MME101 Introduction to Metallurgy and Materials Engineeringdepo.btu.edu.tr/dosyalar/metalurji/Dosyalar/MME101... · Metallurgical and Materials Engineering Metallurgical and Materials

Asst. Prof. Dr. Ayşe KALEMTAŞ

MME101 Introduction to Metallurgy and Materials

Engineering

Asst. Prof. Dr. Ayşe KALEMTAŞBursa Technical University, Metallurgical and Materials Engineering Department

Office Hours: Tuesday, 16:00-17:[email protected], [email protected]

mailto:[email protected]











Materials Science and EngineeringA Multidiciplinary Approach


Materials Knowledge Diagram

This diagram illustrates how materials science

and engineering form a bridge of knowledge from the basic sciences to the engineering disciplines


Materials Tetrahedron

Performance behavior in a particularapplication

Processing method of preparingmaterial

Structure arrangement of internal components

subatomic atomic

microscopic macroscopic (bulk)

Different ways forshaping materialsinto usefulcomponents orchanging theirproperties.

Properties material characteristic response to externalstimulus mechanical, electrical,thermal, magnetic,optical, deteriorative


Materials science : A field of science that emphasizes studies ofrelationships between the internal or microstructure, synthesisand processing and the properties of materials.

Materials engineering : An engineering oriented field that focuseson how to translate or transform materials into a useful deviceor structure.

Materials science and engineering (MSE) : An interdisciplinaryfield concerned with inventing new materials and improvingpreviously known materials by developing a deeper understandingof the microstructure-composition-synthesis-processingrelationships between different materials.

Materials Science and Engineering


Materials Science and Engineering

Materials Science

• Basic knowledge of

materials

Materials Science and

Engineering

• Resultant knowledge

of structure,

properties, processing

and performance of

engineering materials

Materials Engineering

• Applied knowledge of

materials

Using the combined knowledge of materials from materials science andmaterials engineering enables engineers to convert materials into theproducts needed by society


Metallurgical and Materials Engineering

Metallurgical and Materials Engineering plays a significant role in all kindof fabrication processes which convert raw materials into useful productsdesigned to meet the needs of human being.

The principle aim of the Metallurgical and Materials Engineering programis to provide students with a fundamental knowledge-base associatedwith materials-processing, their properties, and their selection andapplication.

The subject of metallurgy broadly divides itself into physical metallurgy, mechanical metallurgy, chemical metallurgy, mineral dressing, powder metallurgy and engineering metallurgy.


Metallurgical and Materials Engineering

Minerals

• Minerals are naturally occurring substancesthat have a definite internal structure.

• They are defined by geologists as“homogenous, naturally occurringsubstances with a definable internalstructure”.

• They are found in various forms and areused for a variety of purposes.

E.g., Diamond, limestone, fluoride,aluminium etc.


What is Ore?

https://www.boundless.com/chemistry/textbooks/boundless-chemistry-textbook/metals-20/metallurgic-processes-142/extractive-metallurgy-559-3578/

Ores : An ore is a type of rock thatcontains minerals withimportant elements such as metals.

Ores are extracted through mining;they are then refined to extract thevaluable element(s).

The grade or concentration of an oremineral, or metal, as well as its formof occurrence, will directly affect thecosts associated with mining it.

The cost of extraction must beweighed against the metal valuecontained in the rock to determinewhich ores should be processed andwhich ores are of too low a grade tobe worth mining.


What is Ore?

https://www.boundless.com/chemistry/textbooks/boundless-chemistry-textbook/metals-20/metallurgic-processes-142/extractive-metallurgy-559-3578/

Metal ores are generally oxides, sulfides and silicates of "native" metals(such as native copper) that are not commonly concentrated in theEarth's crust.

Ore bodies are formed by a variety of geological processes. The processof ore formation is called ore genesis.

Ore Preparation

It takes multiple steps to extract the "important" element from theore:

First, the ore must be separated from unwanted rocks. Then, the minerals need to be separated out of the ore Since most minerals are not pure metals, further separationmethods are required. Most minerals are chemical compounds that contain metals andother elements.


Mineral, Gangue and Liberation

The crude ore from the mines contain a number ofsolid phases in the form of an aggregate. Thevaluable portion of the ore is known as mineralwhile the worthless portion is known as gangue.

During ore dressing, the crude ore is reduced in sizeto a point where each mineral grain becomesessentially free so as to make separation betweenthem. Such a phenomenon of making the mineralgrains free from gangue in an ore is termed asliberation. This is practically carried out by sizereduction performed by crushers and grinding mills.


Earth’s CrustEarth’s crust refers to the outher siliceous shell ofthe earth which is about 16 km thick.

Metallic ores and mineral products are producedfrom this crust. Therefore, the original source ofall metals is the earth’s crust.

Ores are naturally occuring deposits in theearth’s crust. The ores are mined and treatedby various• unit operations (mechanical processes)• unit processes (chemical metallurgical

processes)to extract metals and to convert them intothe metallic form.

ORES AND MINERALS

The mineral content of the ore must be in sufficientconcentration to make its extraction commerciallyviable.

Mine : It is a large area having an abundant quantity of

mineral deposits that can be easily and economically

extracted.


