Mechanical And Thermal Properties Of Pure Nickel As An Alternative Automotive Body Material.
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
MECHANICAL AND THERMAL PROPERTIES OF PURE NICKEL
AS AN ALTERNATIVE AUTOMOTIVE BODY MATERIAL
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Engineering Materials) with Honours
By
GAN BEE GEOK
FACULTY OF MANUFACTURING ENGINEERING
2010
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK:
Mechanical and Thermal Properties of Pure Nickel as an Alternative
Automotive Body Material
SESI PENGAJIAN: 2009/10 Semester 2
Saya GAN BEE GEOK
mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti
Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis.
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis.
3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan
pertukaran antara institusi pengajian tinggi.
4. **Sila tandakan (-.J)
D
D
QJ
SULIT
TERHAD
(Mengandungi maklumat yang berdarjah keselamatan
atau kepentingan Malaysia yang termaktub di dalam
AKTA RAHSIA RASMI1972)
(Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasi/badan di mana penyelidikan dijalankan)
TIDAK TERHAD
Disahkan oleh:
Alamat Tetap:
J 5904 Rumah Awam,
Sempang Pantai
nJOO Merlimau, Melaka
Cop Rasmi:
PROF. MADYA DR. t JOSEPH
F k . ProtQsor f..tao SAHAYA ANAND
.a ultl ｋ･ｪｵｲＺＮｾｴ＠
UniVersiti
Tarikh: __2_5_.0_5_.2_0_10_ _ _ __
Tarikh:
ｔ･ｾｮｩｫ｡ｬ＠
95 MCl;li
: " ｾ･ＧＡ｢ｵ｡ｴＢ＠
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alays,a ｍ･ｬ｡ｾ＠
9.e>
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** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi
berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai
SULIT atau TERHAD.
DECLARATION
I hereby, declared this report entitled “Mechanical and thermal properties of pure
nickel as an alternative automotive body material” is the results of my own research
except as cited in references.
Signature
:
Author’s Name
:
GAN BEE GEOK
Date
:
25.05.2010
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as
a partial fulfillment of the requirements for the degree of Bachelor of
Manufacturing Engineering (Engineering Materials) with Honours. The member
of the supervisory committee is as follow:
………………………………
(
PROF. MADYA. DR. T. JOSEPH SAHAYA ANAND
)
ABSTRACT
This project is represented the study of thermal and mechanical properties of pure nickel
as an alternative automotive body material. Nickel is the chemical element which
categorized in periodic table as transition metal. Nickel is a hard, malleable, ductile
material. It is used for making stainless steel, low alloy steels, cast iron and etc. Nickel
also used in battery manufacturing. Current automotive are mainly use steel as an
automotive body material. Due to the increasing demand of high performance in term of
mechanical properties of the material use in automotive, researched have been done to
find alternative material to replace steel. In this project, annealing is done for pure nickel
at 300 ºC, 500 ºC and 700ºC for 1 hour. The studies on mechanical properties, corrosion
test, composition analysis and crystallography analysis in different annealing
temperatures to alternate current automotive body material. The hardness of both non heat treated and annealed pure nickels do not change as the annealing temperature
increases which in the range of 118 to 123 HV. As the annealed temperature increase, the
ultimate tensile strength, yield strength and young modulus decreases, but the ductility
increase. The highest ultimate tensile strength of pure nickel at 300ºC annealed
temperature which is 758.78 MPa. For corrosion test, the corrosion rate of both non-heat
treated and annealed pure nickel have minor changes with the annealed temperature
which in the range of 0.0266 to 0.048 mm/year. The composition of both non- heat
treated and annealed pure nickels do not change. Pure nickel is face center cubic
structure; the lattice constant is decreasing as the annealing temperature increases.
Besides, the grain size of pure nickel is increasing as the annealed temperature increase.
i
ABSTRAK
Projek ini mengenai kajian berkaitan dengan sifat-sifat mekanikal bagi nikel tulen
sebagai bahan gantian untuk bahagian badan automotif. Nikel adalah unsur kimia yang
dikategorikan dalam jadual berkala sebagai logam peralihan. Nikel adalah satu bahan
mulur yang keras, mudah dibentuk. Ia digunakan untuk membuat keluli tahan karat,
keluli aloi berkomposisi rendah, besi tuangan dan sebagainya. Nikel juga digunakan
dalam penghasilan bateri. Pada masa kini, kebanyakan bahan automotif adalah keluli.
