Chapter 6: Metallurgy

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Questions and Answers

What mechanism primarily facilitates plastic deformation during cold working?

  • Dislocation movements (correct)
  • Diffusion of vacancies
  • Slip along crystal planes (correct)
  • Grain boundary sliding

What is one of the main purposes of sintering in powder metallurgy?

  • To eliminate initial porosity (correct)
  • To cool the material rapidly
  • To melt the powder particles
  • To increase the porosity of the material

What characterizes the temperature-time curve during the solidification of metals?

  • Temperature remains constant throughout the cooling process
  • Temperature increases during the plateau phase
  • A plateau indicates the freezing point (correct)
  • Heat is absorbed as the metal solidifies

What happens to the temperature of a molten metal as it approaches its freezing temperature?

<p>It stabilizes before dropping (B)</p> Signup and view all the answers

What is the role of pressure during sintering?

<p>To aid in atomic diffusion (D)</p> Signup and view all the answers

What is latent heat of fusion in the context of solidification?

<p>Heat released during solidification (D)</p> Signup and view all the answers

What initiates the formation of crystalline nuclei during solidification?

<p>Aggregation of atoms at a specific temperature (C)</p> Signup and view all the answers

In the context of electroforming, what is the process primarily used for?

<p>To plate metal onto a conducting surface (A)</p> Signup and view all the answers

What is a key characteristic of metals in solution?

<p>They ionize positively. (A)</p> Signup and view all the answers

Which of the following is NOT a property of metals?

<p>Low melting and boiling points (C)</p> Signup and view all the answers

What distinguishes metalloids from metals?

<p>Metalloids possess properties of both metals and nonmetals. (B)</p> Signup and view all the answers

What is a method used for shaping metals?

<p>Casting (B)</p> Signup and view all the answers

Which of the following metals is liquid at room temperature?

<p>Gallium (A)</p> Signup and view all the answers

What property of metals contributes to their ability to conduct electricity?

<p>Free electrons (A)</p> Signup and view all the answers

Which two metals are notable for not being white?

<p>Gold and Copper (B)</p> Signup and view all the answers

What cause allows metals to undergo plastic deformation?

<p>Crystal structure and imperfections (B)</p> Signup and view all the answers

What primarily causes elastic deformation in metals?

<p>Stretching of interatomic bonds (A)</p> Signup and view all the answers

What is the localized shear region in a metal crystal called?

<p>Dislocation (C)</p> Signup and view all the answers

What happens to the ductility of a metal when it undergoes cold working?

<p>It decreases (D)</p> Signup and view all the answers

Which of the following best describes the process of recrystallization?

<p>Formation of new grains in a cold worked structure (D)</p> Signup and view all the answers

What effect does cold working have on the strength of metals?

<p>Increases their strength (C)</p> Signup and view all the answers

What is the term for the process of heating a cold worked metal to restore its properties?

<p>Heat treatment annealing (A)</p> Signup and view all the answers

What distinguishes wrought metals from other types of metals?

<p>They are formed by cold working to create a fibrous structure (B)</p> Signup and view all the answers

What occurs during the stress-relief anneal or recovery stage?

<p>Increase in internal stresses without structural change (A)</p> Signup and view all the answers

What is the primary objective of homogenization in alloy processing?

<p>To eliminate coring by reducing compositional differences (A)</p> Signup and view all the answers

Eutectic alloys are characterized by which of the following properties?

<p>They have a heterogeneous structure (D)</p> Signup and view all the answers

Which statement correctly defines a cored structure within an alloy?

<p>It occurs when there is a large temperature range between liquidus and solidus (C)</p> Signup and view all the answers

What describes the primary feature of intermetallic compounds formed upon solidification?

<p>They have unique properties distinct from the constituent metals (C)</p> Signup and view all the answers

Which one of the following statements about solid solution alloys is true?

