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UNIVERSITI TEKNIKAL MALAYSIA MELAKA MECHANICAL AND THERMAL PROPERTIES OF PURE NICKEL AS AN ALTERNATIVE AUTOMOTIVE BODY MATERIAL This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering (Engineering Materials) with Honours By GAN BEE GEOK FACULTY OF MANUFACTURING ENGINEERING 2010

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

MECHANICAL AND THERMAL PROPERTIES OF PURE NICKEL

AS AN ALTERNATIVE AUTOMOTIVE BODY MATERIAL

This report submitted in accordance with requirement of the Universiti Teknikal

Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering

(Engineering Materials) with Honours

By

GAN BEE GEOK

FACULTY OF MANUFACTURING ENGINEERING

2010

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

TAJUK: Mechanical and Thermal Properties of Pure Nickel as an Alternative Automotive Body Material

SESI PENGAJIAN: 2009/10 Semester 2

Saya GAN BEE GEOK

mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:

1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti T eknikal Malaysia Melaka dibenarkan membuat salinan

untuk tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan

pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan (-.J)

D D QJ

SULIT

TERHAD

TIDAK TERHAD

Alamat Tetap:

J 5904 Rumah Awam,

Sempang Pantai

nJOO Merlimau, Melaka

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA RASMI1972)

(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

Disahkan oleh:

Cop Rasmi:

PROF. MADYA DR. t JOSEPH F k . ProtQsor f..tao SAHAYA ANAND

.a ultl Kejur:.~ter ya

Tarikh: __ 2_5_.0_5_.2_0_10 ____ _ UniVersiti Te~nikal :" ~e'!'buata"

alays,a Mela~a

Tarikh: 95 MCl;li 9.e> ro

** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.

DECLARATION

I hereby, declared this report entitled “Mechanical and thermal properties of pure

nickel as an alternative automotive body material” is the results of my own research

except as cited in references.

Signature :

Author’s Name : GAN BEE GEOK

Date : 25.05.2010

APPROVAL

This report is submitted to the Faculty of Manufacturing Engineering of UTeM as

a partial fulfillment of the requirements for the degree of Bachelor of

Manufacturing Engineering (Engineering Materials) with Honours. The member

of the supervisory committee is as follow:

………………………………

( PROF. MADYA. DR. T. JOSEPH SAHAYA ANAND )

i

ABSTRACT

This project is represented the study of thermal and mechanical properties of pure nickel

as an alternative automotive body material. Nickel is the chemical element which

categorized in periodic table as transition metal. Nickel is a hard, malleable, ductile

material. It is used for making stainless steel, low alloy steels, cast iron and etc. Nickel

also used in battery manufacturing. Current automotive are mainly use steel as an

automotive body material. Due to the increasing demand of high performance in term of

mechanical properties of the material use in automotive, researched have been done to

find alternative material to replace steel. In this project, annealing is done for pure nickel

at 300 ºC, 500 ºC and 700ºC for 1 hour. The studies on mechanical properties, corrosion

test, composition analysis and crystallography analysis in different annealing

temperatures to alternate current automotive body material. The hardness of both non -

heat treated and annealed pure nickels do not change as the annealing temperature

increases which in the range of 118 to 123 HV. As the annealed temperature increase, the

ultimate tensile strength, yield strength and young modulus decreases, but the ductility

increase. The highest ultimate tensile strength of pure nickel at 300ºC annealed

temperature which is 758.78 MPa. For corrosion test, the corrosion rate of both non-heat

treated and annealed pure nickel have minor changes with the annealed temperature

which in the range of 0.0266 to 0.048 mm/year. The composition of both non- heat

treated and annealed pure nickels do not change. Pure nickel is face center cubic

structure; the lattice constant is decreasing as the annealing temperature increases.

Besides, the grain size of pure nickel is increasing as the annealed temperature increase.

ii

ABSTRAK

Projek ini mengenai kajian berkaitan dengan sifat-sifat mekanikal bagi nikel tulen

sebagai bahan gantian untuk bahagian badan automotif. Nikel adalah unsur kimia yang

dikategorikan dalam jadual berkala sebagai logam peralihan. Nikel adalah satu bahan

mulur yang keras, mudah dibentuk. Ia digunakan untuk membuat keluli tahan karat,

keluli aloi berkomposisi rendah, besi tuangan dan sebagainya. Nikel juga digunakan

dalam penghasilan bateri. Pada masa kini, kebanyakan bahan automotif adalah keluli.

