METALLURGY

Metallurgy is subdivided into ferrous metallurgy (also known as black metallurgy) and non-ferrous metallurgy (also known as colored metallurgy). Ferrous metallurgy involves processes and alloys based on iron while non-ferrous metallurgy involves processes and alloys based on other metals. The production of ferrous metals accounts for 95 percent of world metal production.

 

Common Engineering​ include aluminium, chromium, copper, iron, magnesium, nickel, titanium and zinc. These are most often used as alloys. Much effort has been placed on understanding the iron-carbon alloy system, which includes steels and cast irons. Plain carbon steels (those that contain essentially only carbon as an alloying element) are used in low-cost, high-strength applications where weight and corrosion are not a problem. Cast irons, including ductile iron, are also part of the iron-carbon system.

Stainless steel or galvanized steel is used where resistance to corrosion is important. Aluminium alloys and magnesium alloys are used for applications where strength and lightness are required.

Copper-nickel alloys (such as Monel) are used in highly corrosive environments and for non-magnetic applications. Nickel-based superalloys like Inconel are used in high-temperature applications such as gas turbines, turbochargers, pressure vessels, and heat exchangers. For extremely high temperatures, single crystal alloys are used to minimize creep.

KNOWLEDGE BASE

Sample Preparation

  • Precision Cutting

  • 1.5″ & 2″ Mounts

  • Thermoset & Thermoplastic Mounting

  • Cold Mounting

  • Automatic and Hand Grinding & Polishing

  • Immersion, Swab & Electrolytic Etching

Micro Analysis

  • Macro-etch (ASTM E340)

  • Grain Flow

  • Weld Qualification

  • Surface Condition

  • Surface Finish

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Microscopic Examinations

  • Microstructure

  • Carburization & Decarburization

  • Grain Size (ASTM E112)

  • Inclusion Rating (ASTM E45)

  • Plating/Coating Thickness

  • Carbide Precipitation

  • Ferrite by Point Count (ASTM E562)

  • Intergranular Attack & Oxidation

  • Alpha Case

  • Intergranular Corrosion (ASTM A262)

  • Sensitization

  • Surface Contamination

  • Nodularity, Nodule Count

  • Eutectic Melting

  • Case Depth

Micro Hardness

    • Case Depth

    • Profiles

    • Knoop & Vickers Testing

    • Carburization & Decarburization

    • Surface Contamination

Tensile Test

  • Ultimate Tensile Strength

  • Modulus of Elasticity

  • Yield Strength

  • Strain Test

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Chemical Test

    • Spectro Maxx (Optical Emission Spectrometer, OES)

    • Follow ASTM, SAE and AMS alloy specifications

    • Adjustments to the alloy composition as needed by Charge Calculations

Impact Test

  • Measuring the energy absorbed when fracturing the sample

  • Toughness of the test material

  • Charpy Impact Test

  • A test specimen is machined to a 10mm x 10mm (full size) cross-section, with either a “V” or “U” notch. Sub-size specimens are used where the material thickness is restricted. Specimens can be tested down to cryogenic temperatures.

NDT Testings

    • Radiography by usting X-rays or gamma rays penetrating through the castings

    • Magnetic Particle Testing in metals like cast iron and steel which can be magnetized

    • Penetrant Testing for detecting very small surface cracks

Additional Tests

  • Failure Analysis & Report Writing

  • Scanning Electron Microscopy (SEM/EDS)

  • Digital Imaging

  • McQuaid-Ehn Grain Size

  • Welder and Procedure Qualification (in accordance with MIL & API specifications, ASME & AWS codes, ASTM & EN standards and the Pressure Equipment Directive)

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