Q.

1 Explain in brief for following terms; a) Brittleness: A brittle material exhibits little deformation before fracture, the strain normally being below 5%. Brittle materials therefore may fail suddenly without visible warning. Included in this group are concrete, cast iron, high strength steel, timber and ceramics. b) Hardness: This is the first of two operations required for the development of high strength steels by heat treatment. Hardening consists of heating above Ac3, soaking at that temperature until the mass is uniformly heated, and then quenching in brine, water, or oil. This treatment produces a fine grain, maximum hardness and tensile strength, minimum ductility and internal strains. In this condition the material is too hard and brittle for practical use. c) Alclad: Alclad is the name given to standard alloys, such as 2017, and 2024 when they have been coated with a thin layer of aluminium or another aluminium alloy which is alloyed to and integral with the base metal core. The name Alclad, a registered trademark, usually reserved for product of the Aluminium Company of America. d) Toughness: The ability of a metal to deform plastically and to absorb energy in the process before fracture is termed toughness. The emphasis of this definition should be placed on the ability to absorb energy before fracture. Recall that ductility is a measure of how much something deforms plastically before fracture, but just because a material is ductile does not make it tough. The key to toughness is a good combination of strength and ductility. A material with high strength and high ductility will have more toughness than a material with low strength and high ductility. Therefore, one way to measure toughness is by calculating the area under the stress strain curve from a tensile test. This value is simply called material toughness and it has units of energy per volume. Material toughness equates to a slow absorption of energy by the material e) Normalizing: Normalizing is a form of annealing which consists in heating the steel above Ac3, and then cooling in still air. Due to the more rapid quenching obtained by air-cooling as compared to furnace-cooling, the steel is harder and stronger but less ductile than annealed material. It is required whenever it is desired to obtain material of, uniform physical characteristics. f) Nitriding: Nitriding is a heat treating process that alloys nitrogen onto the surface of a metal to create a case hardened surface. It is predominantly used on steel, but also titanium, aluminum and molybdenum. g) Carburizing: Carburizing is a heat treatment process in which iron or steel is heated in the presence of another material (but below the metal's melting point) which liberates carbon as it decomposes. The outer surface or case will have higher carbon content than the original material. When the iron or steel is cooled rapidly by quenching, the higher carbon content on the outer surface becomes hard, while the core remains soft and tough.

Q.3. Write the importance of heat treatment and name the different process involved in it? A.3. Every Product Designer wants to make a product with better durability and strength. Heat Treatment process is one such method where in strength of product can be improved. It is used to alter the physical(Casting,Forging,Mould etc) and chemical properties(Microstructure) of a material under specific conditions. It is also used in the manufacture of many other materials, such as glass. Basically it involves the use of heating or chilling, normally to extreme temperature, to attain a desired result such as hardening or softening of a material. Fig: Heat Treating - Aluminum Cooper Equilibrium Diagram For example, see the effect of Heat Treatment on the microstructure and Hardness of Chromium-Nickel Steel. From the product design point of view, Heat Treatment can also be used to alter certain manufacturability characteristics like machinability,formability,restore ductility after a cold working operation,improving hardness(Rockwell and Brinell hardness testing) and many. In a modern technology, Heat Treating is an essential step in a great percentage of manufacturing processes. Heat treatment process differs based on product/component application and its functionality. It can provide significant savings in the weight of material required for a given component. Heat Treatment process also provides a payback by means of longer service life of treated products, fewer part replacements, reduced maintenance and machine downtime resulting in saving cost and time. If your not familiar with Heat Treatment process and latest methods used in Industry here is the site(Wisconsin oven corporation) will help you learn about following topics: Aging -Aluminum Heat Treatment Terms T4,T5,T6 -Batch Aluminum Age ovens -Continuous Aluminum Age ovens Annealing -Annealing purpose like machinability,cold working,improving mechanical properties -Annealing types like Black Annealing,Flame Annealing,Graphitizing,Isothermal Annealing,Quench Annealing and Speroidizing.

-Batch Heat Treating ovens -Continuous Heat Treating ovens Baking -What is Baking : Heating process in order to remove entrained gases -Batch and Walk in ovens -Continuous ovens Direct Gas Fired -Use of Direct Gas Firing Drawing -Draw Batch ovens -Continuous Heat Treating ovens Heat Treatment Heat Treatment solution Normalizing Preheating Quenching Stress Relieving Tempering - Objective of Tempering : To reduce brittleness in hardened steel and to remove internal strains. - Temperature conditions T4 T5 T6