Kajian telah dijalankan untuk menggantikan keluli sebagai alternatif bahan automotif
disebabkan peningkatan permintaan terhadap prestasi yang tinggi bagi sifat-sifat
mekanikal bagi penggunaan bahan dalam automotif, Dalam projek ini, kajian mengenai
pencekalan nikel tulen pada suhu 300 ºC, 500 ºC dan 700ºC telah dijalankan selama satu
jam. Kajian terhadap sifat-sifat mekanikal, ujian penghakisan, analisis komposisi dan
análisis kristalografi dalam suhu pengcekalan yang berbeza untuk mengganti bahan
badan automotif semasa. Kekerasan pada sampel yang tidak malakukan pengcekalan
dan cekalan nikel tulen tak berubah dan dalam lingkungan 118 kepada 123HV. kekuatan
tegangan, kekuatan alah dan modulus mengurang, tetapi kemuluran meningkat.
Kekuatan tegangan tertinggi bagi nikel tulen adalah pada suhu 300ºC cekalan iaitu
758.78MPa. Bagi ujian penghakisan, kadar kakisan kedua-dua perlakuan tanpa haba dan
cekalan nikel tulen mempunyai perubahan kecil dalam lingkungan daripada 0.0266
kepada0.048mm / tahun. Komposisi kedua-dua perlakuan tanpa haba dan cekalan nikel
tulen tak berubah. Nikel tulen berstruktur FCC; pemalar kekisi menurun apabila suhu
cekalan meningkat. Selain itu, saiz butiran nikel tulen semakin meningkat apabila suhu
cekalan meningkat.
ii
DEDICATION
This report is dedicated to my parents and my supervisor Prof. Madya. Dr. T. Joseph
Sahaya Anand who have supported me throughout my Bachelor Degree Project. Without
his patience, understanding and support, the completion of this work would not have
been possible.
iii
ACKNOWLEDGEMENT
I am pleased to say that I would never have been able to complete my Bachelor Degree
Project without the help and encouragement from this group of special individuals. I
would like to thank these people for their show of heartfelt support throughout the
duration of my Bachelor Degree Project. My first gratitude goes to my supervisor Prof.
Madya. Dr. T. Joseph Sahaya Anand for his constant guidance and encouragement. He
always guides me and he is a very nice and helpful person. When I face problem on
doing project, he always guide me to the right way although he is very busy with his
work. I want to thanks to my fellow friends Kwan Wai Loon, Lim Kok Chin, and Pang
Chee Kong for helping me during the time difficulty.
iv
TABLE OF CONTENTS
TITLE
PAGE
Abstract
i
Abstrak
ii
Dedication
iii
Acknowledgement
iv
Table of Content
v
List of Tables
ix
List of Figures
xi
List Abbreviations
xii
1. INTRODUCTION
1
1.1
Introduction
1
1.2
Problem Statement
2
1.3
Objective
3
1.4
Scope of Study
3
1.5
Organization of Report
3
2. LITERATURE REVIEW
5
2.1.
Introduction
5
2.2.
Nickel
5
2.2.1. Commercially Pure Nickel
8
2.2.2. Corrosion properties of Pure Nickel
11
2.2.3. The applications of Nickel
11
2.2.4. Health Effects of Nickel
12
Current Automotive Body Material
13
2.3.1. Steel
15
2.3.
2.3.1.1. High Strength Steel
15
2.3.1.2. Stainless Steel
16
v
2.4.
Alternative Material for Automotive Body Materials
17
2.4.1. Aluminium
17
2.4.2. Magnesium and its Alloys
19
2.4.2.1.
Common Magnesium Alloys
2.4.3. Polymers and Composites
19
20
2.4.4. Comparison Cost and Hardness of Pure Nickel and Current
Automotive Body Materials
21
3.
METHODOLOGY
23
3.1.
Introduction
23
3.2.
Flow Chart of Methodology
24
3.3.
