Materials Engineering Laboratory Manual

PCC-ME 205P

INDEX
SR.
NO. NAME OF EXPERIMENT
DATE
TO STêDY CRYSTAL
STRUCTURE
2 HARDNESS MEASUREMENT USING BRINELL
HARDNESS INSTRUMENT:
HARDNESS MEASUREMENT USIG ROCK WBLL
HARDNESS INSTRUMENT
4 STUDY OF EFFECT OF
ANNEALING &
NORMALIZING.
STUDYOF
MCROSTRUCIUREOF PLA!
CARBONSTEE.
6 PREPARATION OF METALLORPHIC
EXAMINATION OF BAR
STUDY OF
STUDY OF
METALLOGRAPHIC MICROSCOPE.
HARDENABILITY
JOMINI & QUENCH TEST.
OFSTEEL BY
STUDY OF
MICROSTRUCTURE OR CASTRON,
 ,

DXPERIEMENT NO1
Aim :Tostudy of crystal structwe.
Introduction and Theory:
1) LimitCell:
Aunit cell is the smallest regular shape in space whica when repeated , generate the
whole crystal lattice.
Atomic arangement is understand by unit cell shape &size of unit can be defined by
vector A,B,C& angle a, B, y.

2) Space Lattice :
The arrangement of atomin cell can of points be understood in terms of the
arrangement distributioof lattice space, such atom havingidentical types like
i) Simple Cubic
ii) Body Centered Cubic
ii)Face Centered Cubic
iv) Hexagonal Closed packed

i) Simple Cubic:
In simple cubic, the atom are assumed to be the space in such away two
adjacent atom touch each other.
Let, a lattice perimeter
b Radius of Atom
d/2

Arrangement of No. of Atom can be calculated by:

Nc, Nf, Ni
Navg.=

Now,
Ne=8Nf = 0& Ni=0

Navg, =+ + 1

[Link] efficiency =Avg, No of atoni per unit cell x Vol. of an atom

Vol. of unit cell
 = 1x4/3 nr
a
= 4nr
3a
6

i) Body Centered Cubic:

In BCC, central atom touches [Link] atom.
There are eight corner & one centre atom.

Nc + Nf, Ni
Navg. = 8 2 1

8 2 1
= 2
A. P.E. = 2x 4/3 [(av3/4)1 (since, r =3/4 a)
a

=0.68

ii) Face Centered Cubic:

F.C.C., there are eight atoms at eight corners &6 atoms on the faces &no
interior atom.

Nc Nf Ni
Navg.=RT21
8 6 1

=4
A. P. E. = 4xn/3 [a/v81
a
= 16 Xa x 1
3a' 8V8
A. P. E. =0.74

RESULT:
 EXPERIEMENT NO 2
nARDNESS MEASUREMENT USING BRINELL HARDNESSINSTRUMENT.
Introduetion and Theory:
In this hardness of
metal is correlated with the diameter ofindentation &not with the
depth of indentation, as in case of rock-well hardness tester.
In this test, the standard steel ball is
The diameter of indentation pressed into the surface of specimen by definite time.
compression is obtained is display by aborinell microscope on the
screen &measured with the help
found out with the following of micrometer screw guage&brinell hardness no. (BoHoNo) is
formula.
BoHoNo Load
Area of Indentation
OR

BoHoNo 2P (D-VD-)

Where, P=load ( Kg- F)

D= Diameter of ball (mm)
The test is carried out with
f load is used for hardened steel. Our carbide of
testing ferrous material lloyof similar hardness. ball 1Omm
diameter. A300 Kg
When brass &shaft alloys are
specified between 10 &30 sec. dependingtested at 500 kg f load is
upon the alloy being used. The time of load is
Procedure: exclaimed
i) Firstly identify the
material of test piece whose hardness is to be
ii) Select proper size of ball indents &fixed the
meaesee
material to be tested as mention above in T.I. turret. The size &wt to be
ii)
selected as per the
Activated the toggled switched. To switch on the
lamp or light source &
iv) Keep the handle to unload position & weight until started the motar.
position. level &hanger
bracket reaches
its to 'p!
v) The test piece whose hardness to load
position cause gradual load
application.
vi) Now, turned the handled to load position cause gradual load application by lever on the test
piece. The ball in deter penetrate in the specimen to same extent & stops as specimen resists.
vii) The time of loading should be fail 10 to 15 set.

viii) An completion of loading period turn the handle to unload position.

ix) After this positioned lever to Read made. Due to this indenter gets swilled &dia of
indentation is projected on screen.
Result:
Hardness testing of no. of material is calculated in terms of brinell hardness number.

