CEMS 436-Physical Metallurgy II/ CEMS 536-Physical and Mechanical Metallurgy. Fall Semester credits (2 lecture/1 lab).

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1 CEMS 436-Physical Metallurgy II/ CEMS 536-Physical and Mechanical Metallurgy Fall Semester credits (2 lecture/1 lab). Course Outline Instructor: Dr. Alan Meier - McMahon 354C (Lab: McMahon 325) Phone: x2462, meier@alfred.edu Texts: Required: N.E. Dowling, Mechanical Behavior of Materials (3 rd Ed.) Recommended: R.H. Reed-Hill, Physical Metallurgy Principles On Reserve at Scholes Library: G.E. Dieter, Mechanical Metallurgy (3 rd Ed.) N.E. Dowling, Mechanical Behavior of Materials (2 nd Ed.) Course Objective: This course is a continuation of CEMS 336. Important structure/processing/property relationships for metals will be analyzed with an emphasis on mechanical properties. Mechanical testing techniques and the effect of test temperature and strain rate on properties will be examined. Important metallurgical factors in failure analysis, corrosion, fracture, and fatigue will be discussed. A brief introduction to the physical and mechanical metallurgy of aluminum, steel, cast iron, titanium, magnesium, and stainless steel alloys will be presented. Laboratory experiments emphasizing mechanical testing, heat treatment and microstructural development will be performed and analyzed. Prerequisite: CEMS 336 or an equivalent introductory physical metallurgy course, graduate standing, or instructor permission. Lecture Topics: I. Mechanical Testing ~4 weeks -tensile/compression testing -hardness testing -Charpy impact testing -fracture toughness testing II. Mechanical Behavior -temperature effects -strain rate effects -fracture and fatigue ~4 weeks 1

2 III. Alloy Systems -Steel/Cast Iron -Aluminum -Titanium -Magnesium -Stainless Steel IV. Corrosion -corrosion mechanisms -forms of corrosion ~4 weeks ~2 weeks Laboratories (1 week labs unless otherwise noted): Grading: 1. Tensile/Hardness Testing 2. Compression Testing 3. Notch Tension Tests 4. Precipitation Strengthening of Aluminum 5. Strain Rate/Temperature Effects 6. Heat Treatment of Steel/Metallography (2 weeks) 7. Grain Growth/Strengthening. (2 weeks) 8. Corrosion 9. DBTT/Charpy Testing 10. Experimental Error and Uncertainty (In Lab Exercise) 11. Lab Exam Homeworks (2) Lab Write-ups (9 + In Lab Exercise) Exam I (In Class) Lab Quiz Exam II Total 30 pts 300 pts 80 pts 100 pts 80 pts 590 pts An additional project will be assigned to students registered for CEMS 536. Office Hours:(I will be in either McMahon 354C or 325) Tues: 12:20-1:10 Wed: 11:20-12:10 I have an open door policy. If I am in my office or lab, feel free to stop in and ask questions about the class or any other materials questions you may have. 2

3 Tentative Lecture/Exam Schedule: Lecture Date Topic 1-2* Tu 8/25 Tensile Testing 2-3* F 8/28 Hardness Testing/Compression Testing 4-5* Tu 9/1 Aluminum Alloys-Nomenclature and Applications 5-6* F 9/4 Aluminum Alloys-Heat Treatment and Properties 7-8* Tu 9/8 Strain Rate/Temperature Effects 8-9* F 9/11 Strain Rate/Temperature Effects 10-11* Tu 9/15 Alloy Steel/Cast Iron-Nomenclature/Heat Treatment 11-12* F 9/18 Alloy Steel -Heat Treatment 13 Tu 9/22 Charpy Testing F 9/25, Tu 9/29, F 10/2, Tu 10/6 No Class (CEMS 107 Lect) 14 F 10/9 Fracture Mechanics Tu 10/13 No class (Fall Break) 15 F 10/16 EXAM 1 (IN CLASS) 16-17* Tu 10/20 Fracture Mechanics/ Toughness Testing 17-18* F 10/23 Toughness Testing Tu 10/27 No Class MS&T (Lab Meets) 19 F 10/30 Fatigue 20 Tu 11/3 Fatigue 21 F 11/6 Corrosion 22 Tu 11/10 Corrosion 23 F 11/13 Corrosion 24 Tu 11/17 Corrosion 25 F 11/20 Corrosion 26 Tu 11/25 Stainless Steel F 11/27 No class (Thanksgiving Break) 27 Tu 12/1 Stainless Steel 28 F 12/4 Titanium and Magnesium Alloys Wed 12/9 (1:15-3:15 PM) Exam II *11:20 to 12:35 (1.5 lectures) 3