Kajian telah dijalankan untuk menggantikan keluli sebagai alternatif bahan automotif

disebabkan peningkatan permintaan terhadap prestasi yang tinggi bagi sifat-sifat

mekanikal bagi penggunaan bahan dalam automotif, Dalam projek ini, kajian mengenai

pencekalan nikel tulen pada suhu 300 ºC, 500 ºC dan 700ºC telah dijalankan selama satu

jam. Kajian terhadap sifat-sifat mekanikal, ujian penghakisan, analisis komposisi dan

análisis kristalografi dalam suhu pengcekalan yang berbeza untuk mengganti bahan

badan automotif semasa. Kekerasan pada sampel yang tidak malakukan pengcekalan

dan cekalan nikel tulen tak berubah dan dalam lingkungan 118 kepada 123HV. kekuatan

tegangan, kekuatan alah dan modulus mengurang, tetapi kemuluran meningkat.

Kekuatan tegangan tertinggi bagi nikel tulen adalah pada suhu 300ºC cekalan iaitu

758.78MPa. Bagi ujian penghakisan, kadar kakisan kedua-dua perlakuan tanpa haba dan

cekalan nikel tulen mempunyai perubahan kecil dalam lingkungan daripada 0.0266

kepada0.048mm / tahun. Komposisi kedua-dua perlakuan tanpa haba dan cekalan nikel

tulen tak berubah. Nikel tulen berstruktur FCC; pemalar kekisi menurun apabila suhu

cekalan meningkat. Selain itu, saiz butiran nikel tulen semakin meningkat apabila suhu

cekalan meningkat.

iii

DEDICATION

This report is dedicated to my parents and my supervisor Prof. Madya. Dr. T. Joseph

Sahaya Anand who have supported me throughout my Bachelor Degree Project. Without

his patience, understanding and support, the completion of this work would not have

been possible.

iv

ACKNOWLEDGEMENT

I am pleased to say that I would never have been able to complete my Bachelor Degree

Project without the help and encouragement from this group of special individuals. I

would like to thank these people for their show of heartfelt support throughout the

duration of my Bachelor Degree Project. My first gratitude goes to my supervisor Prof.

Madya. Dr. T. Joseph Sahaya Anand for his constant guidance and encouragement. He

always guides me and he is a very nice and helpful person. When I face problem on

doing project, he always guide me to the right way although he is very busy with his

work. I want to thanks to my fellow friends Kwan Wai Loon, Lim Kok Chin, and Pang

Chee Kong for helping me during the time difficulty.

