RESEARCH AND PROJECT MANAGEMENT UNIT (RPMU)

EBLM2103
ENGINEERING MATERIALS
LABORATORY MANUAL

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Program : EBML2103

Course : Engineering Materials

Code : EBML2103

Lab : Material Science (Block 2, Level 5, Room 28)

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Lab Sheet No : EXPERIMENT 1 (1)

Title : SAMPLE PREPARATION AND OPTICAL MICROSCOPE FOR

METALLOGRAPHIC OBSERVATION

1.0 Introduction

In the study of metallic materials it is often to analyze the phases exist and grain size in the
structure. Details of the structure of metals are not readily visible through naked eyes, but grain
structures in metals may be seen with the aid of microscope. Metal characteristics such as grain
sizes, effect of heat treatment, and carbon content of steels may be evaluated by studying the
micrograph. For this purpose, the metal used in the metallurgical examination must be prepared and
polished carefully before a good microscopic image can be seen. It is important to ensure that the
surface is totally flat and smooth before microstructure observation. Any irregularity will appear as a
dark image and may create confusion to the observer who attempts to analyze a structure. In order
to obtain this smooth flat surface, several preparatory steps are required: Cutting, Molding,
Grinding, Polishing and Etching

1.1 Optical Microscope

When a mirror-like metal surface has been obtained, the structure can be observed with the aid of
optical microscope. Schematic diagram of an optical microscope is shown in the Figure 1. Theoptical
microscope magnifies an image by sending a beam of light through the object as seen in
theschematic diagram. The condenser lens focuses the light on the sample and the objective lenses
(10X,40X, . . . , 2000X) magnifies the beam, which contains the image, to the projector lens so the
image canbe viewed by the observer.

Figure 1 : Schematic Diagram of Metallurgical Microscope

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2.0 Objectives

Upon completion of this experiment, students should be able to;

1. Understand the procedure metallographic sample preparation.

2. Understand basic function of optical microscope and it’s operation
3. Perform analysis from the microstructure’s observation
4. Understand theoretical background of sample preparation and metallographic specimens

3.0 Apparatus

Cutter, Mounting Machine, Grinder, Polisher, Dryer and Optical Microscope.

4.0Instruction
1. Students are required to follow standard steps and demonstrated the metallographic
samples preparation.
2. Examples of metallographic specimens will be given to be observed by using optical
microscope with different magnifying beam.
3. Students are required to analyse the experimental result with theoretical background
ofmetallographic specimens.
4. Students are required to sketch the microstructures observed

5.0 Results and Discussion

Discuss your findings. Wherever necessary please use diagrams, charts and table to emphasize on
your findings.

6.0 Conclusion

Conclude your findings

7.0 References

List all references that you have made during the course of your findings.

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Program : EBML2103

Course : Engineering Materials

Code : EBML2103

Lab : Material Science& Heat Treatment (Block 2, Level 5)

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Lab Sheet No : EXPERIMENT 1 (2)

Title : HEAT TREATMENT AND HARDNESS OF METALS

1.0 Introduction

In engineering field, the properties and behaviour of metals and alloys play a vital role especially
duringmanufacturing and performance during their service life. The most common example of
propertiesenhancement is heat treatment of metals and alloys. Such treatment modifies
microstructure, producinga variety of mechanical properties that are important in manufacturing,
such as improved formabilityand machinability.

2.0 Objectives

Upon completion of this experiment, students should be able to;

1. Understand the relation between hardness to the cooling rate of the specimen after been
heated(quenching) using the Jominy test method.
2. Understand microstructure changes to the cooling rate of the specimen after been
heated(quenching) using the Jominy test method.

3.0 Experimental Procedure

1. The specimen is heated in the Jominy End-Quench’s furnace until the temperature reaches
900oC.
2. Next, adjust the water flow until the height reaches approximately 65mm (2 ½”) at Jominy
End Quench test bench.
3. Pull out the safety pin from the furnace so that the specimens fall down to the
quenchingapparatus.
4. Apply the water within 5.5 seconds; care should be taken that the water strikes only the
bottom ofthe specimen as shown schematically in Figure 1.
5. The specimen should be left in the quenching unit for few minutes until it cools.
6. Remove the specimen for hardness test and microstructure evaluation using microscope.
7. Vickers hardness (1kg) readings are taken at 1 mm intervals for the first 10 mm, 5 mm
intervalsfor the next 40 mm and 10mm intervals for the remaining 50 mm length of the
specimen

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 Figure 2 : Jominy Quench End Set-Up

4.0 Results and Discussion

Discuss the findings. Wherever necessary please use diagrams, charts and table to emphasize
onfindings.

5.0 Conclusion

Conclude your findings

6.0 References

List all references that you have made during the course of your findings.

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Program : EBML2103

Course : Engineering Materials

Code : EBML2103

Lab : Strength Lab(Block 2, Level 3)

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Lab Sheet No : EXPERIMENT 2 (1)

Title : BENDING TEST

1.0 Introduction

Bending characterizes the behaviour of a slender structural element subjected to an external load
applied perpendicularly to a longitudinal axis of the element. In this experiment, the deflection of
the beam due to applied load will be measured at two points along the beam and elastic modulus is
calculated as shown in Figure 1.

Figure 1: Deflection in beam.

2.0 Objectives

Upon completion of this experiment, students should be able to;

1. Determine the elastic modulus (E) of beam specimen by method of deflection of Mild Steel,
Aluminium and Brass.
2. Validate the data between experimental and theoretical values

3.0 Apparatus

Mild steel aluminium and brass beam, the cantilever beam setup, dial callipers, weights to be hung
from the end of the beam, tape measure

4.0 Experimental Procedure

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 1. Measure and record the length (L) from the wall to the end of the beam.
2. Measure and record the lengths (x1 and x2) from the wall to the centre of the dial callipers
3. Hang a weight (W) on the weight-hanger starting from lowest 2N, and then increasing by
increments of 2N.
4. Record W and measure the deflection δmax at every increment.

5.0 Results and Discussion

Discuss the findings. Wherever necessary please use diagrams, charts and table to emphasize on
findings.

5.0 Conclusion

Conclude findings from experimental data

6.0 References

List all references that you have made during the course of your findings.

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Program : EBML2103

Course : Engineering Materials

Code : EBML2103

Lab : Strength Lab(Block 2, Level 3)

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Lab Sheet No : EXPERIMENT 2 (2)

Title : TENSILE TEST

1.0 Introduction

Uniaxial tensile test is known as a basic and universal engineering test to achieve material
parameters. These important parameters obtained from the standard tensile testing are useful for
the selection of engineering materials for any applications required.

Figure 1: Schematic diagram of tensile test

2.0 Objectives

Upon completion of this experiment, students should be able to;

1. Determine the tensile properties subjected to tensile loading.

2. Identify Types of fracture surface under tensile loading.
3. Validate the data between experimental and theoretical values.

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3.0 Apparatus

Vernier calliper, tensile test machine, rectangular specimens, extension gauge, load gauge

4.0 Experimental Procedure

1. Measure the length (L), thickness (T) and width (W) of the specimens using Vernier calliper.
2. Mount the specimens to the jaw grip of tensile test machine.
3. Place extensometer on the vertical flat of inner jaw
4. Turn the load anchor is clockwise direction
5. Measure the final length of the specimens
6. Plot the graph of force over elongation and stress over strain from the result obtained.

5.0 Results and Discussion

Discuss the findings. Wherever necessary please use diagrams, charts and table to emphasize
onfindings.

5.0 Conclusion

Conclude findings from experimental data

6.0 References

List all references that you have made during the course of your findings.