Gas Adaptor Examination - Case Study Example

First M. 14 August 2009 Metallurgical Examination of a Gas Adaptor Introduction: Different types of materials have different composition and structure. Some differs in physical appearances like its color, roughness, smoothness, hardness and thickness. Through these differences we can easily identify one material from the other. But we should know that physical structure is not a good basis in identifying a certain types of materials. Proper investigation and examination should be made to assure that you are using the right material for a certain application. The science that studies the chemical and physical properties of metals is Metallurgy. It refers to the procedures used in extracting metals from ore, as well as to the processes related to metals purification and alloy production. It is divided into two subtypes the Process metallurgy and Physical metallurgy. Process metallurgy refers to the ways in producing metals like its refining process through electrolysis or selective oxidation of impurities. On the other hand, Physical Metallurgy studies the structure of metals based on their composition and treatment. It is also concerned with the scientific principles and engineering applications employed in metals fabrication and treatments, and how metal products hold up under their industrial usages. Component manufacturers a lot much of their time in study what type of material is best suited for a certain Products. Every little aspect of the materials is a great issue to them because they want their products to be well equipped for any possible things to happen. They are also concerned to the safety and satisfaction of the Customers. The limitation of their products must be properly stated because they are held liable for whatever accident that might happen in using their products. Last name 2 To perform the said study, we investigate and examined the metallurgy of a gas adaptor (Industrial component). We use gas adaptor as our material because we usually noticed that this material is always exposed to heat and by this we are curious about its composition. We are also concerned with the manufacturing processes of this component on how it comes up to a finished product. This study will enrich our understanding with the proper ways and methods in identifying a certain components, not only of its physical appearance but its chemical composition and capability for a certain application. Experimental Methods and Results: Sample Preparation: 1.) We cut a sample of the metal (Gas adaptor), using a metal cutter in a circular shape. In cutting the sample we make sure that it is enough for the investigation. Upon cutting the sample aside from its outside appearance we also noticed that its inner portion is golden yellow or brassy yellow, so we partially said that it is made up of brass. 2.) To remove the impurities cause by cutting the metal, we prepare a resin and pour in mould. This somehow takes a little time to be done. While doing this we prepare the grinding apparatus available in the laboratory. 3.) When the impurities totally removed we then grind the sample. 4.) We also polished the sample. In metallography and metallurgy, polishing is used to create a flat, defect-free surface for examination of a metals microstructure under a microscope. Silicon-based polishing pads or a diamond solution can be used in the polishing process. 5.) To investigate the composition of the metal we did a microscopy analysis using an optical microscope, SEMS and TEMS. This method allows us to further study the physical characteristics of the metal use in making the gas adaptor. 6.) We then take pictures of the result in a higher magnification. We vary the magnification of our camera so that we can an exact view of our sample and give justice to every details which cannot be seen in the first view. This would be helpful in our documentation. Last name 3 Experimental Results (Photography): Fig. 1: Vertical view Fig. 2: Front view Fig. 3: Inner view Fig. 4: Cut sample of Gas Adaptor Last name 4 Experimental Results (Micro-photography): Picture 1: (Normal magnification) Picture1: (With higher magnification) Last name 5 Picture 2: (Normal magnification) Picture1: (With higher magnification) Last name 6 Comparison: (Shows that Gas Adaptor is made up of Brass metal) Standard Characteristics of Brass “Physical Characteristics of Brass”( galleries) “Standard Brass Microstructure”(Wikipedia) Vs. Experimental Result (Sample of Gas Adaptor) “Sample Physical Characteristics”(Gas Adaptor) “Sample Microstructure”(Gas Adaptor) Last name 7 Chemical composition Of Brass: Material Tensile Strength N/mm Elongation % on 50 MM Vickers Hardness Complies with or falls within ISO JIS 80/20 Brass 265 Min 340 Min 400 Min 40 Min 10 Min 5 Min 80 Max 95 Min 120 Min ISO 426/1 Cu Zn 20 H 3100 C 2400 70/30 (Cartridge Brass) 280 Min 325 Min 350 Min 415 Min 50 Min 35 Min 20 Min 5 Min 80 Max 75 Max 100 Min 125 Min ISO 426/1 Cu Zn 30 H 3100 C 2600 65/35 Brass (2 and 1 Brass) 280 Min 340 Min 385 Min 460 Min 525 Min 45 Min 35 Min 20 Min 5 Min 80 Max 75 Max 110 Min 135 Min 165 Min 63/37 Brass (Brass Metal) 280 Min 340 Min 485 Min 460 Min 525 Min 40 Min 30 Min 15 Min 5 Min     Manufacturing Process: The manufacturing process used to produce brass involves combining the appropriate raw materials into a molten metal, which is allowed to solidify. The shape and properties of the solidified metal are then altered through a series of carefully controlled operations to produce the desired brass stock. The actual manufacturing process depends on the desired shape and properties of the brass stock, as well as the particular machinery and practices used in different brass plants. Here is a typical manufacturing process used to produce brass sheet and strip. Last name 8 Manufacturing steps in Brass production: Melting 1.) The appropriate amount of suitable copper alloy scrap is weighed and transferred into an electric furnace where it is melted at about 1,920°F (1,050°C). After adjusting for the amount of zinc in the scrap alloy, an appropriate amount of zinc is added after the copper melts. A small amount of additional zinc, about 50% of the total zinc required, may be added to compensate for any zinc that vaporizes during the melting operation. If any other materials are required for the particular brass formulation, they are also added if they were not present in the copper scrap. 