Metallurgy for Non-Metallurgists: Alloy Types, Properties and Applications

Introduction

This program will provide an integrated practical overview of metals and alloys and relating it to the mechanical and physical characteristics of metals; starting from materials testing and physical/mechanical properties, through corrosion properties and strength/deformation principals, and to ferrous and non ferrous alloys and heat treatment. The course will then include ferrous alloys (plain and alloy steels, Stainless steels and cast irons) and non ferrous alloys (for corrosion and high temperature applications, such as nickel, cobalt and titanium based alloys). The nature of hot and cold working of metals and heat treatment, including annealing, normalising, tempering and case hardening will be explained. The fundamentals of corrosion and corrosion prevention will also be presented in practical terms with examples to illustrate the key points. The behavior of metals under various loading conditions (static, dynamic, fracture) will be presented and related to design methodology and procedures; rules of thumb, standards, and best industry practices. Each of the major topics will be presented as individual units, and in the context of the overall usage of metal components and structures and failure mechanisms, and mechanical integrity.

Objectives

Upon completion of this course, participants will have gained an understanding of the important principals of engineering involving properties and characteristics of metals and alloys, including fabrication and heat treatment of commercial steels and non-ferrous alloys. Participants will acquire sufficient knowledge and skills to independently evaluate possible metallurgical and design solutions, to recognize crucial metallurgical phenomena and intelligently discuss their metal problems with design engineers, metallurgists and fabricators.

Delegates will enhance their competencies in the following areas:

• Understand the fundamental bases of mechanical testing
• Compare mechanical properties of metals for selection purposes
• Gain an understanding of the nature of metallic bonds and crystal structures of metals
• Understand the solidification process of pure metals
• Learn of examples of probable defects that may occur within the solidified structure of a metal
• Gain a basic understanding of the way metal specimens are prepared prior to microscopic examination
• Understand the use of microscopes for metallurgical examination
• Understand the phenomenon of dislocations; one of the most fundamental properties, related to the strength of metals
• Gain knowledge in controlling the strength of metals by controlling the movement of dislocations
• Gain initial knowledge of softening metals by the application of heat (annealing)
• Understand temperature/time cooling curves of pure substances
• Gain knowledge of thermal equilibrium diagrams (phase diagrams) and related microstructures of selected types of metal alloys
• Gain an understanding of the nature, properties , classifications and uses of a variety of ferrous alloys
• Understand fundamental hardening, softening and grain control processes related to steel
• Understand additional processes such as surface hardening of steel
• Gain knowledge of related topics related to the heat affected zone (HAZ)
• Gain knowledge of additional special application non-ferrous alloys, for corrosion and high temperature applications, such as nickel based, cobalt based and titanium based alloys
• Understand basic metal fabrication techniques
• Gain an fundamental understanding of the nature and types of corrosion
• Learn about various methods of protection against corrosion

Training Methodology

The training methodology is interactive with group exercises and is suitable for all employees involved in functions management. The pace and level of the training workshop is customized to the understanding of the delegates. Ongoing back-up and support is available after the training on request to the supplier, and the training course is also available for in-house presentation as well as for “Competency Transfer”. 

Who Should Attend?

This program is intended for those who use or supervise activities requiring the use of metal parts or structures. Those with little or no prior formal background who functions as supervisors, engineers, planners, inspectors, designers, researchers, investors or procurers, and who seek a basic understanding of the practical aspects of metallurgy should find this course valuable.

Course Outline

DAY 1: Testing and Mechanical Properties of Metals

• Tensile tests
• Impact tests
• Hardness tests
• Compression of mechanical properties

The Crystalline Structure of Metals

• Bonding in metals
• Solidification crystal growth and structures of metals
• Defects in metals during solidification

 DAY 2: Specimen Preparation and Microscopic Examination

• The preparation (Mounting Grinding, Polishing and Etching) of metal specimens
• Metallurgical and Electron Microscopes

Dislocations and Strengthening Mechanisms in Metals

• Edge Dislocation (line imperfections) in crystals
• Strengthening of metals by Grain Size Reduction, Solid Solution and Strain Hardening
• Softening of metals by annealing
• Comparison of Cold and Hot working of Metals

 DAY 3: Binary Equilibrium Diagrams

• Solubility and cooling curves
• Thermal Equilibrium Diagrams (Eutectic Type, Solid Solution Type and Combination Type)

Ferrous Alloys

Definitions and classifications and some uses of ferrous alloys including

• Carbon steels
• Alloy steels
• Stainless steels
• Cast irons

Fabrication of Metals

A selection of metal fabrication methods, including

• Forming
• Casting
• Welding

DAY 4: Heat Treatment of Plain Carbon Steel

• Hardening of carbon steel (by quenching)
• Annealing
• Normalizing
• Tempering
• Austempering
• Surface treatments
• Heat affected zone (HAZ) in welding

Non-Ferrous Alloy

• Nickel and cobal
• Titanium alloys

  DAY 5: Corrosion in Metals

• The electrochemical cell
• Types of electrochemical corrosion
• Pitting
• Crevice
• Stress corrosion
• Hydrogen induced, etc.

 Protection against Electrochemical Corrosion and Inspection

• Coatings
• Internal
• External
• Polymers
• Galvanizing, etc.
• Inhibitors, Types and usage
• Cathodic protection, Impressed current, Sacrificial
• Inspection
• Standards