General Objective
The objective of this laboratory program is to relate the properties of engineering materials to the materials microstructure developed during thermal mechanical processing. Students develop tools to make informed engineering material selection decisions that will be safe and economic. All students must attend the common recitation period before each laboratory period so as to receive important safety information as well as general directives and goals of each laboratory exercise.

General Education Requirements
Globalization Component
Each laboratory experience in MET 231 (Properties of Materials Laboratory) references and uses American Society for Testing of Materials (ASTM) International Standards. The SDSM&T library maintains a current set of ASTM standards in the reference section. In addition past annual issues of ASTM standards are available for student and faculty use.
Writing of Technical Reports Component
Each laboratory requires a memorandum or technical style report. All reports must follow the laboratories established guidelines presented on the lab Web page. All reports are submitted for evaluation using the SDSM&T digital archive. Each report is marked up using the Microsoft Word markup routine, and then recorded in the digital archive under the assessment tool. This allows each student or team to retrieve the corrected report, and if necessary rewrite the report for technical, style and writing errors. The rewritten report is then evaluated and the same process followed.

Freedom in Learning Statement
"Students are responsible for learning the content of any course of study in which they are enrolled. Under Board of Regents and University policy, student academic performance shall be evaluated solely on an academic basis and students should be free to take reasoned exception to the data or views offered in any course of study. Students who believe that an academic evaluation is unrelated to academic standards but is related instead to judgment of their personal opinion or conduct should contact the dean of the college which offers the class to initiate a review of the evaluation." Source: BOR

Prerequisite
MET 232 or concurrent registration in MET 232 or consent of the coordinator. MET 231 laboratory exercises will be conjoined with, as nearly as possible, with MET 232 lectures.

Instructors Expectations
The Laboratory Handouts are posted on the class HPCNet web site.

A link is also provided at the top of this page. Each student is expected to read this information prior to attending class.

Internet delivered laboratory quiz's are available for some of the more complex equipment used in the class. Review of these materials will greatly enhance learning if reviewed before the laboratory class. The laboratory quizzes are available on the class WebCT HOME page. Instructions for access to the class WebCT site will be provided during the first recitation period.

Class Structure
Each week all students will meet for the one-hour common recitation period. Students will then meet during their assigned laboratory periods to complete each laboratory assignment. Students will report their results for each laboratory by either a written report or oral presentation. The reporting format will be specified in the laboratory exercise.

Laboratory Report Styles and Submission
A short discussion of report styles to be used in this class is presented on the HPCNet web page. All laboratory reports are submitted electronically to the SDSM&T's digital archive. Instruction on how to submit papers and other homework assignments to the digital archive will be provided during the first recitation period.

Grades
The laboratory grade will be based on your laboratory reports. The laboratory handout provides a description of the kind of report required for each laboratory exercise. The value of each report is also provided. Conformance to the report requirements are an important part of your grade. Unless otherwise stated, each report is due one week after completion of the laboratory project.

Generally lab grades are quite high because of the team environment. However, if a student's name is not on a lab report, because of poor team performance, as defined by the team members, not the professor, the grade can suffer considerably because that student can have a zero grade for a specific lab report. A missing lab report caused by the team not listing a name on a report must be submitted by the individual student. A copy of the original team report will not be accepted!

The course grade is computed as follows:
One hundred percent is based on equipment quizzes, oral and written laboratory reports.

Attendance
Attendance is MANDATORY for all recitation and assigned laboratory periods. It is not possible to make-up a laboratory. Attendance will be taken on an irregular basis. Students in attendance will be given 2 points extra credit.. A Student with an excused absence will be provided the raw data generated during the laboratory exercise. The due date for a report or oral presentation will be defined at that time.

Late Policy
Lab reports that are not turned in by the announced deadline will be assessed a -10% per day late penalty (not counting weekends and holidays).

Final Course Grade
The grade F will be assigned if all assignments are not completed. The grade "I" is not be used in this class.

Integrity Policy
You are expected to do your own work; however, one can learn by consulting with others. Understand that there is a significant difference between consulting and asking someone a question versus outright copying or plagiarism. If individuals or teams turn in assignments that are clearly not their own work, all parties involved can expect to receive no credit for that assignment.

ADA Policy
Students with special needs or requiring special accommodations should contact the instructor, Dr. Michael K. West ~ 394-1283 and/or the campus ADA coordinator, Jolie McCoy, at 394-1924 at the earliest opportunity.

Laboratory Classes
LAB 0: Library Visit

Students will become acquainted with important sources for Materials Science at the library.
These sources include the ASM Handbooks and ASTM Standards. The student shall also become
familiar with library search databases for engineering such as the "Engineering Index (Village)".
library databases such as the "Engineering Index".

LAB 1: Introduction to Basic Statistical Computations

Given an example of data commonly encountered while collecting experimental data, the student shall compute the Mean, Variance and Standard Deviation.
Given an example of data commonly encountered in process control, the student shall compute the mean and range for each of 20 hours of data, five measurements per hour.
The student shall conduct library research so as to find and illustrate how the process control data are used to control the length of the lithograph plates.

Textbook Reference: William D. Callister, Jr.: Materials Science and Engineering: An Introduction, Fifth Edition, John Wiley & Sons, Inc., 2000, pp. 140-142.

LAB 2: Rolling Mill Operations (Labs 2 and 3 combined)

Given a comprehensive laboratory handout discussing cold rolling, the student will produce a rolling schedule for C11000 copper alloy defining the total cold reduction and number of passes to achieve 70% reduction in area. Students shall accomplish this task, while saving a sample from each rolling pass for the next laboratory.

Textbook Reference: William D. Callister, Jr.: Materials Science and Engineering: An Introduction, Fifth Edition, John Wiley & Sons, Inc., 2000, pp. 128, 352-354.

LAB 3: Hardness Measurement (Labs 2 and 3 combined)

Given a set of samples cut from LAB 2, the student will measure hardness as a function of percent reduction of area, using the Rockwell HRB and HRF scales. The hardness vs. percent reduction in area data for the three laboratory sections will be combined and provided on the WebCT site. The student will download these data and produce a least squares polynomial curve fit of the data and compute the goodness of fit. The student will comment on the quality of the data in relation to the statistical analysis. The student will research the literature to find cold rolling data for C11000 and graph literature and experimental data in the same figure.

Textbook Reference: William D. Callister, Jr.: Materials Science and Engineering: An Introduction, Fifth Edition, John Wiley & Sons, Inc., 2000, pp. 134-140, 316, 317, 370, 413,414,495, 833. Additional Reference: George F. Vander Voort: Metallography Principles and Practice, McGraw-Hill Book Company, 1984, p.334-409. Additional Reference: Look at hardness scale conversion tables found in ASTM Standard E140.

LAB 4: Tensile Testing (this is a two week lab)

Part 1: Given a set of aluminum and steel ASTM E8 tensile specimens subjected to known thermal-mechanical processing steps, the student will set-up and use the TestStar II MTS controller to conduct tensile tests according to ASTM E8, and generate engineering stress-strain plots from the measured load-elongation data. Each student will email the instructor a table with the 0.2% offset yield point, the tensile strength (TS or UTS), the fracture stress and the fracture strain.

Part 2: Each student will perform a statistical analysis on the data set consisting of their data and instructor-provided data. The analysis must answer the question: "Are the experimental results within the expected statistical range of the literature values?"

Textbook Reference: William D. Callister, Jr.: Materials Science and Engineering: An Introduction, Fifth Edition, John Wiley & Sons, Inc., 2000, pp. 115-134, 371-372.

LAB 5: Metallography of Common Alloys (demonstration laboratory)
Students will be able to recognize the microstructure and name of phases present in instructor-provided aluminum, copper, brass, cast iron, and steel alloys.

• Nonferrous alloys such as copper and brass - identify grain and twin boundaries
• Ferrous alloys such as carbon steels - identify pearlite, cementite (iron carbide), ferrite, and martensite
• Cast irons such as gray, white and ductile cast irons - identify flake graphite, nodule graphite, cementite (iron carbide), and ferrite

Textbook Reference: William D. Callister, Jr.: Materials Science and Engineering: An Introduction, Fifth Edition, John Wiley & Sons, Inc., 2000, pp. 81-88.
Additional Reference: George F. Vander Voort: Metallography Principles and Practice, McGraw-Hill Book Company, 1984.
Additional Reference: Metals Handbook, ninth edition, vol. 9, American Society for Metals, Metals Park, Ohio 44073, 1985.

LAB 6: Quantitative Image Analysis (first week is training on the equipment)

Part 1: Each student will be able to operate the Olympus microscope and the LECO Image Analysis System to perform an ASTM E112 grain size analysis and area fraction measurement.

Part 2: Each student will use the Olympus Metallograph with LECO Image Analysis System to measure the ASTM E112 grain size and area fraction of pearlite in a minimum of ten connecting areas of the specimen and perform a statistical analysis of collected data.

Reference: Robert T. DeHoff and Frederick N. Rhines: Quantitative Metallography, McGraw-Hill Book Company, 1968.
Additional Reference: George F. Vander Voort: Metallography Principles and Practice, McGraw-Hill Book Company, 1984, pp. 410-508.
Additional Reference: Metals Handbook, ninth edition, vol. 9, American Society for Metals, Metals Park, Ohio 44073, 1985.

LAB 7: Charpy Impact Testing -- ASTM E 23 Type A Specimens (two week laboratory)

Part 1: Given a set of plain carbon steel Charpy impact specimens, machined from hot rolled steel, students will measure the energy required to fracture the plain carbon steel alloy at four temperatures between –78oC and 100oC. The data set, from 15 and 25 specimens tested at each temperature, of the three laboratory sections will be published in the class WebCT site. Search the literature for published Charpy data for the alloy tested. Students will report their findings on the statistical analysis of their data and compare it to literature data.

Textbook Reference: William D. Callister, Jr.: Materials Science and Engineering: An Introduction, Fifth Edition, John Wiley & Sons, Inc., 2000, pp. 205-208.

Part 2: SEM Fracture Morphology Charpy impact fracture surfaces from LAB 7, Part 1 will be examined to determine their characteristics and modes of failure. Before this laboratory review ASM Metals Handbook, ninth edition, Vol. 11 and 12, to learn what mode 1, mode 2 and mode 3 stress-states mean. Students will photograph and characterize fractures for their report. Students will use the SEM data to report the change in fracture morphology as a function of absorbed energy.

Textbook Reference: William D. Callister, Jr.: Materials Science and Engineering: An Introduction, Fifth Edition, John Wiley & Sons, Inc., 2000, pp. 85, 128-129, 185-186, 189-190, 839.

LAB 8: Hardness Profile of Case Hardened Steel (two week laboratory)

Part 1: Given a polished and etched case hardened gear tooth, the student will measure the hardness profile of a case hardened part using the LECO microhardness tester (HV scale).

Part 2: Metallography of a Case Hardened Zone Given a polished and etched case hardened gear tooth, the student, using the LECO image analyzer, will photograph and characterize the microstructure of the steel in the case hardened zone and core of the case hardened part.

Textbook Reference: William D. Callister, Jr.: Materials Science and Engineering: An Introduction, Fifth Edition, John Wiley & Sons, Inc., 2000, pp. 134-138.

LAB 9: Jominy End-Quench Test -- Measurement of Hardenability (ASTM A255)

Given ASTM A255 samples of a moderate and high hardenability steel alloy, the student will measure the hardness profile of each alloy and compare the results to literature data.

Textbook Reference: William D. Callister, Jr.: Materials Science and Engineering: An Introduction, Fifth Edition, John Wiley & Sons, Inc., 2000, pp. 332-336,833.

LAB 10: Experimental Measurements of Mechanical Properties Using Strain Gauges

During this laboratory the elastic properties of steel and aluminum will be measured and compared to values found in the literature.

Seminar (last scheduled laboratory class in the semester)

Each laboratory group presents a 15-minute seminar talk. The instructor will select a seminar subject for each group.