2.) The molten metal is poured into molds about 8 in x 18 in x 10 ft (20 cm x 46 cm x 3 m) and allowed to solidify into slabs called cakes. In some operations, the melting and pouring are done semi-continuously to produce very long slabs. Last name 9 3.) When the cakes are cool enough to be moved, they are dumped out of the molds and moved to the rolling area where they are stored. Hot rolling 4.) The cakes are placed in a furnace and are reheated until they reach the desired temperature. The temperature depends on the final shape and properties of the brass stock. 5.) The heated cakes are then fed through a series of opposing steel rollers which reduce the thickness of the brass step-by-step to about 0.5 in (13 mm) or less. At the same time, the width of the brass increases. This process is sometimes called breakdown rolling. 6.) The brass, which is now much cooler, passes through a milling machine called a scalper. This machine cuts a thin layer off the outer faces of the brass to remove any oxides which may have formed on the surfaces as a result of the hot metals exposure to the air. Annealing and cold rolling 7.) As the brass is hot rolled it gets harder and more difficult to work. It also loses its ductility, or ability to be stretched further. Before the brass can be rolled further, it must first be heated to relieve some of its hardness and make it more ductile. This process is called annealing. The annealing temperatures and times vary according to the brass composition and desired properties 8.) The annealed pieces of brass are then fed through another series of rollers to further reduce their thickness to about 0.1 in (2.5 mm). This process is called cold rolling because the temperature of the brass is much lower than the temperature during hot rolling. Cold rolling deforms the internal structure of the brass, or grain, and increases its strength and hardness. The more the thickness is reduced, the stronger and harder the material becomes. 9.) Steps 7 and 8 may be repeated many times to achieve the desired thickness, strength, and degree of hardness. In some plants, the pieces of brass are connected together into one long, continuous sheet and are fed through a series of annealing furnaces and rolling mills arranged in a vertical serpentine pattern. At this point, the wide sheets may be slit into narrower sections to produce brass strip. The strip may then be given an acid bath and rinse to clean it. Last name 10 Finish rolling 10.) The sheets may be given a final cold rolling to tighten the tolerances on the thickness or to produce a very smooth surface finish. The strip may also be given a final finish rolling before it is cut to length, and coiled. During production, brass is subject to constant evaluation and control of the materials and processes used to form specific brass stock. The chemical compositions of the raw materials are checked and adjusted before melting. The heating and cooling times and temperatures are specified and monitored. The thickness of the sheet and strip are measured at each step. Finally, samples of the finished product are tested for hardness, strength, dimensions, and other factors to ensure they meet the required specifications. Discussion: From the experimental results we found out that the material use in making the component is Brass. Brass is a metal composed primarily of copper and zinc “..brass is the generic term for a range of copper-zinc alloys”(qtd. in copperinfo ”Brass Alloy”). Copper is the main component, and brass is usually classified as a copper alloy. It is said that “brasses are easy to hot work and machine, but cold formability is limited”(qtd. in “Properties and microstructure of brasses” par.1), the reason why most of the component with much exposure to heat is made up of brass. “Brass composed of 32% to 39% zinc have a higher strengths and lower ductility at room temperature than the alloy containing less zinc”( (qtd. in “Properties and microstructure of brasses” par.1). In our experimental result (Photography), we have also found out that our sample has the same characteristics with the brass metal therefore we said that the Gas Adaptor is made up of brass. We learned that brass containing zinc more than 32% has a high strength and harder than the one having less zinc. Though brass is basically hard, it also encounters problem especially in ”dezincification where removal of zinc from the surface of brass occurs, leaving relatively porous and weaken the entire component” (qtd. in “Properties and microstructure of brasses” par.2). Last name 11 Conclusion: After doing the experiment, I can now conclude that proper investigation and metallurgical examination of a metal is very important because through this we can determine scope and limitation of a material. Knowing the metallurgy of a certain metal, enable us to understand its capability for a certain application. This is also important in designing process because it can give as a more accurate and safety design. As a material engineering student this experiment is very helpful to me because it makes me realized that importance of metallurgy in my field of specialization. Therefore I should have to be patient enough in investigating each characteristic of the materials before making a design. Proper way of investigating a certain material is not buy what you see in physical alone, one must get a sample of the component and must undergo a thorough examination. Because what you see outside might not the same inside. Relevant References: Brady, George S., Henry R. Clauser, and John A. Vaccari. "Brass." In Materials Handbook, 14th ed. New York: McGraw-Hill, 1997. ”Brass Alloy”. Copper info. 11 August 2009 . Hombostel, Caleb. "Brass." In Construction Materials: Types, Uses, and Applications. New York: John Wiley and Sons, 1991. Kroschwitz, Jacqueline I., and Mary Howe-Grant, eds. "Copper Alloys." In Encyclopedia of Chemical Technology, 4th ed. New York: John Wiley and Sons, Inc., 1993. “Properties and microstructure of brasses”. Copper. 11 August 2009. . Wales, Jimmy Donal “Brass”. Wikipedia. 11 August 2009 ASSESSMENT: Read More