MSMT Lab Manual
MSMT Lab Manual
MSMT Lab Manual
MMS LAB
AIM:
To mount the given pure metals like Iron, Cu, and Al specimen in a thermosetting
material by using a mounting press and to draw their microstructure.
APPARATUS:
Mounting press
Thermosetting powder
Specimen
Microscope
DESCRIPTION:
The mounting press consists of top plate and bottom plate with movable centre
stage plate which is moving up and down along the guide ways. The middle part is
raised and lowered by hydraulic jack. The mould part is the space between the guide
ways. Its temperature is controlled by a knob. A digital timer is also provided on the
panel to maintain the constant temperature of the mould for a certain period of time.
In belt polishing machine, an endless belt rotates between two shafts. In plate
polishing machine different grades of emery papers are placed on the stand. In disc
polishing machine emery cloth is placed over the two rotating plates.
The given specimen is placed in the desired position preferably at the centre of the
mould .Bakelite powder is poured up to the required level. The spindle is tightened. Set
400 sec in the digital timer. Switch ON the power supply. When 0 sec is reached in the
digital timer, press the reset button, so that it again shows 400 seconds. Then for every
100 sec apply the pressure through hydraulic jack. When the digital timer shows 0 sec
switch OFF the power. After three to five minutes take out the mounted specimen.
Finally the specimen is mounted in the thermosetting material.
The mounted specimen is polished successively on belt, plate and disc polishing
machines to obtain the fine surface finish. Place the specimen under the microstructure
ad draw the microstructure of the same.
PRECAUTIONS:
RESULT:
CONCLUSION:
AIM:
To prepare the specimens of pure metals like mild steels, low carbon steel and
High carbon steels and observes the microstructure of the same
APPARATUS:
Given specimen
Belt grinder
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 not considered. The plain carbon steels are broadly classified in to low carbon
steels with carbon content less than 0.3 percent and medium carbon steels contain Carbon
between 0.3 to 0.7. The high carbon steels contain carbon from 0.7 to 1.5 percent.
PROCEDURE:
The specimens of pure metals like Mild steel, Low carbon steel and high carbon
steels are mounted in a thermosetting material as explained in the experiment no. 1. Polish
the specimen by using (80,120,240,400and 600) grade emery papers. Subject the given
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 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.
PRECAUTIONS:
RESULT:
CONCLUSION:
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 specimen
Belt grinder
Microscope
THEORY:
Cast irons contain 2 to 6.67 % of carbon. Since high carbon content tends to make the
Cast iron very brittle, most commercially manufactured types are in the range of2.5 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 to final 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 of any cast iron can be varied over a wide range.
Polish the specimen by using (80,120,240,400,600) grade emery papers. Subject the
given specimen to mirror like finish by using disc polishing machine and with
suitable abrasive. clean the specimen with alcohol and wash it under the stream of
flowing water
After washing the specimen is dried. After drying supply the suitable etching agent
for 30 to 50 sec.
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 brittle and difficult to machine.
White cast irons are limited in engineering applications because of brittleness and
lack of mach inability. They are used where resistant to wear is important and service
does not require, such as cement mixer, ball mills certain types of drawing dies and
extrusion nozzle. A large tonnage of white cast iron is used as a raw material for
manufacture of malleable cast iron.
The composition of typical malleable cast iron is as follows
Carbon: 2.9%
Silicon: 1.15%
Manganese: 0.6%
Phosphorous: 0.15%
In which most or all of the carbon is uncombined form of graphite flakes. The
tendency of carbon to form as graphite flakes is due to increased silicon and carbon
content and there by 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 capacity and 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 provides lubricating effect to sliding
bodies.
Nodular cast iron is also known as ductile iron. Spheroidal graphite iron is a cast
iron in which graphite is present as tiny balls or spheroids. The compact spheroids
interrupt the continuity of the matrix much less than graphite flakes. This result in
higher strength and toughness compared with a similar structure of grey cast iron.
Nodular cast iron differs from malleable cast iron in that it is usually obtained as a
result of solidification and does not require heat treatment. The spheroids are more
rounded than irregular aggregates of temper carbon found in malleable cast iron. The
formation of spherical graphite is due to addition of magnesium to the molten grey iron.
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.
AIM:
To study the microstructures of Non ferrous specimen alloy specimens like Cu, Al,
alloys and bearing metal
APPARATUS:
Metallurgical microscope
Suitable etchants
THEORY:
Non ferrous metals ad 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.