Material Preparation
25
3.3.1. Number of Samples
26
Heat Treatment (Annealing)
26
3.4.1. Test Specimen Condition
26
3.4.2. Procedure
27
Mechanical Testing
27
3.5.1. Tensile Test
28
3.4.
3.5.
3.6.
3.7.
3.5.1.1.
Test Machine
28
3.5.1.2.
Test Sample
29
3.5.1.3.
Test Method for Tensile Test
29
3.5.2. Hardness Test
30
3.5.2.1.
Test Machine
30
3.5.2.2.
Test Sample
31
3.5.2.3.
Test Procedure
32
Corrosion Test
32
3.6.1. Test Equipment and Specimen
32
3.6.2. Test Method
33
Crystallographic Analysis
33
3.7.1. X Ray diffraction
33
vi
3.8.
3.9.
Composition Analysis
34
3.8.1. Scanning Electron Microscope
34
Summary
35
4. RESULTS & DISCUSSIONS
36
4.1.
Introduction
36
4.2.
Mechanical Testing
36
4.2.1. Hardness Analysis
37
4.2.2. Tensile Analysis
38
4.3.
Corrosion Test
42
4.4.
Composition Analysis
45
4.4.1. Energy Dispersive X ray Analysis
45
Crystallographic Analysis
46
4.5.1. X-Ray Diffraction Analysis
46
4.5.
4.6.
Summary of Mechanical Properties and Chemical Properties of
Pure Nickel in Different Annealing Temperature
4.7.
51
Comparison mechanical properties of both of Annealed Pure Nickel
and Current Automotive Body Material.
52
4.7.1. Corrosion Resistance of Automotive Body Materials
52
5. CONCLUSION AND FUTURE WORK
54
5.1.
Conclusion
54
5.2.
Suggestion for Future Work
55
REFERENCES
56
APPENDICES
61
A. Gantt Chart PSM I
61
B. Gantt Chart PSM II
62
vii
C. Yield Strength Finding
63
D. Image of Necking Forming during Tensile Test
65
viii
LIST OF TABLES
TITLE
PAGE
Table 2.1
Chemical, Mechanical and Thermal Properties of Nickel
7
Table 2.2
Chemical Composition of Nickel Alloy
8
Table 2.3
Room Temperature Mechanical Properties and Physical
9
Properties of Commercially Pure Nickel and Low Alloy
Nickel
Table 2.4
Description and Major Applications of Commercially Pure
10
Nickel
Table 2.5
Results Of Atmospheric Corrosion And Pitting Of Nickel-
12
Base Alloy of 20-Year Exposure 24.4m From Ocean At
Kure Beach, NC
Table 2.6
Main Criteria and Ratings for Realistic Selection of
14
Automotive Body Materials
Table 2.7
Material Properties of Various Steels
16
Table 2.8
Automotive Aluminium alloys in Current Use
18
Table 2.9
Common Automotive Magnesium Alloys
19
Table 3.1
Number of Samples
26
Table 3.2
Annealing Condition of Pure Nickel
27
Table 3.3
The Dimensions of the Specimen
29
Table 4.1
Hardness Result of Pure Nickel with Different Annealing
37
Temperature
Table 4.2
Ultimate Tensile Strength, Young Modulus and Yield
39
Strength of Pure Nickel in Different Annealed Temperature
Table 4.3
Results of Corrosion Analysis by using Tafel Extrapolation
Technique
ix
44
Table 4.4
Theoretical XRD Lattice Parameter of Pure Nickel
47
Table 4.5
Comparison between Theoretical and Experimental of
47
Interplanar Spacing of Non-heat treated Pure Nickel.
