Material Techno

POLITEKNIK KOTA KINABALU, SABAH

JABATAN KEJURUTERAAN MEKANIKAL

SESI DISEMBER 2011

Syllabus: JF302 – MATERIAL TECHNOLOGY 1

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1.0 MATERIAL STRUCTURE AND BINARY ALLOY SYSTEM (Notes Updated!!!)

1.1   Understand material structure and Element Periodical Table (EPT)

1.1.1         Define the terminology of

1.1.1.1    Atom

1.1.1.2    Element

1.1.1.3    Mixture

1.1.1.4    Compound

1.1.2         Atomic number and atomic mass of EPT

1.1.3         Determine the total number of atomic orbits

1.1.4         Explain the elements sequence in EPT

1.1.5         Explain these crystallized structure

1.1.5.1    Simple cubic

1.1.5.2    Body-centered cubic

1.1.5.3    Face-centered cubic

1.1.5.4    Hexagonal close-packed

1.1.6         Explain terms use in recrystallization process

1.1.6.1    Crystal

1.1.6.2    Space lattice

1.1.6.3    Grain

1.1.6.4    Grain boundary

1.1.7         Explain these types of bonds

1.1.7.1    Covalent bond

1.1.7.2    Ionic bond

1.1.7.3    Metallic bond

1.2   Describe the metal and alloy solidification

1.2.1         Explain solidification phases of

1.2.1.1    Nucleus

1.2.1.2    Dendrite

1.2.1.3    Grain

1.2.2         Differentiate between metals and alloys

1.2.3         Define term and formation of solid solution

1.2.4         Distinguish between substitution and interstitial solid solution

1.2.5         Explain the process of solidification for pure metal and alloy according to the cooling curve

1.2.6         Explain the phase balance diagram, which comprises of a few cooling curves for solid solution

1.2.7         Explain terms of equilibrium phase diagram

1.2.7.1    Phase

1.2.7.2    Equilibrium phase

1.2.7.3    Composition

1.2.7.4    Liquidus

2.0 FERROUS MATERIAL STRUCTURE AND BINARY ALLOY SYSTEM

2.1   Understand the metal production

2.1.1         State the content of iron ore

2.1.1.1    Magnetite

2.1.1.2    Iron carbonate

2.1.1.3    Hematite

2.1.1.4    Limonite

2.1.2         Explain the process of iron production by using Blast Furnace

2.2   Understand the steel production

2.2.1         Explain the process of steel production by using these methods

2.2.1.1    Basic Oxygen Furnace (BOP)

2.2.1.2    Electric Arc Furnace

2.3   Describe the plain carbon steel

2.3.1         Sketch completely the different phases in equilibrium phase diagram up to 1.7% carbon

2.3.2         Differentiate between iron, steel and cast iron in the iron-carbon equilibrium phase diagram

2.4   Describe the alloy steel

2.4.1         Define term and purpose of alloy steel

2.4.2         Explain elements in the alloy which influence steel properties.

2.4.3         Identify the characteristic of alloy steel

2.4.3.1    Structure steel

2.4.3.2    Corrosion resistant steel

2.4.3.3    Heat resistant steel

2.4.3.4    Tool and mould steel

2.4.3.5    Magnetic steel

2.5   Describe the cast iron

2.5.1         Explain position of cast iron in iron-carbon phase diagram

2.5.2         Explain of cast iron properties effect

2.5.2.1    Cooling rate

2.5.2.2    Carbon content

2.5.2.3    Cross sectional area

2.5.2.4    Element content

2.5.3         Explain the characteristics and applications of the cast iron

2.5.3.1    Grey cast iron

2.5.3.2    White cast iroN

2.5.3.3    Black malleable cast iron

2.5.3.4    White malleable cast iron

2.5.3.5    Nodular cast i ron

3.0   METAL WORK, CASTING PROCESS AND HEAT TREATMENT ON STEEL

3.1   Understand the cold work process

3.1.1         Define cold work

3.1.2         Explain the function of cold work processes

3.1.2.1    Rolling

3.1.2.2     Wire and tube drawing

3.1.3         List the advantages and disadvantages of cold work

3.2    Understand the hot work process

3.2.1         Define hot work

3.2.2         Explain the process of recrystallization of grain

3.2.3         Explain the function of hot work processes

3.2.3.1     Forge and Smith forge

3.2.3.2    Hot rolling

3.2.3.3    Forward and invented extrusion

