Materials

• Classification of Engineering Materials

• Composition of Cast Iron and Carbon Steel
• Mechanical Properties of Materials
• Hooks Law and Modulus of Elasticity
• Stress Strain Diagram for Ductile and brittle Material
• Introduction to UTM (Universal Testing Machine)
Classification of Engineering Materials
Metal: Metal is a solid material that conducts heat & electricity,
hard, shiny, malleable, fusible, and ductile.
Non-Metal: Non-metals are the elements which form negative
ions by accepting or gaining electrons. Non-metals usually have
4, 5, 6 or 7 electrons in their outermost shell.
Ceramic: A ceramic is a crystalline non-metallic inorganic
material. Most ceramic are hard, brittle and corrosion
resistant.
Organic Polymer: The preparation or fabrication of organic
polymers include polymerization reaction in which simple
molecules called monomer are chemically combined into
long chain molecules or 3- dimensional structure called
polymers.
Composite: Composites are also a mixture of two or more elements, but it does not
contain metals. A composite is always a heterogeneous mixture.

Alloy: An Alloy is a mixture of one or more metals with other elements. An alloy
can either be a homogeneous or a heterogeneous mixture.
 Cast Iron
• Pig Iron: Pig iron is obtained by smelting (called chemical reduction) of iron
ore in the blast furnace. Pig iron is the basic raw material from which all cast
iron, wrought iron and steel are made.
• Cast Iron: The pig iron is tapped from blast furnace is still the crude form of
raw material and is not suitable for making castings without some degree of
refining.
The pig iron is refined in cupola furnace which is small form of blast
furnace.
This refined pig iron tapped from cupola is called cast iron
Cast iron is an iron alloy consisting of 2-4% carbon, as well as varying
amounts of silicon and manganese, and small quantities of impurities
like sulfur and phosphorus.
Applications: Frames, Pulleys, flywheel, coupling, pipe fittings, automobile
cylinder, pistons, machine beds.
 Types of Cast Iron
• Grey Cast Iron : When the carbon is not chemically combined with iron, it is
known as free carbon or graphite carbon and resulting cast iron is known as
grey cast iron.
• Composition:
Carbon – 2.5 to 4%
Manganese – 0.4 to 1%
Sulphur – 0.02 to 0.15%
Silicon – 1 to 3%
Phosphorous – 0.15 to 1%
Remaining is iron
Properties or Characteristics:
• Good compressive strength
• Good torsional & shear strengths
• Good corrosion resistance
• Good Wear resistance
• Excellent machinability
 Types of Cast Iron
• White Cast Iron : Its white color is due to the fact that it contains no graphite
and all the carbon is in the form of carbide known as cementite, the hardest
component of iron.
• Composition:
Carbon: 1.75-2.3%
Silicon: 0.85-1.2%
Manganese: Less than 0.40%
Phosphorous: Less than 0.2%
Sulphur: Less than 0.12% and
remaining percentage is Iron.
Properties or Characteristics:
• Hard & Brittle
• High abrasion resistance
• High tensile strength & low compressive strength
 Types of Cast Iron
• Malleable Cast Iron : Malleable Cast Iron is a type of cast iron that is manufactured by
heat treating White Cast Iron to break down the iron carbide back into free graphite.
This produces a malleable and ductile product that has good fracture toughness at
low temperatures.
• Composition:
Carbon – 2.0 to 3.0%
Manganese – 0.2 to 0.6%
Sulphur – 0.10%
Silicon – 0.6 to 1.3%
Phosphorous – 0.15 %
The remaining is iron.
Properties or Characteristics:
• Good ductility & machinability
• High yield strength & tensile strength
• Excellent impact strength
• Not as brittle as grey cast iron
• High Young’s modulus & low coefficient of thermal expansion.
• Good wear resistance & vibration damping capacity
• Excellent machinability
 Types of Cast Iron
• Nodular (Ductile) Cast Iron : Ductile Cast Iron is produced by adding a small amount
of magnesium, approximately 0.2%, which makes the graphite form spherical
inclusions that give a more ductile cast iron. It can also withstand thermal cycling
better than other cast iron products.
• Composition:
Carbon – 3.2 to 4%
Manganese – 0.2 to 0.5%
Sulphur – 1.8 to 3%
Silicon – 1.8 to 3%
Phosphorous – 0.08% max
Remaining is iron
Properties or Characteristics:
• Good fatigue strength
• Good impact strength
• Hardness & high modulus of elasticity
• Corrosion resistance similar to that of grey iron
• Excellent castability & wear resistance
• Good machinability
• Ability to resist oxidation at high temperatures
 Carbon Steel
• Carbon steel is an iron-carbon alloy, which contains up to 2.1 wt.% carbon.
For carbon steels, there is no minimum specified content of other alloying
elements, however, they often contain manganese.
Types of Carbon Steel
Low Carbon Steel: Low-carbon steel is the most widely used form of carbon
steel. These steels usually have a carbon content of less than 0.25 wt.%.
Carbon steels are usually relatively soft and have low strength. They do,
however, have high ductility, making them excellent for machining, welding and
low cost.
• Applications: Steel wire, sheets, rivets, screw, pipe, chain.
Medium Carbon Steel: Medium-carbon steel has a carbon content of 0.25 –
0.60 wt.% and a manganese content of 0.60 –1.6.
medium-carbon steels have greater strength than low-carbon steels, however,
this comes at the expense of ductility and toughness.
Applications: Railway wheels, gears, crankshafts, connecting rods, wires and
rods
High Carbon Steel: High-carbon steel has a carbon content of 0.60– 1.25 wt.%
and a manganese content of 0.30 – 0.90wt.%. It has the highest hardness and
toughness of the carbon steels and the lowest ductility
Applications: hard tools, press tools, machine parts, reamers, metal cutting
saws, twist drills.
 Mechanical Properties of Materials
Elasticity: It is the property of materials to regain its original shape after deformation
when the external forces are removed. Example is the extension or compression of a
spring.

Plasticity: It is the ability of material to undergo some degree of permanent

deformation without rupture or failure. That means, this is the property of a material
to deform permanently under the application of a load.

Ductility: It is the property of a material which enables it to draw out into thin wire
with the application of a tensile force.

Brittleness: Breaking of a material with little permanent distortion simply states the
property of brittleness. Brittle materials when subjected to tensile loads snap off
without giving any sensible elongation.

Malleability: It is the ability of materials to be rolled, flattened or hammered into thin

sheets without cracking by hot or cold working.

Stiffness: It is the ability of a material to resist deformation under stress. Modulus of

elasticity is the measure of stiffness.
 Mechanical Properties of Materials
Toughness: It is the ability of a material to withstand bending without
fracture due to high impact loads.

Resilience: The property of a material to absorb energy and to resist shock

and impact loads are known as resilience. Generally, it is mentioned by the
amount of energy absorbed per unit volume within elastic limit.

Creep: When a part is subjected to a constant stress at high temperature for

a long period of time, it will undergo a slow and permanent deformation
called creep. Property is considered in designing IC engines, boilers, turbines.

Fatigue: It is a failure of materials under cyclic loads. When a part is subjected

to a repeated or fluctuating stresses.

Hardness: Property of a material to resist penetration by another material is

known as hardness. It embraces many different properties such as resistance
to wear, scratching, indentation, deformation etc.
 Hooke’s Law and Modulus of Elasticity
Hooke’s Law: Within elastic limit stress is directly proportional to strain.

Stress (σ ) ∝ Strain (ε)

σ=Eε
E=σ/ε

Where,
E= Modulus of elasticity/ Elastic Constant/ Young’s Modulus of Elasticity
Unit- N/m2
 Stress Strain Diagram

• For Ductile Materials

 Stress Strain Diagram

• For Brittle Materials

 Universal Testing Machine (UTM)
Specimen of UTM