Cover
About the Author
Title Page
Copyright Page
Dedication
Contents
Preface
THE FUNDAMENTALS
Chapter 1 Introduction
What is Material
Engineering Materials
Metallic Materials
Non-metallic Materials
Composites
History of Materials
Materials and Engineering
Branches of Metallurgy
Review Questions
Chapter 2 Structure of Materials
Atomic Structure
Electronic Structure of the Atom
Atomic Bonding
Bonding and Properties
Structure of Solids
Crystal Structure
Metallic Crystal Structures
Directions and Planes in an Unit Cell
Crystallisation of Pure Metals
Nuclei Formation
Crystal Growth
Grain Size
Crystal Defects
Point Defects
Line Defects
Planar Defects
Microstructure
Review Questions
PART I ALLOYS AND PHASE DIAGRAMS
Chapter 3 Alloys and Phase Diagrams
Classification of Alloys
Solid Solutions
Intermediate Phases or Compounds
Phase Diagrams
Phase Rule
Binary Alloy Phase Diagrams
Isomorphous System
Chemical Composition of Phases
Amount of Each Phase (Lever Rule)
Equilibrium Cooling
Non-equilibrium Cooling
Eutectic System—I Type
Cooling of Alloy 1 (60Bi–40Cd)—Eutectic
Cooling of Alloy 2 (80Bi–20Cd)—Hypoeutectic
Cooling of Alloy 3 (20Bi–80Cd)—Hypereutectic
Eutectic System—II Type
Cooling of Alloy 1 (98Pb–2Sn)
Cooling of Alloy 2 (38Pb–62Sn)—Eutectic
Cooling of Alloy 3 (60Pb–40Sn)
Cooling of Alloy 4 (90Pb–10Sn)
Peritectic System
Cooling of Alloy 1 (46Ag–54Pt)
Cooling of Alloy 2 (60Ag–40Pt)
Solid State Reactions
Eutectoid Reaction
Peritectoid Reaction
Solved Problems
Review Questions
Chapter 4 Iron-Iron Carbide Equilibrium Diagram and Plain Carbon Steels
Allotropy of Iron
The Iron-Iron Carbide Diagram
Plain Carbon Steels
Slow Cooling of Plain Carbon Steels
Critical Temperatures
Properties and Uses of Plain Carbon Steels
Solved Problems
Review Questions
PART II HEAT TREATMENT
Chapter 5 Heat Treatment of Steels
Heat Treatment
Isothermal Transformation
TTT Diagram
Transformation Mechanisms
Cooling Curves and the IT Diagrams
CCT Diagram
Heat Treatment Processes for Steels
Annealing
Full Annealing
Spheroidising Annealing
Stress Relief Annealing
Recrystallisation Annealing
Normalising
Normalising Versus Annealing
Hardening
Mechanism of Heat Removal During Quenching
Factors Affecting Hardening Process
Tempering
Austempering or Isothermal Quenching
Martempering or Marquenching
Hardenability
Jominy End Quench Test
Representation of Hardenability Data
Use of Hardenability Data
Surface and Selective Hardening
Carburising
Methods of Carburising
Heat Treatment after Carburising
Carbonitriding
Cyaniding
Nitriding
Vacuum and Plasma Surface Hardening
Vacuum Surface Hardening
Plasma Surface Hardening
Flame Hardening
Induction Hardening
Solved Problems
Review Questions
PART III FERROUS AND NON-FERROUS ALLOYS
Chapter 6 Alloy Steels
Purpose of Alloying
General Effects of Alloying Elements
Classification of Alloy Steels
Structural Grade Alloy Steels
Nickel Steels
Chromium Steels
Nickel-Chromium Steels
Manganese Steels
Silicon Steels
Molybdenum Steels
Vanadium Steels
Boron Steels
Tungsten Steels
Steels with Titanium
Stainless Steels
Ferritic Stainless Steels
Martensitic Stainless Steels
Austenitic Stainless Steels
Precipitation Hardening (PH) Stainless Steels
Duplex Stainless Steels
Tool and Die Steels
Water Hardening Tool Steels
Shock Resisting Tool Steels
Cold Work Tool Steels
Hot Work Tool Steels
High Speed Steels
Mould Steels
Special Purpose Tool Steels
Special Alloy Steels
Free Machining Alloy Steels
Austenitic High Manganese Steels
High Strength Low Alloy (HSLA) Steels
Interstitial Free (I-F) Steels
Dual Phase Steels
Maraging Steels
Indian Standard Code for Designation of Steels (IS: 1762–1974)
Steels Designated on the Basis of Mechanical Properties
Steels Designated on the Basis of Chemical Properties
Solved Problems
Review Questions
Chapter 7 Cast Irons
Classification of Cast Iron
Factors Influencing Structure of Cast Iron
Effect of Rate of Cooling
Effect of Chemical Composition
White Cast Iron
Grey Cast Iron
Chilled Cast Iron
Malleable Cast Iron
Malleabilisation Heat Treatment
Types of Malleable Cast Iron
Nodular Cast Iron
Compacted Graphite Iron
Alloy Cast Irons
Indian Standard Code for Designation of Cast Irons (IS: 4843–1968)