Apart from these various Heat Treatment process definitions, you will get a chance to know about Pit type furnace,Retort Furnace etc., I wish this article would help to get deep insight of Heat Treating, latest methods in various alloys, and its impact on manufacturing process Q.4. Write in brief about steel numbering with an example? A.4. In the U.S. the society of automatic engineers numbering system is commonly used to designate the steels used in an aircraft and automotive constructions. By means of a simple numerical system , the composition of a steel is partially identified. The first two numbers indicate the alloy according the chart below. The last two numbers indicate the amount of carbon in the alloy, where the digits 10, for example, represent 0.10% carbon. Example AISI/SAE 1020 the first two digits indicate this is plain carbon steel. the last two digits indicates that the steel contains approximately 0.20% carbon. Example AISI/SAE 4340 the first two digits indicate this is a Nickel-Chromium-Molybdenum alloy steel the last two digits indicate that the steel contains approximately 0.4% carbonAISI/SAE Steel Numbering System Carbon steels 10XX Plain carbon, Mn 1.00% max 11XX Resulfurized free machining 12XX Resulfurized/rephosphorized free machining 15XX Plain carbon, Mn 1.00-1.65% Manganese steel 13XX Mn 1.75% Nickel steels 23XX Ni 3.50% 25XX Ni 5.00% Nickel-chromium steels 31XX Ni 1.25%, Cr .65-.80% 32XX Ni 1.75%, Cr 1.07% 33XX Ni 3.50%, Cr 1.50-1.57% 34XX Ni 3.00%, Cr .77% Molybdenum steels 40XX Mo .20-.25% 44XX Mo .40-.52% Chromium-molybdenum steels 41XX Cr .50-.95%, Mo .12-.30% Nickel-chromium-molybdenum steels 43XX Ni 1.82%, Cr .50-.80%, Mo .25% 47XX Ni 1.05%, Cr .45%, Mo .20-.35% Nickel-molybdenum steels 46XX Ni .85-1.82%, Mo .20-.25% 48XX Ni 3.50%, Mo .25% Chromium steels 50XX Cr .27-.65% 51XX Cr .80-1.05% 50XXX Cr .50%, C 1.00% min 51XXX Cr 1.02%, C 1.00% min

52XXX Cr 1.45%, C 1.00% min Chromium-vanadium steels 61XX Cr .60-.95%, V .10-.15% Tungsten-chromium steels 72XX W 1.75%, Cr .75% Nickel-chromium-molybdenum steels 81XX Ni .30%, Cr .40%, Mo .12% 86XX Ni .55%, Cr .50%, Mo .20% 87XX Ni .55%, Cr .50%, Mo .25% 88XX Ni .55%, Cr .50%, Mo .35% Silicon-manganese steels 92XX Si 1.40-2.00%, Mn .65-.85%, Cr 0-.65% Nickel-chromium-molybdenum steels 93XX Ni 3.25%, Cr 1.20%, Mo .12% 94XX Ni .45%, Cr .40%, Mo .12% 97XX Ni .55%, Cr .20%, Mo .20% 98XX Ni 1.00%, Cr .80%, Mo .25% Q.5 What is corrosion and name different types of corrosion? A.5. Corrosion is the disintegration of an engineered material into its constituent atoms due to chemical reactions with its surroundings. In the most common use of the word, this means electrochemical oxidation of metals in reaction with an oxidant such as oxygen. Formation of an oxide of iron due to oxidation of the iron atoms in solid solution is a well-known example of electrochemical corrosion, commonly known as rusting. This type of damage typically produces oxide(s) and/or salt(s) of the original metal. Corrosion can also refer to other materials than metals, such as ceramics or polymers, although in this context, the term degradation is more common. In other words, corrosion is the wearing away of metals due to a chemical reaction. Many structural alloys corrode merely from exposure to moisture in the air, but the process can be strongly affected by exposure to certain substances (see below). Corrosion can be concentrated locally to form a pit or crack, or it can extend across a wide area more or less uniformly corroding the surface. Because corrosion is a diffusion controlled process, it occurs on exposed surfaces. As a result, methods to reduce the activity of the exposed surface, such as passivation and chromateconversion, can increase a material's corrosion resistance. However, some corrosion mechanisms are less visible and less predictable. The types of corrosion are: Generalized corrosion is the well distributed and low level attack against the entire metal surface with little or no localized penetration. It is the least damaging of all forms of corrosion. Generalized corrosion usually occurs in environments in which the corrosion rate is inherently low or well controlled - such as for chemically treated closed circulating systems, and in some open water systems. It is the only form of corrosion whereby weight loss or metal loss data from corrosion coupons or ultrasonic testing can be used to accurately and reliably estimate corrosion rates and future pipe life expectancy. Often termed "under deposit corrosion," this is a localized, deep penetration of the metal surface with little general corrosion in the surrounding area. Due to surface

