This document provides an overview of basic metallurgy. It discusses the classification of materials, including metals and alloys, ceramics, polymers, and composites. The key metallurgy processes of casting, forming, welding, and powder metallurgy are described. Advanced materials like electronic materials, biomaterials, and nanomaterials are also introduced. The document is authored by K. Sevugarajan of Metz Lab Pvt. Ltd and provides their contact information.

1. Basic Metallurgy
By - K.Sevugarajan
Contact details
Metz Lab Pvt.Ltd.
First floor, Thangavel Nagar
Walajabad Main Road,
Mannivakkam-600048
Cell: +91-8190810222
Mail: metz@metzlab.in
www.metzlab.in

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1. Introduction
2. Materials science
3. Classification of materials
4. Applications
5. Advanced materials
6. Metallurgy processes (Castings, Formings,
Powder Metallurgy, Welding etc,..)
Outline

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1. Introduction Ages
Basic steps in metallurgy
Materials:
Substances of which something is composed or made.
Every segment of our everyday lives is influenced to one
degree or another by materials.
Material Science:
Investigating the relationship between the structure and
properties of the materials
Metallurgy:
The science and technology of extracting metals from
their natural sources and preparing them for practical use

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1. Introduction Ages
Basic steps in metallurgy
Age of Steel
 Petroleum Age
 Industrial Age
 Age of Flight
 Space Age -Sputnik
 Nuclear Age
 Computer Age
 Composite Material Age
 Nano Tech Age
 Green Age ?
Modern Metal
Age consists of
many overlapping
Technical Ages
after 1300
Basic ages of
metals in the
ancient world

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1. Introduction Ages
Basic steps in metallurgy
The development of metallurgy was a long, and
sometimes devious process that involved five basic steps.
1. Identifying and discovering its usefulness
2. Locating metals in quantity
3. Mining the ores.
4. Smelting the metal.
5. Shaping the metal into something useful.

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2. Material science
Structure
Property
Processing
Performance
Material science has four basic elements.
1. Structure
2. Property
3. Processing
4. Performance
Property

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2. Material science
Structure
Property
Processing
Performance
The structure of a material usually relates to the arrangement of
its internal components.
subatomic atomic microscopic macroscopic
Electrons within
individual atom
and interaction
with nuclei
Organization
of atoms or
molecules related
to one another
Large groups of
atoms, direct
observation
by microscope
Structural elements
may be viewed
with naked eye

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2. Material science
Structure
Property
Processing
Performance
Property is a material trait in terms of the kind and magnitude of
response to a specific imposed stimulus.
Mechanical
(Strength, Hardness,
Ductility, Stiffness)
Electrical
(Electrical conductivity,
Dielectric constant)
Thermal
(Heat capacity,
Thermal conductivity)
Magnetic
(Magnetic moment,
Magnetic permeability)
Optical
(Refraction index,
Reflectivity)
Deteriorative
(Corrosion)

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2. Material science
Structure
Property
Processing
Performance
Processing: different ways for shaping materials into useful
components or changing their properties.
 Casting
 Forming
 Welding
 Powder metallurgy

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2. Material science
Structure
Property
Processing
Performance
Performance: a function of a material’s properties.

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3. Classification of Materials
 Metals and Alloys
 Ceramics, Glasses, and Glass-ceramics
 Polymers (plastics), Thermoplastics and Thermosets
 Composite Materials

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3. Classification of Materials
Materials

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• Principles
• Types of failures
• Failure modes
• How to conduct failure analysis
• Analyze data
• Materials
• Manufacturing process
• Report preparation
• Failures examples
Component Material
4. Applications

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Component Material
4. Applications

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Component Material
4. Applications

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4. Advanced Materials
Materials that are utilized in high-technology applications are
sometimes termed advanced materials.
• Electronic materials
• Bio materials
• Nano materials
Electronic materials
Bio materials
Nano materials

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4. Advanced Materials
Electronic materials
Semi conductor
• Have electrical properties that are intermediate between the
electrical conductors and insulators.
 Electrical characteristics are extremely sensitive to impurity
concentration
 Si, Ge, ZnO
Super conductor
• A superconductor is a material that can conduct electricity or
transport electrons from one atom to another with no resistance.
Tl7Sn2Ba2MnCu10O20+
Electronic materials
Bio materials
Nano materials

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4. Advanced Materials
Bio materials
Electronic materials
Bio materials
Nano materials
Employed in components implanted into the human body for
replacement of diseased or damaged body parts.
 not produce toxic substances
 be compatible with body tissues

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4. Advanced Materials
Nano materials
It enables to carefully arrange atoms to develop mechanical,
electrical, magnetic, and other properties. “Bottom-up”
sciences called nanotechnology.
Nano = 10-9, nanotechnology < 100 nm
equivalent 500 atom diameters
Electronic materials
Bio materials
Nano materials
Carbon based nanotubes
Bucky Ball (C60)

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5.Metallurgy process
Casting
Forming
Welding
Powder metallurgy
Casting
Casting A manufacturing process that pours a liquid material
into a hollow mould until the material cools into a solidified
shape

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5.Metallurgy process
Casting
Forming
Welding
Powder metallurgy
Forming
Forming operations change the geometry of the starting
material without cutting it.
Rolling: Compressive deformation process in which the thickness of a plate is
reduced by squeezing it through two rotating cylindrical rolls.
Forging: The work piece is compressed between two opposing dies so that
the die shapes are imparted to the work.
Extrusion: The work material is forced to flow through a die opening taking
its shape
Drawing: The diameter of a wire or bar is reduced by pulling it through a die
opening (bar drawing) or a series of die openings (wire drawing)

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5.Metallurgy process
Casting
Forming
Welding
Powder metallurgy
Forging
A metal is shaped by compressive forces Oldest metal working
process – 4000BC Can be performed with a hammer and anvil

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5.Metallurgy process
Casting
Forming
Welding
Powder metallurgy
Welding
Combining processes join two materials or deposit material
onto the exterior surface of the starting material
BASE METAL
WELD
SOLIDIFIED SLAG
ARC POOL
WELDING ATMOSPHERE
CORE WIRE
ELECTRODE COATING
ARC STREAM
PENETRATION DEPTH

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5.Metallurgy process
Casting
Forming
Welding
Powder metallurgy
Powder Metallurgy
Powder metallurgy is a process by which fine powdered materials
are blended, pressed into a desired shape, and then heated to
bond surfaces

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