v

TABLE OF CONTENTS

TITLE PAGE

Abstract i

Abstrak ii

Dedication iii

Acknowledgement iv

Table of Content v

List of Tables ix

List of Figures xi

List Abbreviations xii

1. INTRODUCTION 1

1.1 Introduction 1

1.2 Problem Statement 2

1.3 Objective 3

1.4 Scope of Study 3

1.5 Organization of Report 3

2. LITERATURE REVIEW 5

2.1. Introduction 5

2.2. Nickel 5

2.2.1. Commercially Pure Nickel 8

2.2.2. Corrosion properties of Pure Nickel 11

2.2.3. The applications of Nickel 11

2.2.4. Health Effects of Nickel 12

2.3. Current Automotive Body Material 13

2.3.1. Steel 15

2.3.1.1. High Strength Steel 15

2.3.1.2. Stainless Steel 16

vi

2.4. Alternative Material for Automotive Body Materials 17

2.4.1. Aluminium 17

2.4.2. Magnesium and its Alloys 19

2.4.2.1. Common Magnesium Alloys 19

2.4.3. Polymers and Composites 20

2.4.4. Comparison Cost and Hardness of Pure Nickel and Current

Automotive Body Materials 21

3. METHODOLOGY 23

3.1. Introduction 23

3.2. Flow Chart of Methodology 24

3.3. Material Preparation 25

3.3.1. Number of Samples 26

3.4. Heat Treatment (Annealing) 26

3.4.1. Test Specimen Condition 26

3.4.2. Procedure 27

3.5. Mechanical Testing 27

3.5.1. Tensile Test 28

3.5.1.1. Test Machine 28

3.5.1.2. Test Sample 29

3.5.1.3. Test Method for Tensile Test 29

3.5.2. Hardness Test 30

3.5.2.1. Test Machine 30

3.5.2.2. Test Sample 31

3.5.2.3. Test Procedure 32

3.6. Corrosion Test 32

3.6.1. Test Equipment and Specimen 32

3.6.2. Test Method 33

3.7. Crystallographic Analysis 33

3.7.1. X Ray diffraction 33

vii

3.8. Composition Analysis 34

3.8.1. Scanning Electron Microscope 34

3.9. Summary 35

4. RESULTS & DISCUSSIONS 36

4.1. Introduction 36

4.2. Mechanical Testing 36

4.2.1. Hardness Analysis 37

4.2.2. Tensile Analysis 38

4.3. Corrosion Test 42

4.4. Composition Analysis 45

4.4.1. Energy Dispersive X ray Analysis 45

4.5. Crystallographic Analysis 46

4.5.1. X-Ray Diffraction Analysis 46

4.6. Summary of Mechanical Properties and Chemical Properties of

Pure Nickel in Different Annealing Temperature 51

4.7. Comparison mechanical properties of both of Annealed Pure Nickel

and Current Automotive Body Material. 52

4.7.1. Corrosion Resistance of Automotive Body Materials 52

5. CONCLUSION AND FUTURE WORK 54

5.1. Conclusion 54

5.2. Suggestion for Future Work 55

REFERENCES 56

APPENDICES 61

A. Gantt Chart PSM I 61

B. Gantt Chart PSM II 62

viii

C. Yield Strength Finding 63

D. Image of Necking Forming during Tensile Test 65

ix

LIST OF TABLES

TITLE PAGE

Table 2.1 Chemical, Mechanical and Thermal Properties of Nickel 7

Table 2.2 Chemical Composition of Nickel Alloy 8

Table 2.3 Room Temperature Mechanical Properties and Physical

Properties of Commercially Pure Nickel and Low Alloy

Nickel

9

Table 2.4 Description and Major Applications of Commercially Pure

Nickel

10

Table 2.5 Results Of Atmospheric Corrosion And Pitting Of Nickel-

Base Alloy of 20-Year Exposure 24.4m From Ocean At

Kure Beach, NC

12

Table 2.6 Main Criteria and Ratings for Realistic Selection of

Automotive Body Materials

14

Table 2.7 Material Properties of Various Steels 16

Table 2.8 Automotive Aluminium alloys in Current Use 18

Table 2.9 Common Automotive Magnesium Alloys 19

Table 3.1 Number of Samples 26

Table 3.2 Annealing Condition of Pure Nickel 27

Table 3.3 The Dimensions of the Specimen 29

Table 4.1 Hardness Result of Pure Nickel with Different Annealing

Temperature

37

Table 4.2 Ultimate Tensile Strength, Young Modulus and Yield

Strength of Pure Nickel in Different Annealed Temperature

39

Table 4.3 Results of Corrosion Analysis by using Tafel Extrapolation

Technique

44

x

Table 4.4 Theoretical XRD Lattice Parameter of Pure Nickel 47

Table 4.5 Comparison between Theoretical and Experimental of

Interplanar Spacing of Non-heat treated Pure Nickel.