Comparison between Brinell& Rockwell

Advantages:
Suitable for either hard & soft material or specimen.
hardness
Surface condition of specimen/ component to be tested is not so critical because
is correlated to the depth of penetration,. But for high degree of accuracy surface should
be polished force from surface defects.
Hardness no can be obtained directly from dial & hence, force from surfaces personal
defects.
Little forcing for operating the instrument.
Test is very fast as time required for experiment person is less than a min.

Drawbacks of BHT:
Not suitable for heterogeneous material.

Results:
 NO3
EX PERIDMENI
Rockwell Hardness Test:
Aim:-HARDNESS MEASUREMENT USINGROCKWELL HARDNESS INSTRUMENT
Theory:
In this method hardness of specinmen is
not with the area of indentation, as in case of correlated with the depth of indentation &
Brinell
concept of in this case is harder material deph of hardness tester. The thumb rule or
Vice-versa. Hence, haraness is inversely [Link] is less for given load &
tothe depth of indentation. The
1S calibrated in as dial
inverse fashion so that hardness nunber
hardness number of material. becomes fashion so that
In this test two types of
indent are used :
Hard steel ball of 1/16", 1/8", 1/4",
1/2" ala".
Brateindentors
is
made of diamond in the form of
cone with
accurately ground to ihe radius of 0.2mm. inducted angle of 120. The hp
Loads are applid to the two
major load are 60,100,130 stages 1" a constant minor
kg. The various load is
letters A,B,C, etc. combination of indents &load applied. The
are indented by
A, letter indicates 60 kg
loads &brateintented.
B,letter indicates 100 Kg
loads 1/16" diameter ball
C. letter indicates 160 Kg loacs &brell
intents &so on.
Procedure:
> First put
specimen on anvil &raise anvil
touches the indenter. along with specimen
is raise so that
Further rising the anvil slowly a minor load of
dial coincides with the long is applied at this specimen
index. Mark and large pointer will be stage small
automatically matches with 0' mark.
Major load of 60 or 100 or 150 Kg is vertical position pointer
&
on
applied by means
on right sidee of an
instrument. This load is applied of release disc or handle provided
arrangement due to this pointer moves in C.C.,W. generally
by means of
Without removing mino load of 10Kg the major loud from set point. dash - pot
direction
consequence of elastic recovery of by specimen the (above mentioned) is removed as
direction. largor pointer
rotates in C.C.W.
 Thus, hardness number can be read direction from dial by using guideline &irrespective
scale in [Link]. &T. IIwithout removing the major load.

Advantages:
Suitable for either hard & soft material or specimen
Surface condition of specimen / component to be tested is. not so critical because hardness
iscorrelated to the depth of accuracy, penetration.
Hardness no can be obtained directly from the dial &hence free from pesonal error &
further calculation are not required.
A Little training for operating the instrument is required.
A The test is very fast on time required for experience person is less than a min.

Results:
 intern
satr
l e: s

G r as
in

EXPERIEMENT NÌ 4
Alm:-STUDY OF EFFECT OF ANNEALING &NORMALIZING TREATMENT ON
PROPERTIES OF STEEL.
Introduction:-Aim of annealing &normalizing as follows:
> To reduce hardness of
steel
To impart ductility of sicel sample
Tomake the sarmple
steel
machinable
To refine microstructure
To make material homogeneous in respect of
To relieve internal stresses. chemical composition.
> To increase the uniformityof phase distribution.
Annealing:
Heating the steel above austenising temperatuze & then
> Furnace cooling is slow, cooling process result into cooled slowly in the furnace.
coarse grained structure.
Types:
A. Conventional (Full
B. Isothermal ( Cycle
Anneaiing )
Annealing)
C. Spheroidise Annealing
D. Sub- Critical anneling