deposits, electrical imbalance or some other initiating mechanism, all existing corrosion potential attacks a select number of individual sites. In most cases, pitting is extended throughout the entire metal surface, creating an irregular or very rough surface profile. In other instances, pits are concentrated in specific areas, leaving the majority of the metal surface in like new condition. Pitting is the most common form of corrosion found where there are incomplete chemical protective films, and insulating or barrier deposits of dirt, iron oxide, organic, and other foreign substances at the pipe surface. It is prevalent at galvanized steel pipe, where any failure of the galvanizing invokes a pitting condition. Pitting corrosion may include: crevice corrosion, water-line attack, under deposit attack, impingement or erosion corrosion attack, and concentration-cell corrosion. This is an aggressive and localized form of corrosion due to the electrochemical reaction often found between two or more dissimilar metals in an electrically conductive environment. It occurs because the more electronegative material (the anode) is attacked by the more electropositive material (the cathode). The most common example of such corrosion activity, widely found throughout HVAC and process plant operations, is the direct connection of brass valves to carbon steel pipe, or between copper tubing and steel pipe - where the steel serves as the anode, and the brass or copper the cathode. Carbon steel pipe, without the protection of a galvanic insulator, will show the highest rate of corrosion under such conditions usually developing over many years. The severity of pipe loss due to galvanic activity is often found relative to the general corrosion activity of the piping system itself - with little or no galvanic activity found where extremely low general corrosion rates exist. Under conditions of high corrosion rate activity, galvanic losses often become aggressive - making an existing pipe corrosion problem significantly worse at the threads - its already most weakened area. While galvanic corrosion is generally assumed to involve only dissimilar metals, millivolt potentials can actually be measured between similar metals under certain conditions. New steel pipe installed during a repair or renovation is often more electronegative than older existing pipe, and therefore may suffer from some degree of galvanic attack. Microbiologically Influenced Corrosion (MIC) is, by far, the most severe and threatening form of corrosion to HVAC piping systems. Corrosion rates of 100 MPY have been documented. MIC is caused by the presence of various microbiological agents under specific environmental conditions - in some cases resulting in advanced and widespread failure of entire piping systems within a few years. An MIC presence usually signals a very severe threat to the entire system - requiring extensive cleaning and sterilization at great expense. For many affected systems, MIC

cannot be eliminated, and an elevated corrosion and pitting condition will exist for the remainder of system life. MIC produces large and deep pits due to the microorganism's utilization of iron as an energy source (often as an alternative to oxygen), and through the production of strongly corrosive metabolic by-products such as sulfuric acid - which further assists the microorganism in dissolving pipe metal. MIC exists to varying degrees of severity, and is not exclusive to carbon steel piping systems or open condenser water systems. MIC is less commonly found in closed chill water piping, in hot water heating and domestic water systems, and has been documented to destroy copper, brass, and stainless steel pipe. See Technical Bulletin # C-5 for more about the threat of MIC. This is the gradual and selective deterioration of a metal surface due to mechanical wear and abrasion. It is attributed to entrained air bubbles, suspended matter and particulates under a flow rate of sufficient velocity. Erosion is similar to impingement attack, and is primarily found at elbows and tees, or in those area where the water sharply changes direction. Softer metals such as copper and brass are inherently more susceptible to erosion corrosion than steel. High pressure steam will often contribute to the erosion of carbon steel. Though typically not a problem at the water velocities encountered within most HVAC piping systems, high corrosion rates and the entrainment of high volumes iron oxide particulates can produce an erosion condition under certain conditions. Erosion at the base of elbows or after multiple sharp turns of the pipe has been documented to occur. Corrosion Under Insulation, CUI is a significant threat to any piping system or holding tank which operates at lower temperatures in humid environments. In the absence of an effective moisture barrier and a protective metal coating, any available moisture will penetrate commonly used fiberglass or foam insulation to condense at the cold metal surface. Often, moisture can accumulate sufficiently to waterlog the insulation and cause its total deterioration. This effectively creates an untreated water condition at the outer pipe surface, and produces a corrosion problem on two fronts. In outdoor environments, moisture, rain, snow, and ice can also penetrate the insulation due to physical damage, wear, or by the failure to install sealants at the overlap of the hard metal outer shell. CUI is commonly found at cold water domestic piping, free cooling condenser water systems, and especially at chill water piping - being most severe at the colder supply side piping. The degree of CUI type corrosion depends upon a combination of pipe temperature, insulation thickness, vapor barrier, and humidity.

In extreme examples of high humidity, CUI corrosion will even occur on typically warm condenser water piping. Conversely, the extremely cold temperatures of a brine or ammonia refrigeration plant can create substantial exterior pitting even from a relatively dry atmosphere. CUI corrosion usually remains hidden until severe damage has occurred to the pipe, producing telltale discoloration at the insulation itself, or failure. In many cases, CUI corrosion can exceed the degree of physical damage caused by internal corrosion of poorly treated open condenser or process cooling water piping.