Table 4.6
XRD Lattice Parameters Comparison
48
Table 4.7
The Grain Size Range of Non- heat Treated and Annealed
48
Pure Nickel
Table 4.8
Mechanical and Chemical Properties of Pure Nickel at
Different Annealed Temperature for 1 Hour
x
51
LIST OF FIGURE
TITLE
PAGE
Figure 2.1
Nickel in Various Form
6
Figure 2.2
The Galvanic Series of Metals
11
Figure 2.3
Graph of Price Against Hardness Between Pure Nickel
21
and Current Automotive Materials
Figure 3.1
Flow Chart of Methodology
24
Figure 3.2
Image of diamond cutter
25
Figure 3.3
Image of horizontal band saw
25
Figure 3.4
Image of CWF-1300 Furnace
27
Figure 3.5
Image of Universal Testing Machine
28
Figure 3.6
Image of tensile testing specimens dimension and shape
29
Figure 3.7
Micro Vickers Hardness Testing Machine
30
Figure 3.8
Image of Metkon FinoPress Automatic Mounting Press
31
Figure 3.9
Buehler Grinder and Polisher
31
Figure 3.10
Buehler grinder polisher
31
Figure 3.11
The EuroCell
32
Figure 3.12
Image of X-Ray X-Ray Diffractormeters
33
Figure 3.13
Image of Scanning Electron Microscopy
34
Figure 4.1
Indentation of Diamond Pyramid Indenter with A 90°
37
Angle Between Opposite Faces. Image Is Magnified At
50x
Figure 4.2
Graph of Hardness against Annealing Temperature
38
Figure 4.3
Graph of Ultimate Tensile Strength against Different
39
Annealing
Figure 4.4
Graph of Yield Strength against Different Annealing
Temperature of Pure Nickel
xi
40
Figure 4.5
Graph of Young’s Modulus in Different Annealing
40
Temperature of Pure Nickel
Figure 4.6
Graph of Tensile Stress against Elongation of Pure
41
Nickel In Different Annealing Temperature
Figure 4.7
Tafel graph for non- heat treated and 300°C pure nickel
42
Figure 4.8
Tafel graph for 500°C and 700°C annealed pure nickel
43
Figure 4.9
Graph of Corrosion Rate against the Different Annealing
44
Temperature
Figure 4.10
Data Obtained from EDX for Non Heat Treated and
45
Annealed Pure Nickel
Figure 4.11
Results Obtained from X -Ray Diffraction
46
Figure 4.12
Intensity of Non- heat Treated and Different Annealed
50
Temperature of Pure Nickel
xii
LIST OF ABBREVIATIONS
ASTM
-
American Society for Testing Material
CFRP
-
Carbon Fiber Reinforce Polymer
ECAP
-
Equal- Channel Angular Pressing
EDX
-
Energy Dispersive X-Ray
FCC
-
Face Centered Cubic
FKP
-
Falkuti Kejuruteraan Pembuatan
GMT
-
Glass Mat Thermoplastic
HSS
-
High Strength Steel
HV
-
Vickers Hardness
SEM
-
Scanning Electron Microscopy
UTEM
-
Universiti Technikal Malaysia Melaka
UTM
-
Universal Testing Machine
UTS
-
Ultimate Tensile Strength
XRD
-
X-Ray Diffraction
xiii
CHAPTER 1
INTRODUCTION
1.1
Introduction
The main purpose of this project is to study the mechanical properties and thermal
properties of pure Nickel as an alternative of automotive body.
Nickel is the
chemical element with the symbol, Ni which discovered in 1751 by Baron Axel
Frederik Cronstedt. Nickel is categorized as a transition metal in periodic table.
Nickel is a lustrous material which in silvery- white colour. Pure nickel is good in
electrical conductivity, thermal conductivity, and strength and corrosion resistance. It
is a reactive element but slow reacting with air at normal temperatures and pressures
due to the formation of a protective oxide surface. Nickel is used in coin ad also
plating for brass and iron element. The thermal properties of pure nickel can be
obtained by do annealing in different temperature for pure nickel. Various tests had
been conducted to obtain mechanical properties of pure nickel. The testing includes
tensile test, microhardness test, corrosion test and morphology study by using XRay Diffraction and Energy-dispersive X-ray spectroscopy. This research is to
compare the mechanical properties of pure nickel with others automotive body
material. Current automotive body materials include high strength steel, aluminium,
and composite materials. Researchers have done in finding the alternative materials
which can achieve the optimal production efficiencies in automotive body.
1
1.2
Problem Statement
Due to the increasing demand of high quality exterior panels, better functional
properties and lower weight in the automotive industry, the researches on different
materials have been conducted to alternate the existing automotive body material.
One of the changes is due to the weight deduction. Therefore, automotive body
materials change from steel to aluminium. The weight of the steel is higher than
aluminium but the cost of the steel is lower than aluminium. This is due to the weight
of the automotive body will affect the energy consumption of the automotive.