<p>They typically exhibit higher strength than eutectic alloys (D)</p> Signup and view all the answers

Why are eutectic alloys considered brittle?

<p>Presence of insoluble phases hinders dislocation movement (C)</p> Signup and view all the answers

What is a characteristic of the phase diagram for a binary system with complete insolubility?

<p>It lacks a eutectic point (C)</p> Signup and view all the answers

What effect does the cored structure have on the corrosion resistance of an alloy?

<p>It generally decreases corrosion resistance (D)</p> Signup and view all the answers

What type of alloy is entirely soluble in both the liquid and solid states?

<p>Solid solution alloy (C)</p> Signup and view all the answers

Which of the following is a condition for the formation of substitutional solid solutions between two metals?

<p>Same type of space lattice (B)</p> Signup and view all the answers

What does the line ABC represent in a phase diagram?

<p>Liquidus line (D)</p> Signup and view all the answers

What occurs when there is a high chemical affinity between two metals?

<p>Formation of intermetallic compounds (B)</p> Signup and view all the answers

In substitutional solid solutions, what characterizes the arrangement of atoms?

<p>Two different types of atoms occur in different positions (C)</p> Signup and view all the answers

Which phase of an alloy is characterized by being partly liquid and partly solid?

<p>Eutectic phase (C)</p> Signup and view all the answers

What is the primary feature of coring in alloys?

<p>A cored structure with non-uniform composition (C)</p> Signup and view all the answers

What is an example of an interstitial solid solution?

<p>Carbon in iron (C)</p> Signup and view all the answers

What occurs during the stress-relief recovery process in metals?

<p>No visible change in the fibrous structure (B)</p> Signup and view all the answers

What is the primary reason for annealing cold worked structures before dental applications?

<p>To relieve internal stresses and increase corrosion resistance (B)</p> Signup and view all the answers

What happens to the metal when it undergoes recrystallization at higher temperatures for extended periods?

<p>The metal possesses low strength and high ductility (C)</p> Signup and view all the answers

What is an effect of prolonged exposure to high temperatures during grain growth?

<p>Further grain growth leading to coarse crystal structure (A)</p> Signup and view all the answers

What characterizes pure metals in terms of their suitability for dental applications?

<p>They are too soft and ductile for practical use (A)</p> Signup and view all the answers

What is a binary alloy?

<p>An alloy consisting of two constituents (B)</p> Signup and view all the answers

When two molten metals are combined and cool, what could potentially happen?

<p>A solid solution alloy can be formed with randomly distributed atoms (D)</p> Signup and view all the answers

What characterizes the microstructure of solid solution alloys?

<p>Their grains resemble those of pure metals due to their homogenous nature (A)</p> Signup and view all the answers

Flashcards

What is a metal?

Any element that forms a positive ion (cation) when dissolved in a solution.

What is ductility?

The property of metals allowing them to be drawn into wires.

What is malleability?

The property of metals allowing them to be hammered or pressed into thin sheets.

What is a crystal?

A solid material with a distinct, regular arrangement of atoms.

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What is casting?

The process of heating a metal to its liquid state and pouring it into a mold to solidify.

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What is cold working?

The process of shaping a metal by applying mechanical force at room temperature.

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What is an alloy?

A substance that conducts electricity and heat well, usually made of a combination of metals.

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What is delocalization of valence electrons?

The movement of free electrons within a material, like metals.

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Elastic Deformation

The ability of a material to deform elastically under stress, caused by the stretching of interatomic bonds. It's independent of the material's microstructure.

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Modulus of Elasticity

A measure of a material's resistance to elastic deformation. It is determined by the chemical composition and type of atomic bond.

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Plastic Deformation

A permanent deformation of a material caused by the sliding of atomic layers over each other along specific planes within the crystal structure.

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Dislocation

A localized region of shear within a material where atoms slide over each other during plastic deformation.

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Wrought Metals

Metals that have been shaped from their original cast or grain structure by cold working, creating a fibrous microstructure.

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Cold Working

The process of strengthening and hardening a metal by plastically deforming it at room temperature. This makes it harder for dislocations to move.

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Annealing

The process of reducing the stresses and improving the ductility of a cold-worked metal by heating it.

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Recrystallization

The process of restoring the original grain structure of a cold-worked metal by heating it to a specific temperature.

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Sintering

The process of bonding solid particles by heat without any liquid present. It involves merging powder particles and eliminating initial porosity to create a denser product.

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Fusion Temperature (Tf)

The temperature at which a metal transitions from a liquid to a solid state. This is also known as the freezing point.

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Nucleus Formation

The process of forming tiny seeds or starting points for crystals during solidification. These nuclei can form spontaneously in the liquid or with the aid of foreign particles.

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Homogeneous Nucleation

The process of forming nuclei in a liquid metal without any foreign particles. This happens spontaneously when the liquid is cooled below its freezing point.

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Heterogeneous Nucleation

The process of forming nuclei in a liquid metal with the help of foreign particles. These particles act as starting points for crystal growth.

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Electroforming

A type of metal processing where a metal layer is deposited onto a conductive surface using a process similar to corrosion in reverse. This technique utilizes electrolysis to transfer metal ions to the desired surface.

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Stress-Relief Recovery

The first stage of annealing where the material recovers from stress but remains in its original form.

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Grain Growth

Continued heating leads to larger grains and a coarser structure, further affecting mechanical properties.

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Alloy

A combination of two or more metals, which are soluble in the molten state.

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Solid Solution Alloy

A type of alloy where atoms of different metals are mixed randomly within a single crystalline structure.

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Binary Alloy

An alloy with two constituent metals.

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Miscibility of Metals

Two or more metals blend together in the liquid state, but may or may not mix in the solid state.

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Substitutional Solid Solution

When two different types of atoms occupy different positions within the same crystal structure.

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Interstitial Solid Solution

When much smaller atoms fit into the spaces between larger atoms in a crystal structure.

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Phase Diagram

A temperature-composition graph that shows the different phases of an alloy system at different temperatures.

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Liquidus Line

A curve on a phase diagram representing the temperatures at which an alloy begins to solidify.

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Solidus Line

A curve on a phase diagram representing the temperatures at which an alloy is completely solidified.

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Coring

The non-uniform composition of a grain due to different melting points of the alloy components. The core is richer in the higher melting point component.

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Eutectic Alloy

An alloy that contains two distinct phases, typically formed when two metals are partially soluble in the solid state.

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Cored Structure

A structure formed when an alloy is rapidly cooled after solidifying, leading to variations in composition within the solid. This occurs when the temperature range between the liquidus and solidus lines is large.

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Homogenization

A process used to eliminate coring in alloys. It involves heating the cored structure below its solidus temperature to allow atomic diffusion to equalize composition.

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Eutectic Point

The lowest melting point alloy within a binary eutectic system.

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Eutectic Temperature

The temperature at which a eutectic alloy completely solidifies.

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Intermetallic Compound

A compound formed when two metals have a strong chemical affinity upon solidification, resulting in a specific composition and properties.

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Melting Range

The property of a solid solution alloy characterized by a range of temperatures over which it melts, rather than a single melting point.

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Phase Diagram for Complete Solid Insolubility

A phase diagram depicting a binary system where two metals are completely insoluble in the solid state. It shows the liquidus and solidus lines.

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Study Notes

Chapter 6: Metallurgy

  • Metallurgy is the study of metals and alloys.
  • A metal is an element that ionizes positively in solution.
  • About 80 of the 103 listed elements in the periodic table are classified as metals.
  • Valence electrons in metals are delocalized, unbound, and move throughout the metal rather than being bound to individual atoms.
  • Nonmetals are on the right side of the periodic table. Metalloids/semiconductors are on the border between metals and nonmetals. They have characteristics of both. Examples include Carbon, Silicon, and Boron.

Properties of Metals

  • Metals ionize positively in solution.
  • Typically crystalline solids at normal temperature, with exceptions like mercury and gallium, which are liquid.
  • Metals exhibit a distinctive luster, difficult to replicate in other solids. The luster arises from the response of unbound electrons to light frequencies, which reflects light.

Shaping of Metals

  • Casting: Melting metal/alloy and shaping it in a mold to the desired shape.
  • Cold Working: Mechanical working a solid metal block into rods, wires, tubes, or other shapes. The stresses applied are above the metal's yield strength, causing plastic deformation (slip along crystal planes involving dislocation movements).
  • Powder Metallurgy (Sintering): Bonding solid particles by heat without a liquid. A process that eliminates initial porosity in a powder to create a denser product.

Solidification of Metals

  • Cooling a melted metal produces a temperature-time curve.
  • Temperature decreases from A to B, is constant until C, then decreases to room temperature.
  • The freezing point (or fusion temperature) is indicated by a straight/flat portion (plateau BC) on the curve.
  • During freezing, heat is released as the metal changes from liquid to solid; this is the latent heat of fusion.

Structure During Solidification

  • Nuclei formation: atoms aggregate to form initial crystallization points (nuclei) at the supercooling point (homogeneous nucleation) or from existing solid particles (heterogeneous nucleation).
  • Crystallization: Nuclei grow in three dimensions, forming crystals (grains). Growth stops when grains touch.
  • Grain boundaries: Regions between crystals with different orientation where atoms are in distorted positions. Boundaries have higher energy.
  • Grain boundaries impact mechanical properties (e.g., impact crystallization and diffusion).

Control of Grain Size

  • Smaller grain sizes generally lead to better mechanical properties.
  • Rate of cooling from the liquid state affects the number of nuclei that form during solidification, which in turn impacts grain size. Faster cooling results in smaller grains.
  • Nucleating agents (grain refiners) can be added to increase the number of nuclei for smaller grain sizes.

Effect of Stress on Microstructure of Metals

  • Elastic Deformation: Temporary deformation from stress below the elastic limit, directly related to the bonds of the metal.
  • Plastic Deformation: Slip of atom layers over each other in certain planes. This process is characterized by dislocation movement within a localized zone (dislocation).

Wrought Metals

  • Metals that were cold worked to form a fibrous structure from their cast or grain structures. This method includes techniques such as hammering, rolling, or drawing metals into wire.

Cold Working and Strain Hardening

  • A plastically formed structure that's experienced above the yield point and ambient temperature.
  • Cold working produces an increase in hardness, strength, and yield strength, but a reduction in ductility.
  • Recovery, recrystallization, and grain growth are heat treatment processes that can reverse the effects of cold working.

Classification of Alloys

  • Alloys are combinations of two or more metals.
  • Classified according to the number of alloying elements (binary, ternary, etc.).
  • Classified according to miscibility of constituent atoms (solid solution alloys, eutectic alloys, intermetallic compounds).

(1) Solid Solution Alloys

  • Metals that are completely soluble in each other in both liquid and solid states.
  • Substitutional: different atoms fill different positions in the same crystal lattice.
  • Interstitial: smaller atoms fit into spaces between larger atoms in the lattice.

(2) Eutectic Alloys

  • Lowest melting alloy in a given system.
  • Cooling curve has a horizontal plateau at the eutectic temperature.
  • Often brittle due to heterogeneous phase structure.
  • Used for soldering due to low melting temperature.

(3) Intermetallic Compounds

  • Formed due to chemical affinity between constituent metals.
  • Intermetallic compounds typically have unique properties (e.g., hardness, brittleness) compared to their constituent metals.
  • Solid-state reactions are temperature assisted diffusion in metals where it is useful for homogenization in alloys.

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