Materials and Consumables in Axle Shop
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Questions and Answers

What is the primary requirement for the steel used in the manufacturing of steel blooms for axle forging?

  • Hydrogen content must be determined only during solidification.
  • Steel must be quenched and tempered.
  • Steel must contain a minimum of 2% nitrogen.
  • Steel must be manufactured using basic electric arc furnace. (correct)

    • Which material is specified for the forging hammers used in the Rail Wheel Factory?

  • DIN 52CrMo4 steel
  • Carbon Steel Grade 1018
  • DIN 56NiCrMoV7 steel (correct)
  • Alloy Steel 4140

    • What does the yield strength of a material signify?

  • The force required to permanently deform the material.
  • The stress at which plastic deformation begins. (correct)
  • The maximum stress the material can withstand before fracture.
  • The stress at which the material regains original shape.

    • In the context of ductility, which measurement indicates a material's ability to deform under tensile load?

    <p>Percentage elongation</p> Signup and view all the answers

    Which test provides the most comprehensive information about the mechanical properties of materials?

    <p>Tensile test</p> Signup and view all the answers

    What process related to the forging hammers must be documented and made available to inspecting officials?

    <p>The reclamation process</p> Signup and view all the answers

    Which of the following statements correctly describes the role of hydrogen content testing in steel manufacturing?

    <p>Hydrogen content must be evaluated to ensure proper steel properties.</p> Signup and view all the answers

    What factors are involved in calculating yield strength as represented by the formula σy = Py / A0?

    <p>Load at yield point and original area of cross section</p> Signup and view all the answers

    What key characteristic does high ductility in a material indicate?

    <p>Ability to undergo plastic deformation before fracture</p> Signup and view all the answers

    Which of the following tests assess the shear strength of materials?

    <p>Shear test</p> Signup and view all the answers

    What does malleability refer to in materials science?

    <p>The ability to undergo plastic deformation under compressive load.</p> Signup and view all the answers

    At what point does necking occur in a tensile testing scenario?

    <p>After reaching the ultimate tensile strength.</p> Signup and view all the answers

    What represents the fracture strength of a material?

    <p>The stress corresponding to the load at which fracture occurs.</p> Signup and view all the answers

    Which crystal structure does pure iron exhibit at room temperature?

    <p>Body-centered cubic (BCC)</p> Signup and view all the answers

    What is the temperature at which BCC iron transforms into FCC iron?

    <p>912 degrees Celsius</p> Signup and view all the answers

    What does the toughness of a material represent?

    <p>The energy a material can absorb before it fractures.</p> Signup and view all the answers

    In the iron carbon equilibrium diagram, what does the left vertical axis represent?

    <p>Allotropic changes of pure iron with temperature.</p> Signup and view all the answers

    What is the significance of the right vertical axis in the iron carbon equilibrium diagram?

    <p>It represents 6.67% C by weight.</p> Signup and view all the answers

    How is ultimate tensile strength mathematically defined?

    <p>σu = Pu / A0</p> Signup and view all the answers

    What happens to the load after reaching the ultimate tensile strength?

    <p>It starts to decrease leading to potential fracture.</p> Signup and view all the answers

    What is the maximum solid solubility of carbon in ferrite at room temperature?

    <p>0.008%</p> Signup and view all the answers

    Which phase forms when austenite is cooled very slowly to below 727 degrees Celsius with exactly 0.83% carbon?

    <p>Pearlite</p> Signup and view all the answers

    What is the primary characteristic of cementite in terms of carbon content?

    <p>Contains exactly 6.67% carbon</p> Signup and view all the answers

    Austenite is characterized by which of the following properties?

    <p>FCC structure and not magnetic</p> Signup and view all the answers

    At what temperature does austenite transition from FCC to BCC structure?

    <p>1394 degrees Celsius</p> Signup and view all the answers

    Which phase is described as not being stable below 727 degrees Celsius?

    <p>Austenite</p> Signup and view all the answers

    What is the structural form of pearlite?

    <p>Lamellar structure of α-ferrite and cementite</p> Signup and view all the answers

    What type of iron structure does δ-ferrite represent?

    <p>Body-centered cubic structure</p> Signup and view all the answers

    What percentage of carbon is present in leadburite?

    <p>4.33%</p> Signup and view all the answers

    How does cementite contribute to the properties of steel?

    <p>Enhances hardness</p> Signup and view all the answers

    Study Notes

    Consumables Used in Axle Shop

    • Consumables used in Rail Wheel Factory are multi-sourced
    • Steel Blooms for forging Diesel/Electric loco and EMU Driving axles are needed
    • Steel blooms must be manufactured using basic electric arc furnace or equivalent, approved process
    • Hydrogen content in liquid steel is analyzed using LECO hydrogen analyzer
    • Nitrogen content of the steel is also analyzed using LECO nitrogen analyzer
    • Forging hammers are used for forging steel axles and armature shafts
    • Forging hammers are made from DIN 56NiCrMoV7 steel, quenched and tempered to 34 HRC
    • Reclamation process for hammers is documented and available to inspecting officials

    Mechanical Properties of Materials

    • Materials are known by their properties, evaluated via various tests
    • Tensile tests provide maximum information about mechanical properties
    • Key mechanical properties include:
      • Yield Strength (stress at which plastic deformation begins)
      • Yield stress
      • Ultimate stress
      • Proportional limit
      • Fracture
      • Necking
      • Strain hardening

    Properties of Materials (cont.)

    • Ductility: Ability to undergo plastic deformation under tensile load. Measured by percentage elongation.
    • Malleability: Ability to undergo plastic deformation under compressive load
    • Ultimate Tensile Strength: Stress at which a material fractures under a tensile load.
    • Fracture Strength: Stress at which material actually fails
    • Toughness: A material's ability to withstand both elastic and plastic deformation before fracture.

    Iron-Carbon Equilibrium Diagram

    • Study of steel and iron constitution and structure starts with the Iron-Carbon equilibrium diagram
    • Iron is allotropic, existing in different crystal structures depending on temperature
    • Different phases of iron include:
      • ferrite (BCC)
      • austenite (FCC)
    • The diagram shows the relationship between temperature, carbon content, and the phases present in iron-carbon alloys
    • Different phases present include:
      • L (liquid)
      • Austenite
      • Ferrite
      • Cementite
      • Pearlite
      • Ledeburite

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    Consumables Used in Axle Shop (PDF)

    Description

    This quiz covers the essential consumables and materials used in an axle shop, focusing on the Rail Wheel Factory's processes. It includes the evaluation of mechanical properties and the specifications of materials such as steel blooms and forging hammers. Test your knowledge of material properties and their applications in forging.

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