Average Analysis of the Earth’s Crust

It is clear that :

Oxygen Silicon

Aluminum Iron

are the 4 mostabundant elements

Since engineering metals Al, Fe,Mg and Ti are far moreabundant than the othermetals, there is never likely tobe a shortage of those metalsdue to exhaustion of the oredeposits.

The commonly known metalslike Au, Pb, Sn are in so smallquantities in the earth’s crustthat their commercial recoveryis impossible.

Most commonelements in the crust


Ores

ORES AND MINERALS


The subject of metallurgy

The subject of metallurgy broadly divides itself into

physical metallurgy,

mechanical metallurgy,

chemical metallurgy,

mineral dressing,

powder metallurgy and

engineering metallurgy.

Metallurgy-the art and science of economically concentrating, extracting,refining, and fabricating metals and alloys - has existed on Earth fromantiquity. Gold, silver, and copper-elements that can occur as metals in theirnatural state-were used as long as 10 000 years ago. Metals extractiontechnology can be traced back at least 6000 years. Recently, major advanceshave been made in metallurgical processing. This developed field may now beready for application to the production of metals in space.


Mineral Dressing

http://www.nss.org/settlement/nasa/spaceresvol3/pmofld1.htm

Steps in the Production of Mineral-Based Materials for Commerce


The Subject of Metallurgy

The area of mineral dressing concerns itself with the startingoperations and involves crushing and grinding either forpurposes of liberation of the desired substances that arephysically entrapped with others or for making them adoptablefor further processes.

Once liberated, they normally go through such physicalbeneficiation processes as

magnetic separation, electrostatic separation, screening, flotation,to name some, to produce a beneficiated product usuallycalled a concentrate and chemical metallurgy normally takesover from then onwards.


Mineral Dressing

http://ytjinpeng.en.alibaba.com/product/292165283-209879641/High_efficiency_high_quality_crushing_machine_cone_crusher_PYB_PYZ_PYD.html



Chemical metallurgy according to one definition, isthe branch of metallurgy that deals with theextraction of metals from naturally occurringcompounds and their refinement to levels of puritysuitable for commercial use.

The starting raw materials, however, in manycases are not restricted to naturally occurringcompounds. Nor in all cases are the end productsdesired as metals.


Metal Extraction

Extracting of metal from its ore and purifying it

• Fe2O3 (Hematite)

• Fe3O4 (Magnetite)

• CuFeS2 (Chalcopyrite)

• Al2O3.H2O (Boehmite)

Mining

Mineral Dressing

Chemical Metallurgy

Ore (e.g. İron)Open Pit mining or underground mining

Crushing, Grinding, Screening

PRYROMETALLURGY (High Temperature)e.g. İron, steel, Pb, Sn, CuHYDROMETALLURGY (Taking it into solution)e.g. Au, Ag, V, AlELECTROMETALLURGY (Electric current)e.g. Pb, Ni, Cu

Chemical Metallurgy


Powder metallurgy is concerned with production andprocessing of powdery forms of metals and materialsand of solid industrial products therefrom.

http://www.autoinspectproject.eu/project/index.jsp

Powder Metallurgy

Asst. Prof. Dr. Ayşe KALEMTAŞhttp://www.autoinspectproject.eu/project/index.jsp

Powder Metallurgy


Powder Metallurgy

http://www.chenghai-metallurgy.com/powder-

metallurgy/powder-metallurgy-gears.html

Applications of powder metallurgy in automotiveCamshaftValve ControlOil supply systemExterior mirrorClimate, heating and ventilationSeat adjustment systemWindow openerDoor lock systemMiddle armrestNeckrestHard top / Folding topDoor armaturesSeat beltsystem / AirbagsystemParking brakeIgnition lockElectrical power steeringSteering pillar adjustment / Steering pillar lockExhaust gas systemGear box / Automatic transmissionTurbochargerCamshaft drivePumpsFuel system

http://www.sintermetalltechnik.com/en/sst/ApplicationsPowdermetallurgy/schunk01.c.45991.en



Engineering metallurgy mainly deals with the processing ofmetals and materials in the molten condition. Foundry, metaljoining and other related areas appear to come under itscoverage.

http://www.perrysclocks.com/aihc/metallurgy http://www.boschrexroth.com/en/xc/industries/machinery-applications-and-engineering/metallurgy/index



Mechanical Metallurgy : Response of metals to forces or loads.

Mechanical Metallurgy

Mechanical assessment of materials

- Structural materials

- Machine, aircraft, ship, car, etc.

Forming of metals into useful shapes

- forging, rolling, extrusion, drawing,

machining, etc.

We need to know limitingvalues of which materials inservice can withstand withoutfailure

We need to know conditionsof load and temperature tominimise the forces that areneeded to deform metalwithout failure



Physical metallurgy is concerned with the scientificstudy of materials.

Phase transformations, recovery and recrystallization, precipitation hardening, structure–property correlations, characterization of microstructure bymicroscopy (optical, electron and field-ion),

are some specific examples among the many topicscovered under physical metallurgy.


QUESTIONS

Documents

MME101 Introduction to Metallurgy and Materials Engineeringdepo.btu.edu.tr/dosyalar/metalurji/Dosyalar/MME101... · Metallurgical and Materials Engineering Metallurgical and Materials