3.2.4          List the advantages and disadvantages of hot work

3.3    Describe the casting process

3.3.1         Define the purpose of casting

3.3.2         Explain casting processes

3.3.2.1     Sand casting

3.3.2.2     Lost wax/investment casting

3.3.2.3     Pressure die casting

3.3.3          List the advantages and disadvantages of casting processes

3.4   Describe the heat treatment of steels

3.4.1         Explain the purpose of steel heat treatment

3.4.2         Explain the three stages in heat treatment cycle (heating, soaking and cooling)

3.4.3         Explain process and effect of steel heat treatment types

3.4.3.1     Full annealing

3.4.3.2     Stress relief annealing

3.4.3.3     Spheroidizing

3.4.3.4     Normalizing

3.4.4         Explain process and purpose of quench hardening

3.4.5         List quenching media used to prevent quench fracture

4.0    MATERIAL TESTING

4.1   Describe material testing

4.1.1         Explain the purpose and types of material testing deformation

4.1.2         Define mechanical properties in material testing

4.1.2.1    Strength

4.1.2.2    Hardness

4.1.2.3    Elasticity

4.1.2.4    Elasticity

4.1.2.5    Ductility

4.1.2.6    Toughness

4.1.2.7    Brittleness

4.1.3         Define Destructive Test

4.1.4         Explain the principle of hardness tests

4.1.4.1    Brinell Test

4.1.4.2     Vickers Test

4.1.4.3     Rockwell Test

4.1.4.4     ShoreTest

4.1.5         Explain principle and results of toughness tests

4.1.5.1     Izod Test

4.1.5.2     Charpy Test

4.1.6          Define Non-Destructive Test

4.1.7         Explain the methods for non destructive test

4.1.7.1    Penetration test

4.1.7.2     Magnet powder test

4.1.7.3     Ultrasound test

4.1.7.4     X-ray test

5.0  CORROSION AND NON-FERROUS METAL

5.1    Describe the corrosion process

5.1.1         Define corrosion

5.1.2         Distinguish two main categories of corrosion

5.1.2.1     Dry corrosion

5.1.2.2     Wet/Electrochemical corrosion

5.1.3         Define dry corrosion

5.1.4         Explain the basic principle in electrochemical corrosion (galvanic) and chemical equations.

5.1.4.1     Zinc sheet is soaked in hydrochloric acid (HCl)

5.1.4.2     Anode and cathode reaction in electrochemical cell; (iron and copper in electrolyte)

5.1.5         Explain the phenomena in the electrochemical series: anode metal is more corrosive to the cathode metal in electrolyte environment

5.1.6         Explain differences between types of corrosion

5.1.6.1     Varying stress

5.1.6.2     Varying oxygen convergence

5.1.6.3     Grain interface

5.1.6.4     Crevice

5.1.7         Explain the corrosion remedial action

5.1.7.1     Cathode and anode protection

5.1.7.2     Material selection

5.1.7.3     Coatings-metals, organic and non organic

5.1.7.4     Des i gn

5.2    Describe non-ferrous metals

5.2.1         Define term and types of non-ferrous metals

5.2.2         Explain the characteristics and application of

5.2.2.1     Aluminium

5.2.2.2     Copper

5.2.2.3     Zinc

6.0  PLASTIC

6.1    Explain the important uses of plastic

6.1.1          Explain the polymeric structure and related terms

6.1.2         Differentiate thermosetting plastic and thermo-plastic

6.1.3         List the application and mechanic properties of thermo plastics

6.1.3.1     Polyethylene

6.1.3.2     Polypropylene

6.1.3.3     Polystyrene

6.1.3.4     Polyvinyl chloride (PVC)

6.1.3.5     Poly methyl Methacrylate (Perspex)

6.1.3.6     Polyamide (nylon)

6.1.4         Explain the plastic polymerisation process

6.1.5         List the application and mechanic properties of thermosetting plastic

6.1.5.1    Phenol formaldehyde

6.1.5.2    Epoxide

6.1.5.3    Polyester

6.1.5.4    Urea formaldehyde

6.1.5.5    Elamine formaldehyde

6.1.6          List advantages and disadvantages of plastics application in the engineering field

6.1.7          Explain the making of plastic products processes

6.1.7.1     Injection moulding

6.1.7.2     Extrusion moulding

6.1.7.3     Compression moulding

6.1.7.4     Blow moulding