Chapter 1

The Structure of Metals

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Metal and Non-metal Use in Automobiles

Figure I.1 Some of the metallic and nonmetallic materials used in a typical automobile

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Engineering Materials of Part I

Figure I.2 An outline of the engineering materials described in Part I.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Behavior and Manufacturing Properties of Part I

Figure I.3 An outline of the behavior and the manufacturing properties of

materials described in Part I.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Chapter 1: The Structure of Metals

Figure 1.1 An outline of the topics described in Chapter 1.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Crystal Structure of Metals

Common crystal structures for metals:

Body-centered cubic (BCC) - alpha iron, chromium, molybdenum, tantalum,

tungsten, and vanadium.
Face-centered cubic (FCC) - gamma iron, aluminum, copper, nickel, lead,
silver, gold and platinum.
Hexagonal close-packed - beryllium, cadmium, cobalt, magnesium, alpha
titanium, zinc and zirconium.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Body-centered Cubic Crystal Structure

Figure 1.2 The body-centered cubic (bcc) crystal structure: (a) hard-ball model;
(b) unit cell; and (c) single crystal with many unit cells

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Face-centered Cubic Crystal Structure

Figure 1.3 The face-centered cubic (fcc) crystal structure: (a) hard-
ball model; (b) unit cell; and (c) single crystal with many unit cells

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Hexagonal Close-packed Crystal Structure

Figure 1.4 The hexagonal close-packed (hcp) crystal structure:

(a) unit cell; and (b) single crystal with many unit cells.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Permanent Deformation

Figure 1.5 Permanent deformation (also called plastic deformation) of a

single crystal subjected to a shear stress: (a) structure before
deformation; and (b) permanent deformation by slip. The b/a ratio
influences the magnitude of the shear stress required to cause slip.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Permanent Deformation and Twinning in Crystal

Figure 1.6 (a) Permanent

deformation of a single crystal under
a tensile load. Note that the slip
planes tend to align themselves in
the direction of the pulling force.
This behavior can be simulated
using a deck of cards with a rubber
band around them. (b) Twinning in
a single crystal in tension.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Slip Lines and Slip Bands in Crystal

Figure 1.7 Schematic illustration of

slip lines and slip bands in a single
crystal (grain) subjected to a shear
stress. A slip band consists of a
number of slip planes. The crystal at
the center of the upper illustration is
an individual grain surrounded by
several other grains

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Defects in a Single-Crystal Lattice

Figure 1.8 Schematic illustration of types of defects in a single-crystal lattice:

self-interstitial, vacancy, interstitial, and substitutional

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Dislocations in Crystals

Figure 1.9 Types of dislocations in a single crystal:

(a) edge dislocation; and (b) screw dislocation

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Edge Dislocation Movement

Figure 1.10 Movement of an edge dislocation across the crystal

lattice under a shear stress. Dislocations help explain why the actual
strength of metals is much lower than that predicted by theory.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Solidification of Molten Metal

Figure 1.11 Schematic illustration of the stages during solidification of molten

metal; each small square represents a unit cell. (a) Nucleation of crystals at
random sites in the molten metal; note that the crystallographic orientation of
each site is different. (b) and (c) Growth of crystals as solidification continues.
(d) Solidified metal, showing individual grains and grain boundaries; note the
different angles at which neighboring grains meet each other.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Grain Sizes

ASTM Grain Size:

N = 2n-1
where
N = Grains per square
inch at 100x
magnification
n = ASTM grain size
number

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Plastic Deformation of Idealized Grains

Figure 1.12 Plastic deformation of idealized (equiaxed) grains in a specimen

subjected to compression (such as occurs in the forging or rolling of metals): (a)
before deformation; and (b) after deformation. Note the alignment of grain
boundaries along a horizontal direction; this effect is known as preferred orientation.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Cracks in Sheet Metal

Figure 1.13 (a) Schematic illustration of a crack in sheet metal that has
been subjected to bulging (caused by, for example, pushing a steel ball
against the sheet). Note the orientation of the crack with respect to the
rolling direction of the sheet; this sheet is anisotropic. (b) Aluminum sheet
with a crack (vertical dark line at the center) developed in a bulge test; the
rolling direction of the sheet was vertical. Source: Courtesy of J.S. Kallend,
Illinois Institute of Technology
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Recovery, Recrystallization, and Grain Growth Effects

Figure 1.14 Schematic illustration

of the effects of recovery,
recrystallization, and grain growth
on mechanical properties and on
the shape and size of grains. Note
the formation of small new grains
during recrystallization.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Temperature Ranges for Cold, Warm
and Hot Working

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.