Therefore, researches on lightweight material have been conducted to achieve fuel
efficiency. Cui, X.T.et al, (2007) stated that approximately 40% of the weights of the
automotive are from automotive body and interior account. Every 56.69kg weight
reduction results in a gain of 0.09-0.21 km per liter fuel economy. Besides the weight
of the material, the mechanical properties of the material in automotive body also
important in order to increase the performance of the automotive. Edwards, K .L.
(2004) stated that materials with high specific stiffness and strength properties for
example allow highly efficient lightweight load bearing structures to be produced.
High strength and strain alloy steel sheets with transformation-induced plasticity are
used for body panel. The properties of alloy steel allow deep drawing; provide
resistance to denting, and opportunity to use a lighter gauge to reduce vehicle weight.
The material used in automotive body should have the properties of high fracture
toughness due to the ability to absorb energy in case of high speed crashes.
Klarstrom, D.L. (2001) stated that nickel and nickel base alloys are important to
modern industry due to the ability to withstand a wide variety of severe operating
conditions involving corrosive environments, high temperatures and high stress.
Nickel is widely used in variety applications of food processing equipment, chemical
shipping drums, aircraft gas turbine, caustic, handling equipment and piping. For this
project, pure nickel have been use to compare the mechanical properties and thermal
properties in automotive body material.
2
1.3
Objectives
The objectives of this project are:
To study the mechanical properties and corrosion test of pure nickel at
different annealing temperature.
To compare the mechanical properties of pure nickel as an alternative for
automotive body material.
1.4
Scope of Study
This project involves the study of different annealing conditions for pure nickel of
their mechanical properties and thermal properties. Apply pure nickel as an
alternative automotive body by study the mechanical and chemical properties of pure
nickel at different annealing temperature .This project consists of the comparison
between pure nickel and current automotive body material. An experiment on
mechanical and chemical studies with thermal effect of pure nickel has to be
conducted. Thermal properties will be studied by doing annealing in different
temperature. Mechanical studies include tensile and hardness test. Chemical study
include corrosion test was carried out to obtain the corrosion rate of pure nickel in
different annealing temperature.
1.5
Organization of the Report
The whole report is divided into six major parts, which is known as Introduction,
Literature Review, Methodology, Results, Discussion, and Conclusion and future
work.
Basically, each of the content of each chapter is;
Chapter 1 : Introduction
This chapter contains the background of the problem statement generally and
includes the objectives and the scope of the study. This chapter summarizes
3
the project with material properties and techniques involved to study the
suitable alternative material for automotive body.
Chapter 2: Literature Review
In this chapter, any information which is related to the project is studied and
summarized. The source of the information can be from journals, books,
internet, articles and etc. Based on the information from past studies and
research, it will guide a correct path for the success of the project.
Chapter 3 : Methodology
It describes overview of the research methods to conduct the various
experiments. It provide the details of introduce the test to be conduct; the
function of the machine and the details of the specimens and the parameter to
be used for the experiments.
Chapter 4: Results
It states all the results such as tables, figures and graphs when research
carrying out. All the important findings will be presented in a comprehensive
way. It also analyzes the results statistically.
Chapter 5: Discussion
Discuss the results obtain and compare with the current automotive body
material. Besides, comparison of finding between theoretically and
practically practices.
Chapter 6 : Conclusion
It summarizes the main findings and how the scope is covered fully and brief
recommendation for further study.
4
CHAPTER 2
LITERATURE REVIEW
2.1.
Introduction
This chapter consists of information related to the study of pure nickel, current
automotive body materials and comparison properties between pure nickel and
current automotive body material. This chapter introduces the history of current
automotive materials and the changes occurring. Besides, this chapter discuss about
the mechanical and chemical properties of pure nickel with respect to thermal effect.
Also the possibility of replacing the current automotive body materials proposed
based on the work done by others.
2.2.
