Elements of Metallurgy

Description

This course provides a broad introduction to the fundamental principles of metallurgy. The student will gain an understanding of basic and practical applications in various fields of metals and alloy behavior and manufacturing processes. This course is a valuable prerequisite for taking more technically challenging courses that will be required for career development.

Practical knowledge of both chemistry and physics is beneficial for problem solving. Please bring a scientific calculator to this course.

Target Audience

• Engineers and Materials Technologists
• Mechanical, Industrial, Aerospace and Manufacturing Engineers
• Forging, Casting, Rolling and Extrusion Process Engineers
• Laboratory Managers

Required Pre-requisites

College level chemistry and physics.

Learning Objectives

Upon completion of this course, you should be able to:

• Describe the recovery of metals from their ores
• Discuss the reasons for alloy behavior in tensile, hardness, and impact tests
• Choose between means of strengthening metal alloys
• Differentiate between hot and cold working
• Interpret microstructures
• Interpret a phase diagram
• Describe heat treatment of steels and nonferrous alloys
• Recognize potential failure modes in metal products

Course outline

Atoms, Molecules and Crystals: common elements; atomic structure; periodic table; how atoms combine; crystals and crystalline materials

The Physics and Chemistry of Metals: physical quantities and their measurement; conservation of mass and energy; chemical solutions, formulas and equations; acids, bases and salts

Chemical Equilibrium, Heat and Temperature: compound formation; types of reactions; effects of heat; instruments for measuring temperature

Elements of Extractive Metallurgy: steps in processing common ores to metals; beneficiating and reducing methods; types of furnaces; refractories

Metal Refining: primary methods for refining steel; basic-oxygen and electric-furnace processes; ladle metallurgy; electrolytic refining of non-ferrous metals

Solidification of Metals: patterns of atoms in solid metals; stages of crystal growth; formation of grain boundaries; phase diagrams; ingot casting and continuous casting

Solid Solutions: effects of alloy additions; substitutional and interstitial solid solutions; movement of atoms in solid solutions; diffusion; important commercial alloys

Heat Treatment of Steel: Fundamentals: types of steel; structure of iron; relation between carbon content and microstructure; austenite, bainite and martensite; hardness and hardenability

Heat Treatment of Steel: Equipment and Processes: main types of heat treating furnaces, atmospheres and quenching media; temperature control systems; case hardening and localized hardening processes

Precipitation Hardening Heat Treatments: solution annealing and precipitation hardening; coherency theory; effects of aging on properties of alloys; requirements for hardening by precipitation

Failure of Metals Under Service Conditions: major causes of metal failure during service; major methods of preventing corrosion; factors that cause metal failure due to rupture and wear; effects of high and low temperatures

Forming of Metals - Part I: Primary Forming Processes: plastic and elastic deformation; effects on grain structure; forging operations and machines; rolling, extruding and wire drawing; lubricants and coolants

Forming of Metals - Part II: Secondary Forming Processes: casting methods and molds; mechanical forming; welding, soldering and brazing; powder metallurgy; hot isostatic pressing

Metallurgical Testing and Inspection: techniques and instruments for mechanical and nondestructive testing and metallographic examination; metal properties determined by testing