Normalizing :
Healing the steel above austenizing temp & after ging
required into fined grained structure. soaking time cooled it in air

Temperature range of steel

Temperaturee
Hypoeutectoid steel Annealing Normalizing
Ac, + 5âc
Hypereuctectoid steel Ac: + 5âc
Ac + 5c Acm + 5Oc
Observation:
Anneatead Sample
Normalized Sample
" Less hardness, tensile strength & toughress,
Slightiy more hardness, tensile
course grain of ferrite and'pearlite are obtained strength &toughness, very fine grain
 internal stress are least. of ferrite and perlite are obtained
internal stresses are slightly more.

Grain size distribution is more uniform. Grain size distribution is slightly less
uniform.

Appearance get resolved by electro

Appearance of pearlite get resolved by microscope but not possible by
optical microscope.
optical microscope.

Result:
 EXPEREMENT NO 5
Alm:- STUDY AND DRAWING OFMICROSTRUCTUREOF LANE CARBON STEEL.
Introduction :
Microstructure of different type of r laincarbon steel can be studied with the help of
metallurgical microscope &study the iron carbide equilibrium diagram & general
of temp &
Composition. representation
Austenite:-It is a interstitial soBid solution of iron & carbon.
Cementite:-It is an metallurgarphic compound of iron and carbon having
a Ferrite:- It is an interstitial carbon solutiòn of solid in a
orthorhombic Crystal.
iron.
Pearlite: - It is an eutectoid mixture of a
Ferriteand cementite.
Rough Grinding: - Sample may be made fiat by
moving up and tlock across the surface of flat
smooth grinder.
Finer Polishing:-The final
approximate to flat straten free surface is obtained by the use of
rotating wheel covered with abrasive particle.
for ferrous alloy performance is given to
aluminum oxide abrasive powder.
Intermediate Polishing:
Mounted,specimen is polished on a series of energy paper i.e.
polishing paper from the camble 1l to 90% so that new while changing the
to previous one direction of scratches should be exactly
perpendicular
polishing on various energy are shown in fig.
Etching Reagent Uses
2% (Nitric Acid to 98ml mnethyl or ethyl alcohol)
For plain carbon steel &
iron.
cast
Ferrite chloride (FeCl) + hydrochloric acid, Ferric
chloride Sgm, Hydrochloric acid = 50ml,
For Copper & its alloy
water = 100ml
Hydrofericacid (H7) 0.00+[Link]+H2o =9.5ml For aluminum & its
NaOH = 10.9ml + water =) ml
For aluminum & its
alloy
alloy
Result:
 EXPERIEMENT NO 6

Aim:- Preparation Of Metallogrphic Examination Of Bar.

Theory:
Microscopy study depends largely upon the care taken in the preparation of the specimen of
in a
procedure to be followed in the preparation of specimen comparatively simple & involve
produce a flat
technique which is developed only after constant particle aultimate object as to be
created file mirror line surface.

Steps involving to produce a metallographic specimen are as follows:

Sampling:
If the material is soft & section may be obtain by material rack saving. If the material be
hard. The section may cut by use of abrasive cut of steel the specimen should be kept cool during
cutting operation.
Mounting:
The material that are smallor accurate shaped should be measured to facilitate.

Microstructure of Plain Carbon Steel at Room Temp.

Low Carbon Steel (0% Cto 25% C)

Medium Carbon Steel (% C to 0.25 to 0.65)
High Carbon Steel ( %C0.65 to 2%)
Eutectoid Steel:
If steel contain 0.85 % carbon called as euctectoid steel allsteel having carbon from 0.13 to2
% called hypo - euctectoid steel.

Composition:
As per Fe-Fe,C equilibrium diagramall hypo- euctectoid steel shows a - Ferrite & perlite
&euctectoid steel shows 100% pearlite. Ahypo-euctectoid steel shows pearlite cementite,
Specimen 1;
Low Carbon Steel

Composition
Magnification
Etching Reagent
Microstructure
Specimen 2:
Medium Carbon Steel
Composition
Magnification
Etching Reagent
Microstructure
Specimen 3:
High Carbon Steel
Composition
Magnification
Etching Reagent
Microstructure
Specimen 4;
Eutectoid Steel
Composition
Magnification
Etching Reagent
Microstructure

Result :
 EXPERIEMENT NO 7

Aim:- Study Of Metallographic Microscope.

