Mechanical Properties of Steel and Manufacturing

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Questions and Answers

What is the primary purpose of using steel blooms in the axle manufacturing process?

  • To enhance aesthetic appearance of the axles
  • To improve electrical conductivity
  • To reduce the weight of the axles
  • To provide a base material for forging axles (correct)

Which mechanical property is defined as the stress at which plastic deformation begins?

  • Elastic modulus
  • Yield strength (correct)
  • Ultimate strength
  • Tensile strength

What material is commonly used for forging hammers in the railway industry?

  • DIN 56NiCrMoV7 (correct)
  • CAST Iron
  • Stainless Steel
  • Aluminium Alloy

How is ductility measured?

<p>Through the percentage elongation before fracture (B)</p> Signup and view all the answers

What must be documented during the reclamation process of forging hammers?

<p>The entire reclamation procedure (D)</p> Signup and view all the answers

Which property gives the maximum information about a material's mechanical characteristics?

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

What analysis method is used to determine the hydrogen content in liquid steel?

<p>LECO hydrogen analyzer (D)</p> Signup and view all the answers

What is the formula for calculating yield strength?

<p>$ rac{Py}{A0}$ (A)</p> Signup and view all the answers

What does a high percentage elongation indicate about a material?

<p>It has high ductility (B)</p> Signup and view all the answers

Which process is required for producing steel blooms for axles?

<p>Basic electric arc furnace process or equivalent (C)</p> Signup and view all the answers

What does malleability refer to in materials?

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

What is ultimate tensile strength defined as?

<p>The maximum load a specimen can handle before necking occurs (A)</p> Signup and view all the answers

How is fracture strength mathematically represented?

<p>σf = Pf / A0 (B)</p> Signup and view all the answers

What does toughness measure in a material?

<p>The energy a material can absorb before fracture (D)</p> Signup and view all the answers

At what temperature does BCC iron undergo allotropic changes to become FCC iron?

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

What structure does pure iron exist in at room temperature?

<p>BCC structure (D)</p> Signup and view all the answers

What is the point at which necking occurs in a material?

<p>After the ultimate load is reached (B)</p> Signup and view all the answers

Which form of iron is known as austenite?

<p>γ-iron (D)</p> Signup and view all the answers

What does the right vertical axis of the Iron carbon equilibrium diagram represent?

<p>Percentage of carbon by weight (A)</p> Signup and view all the answers

How does fracture strength differ from ultimate tensile strength?

<p>Fracture strength is lower than ultimate tensile strength (B)</p> Signup and view all the answers

What is the maximum amount of carbon that can be added to molten iron before it becomes saturated?

<p>6.67% (D)</p> Signup and view all the answers

Which phase of iron has a maximum solid solubility of 0.025% carbon at 727 degrees Celsius?

<p>α-Ferrite (A)</p> Signup and view all the answers

Austenite has which of the following characteristics?

<p>Non-stable below 727 degrees Celsius and has an FCC structure (D)</p> Signup and view all the answers

What phase of iron is considered the hardest structure on the Fe-C diagram?

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

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

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

What is the solid solubility of carbon in δ-Ferrite at its maximum temperature of 1495 degrees Celsius?

<p>0.1% (B)</p> Signup and view all the answers

What is the crystal structure of Cementite?

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

Ledeburite is formed from a mixture of which two phases?

<p>Austenite and Cementite (D)</p> Signup and view all the answers

Which phase is described as having a fingerprint-like appearance?

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

What happens to the structure of austenite at 1394 degrees Celsius?

<p>It changes from FCC to BCC (A)</p> Signup and view all the answers

Flashcards

Ductility

The ability of a material to undergo permanent deformation without breaking. It's measured by how much the material stretches before it fractures. Higher ductility means more stretch.

Yield Strength

The stress at which a material begins to permanently deform. It's a measure of how much force a material can withstand before it starts to change shape permanently.

Tensile Test

A type of test that measures the strength of a material by subjecting it to a pulling force. It provides information about yield strength, ultimate tensile strength, and ductility.

Shear Test

A test that measures the ability of a material to resist a shearing force, which is a force that tries to slide one part of the material past another.

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Impact Test

A test that assesses the toughness of a material by measuring its resistance to impact forces. It helps determine how well a material can handle sudden shocks.

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Hardness Test

A test that measures the resistance of a material to indentation. It provides an indirect measure of the material's hardness and strength.

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Compression Test

A test that evaluates the ability of a material to withstand compression (pushing force) before it breaks. It's commonly used for materials like concrete and bricks.

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Bending Test

A test that measures the ability of a material to bend under a load. It helps determine a material's flexibility and how well it can withstand bending forces.

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Steel Blooms for Forging Axles

Steel blooms are the starting material used in the forging process for axles. They should be made with specific properties for the desired application.

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Forging Hammers

Forging hammers are crucial for shaping and forming steel axles into their required shapes. They must meet specific standards for durability and performance.

