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MATERIAL SCIENCE
DAM 20802
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SECTION
:1
YEAR PROGRAMME
: 2 DAM
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MATRIX NUMBER
AA 130097
AA 130417
AA 131173
AA 130249
AA 130072
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MATERIAL SCIENCE
CONTENT
TITLE
1.0 INTRODUCTION
2.0 OBJECTIVE
PAGE
3-4
5-6
8-13
6.0 QUESTION
14
7.0 CONCLUSION
15
8.0 REFERENCE
16
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MATERIAL SCIENCE
1.0 INTRODUCTION
METAL
Metal is an element, compound or alloy that is a good conductor of both electricity and heat.
Metal crystal structure and specific metal properties are determined by metallic bonding force,
holding together the atoms of a metal.
FERROUS METAL
Ferrous metals are metals that consist mostly of iron and small amounts of other elements. They
are usually important as engineering construction materials. Their widespread use is accounted
for by three factors:
Ferrous metals are prone to rusting if exposed to moisture. Ferrous metals can be picked up by a
magnet. The rusting and magnetic properties in ferrous metals are both down due to the iron. The
examples of ferrous metals are:
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MATERIAL SCIENCE
STEELS
Steels are iron-carbon alloys. It contains 0.01%-2.00% wt carbon,C + other alloying elements.
The mechanical properties are sensitive to the content of the carbon. Most common steels are
classified according to carbon concentration that is, low carbon, medium carbon and high carbon
types. Subclasses also exist according to the concentration of other alloying elements such as
plain carbon steels & alloy steels. Plain carbon steels contains carbon + a little manganese while
alloy steels contains carbon + more alloying elements (added in specific concentrations).
2.0 OBJECTIVE
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MATERIAL SCIENCE
3.0 LOW CARBON STEEL
MATERIAL SCIENCE
Contains carbon + manganese + other alloying elements (copper, nickel, vanadium,
molybdenum)
Properties:
Higher strength than plain low carbon steels.
Ductile
Formable
Machinable
More resistant to corrosion than plain carbon steels.
Applications: Bridges, towers, pressure vessels, etc.
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MATERIAL SCIENCE
High carbon steel is a type of metal that has an alloying element made up of a relatively high
amount of carbon. It contains 0.60 wt% - 1.4 wt% of carbon. The steel has one major
constituent which is pearlite.
The properties of high carbon steels are:
High hardness
High strength
Good wear resistance
Low ductility
It is also used for cutting tools, such as chisels, high strength wires, screwdrivers, hammers,
saws and garden tools. These applications require a much finer microstructure, which
improves the toughness. It has a melting point of 1800 C.
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MATERIAL SCIENCE
Cast iron is iron or a ferrous alloy which has been heated until it liquefies, and is then poured
into a mould to solidify. It is usually made from pig iron. Cast iron contains 2.14 wt% - 4 wt
% carbon, along with varying amounts of silicon and manganese and traces of impurities
such as sulfur and phosphorus. The carbon exists as graphite. It is made by reducing iron ore
in a blast furnace. The liquid iron is cast, or poured and hardened, into crude ingots called
pigs, and the pigs are subsequently re-melted along with scrap and alloying elements in
cupola furnaces and recast into molds for producing a variety of products. Cast iron is used
as a car brake discs, car cylinders, metalwork vices, manhole covers, machinery base (Pillar
drill). It has a melting point of 1200 C.
MATERIAL SCIENCE
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MATERIAL SCIENCE
More ductile
Graphite in nodules not flakes
Much stronger
Casting stronger & more ductile than gray iron
Can be welded
Mechanical properties approaching steel
Applications: crankshafts, gears, other automotive, etc.
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MATERIAL SCIENCE
White appearances
Superior tensile strength and malleability
Brittle
Cannot be welded
More cementite
Applications: Rollers in rolling mills, Intermediate product for malleable iron
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MATERIAL SCIENCE
Graphite in rosettes
Can be welded
More ductile
Shock resistance
Applications: Connecting rods, pipe fitting, flanges, etc.
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MATERIAL SCIENCE
6.0 QUESTION
1. List two examples of steels. For each, briefly describe the properties and typical applications.
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MATERIAL SCIENCE
ANSWER
Two examples of steels are low carbon steels and high carbon steels. The properties of low
carbon steels are ductile, formable, machinable and least expensive. While the properties of
high carbon steels are high hardness, high strength, good wear resistance and low ductility.
The example of applications for low carbon steels are bridge, automobile body components,
towers and pressure vessels. While the example of applications for high carbon steels are
chisels, knives, razors and springs.
2. List four types of cast iron. For each, briefly describe the properties and typical applications.
ANSWER
Four types of cast iron are gray, malleable, ductile and white iron. The properties of gray iron
are weak & brittle in tension, high resistance to wear and least expensive. Next, the
properties of malleable iron are high strength and appreciable ductility. The properties of
ductile iron are much stronger and its mechanical properties are approaching steel. Lastly, the
properties of white iron are hard, brittle, unmachinable and wear resistance. The examples of
applications for gray iron are piston, cylinders, diesel engine and clutch plates. While the
examples of applications for malleable iron are connecting rods, pipe fitting and flanges.
Next, the examples of applications of ductile iron are valves, high-strength gears, rollers and
crankshaft. Lastly, the examples of applications of white iron are rollers in rolling mills and
as intermediate product for malleable iron.
7.0 CONCLUSION
This chapter began with a discussion of various fabrication techniques that may be applied to
metallic materials. Forming operations are those in which a metal piece is shaped by plastic
deformation. Forging, rolling, extrusion and drawing are four of the common forming
techniques. Depending on the properties and shape of the finished piece, casting may be the most
desirable and economical fabrication process; sand, die, investment, and continuous casting
methods were also treated.
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MATERIAL SCIENCE
Ferrous alloy are those in which iron is the prime constituent. Most steels contain less than
1.0 wt% of Carbon, and in addition, other alloying elements, which render them susceptible to
heat treatment and more corrosion resistant. Plain low-carbon steels and high-strength low alloy,
medium-carbon, tool, and stainless steels are the most common types.
Cast irons contain a higher carbon content, normally between 3.0 and 4.5 wt% of carbon, and
other alloying elements, notably silicon. For these materials, most of the carbon exists in graphite
form rather than combined with iron as cementite. Gray, malleable, ductile and white are the
common types of cast irons.
8.0 REFERENCE
MATERIAL SCIENCE
4. Cast iron.
http://en.wikipedia.org/wiki/Cast_iron#White_cast_iron
5. Carbon steel
http://en.wikipedia.org/wiki/Carbon_steel
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