Principle:
in the
In a comparison with biological types the metallo-graphical microscopebydiffers
regulated source. A
illuminated
manners by which specimen illuminated. The sample must be
Glass reflective downward
horizontal beam of light source is reflected by means of plane. through the
magnificd to parting
through the microscopic objective lense into the surface willbe through the plain glass
upward
power lens system. The objective & will obtain continuous
reflector & magnitude again by the upper lcns system.
metallurgical microscope is about 150%.
The [Link] obtained with the
Procedure:
microsçope as shown in fig.
Observe the different part of microstructure under
objective lens.
Note the magnifying power makes an eyepiece &
Find the total magnification used.
Used the etched sample under objective lense.
the sample.
Observed an eyepiece &terythe focus. The image by rising or lowering
> Use fine focusing for clear image.
brightness.
By using light intensity knob, adjust the sufficient
> Draw the observed structure by magnification.
> Make the microscope off immediately after used.

Observation:
The Magnification = Magnifying power of eyepiece X Magnifying Power of object

Result:
 EXPERIEMINT
NO8
Aim:-Determination Of Harde::ability Of Steel By Jomini& Quench Test.
Hardenability:
It can be defined as the ability of steel to be hardened up-to certain depth by ideal quenching
test (prOcess)
> Total length of test piece 100 0.5mm
Diameter of test piece 25 +).5mm
> Time during which test piece is
maintain hardening ten p. of steel sample. 45 min
> Temp. Of sample 5To 30 C
Time seconds between removal of test
piece from furnace & sxt [Link] 5 sec
> Diameter ofvertical suppiy pipe. 12.5 +0:5mm
Ht of force water jet 65± 10mm
> Distance from H.P. &nozzle to bottom
of test piece. 12.5+ 0.5mm
Depth of grinding flat for measurement
of Hardness 0.4min

Principle of Test:
The test consist of heating a test given temp for a specified period of time followed by
water quenching at one end of measuring ths hardness of various point from the quench end
along the length of test piece.

Procedure:
The specimen is prepared of cylindricai shape of 25.4mm of diameter. A5 nmm thick
collar of diameter of 28mun (approx).is provided at one end which supportsthe specimen
in fixture.
A suitable fixture is design to hold the specimcn nozzle force water jet.
The fixture is placed in plate to collect water &dispose it off.
The size of specimen the size of jet the distance of the specimen from bottom of the jet &
the pressure of water ail are standardized . Initially the specimen is heated to temp. (AC,
to 50 c) in furnace.
The specimen is then removed from furnace ard placed on fixture.
> Immediately the water is impinged on specimen by the nozle provided its the pipe hus
inner diameter 12.7mm 7 also distance between them is 12.7m
> The specimen is quencied at one end &other end is air cooled.
The rate of cooling at jet end is 300 c/ sec while other end which is air cooled 3 c/sec.
 > Once the specimen attains room temp. it is removed from fixture.
> Graph of hardness at different points is draw as follow ;

Result:
 EXPERIEMENT N09
Aim:-Study and drawing of M'crostructure of Cat Iron.
Introduction:
Cast iron are alloy of iron &carbon in which carbon varies 2 to 6.67 %.
Cast Iron

White C.I. Grey C.I. Malleable C.I. Nodular CJ.

Carbon in cast iron is above 2%.Thic cerbon maybe existing in cast iron either in combined
form i.e. ceinentite (FeC) or ir: the free form i.e. graphite.

Microssructure of Cast Iron:

Specimen 1:
White Cast Iron

Magnification 100x

Etching Reagent
Microstructure

Specimen 2:
Pearlite Grey Cast Iron
Magnification (M0x

Etching Reagent
Microstructure
Specimen 3:
Ball's Eye, Malleable Cast Iron
Magnification 100x

Etching Reagent
Microstructure