47

Table 4.6 XRD Lattice Parameters Comparison 48

Table 4.7 The Grain Size Range of Non- heat Treated and Annealed

Pure Nickel

48

Table 4.8 Mechanical and Chemical Properties of Pure Nickel at

Different Annealed Temperature for 1 Hour

51

xi

LIST OF FIGURE

TITLE PAGE

Figure 2.1 Nickel in Various Form 6

Figure 2.2 The Galvanic Series of Metals 11

Figure 2.3 Graph of Price Against Hardness Between Pure Nickel

and Current Automotive Materials

21

Figure 3.1 Flow Chart of Methodology 24

Figure 3.2 Image of diamond cutter 25

Figure 3.3 Image of horizontal band saw 25

Figure 3.4 Image of CWF-1300 Furnace 27

Figure 3.5 Image of Universal Testing Machine 28

Figure 3.6 Image of tensile testing specimens dimension and shape 29

Figure 3.7 Micro Vickers Hardness Testing Machine 30

Figure 3.8 Image of Metkon FinoPress Automatic Mounting Press 31

Figure 3.9 Buehler Grinder and Polisher 31

Figure 3.10 Buehler grinder polisher 31

Figure 3.11 The EuroCell 32

Figure 3.12 Image of X-Ray X-Ray Diffractormeters 33

Figure 3.13 Image of Scanning Electron Microscopy 34

Figure 4.1 Indentation of Diamond Pyramid Indenter with A 90°

Angle Between Opposite Faces. Image Is Magnified At

50x

37

Figure 4.2 Graph of Hardness against Annealing Temperature 38

Figure 4.3 Graph of Ultimate Tensile Strength against Different

Annealing

39

Figure 4.4 Graph of Yield Strength against Different Annealing

Temperature of Pure Nickel

40

xii

Figure 4.5 Graph of Young’s Modulus in Different Annealing

Temperature of Pure Nickel

40

Figure 4.6 Graph of Tensile Stress against Elongation of Pure

Nickel In Different Annealing Temperature

41

Figure 4.7 Tafel graph for non- heat treated and 300°C pure nickel 42

Figure 4.8 Tafel graph for 500°C and 700°C annealed pure nickel 43

Figure 4.9 Graph of Corrosion Rate against the Different Annealing

Temperature

44

Figure 4.10 Data Obtained from EDX for Non Heat Treated and

Annealed Pure Nickel

45

Figure 4.11 Results Obtained from X -Ray Diffraction 46

Figure 4.12 Intensity of Non- heat Treated and Different Annealed

Temperature of Pure Nickel

50

xiii

LIST OF ABBREVIATIONS

ASTM - American Society for Testing Material

CFRP - Carbon Fiber Reinforce Polymer

ECAP - Equal- Channel Angular Pressing

EDX - Energy Dispersive X-Ray

FCC - Face Centered Cubic

FKP - Falkuti Kejuruteraan Pembuatan

GMT - Glass Mat Thermoplastic

HSS - High Strength Steel

HV - Vickers Hardness

SEM - Scanning Electron Microscopy

UTEM - Universiti Technikal Malaysia Melaka

UTM - Universal Testing Machine

UTS - Ultimate Tensile Strength

XRD - X-Ray Diffraction

1

CHAPTER 1 INTRODUCTION

1.1 Introduction

The main purpose of this project is to study the mechanical properties and thermal

properties of pure Nickel as an alternative of automotive body. Nickel is the

chemical element with the symbol, Ni which discovered in 1751 by Baron Axel

Frederik Cronstedt. Nickel is categorized as a transition metal in periodic table.

Nickel is a lustrous material which in silvery- white colour. Pure nickel is good in

electrical conductivity, thermal conductivity, and strength and corrosion resistance. It

is a reactive element but slow reacting with air at normal temperatures and pressures

due to the formation of a protective oxide surface. Nickel is used in coin ad also

plating for brass and iron element. The thermal properties of pure nickel can be

obtained by do annealing in different temperature for pure nickel. Various tests had

been conducted to obtain mechanical properties of pure nickel. The testing includes

tensile test, microhardness test, corrosion test and morphology study by using X-

Ray Diffraction and Energy-dispersive X-ray spectroscopy. This research is to

compare the mechanical properties of pure nickel with others automotive body

material. Current automotive body materials include high strength steel, aluminium,

and composite materials. Researchers have done in finding the alternative materials

which can achieve the optimal production efficiencies in automotive body.

2

1.2 Problem Statement

Due to the increasing demand of high quality exterior panels, better functional

properties and lower weight in the automotive industry, the researches on different

materials have been conducted to alternate the existing automotive body material.

One of the changes is due to the weight deduction. Therefore, automotive body

materials change from steel to aluminium. The weight of the steel is higher than

aluminium but the cost of the steel is lower than aluminium. This is due to the weight

of the automotive body will affect the energy consumption of the automotive.

Therefore, researches on lightweight material have been conducted to achieve fuel

efficiency. Cui, X.T.et al, (2007) stated that approximately 40% of the weights of the

automotive are from automotive body and interior account. Every 56.69kg weight

reduction results in a gain of 0.09-0.21 km per liter fuel economy. Besides the weight

of the material, the mechanical properties of the material in automotive body also

important in order to increase the performance of the automotive. Edwards, K .L.

(2004) stated that materials with high specific stiffness and strength properties for

example allow highly efficient lightweight load bearing structures to be produced.

High strength and strain alloy steel sheets with transformation-induced plasticity are

used for body panel. The properties of alloy steel allow deep drawing; provide

resistance to denting, and opportunity to use a lighter gauge to reduce vehicle weight.

The material used in automotive body should have the properties of high fracture

toughness due to the ability to absorb energy in case of high speed crashes.

Klarstrom, D.L. (2001) stated that nickel and nickel base alloys are important to

modern industry due to the ability to withstand a wide variety of severe operating

conditions involving corrosive environments, high temperatures and high stress.

Nickel is widely used in variety applications of food processing equipment, chemical

shipping drums, aircraft gas turbine, caustic, handling equipment and piping. For this

project, pure nickel have been use to compare the mechanical properties and thermal

properties in automotive body material.

3

1.3 Objectives

The objectives of this project are:

To study the mechanical properties and corrosion test of pure nickel at

different annealing temperature.

To compare the mechanical properties of pure nickel as an alternative for

automotive body material.

