Engineering Materials and Processes Lecture 9 – Equilibrium diagrams Prescribed Text: Ref 1: Higgins RA & Bolton, 2010. Materials for Engineers and Technicians, 5th edition, Butterworth Heinemann. ISBN: 9781856177696 Readings: Callister: Callister, W. Jr. and Rethwisch, D., 2010, Materials Science and Engineering: An Introduction, 8th Edition, Wiley, New York. ISBN 9780470419977 Ashby 1: Ashby, M. & Jones, D., 2011, Engineering Materials 1: An Introduction to Properties, Applications and Design, 4th edition, Butterworth-Heinemann, Oxford UK. IBSN: 9780080966656 Ashby 2: Ashby, M. & Jones, D., 2011, Engineering Materials 2: An Introduction to Microstructures and Processing, 4th edition, Butterworth-Heinemann, Oxford UK. IBSN: 9780080966687   Lecture (2 hrs): Ref 1, Ch 1: Engineering materials; Ref 1 Ch 2: Properties of materials. Laboratory 1 (2 hrs): Hardness test Callister: Ch 1, 2, 18-21 Ashby 1: Ch 1, 2 Ashby 2: Ch 1 1

Equilibrium diagrams Reference Text Section Higgins RA & Bolton, 2010. Materials for Engineers and Technicians, 5th ed, Butterworth Heinemann Ch 9 Additional Readings Section Callister, W. Jr. and Rethwisch, D., 2010, Materials Science and Engineering: An Introduction, 8th Ed, Wiley, New York. Ch 10 Engineering Materials and Processes

Note: This lecture closely follows text (Higgins Ch9) Equilibrium diagrams Note: This lecture closely follows text (Higgins Ch9) Engineering Materials and Processes

Equilibrium diagrams An equilibrium diagram (or phase diagram) is a graphical method of illustrating the relationship between the composition, temperature, and structure, or state, of any alloy in a series. “Series” might be iron/carbon, lead/tin, copper/zinc, where the diagram is plotted over a range of percentage mixtures. The diagram can help us to decide suitable heat-treatment processes for a particular carbon-steel. For a non-ferrous alloy system, the equilibrium diagram will often give us a pretty good indication of the structure - and hence the mechanical properties. Engineering Materials and Processes

This diagram will meet you again soon (not today). The Iron-Carbon equilibrium diagram over a very small range of Carbon (0 to 2% by weight, or 0 to 7% by atoms) This is as much carbon as steel can handle before it turns into cast iron, and then useless rock. This diagram will meet you again soon (not today). Engineering Materials and Processes

Obtaining equilibrium diagrams (Higgins 9.2) How are equilibrium diagrams obtained? Even for a simple binary alloy, some poor person had to carefully study each percentage just to plot a single dot on the curve! There are about 70 metals, so that would mean 2415 combinations! Not quite – some don’t mix – e.g. high melting-point tungsten with very reactive caesium. However, lots of metallic elements have been successfully alloyed with each other and with some of the non-metallic elements like carbon, silicon and boron. There are a lot of alloys! Engineering Materials and Processes

Melting / Boiling of Elements Lots of metal elements. There are about 70 metals, so that would mean 2415 combinations! Not really – some don’t mix – e.g. high melting-point tungsten with very reactive caesium. www.ptable.com Engineering Materials and Processes

Lead-tin alloys (Higgins 9.2.1) Engineering Materials and Processes

Gas to Liquid. (Metal Vapour Condensing) The temperature of a metal vapour (gas) falls until it reaches the boiling point where it starts to turn into liquid (condense). In a liquid the atoms are randomly mixed together and are free to slide around. The atoms are held together only by weak forces of attraction at this stage, the liquid lacks cohesion and will flow. Higgins RA & Bolton, 2010. Materials for Engineers and Technicians, 5th edition, Butterworth Heinemann. Ch 1.2.1 Gas Animations: Tim Lovett 2012 Engineering Materials and Processes 9

Latent Heat A pure metal solidifies at a fixed temperature (melting point). The liquid resists cooling below the melting point until the liquid has solidified. This requires removal of the Latent Heat. This energy is called the latent heat of fusion (solidification in this case). Alloys (metal mixtures) can have a range of melting temperatures. Higgins: Fig 4.1 Higgins RA & Bolton, 2010. Materials for Engineers and Technicians, 5th edition, Butterworth Heinemann. Ch 4 http://www.ami.ac.uk/courses/topics/0131_mb/index.html Engineering Materials and Processes 10

Lead-tin alloys (Higgins 9.2.1) Other ratios are tested for mushy and freezing points. They must be cooled slowly (to keep in EQUILIBRIUM) Engineering Materials and Processes

Lead-tin alloys (Higgins 9.2.1) Plotting the data on a composition axis vs temperature. This is the beginning of an equilibrium diagram. Engineering Materials and Processes