Nickel
Nickel was first found by the Swedish chemist Axel Cronstedt in 1751. The name of
Nickel comes from the German word “kupfernickel”. It is occur in white colour
metal. The sulfide ores were found contain nickel, copper, cobalt, iron, and precious
metals (gold, silver, and the platinum-group metals). Researchers are finding the way
to separate nickel from copper. Mankins, W.L and Lamb, S., (1990) mentioned that
Pyrometallurgical, Hydrometallurgy, and vapometallurgy processes have been used
to separate the metallic ores and rock. Nickel is a metallic element which occurs in
group VIII of the periodic table. According to Klarstrom, D.L. (2001), pure nickel is
a ductile and tough due to it possesses a face-centered cubic crystal structure up to its
melting point. Nickel is a transition metal. The appearance of Nickel is silvery- white
metal; it looks lustrous, malleable and highly reflective. The compounds of the
nickel are in green or blue colour. Nickel is the metal which good in corrosion
5
resistance. Nickel is reacting with all acids except concentrated nitric acid. Nickel is
not influenced by alkaline. It is a conductor of heat and electricity. The chemical,
mechanical and thermal properties of nickel are shown in Table 2.1. Figure 2.1 show
the difference size and various forms of nickel.
Figure 2.1: Nickel in various forms
6
Table 2.1: Chemical, mechanical and thermal properties of nickel CES EduPack, (2009).
Values (S.I.)
Property
0.0065-0.0067
Atomic Volume (average)
8.83-8.95
Density
162-200
Bulk Modulus
70-1000
Compressive Strength
80-110
Fracture Toughness
Units (S.I.)
m3/kmol
g/cm3
GPa
MPa
MPa.m1/2
0.305-0.315
Poisson's Ratio
72-86
Shear Modulus
345-1000
Tensile Strength
190-220
Young's Modulus
70-900
Yield Strength (elastic limit)
2-60
Elongation
135-500
Fatigue strength at 107 cycles
80-300
Hardness -Vickers
1716-1743
Melting Point
452-460
Specific Heat
67-91
Thermal Conductivity
12-13.5
Thermal Expansion
8-10
Resistivity
7
GPa
MPa
GPa
Mpa
%
MPa
HV
K
J/kg.K
W/m.K
10-6/K
10-8 ohm.m
MECHANICAL AND THERMAL PROPERTIES OF PURE NICKEL
AS AN ALTERNATIVE AUTOMOTIVE BODY MATERIAL
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Engineering Materials) with Honours
By
GAN BEE GEOK
FACULTY OF MANUFACTURING ENGINEERING
2010
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK:
Mechanical and Thermal Properties of Pure Nickel as an Alternative
Automotive Body Material
SESI PENGAJIAN: 2009/10 Semester 2
Saya GAN BEE GEOK
mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti
Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis.
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis.
3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan
pertukaran antara institusi pengajian tinggi.
4. **Sila tandakan (-.J)
D
D
QJ
SULIT
TERHAD
(Mengandungi maklumat yang berdarjah keselamatan
atau kepentingan Malaysia yang termaktub di dalam
AKTA RAHSIA RASMI1972)
(Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasi/badan di mana penyelidikan dijalankan)
TIDAK TERHAD
Disahkan oleh:
Alamat Tetap:
J 5904 Rumah Awam,
Sempang Pantai
nJOO Merlimau, Melaka
Cop Rasmi:
PROF. MADYA DR. t JOSEPH
F k . ProtQsor f..tao SAHAYA ANAND
.a ultl ｋ･ｪｵｲＺＮｾｴ＠
UniVersiti
Tarikh: __2_5_.0_5_.2_0_10_ _ _ __
Tarikh:
ｔ･ｾｮｩｫ｡ｬ＠
95 MCl;li
: " ｾ･ＧＡ｢ｵ｡ｴＢ＠
ya
alays,a ｍ･ｬ｡ｾ＠
9.e>
ro
** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi
berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai
SULIT atau TERHAD.
DECLARATION
I hereby, declared this report entitled “Mechanical and thermal properties of pure
nickel as an alternative automotive body material” is the results of my own research
except as cited in references.