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Malleability

The ability of a material to deform permanently under compressive load without cracking.

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Ultimate Tensile Strength

The maximum stress a material can withstand before it starts to deform permanently.

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Fracture Strength

The stress at which a material fractures or breaks.

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Toughness

The ability of a material to absorb energy before fracture, taking into account both elastic and plastic deformation.

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Allotropy

The ability of a metal to exist in different crystal structures depending on temperature.

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Ferrite (α-iron)

The body-centered cubic (BCC) structure of iron that exists at room temperature.

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Austenite (γ-iron)

The face-centered cubic (FCC) structure of iron that exists between 912°C and 1394°C.

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δ-Ferrite

The body-centered cubic (BCC) structure of iron that exists between 1394°C and 1538°C.

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Iron-Carbon Equilibrium Diagram

A graphical representation of the stable phases of iron and carbon at different temperatures and compositions.

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Elasticity

A material's ability to return to its original shape after being deformed.

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Austenite

An interstitial solid solution with carbon dissolved in FCC iron. It has a maximum carbon solubility of 2.1% at 1148°C, but it is not stable below 727°C. Austenite has an FCC structure and is non-magnetic.

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Cementite (Iron Carbide)

A chemical compound with the formula Fe3C. It is the hardest phase in the Fe-C system and always contains 6.67% carbon by weight. It has an orthorhombic crystal structure.

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Pearlite

A lamellar structure formed when austenite with 0.83% carbon is cooled slowly below 727°C. It consists of alternating layers of α-ferrite and cementite.

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Ledeburite

The eutectic mixture of austenite (lighter phase) and cementite (darker phase) that forms at 1148°C and 4.33% carbon.

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Carbon Saturation Point in Molten Iron

The maximum carbon concentration that can be dissolved in molten iron before it becomes saturated.

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Pearlitic Transformation

The phenomenon where austenite transforms into pearlite when cooled slowly below 727°C.

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Equilibrium Cooling

The process of very slow cooling of alloys to achieve equilibrium phases, resulting in a stable and predictable microstructure.

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Fe-C Equilibrium Diagram

A diagram showing the equilibrium phases present in the iron-carbon system at different temperatures and carbon concentrations.

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Study Notes

Consumables Used in Axle Shop

  • Consumables used in Rail Wheel Factory are required from multiple suppliers
  • Specifications are provided to help suppliers develop and supply to RWF
  • Steel Blooms for forging Diesel/Electric locomotives and EMU driving axles:
    • Manufactured using basic electric arc furnace or other approved processes
    • Steel must meet requirements from IRS R 43 and IRS R 16
    • Hydrogen and nitrogen content must be analyzed using standard LECO analyzers
  • Forging Hammers:
    • Used to forge steel axles and armature shafts
    • Made from DIN 56NiCrMoV7 steel, quenched and tempered to 34 HRC
    • Reclamation process documentation is required and made available to inspecting officials

Properties of Materials

  • Materials are characterized by various properties
  • Mechanical properties are evaluated and compared using tests
  • Popular tests include tensile tests, compression tests, shear tests, hardness tests, impact tests, and bending tests
  • Tensile tests provide the most comprehensive information about mechanical properties

Mechanical Properties (Tensile Tests)

  • Yield Strength: Stress at which plastic deformation begins without significant load increase
  • Ultimate Stress: Highest stress the material can withstand before failure
  • Yield Stress: Stress at which the material starts to deform permanently
  • Proportional Limit: Stress limit where stress and strain are directly proportional
  • Fracture: Point of material failure
  • Necking: Reduction in cross-sectional area of the specimen at the point of failure
  • Linear region /Plasticity or yielding: region where stress and strain are linearly related
  • Perfect hardening: Region where the specimen continues to deform plastically without any noticeable increase in strength

Ductility

  • Ability of a material to undergo plastic deformation under tensile load
  • Measured by percentage elongation: ((L-Lâ‚€)/Lâ‚€) *100, Where L = length after test, Lâ‚€ = Original length

Malleability

  • Ability of a material to undergo plastic deformation under compressive load

Ultimate Tensile Strength

  • Maximum stress a material can withstand before failure
  • Calculated as (Ultimate load / Original cross-sectional area)

Fracture Strength

  • Stress at the point of material failure
  • Calculated as (Fracture load / Original cross-sectional area)

Toughness

  • Material's ability to withstand both elastic and plastic deformation before failure
  • Higher toughness indicates the material can absorb more energy before fracture

Iron-Carbon Equilibrium Diagram

  • Study of the constitution and structure of steels and irons
  • Iron exhibits allotropy (exists in multiple crystal structures at different temperatures)
  • Different phases of iron and carbon at varying temperatures and compositions are detailed on the diagram

Phases in the Iron-Carbon System

  • Alpha ferrite, Austenite, Delta ferrite, Cementite, Pearlite, and Ledeburite are explained
  • Their properties and structures are described.
  • Solid solubility of carbon is discussed for each phase at various temperatures.

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