Lead-tin alloys (Higgins 9.2.1) This is the whole thing for Lead and Tin. http://www.ami.ac.uk/courses/topics/0244_tsm/index.htm l Engineering Materials and Processes

Types of equilibrium diagrams (Higgins 9.3) A useful alloy must be soluble when molten, or there is no chance of any solid mixture. (E.g. Molten lead with zinc floating on top). In the solid state the metals may be; Completely soluble. Completely insoluble. Partially soluble. To stay in equilibrium, some alloys need to be cooled extremely slowly – way too slowly for many industrial situations. Engineering Materials and Processes

Two metals fully soluble (Higgins 9.3.1) Above the liquidus, mixture is liquid. Below the solidus, mixture is solid. Engineering Materials and Processes

Two metals fully soluble (Higgins 9.3.1) Follow notes in Higgins 9.3.1 in detail Engineering Materials and Processes

Two metals completely insoluble (Higgins 9.3.2) Engineering Materials and Processes

Dendritic solidification (Higgins 4.3.1) As the molten pure metal cools below its freezing point, crystallisation will begin. It starts out with a single unit – (e.g. BCC for Tungsten). New atoms will join the 'seed crystal' and grow onto the structure much like a snowflake (except the metal is forming in liquid, not a cloud of droplets). BCC Unit: Higgins Fig 4.3 The branched crystal is called a 'dendrite‘ (Greek for tree). Snowflake: Wikipedia Higgins RA & Bolton, 2010. Materials for Engineers and Technicians, 5th edition, Butterworth Heinemann. Ch 4 Higgins Fig 4.4 Engineering Materials and Processes 18

Dendrite of Silver: Wikipedia Engineering Materials and Processes

Two metals completely insoluble (Higgins 9.3.2) Above the liquidus, mixture is liquid. Below the solidus, mixture is solid. Engineering Materials and Processes

Two metals completely insoluble (Higgins 9.3.2) Follow notes in Higgins 9.3.2 in detail Engineering Materials and Processes

Two metals are partially soluble (Higgins 9.3.3) Engineering Materials and Processes

Two metals completely insoluble (Higgins 9.3.3) Follow notes in Higgins 9.3.3 in detail Engineering Materials and Processes

Precipitation from a solid solution (Higgins 9.4.2) Follow notes in Higgins 9.4 in detail At higher temperature, water can dissolve more salt. Likewise, at higher temperature, metal A can dissolve more metal B Engineering Materials and Processes

Precipitation from a solid solution (Higgins 9.4) Follow notes in Higgins 9.4.2 in detail Copper solute in Aluminium (Cu/Al diagram) Fast cooling (quenching) prevents precipitate forming. Age hardening allows precipitate to attempt to form is solid – causing lattice distortion > hindering slip > hardening the alloy. E.g. Duralumin 4%Cu. Engineering Materials and Processes

Ternary equilibrium. (Higgins 9.5) Three metals, a 3D diagram! Higgins RA & Bolton, 2010. Materials for Engineers and Technicians, 5th edition, Butterworth Heinemann. Ch 4 http://www.ami.ac.uk/courses/topics/0131_mb/index.html Engineering Materials and Processes 26

Online Properties Resources. Teach yourself phase diagrams Handout http://www-g.eng.cam.ac.uk/mmg/teaching/phasediagrams/i2a.html Wikipedia: Materials properties Metal Grains and processing h ttp://www.matweb.com S how this website on screen. Will be using this later. Engineering Materials and Processes 27

Coring or cored structure Dendritic Binary Tertiary Solid phase change GLOSSARY Phase Diagram Equilibrium Diagram Liquidus line Solidus line Coring or cored structure Dendritic Binary Tertiary Solid phase change Eutectic Phase Eutectic phase Hypereutectoid alloy Hypoeutectoid alloy Solubility limit System http://www.youtube.com/watch?v=1GFst2IQBEM Engineering Materials and Processes 28

Define all the glossary terms. QUESTIONS Callister: Ch3 (Mostly about calculating atomic packing factors - too esoteric) Moodle XML: Some questions in 10102 Classification and 10105 Steel Define all the glossary terms. There are two names for the same thing: Phase Diagram and Equilibrium Diagram. Both make sense. Describe what phase and equilibrium refer to. Why would it be difficult to make an alloy of Rhenium and Cadmium? Why is it important for a eutectic mixture to cool slowly during the creation of an equilibrium diagram? What happens between the liquidus and solidus lines of a simple binary equilibrium diagram with complete solubility? In the Cadmium-Bismuth thermal equilibrium diagram, What happens as a mixture that crosses the BE line, the AE line, the EC line, the ED line? In the lead-tin thermal equilibrium diagram, what does a and b stand for? What is the difference between Lead, Tin, a and b? What happens as a mixture that crosses the AB line, the CB line, the BE line, the EF line? http://www.youtube.com/watch?v=1GFst2IQBEM Engineering Materials and Processes 29