4 Lab Outline Tentative Schedule: The schedule may shift based on availability of the test equipment. Week of Experiment (Points) Data Due Lab Due 8/24-8/28 Exp #1: Tensile/Hardness Testing (30) 9/4 8/31-9/4 Exp #2: Compression Testing (30) 9/11 9/7-9/11 Exp #3: Notch Tension Tests (25) 9/18 9/14-9/18 Exp #4: Precipitation Strengthening of Al (25) 9/21 9/25 9/21-9/25 Exp #5: Strain Rate/Temperature Effects (30) 9/29 10/2 9/28-10/2 Exp #6: Steel Heat Treatment/Metallography (50) 10/5-10/9 Exp #6 (Continued) 10/14 10/21 10/12-10/16 No Lab (Fall Break) 10/19-10/23 Exp #7: Grain Growth/Strengthening (50) 10/26-10/30 Exp #7 (Continued) 11/2 11/9 11/2-11/6 Exp #8: Corrosion (25) 11/10 11/16 11/9-11/13 Exp #9: DBTT/Charpy Testing (20) 11/16 11/24 11/16-11/20 Experimental Error and Uncertainty In lab (10) 11/23-11/27 Thanksgiving Break (No Lab) 11/30-12/4 Lab Quiz (100) Shared group data are due by 5:00 on the dates specified. The lab format is described in the Lab Reports handout. Labs are due at the start of class (11:20) or at 5:00 if no class is scheduled. Safety: For all labs, long pants or full-length lab coats are required. No sandals or open-toed shoes are allowed. For all mechanical testing, machinists safety glasses are required and for all labs involving acids or other chemicals, chemical safety glasses are required. Safety glasses will be provided. 4

5 CEMS436/CEMS536 Lab Reports The goal of the laboratory is to provide an applied demonstration of several of the concepts presented in the CEMS336/CEMS436 lectures. This may require reviewing material from CEMS336. The lab write-ups should focus on the presentation and analysis of the test data, the sample microstructures, and the fracture surfaces. The following lab format is recommended (you may use another format if it is neat and clearly presents your results): 1. Title Page: CEMS XXX - XXX Experiment #XX- Title Your Name Date Executive Summary: What did you do and what were your most significant results? (One short paragraph.) Skip the Introduction section and only describe deviations from the lab manual for the Experimental Procedure. 2. Results: Figures and Tables. Figure and table captions should clearly describe the data presented (e.g. type of test, temperature, strain rate, gage length, magnification). Examples: Figure 1: Engineering stress versus engineering strain curve for a 6061 aluminum rod tested in tension at room temperature. The rod had an initial diameter of 20 mm and a 15-mm-gage-length. The rod was water quenched from 600 C followed by 3600 s (60 min.) at 180 C. Figure 3: Pearlite/ferrite microstructure of a 1045 steel, air cooled from 1000 C. Light micrograph (500X). Sample was polished to 6 µm with diamond compound and etched with 2% Nital solution. Fit graphs with approximate curves. Do not connect the dots. 3. Discussion: Discuss results and answer any questions from the lab handout or class discussion. Did the data behave as predicted from theory? Why not? What are sources of error? 4. Conclusions: Most significant results and observations. (Similar to executive summary.) 5. References (If applicable). 6. Sample Calculations: Attach rough calculations, pertinent formulas and data spreadsheets. 5