Solved Problems
Review Questions
Chapter 8 Non-ferrous Alloys
Copper and Copper Alloys
Brasses
α-Brasses
α-β Brasses
Cast Brasses
Bronzes
Tin Bronzes
Aluminium Bronzes
Silicon Bronzes
Beryllium Bronzes
Copper-Nickel Alloys
Indian Standard Code for Designation of Copper Alloys (IS: 2378–1974)
Aluminium Alloys
Wrought Alloys
Work Hardenable Alloys
Heat Treatable Alloys
Cast Alloys
Aluminium-Silicon Alloys
Aluminium-Magnesium Alloys
Aluminium-Zinc Alloys
Aluminium-Copper Alloys
Complex Casting Alloys
Indian Standard Code for Designation of Aluminium Alloys (IS: 5052–1993)
Alloy Designation
Temper Designation
Magnesium Alloys
Cast Alloys
Wrought Alloys
Zinc Alloys
Nickel Alloys
Monel Alloys
Nickel-Chromium Alloys
Nickel-Molybdenum Alloys
Nickel based Super Alloys
Titanium Alloys
Lead and Tin Alloys
Precipitation Hardening or Age Hardening
Bearing Alloys
White Bearing Metals
Bearing Bronzes
Aluminium-Tin Bearing Alloys
Silver Bearings
Solved Problems
Review Questions
PART IV NON-METALLIC MATERIALs
Chapter 9 Polymers
Polymerisation
Characteristics of Polymer Molecules
Molecular Weight
Chain Shape
Type of Mers
Chain Structure
Crystallinity of Polymers
Glass Transition
Additives in Polymers
Classification of Polymers
Thermoplastic Polymers
Commodity Thermoplastic Polymers
Engineering Thermoplastic Polymers
Thermoset Polymers
Elastomers
Types of Elastomers
Biodegradable Polymers
Solved Problems
Review Questions
Chapter 10 Ceramics
Traditional Ceramics
Clay Products
Glasses
Cements
Refractories
Advanced Ceramics
Oxide Ceramics
Carbides
Nitrides
Sialon (Si3Al3O3N5)
Borides
Some Special Applications of Advanced Ceramics
Solved Problems
Review Questions
Chapter 11 Composites
Definition and Classification of Composites
Matrix Materials
Reinforcements
Fibres
Whiskers and Particulates
Fibre Reinforced Composites
Fibre Reinforced Plastics (FRP)
Fibre Reinforced Metal Matrix Composites
Fibre Reinforced Ceramic Composites
Carbon-Carbon Composites
Particulate Composites
Particulate Reinforced Polymers
Particulate Reinforced Metal Composites
Ceramic Matrix Particulate Composites
Laminar Composites
Laminates
Clad Metals
Sandwich Structure
Fabrication of Polymer Matrix Composites
Fabrication of Metal Matrix Composites
Liquid Phase Processes
Solid Phase Processes
Fabrication of Ceramic Matrix Composites
Solved Problems
Review Questions
PART V MECHANICAL BEHAVIOUR OF MATERIALS
Chapter 12 Plastic Deformation and Fracture of Materials
Plastic Deformation of Metals
Slip
Slip in a Perfect Lattice
Slip by Dislocation Movement
Critical Resolved Shear Stress
Dislocation Sources
Twinning
Difference between Slip and Twinning
Plastic Deformation in Polycrystalline Metals
Preferred Orientation and Anisotropy
Strengthening of Metals
Strain Hardening or Cold Working
Grain Boundary Hardening
Solid Solution Strengthening
Strengthening from Fine Particles
Fracture of Metals
Ductile Fracture
Brittle Fracture
Ductile–Brittle Transition
Fatigue Failure of Metals
Fatigue Stress Cycles
Mechanism of Fatigue Failure
Fracture Appearance
Factors Affecting Fatigue Strength
Methods for Improving Fatigue Properties
Creep of Metals
Mechanisms of Creep Deformation and Rupture
Creep Resistance Alloys
Deformation of Polymers
Macroscopic Deformation
Deformation Mechanisms
Viscoelasticity and Creep
Fracture of Polymer Materials
Deformation and Fracture of Ceramics
Low Temperature Brittle Fracture
High Temperature Creep Rupture
Thermal Shock
Fracture of Fibre Reinforced Composites
Solved Problems
Review Questions
Chapter 13 Mechanical Testing of Materials
Tensile Test
Properties Obtained from the Tensile Test
Types of Engineering Stress-Strain Curves
Compression Test
Bend Test
Shear Test and Torsion Test
Hardness Test
Brinell Hardness Test
Vickers Hardness Test
Rockwell Hardness Test
Knoop Microhardness Test
Durometer Test
Impact Test
Charpy Test
Izod Test
Properties Obtained from the Impact Test
Fatigue Test
Endurance Limit
Fatigue Life
Creep Test
Creep Curve
Use of Creep Data
Solved Problems
Review Questions
Two Marks Questions and Answers
Solved Question Papers
Index
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