Signature
:
Author’s Name
:
GAN BEE GEOK
Date
:
25.05.2010
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as
a partial fulfillment of the requirements for the degree of Bachelor of
Manufacturing Engineering (Engineering Materials) with Honours. The member
of the supervisory committee is as follow:
………………………………
(
PROF. MADYA. DR. T. JOSEPH SAHAYA ANAND
)
ABSTRACT
This project is represented the study of thermal and mechanical properties of pure nickel
as an alternative automotive body material. Nickel is the chemical element which
categorized in periodic table as transition metal. Nickel is a hard, malleable, ductile
material. It is used for making stainless steel, low alloy steels, cast iron and etc. Nickel
also used in battery manufacturing. Current automotive are mainly use steel as an
automotive body material. Due to the increasing demand of high performance in term of
mechanical properties of the material use in automotive, researched have been done to
find alternative material to replace steel. In this project, annealing is done for pure nickel
at 300 ºC, 500 ºC and 700ºC for 1 hour. The studies on mechanical properties, corrosion
test, composition analysis and crystallography analysis in different annealing
temperatures to alternate current automotive body material. The hardness of both non heat treated and annealed pure nickels do not change as the annealing temperature
increases which in the range of 118 to 123 HV. As the annealed temperature increase, the
ultimate tensile strength, yield strength and young modulus decreases, but the ductility
increase. The highest ultimate tensile strength of pure nickel at 300ºC annealed
temperature which is 758.78 MPa. For corrosion test, the corrosion rate of both non-heat
treated and annealed pure nickel have minor changes with the annealed temperature
which in the range of 0.0266 to 0.048 mm/year. The composition of both non- heat
treated and annealed pure nickels do not change. Pure nickel is face center cubic
structure; the lattice constant is decreasing as the annealing temperature increases.
Besides, the grain size of pure nickel is increasing as the annealed temperature increase.
i
ABSTRAK
Projek ini mengenai kajian berkaitan dengan sifat-sifat mekanikal bagi nikel tulen
sebagai bahan gantian untuk bahagian badan automotif. Nikel adalah unsur kimia yang
dikategorikan dalam jadual berkala sebagai logam peralihan. Nikel adalah satu bahan
mulur yang keras, mudah dibentuk. Ia digunakan untuk membuat keluli tahan karat,
keluli aloi berkomposisi rendah, besi tuangan dan sebagainya. Nikel juga digunakan
dalam penghasilan bateri. Pada masa kini, kebanyakan bahan automotif adalah keluli.
Kajian telah dijalankan untuk menggantikan keluli sebagai alternatif bahan automotif
disebabkan peningkatan permintaan terhadap prestasi yang tinggi bagi sifat-sifat
mekanikal bagi penggunaan bahan dalam automotif, Dalam projek ini, kajian mengenai
pencekalan nikel tulen pada suhu 300 ºC, 500 ºC dan 700ºC telah dijalankan selama satu
jam. Kajian terhadap sifat-sifat mekanikal, ujian penghakisan, analisis komposisi dan
análisis kristalografi dalam suhu pengcekalan yang berbeza untuk mengganti bahan
badan automotif semasa. Kekerasan pada sampel yang tidak malakukan pengcekalan
dan cekalan nikel tulen tak berubah dan dalam lingkungan 118 kepada 123HV. kekuatan
tegangan, kekuatan alah dan modulus mengurang, tetapi kemuluran meningkat.
Kekuatan tegangan tertinggi bagi nikel tulen adalah pada suhu 300ºC cekalan iaitu
758.78MPa. Bagi ujian penghakisan, kadar kakisan kedua-dua perlakuan tanpa haba dan
cekalan nikel tulen mempunyai perubahan kecil dalam lingkungan daripada 0.0266
kepada0.048mm / tahun. Komposisi kedua-dua perlakuan tanpa haba dan cekalan nikel
tulen tak berubah. Nikel tulen berstruktur FCC; pemalar kekisi menurun apabila suhu
cekalan meningkat. Selain itu, saiz butiran nikel tulen semakin meningkat apabila suhu
cekalan meningkat.
ii
DEDICATION
This report is dedicated to my parents and my supervisor Prof. Madya. Dr. T. Joseph
Sahaya Anand who have supported me throughout my Bachelor Degree Project. Without
his patience, understanding and support, the completion of this work would not have
been possible.
iii
ACKNOWLEDGEMENT
I am pleased to say that I would never have been able to complete my Bachelor Degree
Project without the help and encouragement from this group of special individuals. I
would like to thank these people for their show of heartfelt support throughout the
duration of my Bachelor Degree Project. My first gratitude goes to my supervisor Prof.
Madya. Dr. T. