace and automobile industries. Composite
materials of Al showed application in these industries. Most of the researchers tried to reinforce
aluminum metals and their alloys with ceramic particles to improve their properties. These
composite materials presented great applications in the area of commercial as well as industrial
components.
Composite materials when compared to unreinforced alloy showed better mechanical and
tribological properties; moreover, these improved properties can be modified for a particular
requirement. The hardness of the aluminum matrix composites (AMCs) reinforced with Gr
particles decreased with a linear increase in the graphite (Gr) content irrespective of the
manufacturing process employed to manufacture the composite materials.
The wear resistance of the AMCs reinforced with Gr particles increased as compared to that of
pure aluminum matrix due to formation of a thin lubricating film by Gr particles which prevented
direct contact of sliding surfaces and reduced ploughing effects of Al chips which in turn reduced
the wear and friction of the composite material resulting into easy machining of these composite
materials manufactured by various techniques. The wear resistance of a single reinforced
composite increased when Gr is used as a second reinforcement because Gr having self-lubricating
properties enhanced the wear resistance of single reinforced composites by forming a thin
lubricating film of Gr particles in case of hybrid composites irrespective of the manufacturing
process employed for the manufacturing of hybrid composites.
It is revealed from studied literature that the main emphasis has been given on the wear and
mechanical properties, especially hardness of AMCs reinforced with Gr particulates and a limited
research work has been reported on microstructural characterization of AMCs containing wide
range of reinforcements i.e. Gr.
Microstructure of Al:
The Al6082/Gr composites were fabricated by stir casting process. microstructure of cast

Al6082, and the microstructure contains solid solution of aluminum and inter-dendritic network of
aluminum silicon eutectic. The microstructure of cast Al6082 (Fig. 1(b)) reveals the formation of
α-aluminum dendritic network structure which is formed due to super- cooling of casting during
solidification, with less impurities present. The SEM image of manufactured composites is shown
in Fig. 2(a)–(d). The microstructure of all composites reveals that there are large impurities with a
non-uniform distribution of Gr particles along with clustering of Gr particles at some locations.
The low density of Gr particles as compared to that of Al6082 causes the Gr particles to float in
the aluminum melt resulting in non- uniform distribution. The microstructures of all composites
contain solid solution of aluminum and inter-dendritic network of aluminum silicon eutectic. When
the composites are solidifying, the Gr particles are prohibited in the direction of refined α-Al
grains. Because of this, the further refinement of α-Al grains takes place and Gr particles act as
nucleus on which the α-Al grains solidify and Gr particles offer confrontation against growing α-
Al phaseduring the solidification process.
Fig. 1. (a) SEM image of pure Gr reinforcement. (b) SEM image of cast Al 6082.
Fig. 2. SEM image of Al–Gr composites: (a) 3% Gr, (b) 6% Gr, (c) 9% Gr and (d) 12% Gr.
The scanning electron micrograph revealed a reasonably non-uniform distribution of Gr particles
in the matrix.
Experiment 10: Study of The Composite Material with The Help of UTM.
AIM: To Study of the Composite Material with the help of UTM.
Objective: To conduct a tensile test on a composite material specimen and determine the
following: (i) Limit of proportionality (ii) Elastic limit (iii) Yield strength (iv) Ultimate strength
(v) Young’s modulus of elasticity (vi) Percentage elongation (vii) Percentage reduction in area.
Apparatus: (i) Universal Testing Machine (UTM) (ii) Mild steel specimens (iii) Graph paper (iv) Scale
(v) Vernier Caliper, (vi) composite material of aluminium and polyethylene material.
Theory:
Automotive industry is on the verge of development. More and more comforts are being
incorporated in a vehicle. On other hand customers have stringent demand of fuel economy, high
performance at low cost. In order to have high fuel economy the auto-motive manufacturers are
induced to reduce weight. In this research work flat plate is selected as a target weight reduction
composite material. This can be achieved either using high strength low weight material or by
using low weight composite sandwich panel. Aluminium composite (Aluminium skin,
polyethylene core, resin binder material) material being light and strong, it is selected as an
alternative material by considering peer reviewed papers and industrial guidance. By using this flat
plate sandwich panel, tensile strength, bending strength, flexural limit have been carried out for
optimization of composite material for sandwich panel construction. Tensile test, bending test is
tested on Universal Testing Machine (UTM). One can use composite material to optimize mass
and cost of various automobile, marine, aerospace and various structures.
Universal Testing Machine

About of utm & its specifications:
The tensile test is conducted on UTM. It is hydraulically operates a pump, oil in oil sump,
load dial indicator and central buttons. The left has upper, middle and lower cross heads i.e;
specimen grips (or jaws). Idle cross head can be moved up and down for adjustment. The pipes
connecting the lift and right parts are oil pipes through which the pumped oil under pressure flows
on left parts to more the cross-heads.
Specifications:
1. Load capacity = 0-40 Tones.
2. Least count = 8 kgf.
3. Overall dimn. =
4. Power supply = 440 V
Procedure:
1. Measure the original length and diameter of the specimen.
2. The length may either be length of gauge section which is marked on the
specimen with a preset punch or the total length of the specimen.
3. Insert the specimen into grips of the test machine and attach strain-measuring device to it.
4. Begin the load application and record load versus elongation data.
5. Take readings more frequently as yield point is approached.
6. Measure elongation values with the help of dividers and a ruler.
7. Continue the test till Fracture occurs.
8. By joining the two broken halves of the specimen together, measure the final
length and diameter of specimen.
Observation:
(a) Initial diameter of specimen d1 =
(b) Initial gauge length of specimen L1 =
(c) Initial cross-section area of specimen A1 =
(d) Load of yield point Ft. =
(e) Ultimate load after specimen breaking F =
(f) Final length after specimen breaking L2 =
(g) Diameter of specimen at breaking place d2 =
(h) Cross section area at breaking place A2 =

Observation table:
S.No Load (N) Original Extension (mm) Stress = Strain

Gauge (N/mm2)
Length
1
2
3
4
5
Result:
(i) Ultimate tensile strength = N/mm2

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MATERIALS ENGINEERING

MALLA REDDY COLLEGE OF ENGINEERING & TECHNOLOGY

MALLA REDDY COLLEGE OF ENGINEERING & TECHNOLOGY

1. Ability to function on multi-disciplinary teams in the area of materials testing.

To prepare the specimen by mounting powder.

1.The study of Microstructure of Low Carbon Steels.

2.The study of Microstructure of Medium Carbon Steels

3.Thestudy of Microstructure of High Carbon Steels

6.Thestudy of Microstructure Non-Ferrous alloys. (Brass & Bronze).

7.The study of Microstructure Heat treated steels.

9.Tofind out the hardness of various treated and untreated steels.

10.To Study of Microstructure of Composite Material subjected to tensile testing.

NOTE: Minimum a total of 8 experiments are to be conducted.

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Experiment-1: To prepare the specimen by mounting powder

To prepare the given specimen for metallographic examination.

APPARATUS AND MATERIALS REQUIRED:

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carbon steels are broadly classified in to

2. Medium carbon steels contain Carbon between 0.3 to 0.7 percent.

LOW CARBON STEEL:

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MEDIUM CARBON STEEL:

HIGH CARBON STEEL:

Microstructure of high carbon steels consists of continuous network of cementite in matrix to

1. Polish the specimen by using belt grinding machine.

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1) Polishing should be slow, smooth and flat.

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Experiment-3: Study of Microstructure of the Cast Irons

WHITE CAST IRON:

GREY CAST IRON:

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1. The given specimen is mounted in a thermosetting material by using mounting press.

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Pressure should be applied uniformly.

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Aluminum alloy contains silicon up to 12 %. Aluminum- silicon is also called as silumin.

1) Polishing should be slow, smooth and flat

3) Proper Care should be Taken While Etching.

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Experiment- 6: Study Hardenability of Steels by Jominy End Quench Test

1) DETERMINATION OF HARDNESS NO.BY ROCKWELL HARDNESS TEST

2) HEAT TREATMENT IN THE FURNACE

SPECIMEN: Medium carbon (plain Carbon) steel. The percentage of composition is

Carbon - 0.35% to 0.45%

Silicon - 0.35 %( max)

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Sulphur - 0.05 %( max)

Phosphorus - 0.05 % (max)

completely transformed in to Austenite.

3) QUENCHING THE SPECIMENIN JOMINY END QUENCH APPARATUS

distance from the quenched end.

OBSERVATION & TABULAR COLUMN:

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Experiment- 7: Study of Microstructures of Heat-Treated Steels

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