1.4 Scope of Study

This project involves the study of different annealing conditions for pure nickel of

their mechanical properties and thermal properties. Apply pure nickel as an

alternative automotive body by study the mechanical and chemical properties of pure

nickel at different annealing temperature .This project consists of the comparison

between pure nickel and current automotive body material. An experiment on

mechanical and chemical studies with thermal effect of pure nickel has to be

conducted. Thermal properties will be studied by doing annealing in different

temperature. Mechanical studies include tensile and hardness test. Chemical study

include corrosion test was carried out to obtain the corrosion rate of pure nickel in

different annealing temperature.

1.5 Organization of the Report

The whole report is divided into six major parts, which is known as Introduction,

Literature Review, Methodology, Results, Discussion, and Conclusion and future

work.

Basically, each of the content of each chapter is;

Chapter 1 : Introduction

This chapter contains the background of the problem statement generally and

includes the objectives and the scope of the study. This chapter summarizes

4

the project with material properties and techniques involved to study the

suitable alternative material for automotive body.

Chapter 2: Literature Review

In this chapter, any information which is related to the project is studied and

summarized. The source of the information can be from journals, books,

internet, articles and etc. Based on the information from past studies and

research, it will guide a correct path for the success of the project.

Chapter 3 : Methodology

It describes overview of the research methods to conduct the various

experiments. It provide the details of introduce the test to be conduct; the

function of the machine and the details of the specimens and the parameter to

be used for the experiments.

Chapter 4: Results

It states all the results such as tables, figures and graphs when research

carrying out. All the important findings will be presented in a comprehensive

way. It also analyzes the results statistically.

Chapter 5: Discussion

Discuss the results obtain and compare with the current automotive body

material. Besides, comparison of finding between theoretically and

practically practices.

Chapter 6 : Conclusion

It summarizes the main findings and how the scope is covered fully and brief

recommendation for further study.

5

CHAPTER 2 LITERATURE REVIEW

2.1. Introduction

This chapter consists of information related to the study of pure nickel, current

automotive body materials and comparison properties between pure nickel and

current automotive body material. This chapter introduces the history of current

automotive materials and the changes occurring. Besides, this chapter discuss about

the mechanical and chemical properties of pure nickel with respect to thermal effect.

Also the possibility of replacing the current automotive body materials proposed

based on the work done by others.

2.2. Nickel

Nickel was first found by the Swedish chemist Axel Cronstedt in 1751. The name of

Nickel comes from the German word “kupfernickel”. It is occur in white colour

metal. The sulfide ores were found contain nickel, copper, cobalt, iron, and precious

metals (gold, silver, and the platinum-group metals). Researchers are finding the way

to separate nickel from copper. Mankins, W.L and Lamb, S., (1990) mentioned that

Pyrometallurgical, Hydrometallurgy, and vapometallurgy processes have been used

to separate the metallic ores and rock. Nickel is a metallic element which occurs in

group VIII of the periodic table. According to Klarstrom, D.L. (2001), pure nickel is

a ductile and tough due to it possesses a face-centered cubic crystal structure up to its

melting point. Nickel is a transition metal. The appearance of Nickel is silvery- white

metal; it looks lustrous, malleable and highly reflective. The compounds of the

nickel are in green or blue colour. Nickel is the metal which good in corrosion

6

resistance. Nickel is reacting with all acids except concentrated nitric acid. Nickel is

not influenced by alkaline. It is a conductor of heat and electricity. The chemical,

mechanical and thermal properties of nickel are shown in Table 2.1. Figure 2.1 show

the difference size and various forms of nickel.

Figure 2.1: Nickel in various forms

7

Table 2.1: Chemical, mechanical and thermal properties of nickel CES EduPack, (2009).

Property Values (S.I.) Units (S.I.)

Atomic Volume (average) 0.0065-0.0067 m3/kmol

Density 8.83-8.95 g/cm3

Bulk Modulus 162-200 GPa

Compressive Strength 70-1000 MPa

Fracture Toughness 80-110 MPa.m1/2

Poisson's Ratio 0.305-0.315

Shear Modulus 72-86 GPa

Tensile Strength 345-1000 MPa

Young's Modulus 190-220 GPa

Yield Strength (elastic limit) 70-900 Mpa

Elongation 2-60 %

Fatigue strength at 107 cycles 135-500 MPa

Hardness -Vickers 80-300 HV

Melting Point 1716-1743 K

Specific Heat 452-460 J/kg.K

Thermal Conductivity 67-91 W/m.K

Thermal Expansion 12-13.5 10-6/K

Resistivity 8-10 10-8 ohm.m