PROCEDURE:
Polish the specimen by using (1/0, 2/0,3/0,4/0,) grade emery papers. Subject the
given specimen to mirror like finish by using disc polishing machine and with
suitable abrasive. clean the specimen with alcohol and wash it under the stream of
flowing water
After washing the specimen is dried. After drying supply the suitable etching agent
for 30 to 50 sec.
CU- ALLOYS
BRASS:
Brasses are the copper alloys containing zinc up to 30% they possess relatively
good corrosion resistance and good working propewrties. They also posses 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
shows a typical equi axied grain structure with twins in annealed structure. This brass is
used for making cartridge cases. Other applications include4s 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 are there.
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
BEARING METAL:
Bearing metal has high compressive strength and high wear r 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
PRECAUTIONS:
Polishing should be slow, smooth and flat
Uniform pressure is applied through out the polishing
RESULT
AIM:
To identify, draw and to analyze the microstructures of heat treated specimens like
Grey Cast Iron, White Cast Iron, Malleable Cast iron, and S.G. Cast iron etc.
APPARATUS:
Given specimen
Belt grinder
Microscope
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. The various 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 furnace or 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.
PROCEDURE:
Polish the specimen by using (80,120,240,400,600) grade emery papers. Subject the
given specimen to mirror like finish by using disc polishing machine and with
suitable abrasive. clean the specimen with alcohol and wash it under the stream of
flowing water
After washing the specimen is dried. After drying supply the suitable etching agent
for 30 to 50 sec.
PRECAUTIONS:
RESULT:
CONCLUSION:
AIM:
To evaluate the hardenability of the low carbon steel or medium carbon steel by Jomny end
quench test Method.
APPARATUS:
Heat treatment furnace
Jomny end quench apparatus,
Test specimen,
Rockwell test setup
PROCEDURE:
The various steps involved in evaluating the hardenability test for a given specimen are
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.
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.
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 I 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. 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 fro 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.
PRECAUTIONS:
1. Dont use the hard water as it leads to formation of scales in nozzles and copper
conduits.
RESULT:
CONCLUSION:
AIM:
To find the hardness of the given treated and untreated steel specimens by
conducting the hardness test.
APPARATUS:
Hardness tester
Diamond penetrant
THEORY:
The method of testing introduced by J.A.Brinell in 1900 consisting of indenting the
metal with a d mm diameter and tempered steel ball subjected to a definite load. ball of
10 mm , 5 mm , ad 2.5 mm are generally used. The load is maintained for a definite period
(usually 10 or 15 sec) after which 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
Brinnels hardness number HB = Total load / surface area of indentation
2F
---------------------- D (D- (D2 d2)
The face of the specimen is lightly grind and rubbed with fine emery paper if
required.
Select the proper test table based o the size and shape of the specimen and place it
on main screw or elevating screw
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.
Place the required weights on the weight hanger based on the type of material of the
specimen and diameter of the indenter
Turn the hand wheel in clock wise direction so that the specimen touches the ball
indenter
Lift the operating lever fro the horizontal position upwards slightly, after which it
rotates automatically.
PRECAUTIONS:
RESULT:
The Brinnel hardness number of the give material is -------
CONCLUSION:
material P/D2
Dia. of
Applied
indenter load
D mm
Kgf
Brinell
Hardness
number
Ferrous
material
Steel & Iron
Brass
Aluminum
Soft bearing
material
P/D2
30
10
2.5
AIM:
To find the surface and sub surface defects in a given ferromagnetic material by
using Magna flux test.
APPARATUS:
THEORY:
PRINCIPLE OF OPERATION:
The principle of this test consists of inducing a magnetic field in the specimen of
interest either by passing an electric current or by the influence of internal magnetic field
yoke coil surrounding the specimen.
Load flux leakage field, which may be detected by the application of finely, divided
particles or Ferro magnetic powder to the surface of the specimen. The Ferro magnetic
powder of fine size will offer paths of low reluctance to the leakage fields and as a
The Ferro magnetic powder used here is fine iron powder of 250 mesh size. The
specimen is to be magnetized using direct current (D.C) or alternative current (AC) the
detections to only the discontinuities that is open to the surface. This is due to the
phenomenon of skin effect. The use of A.C limits only to small sizes. However, D.C
magnetization makes possible the direction of large and small sub surface discontinuities as
well as located directly on the test surface.
PROCEDURE:
PRECAUTIONS:
LIMITATION:
RESULT:
CONCLUSION :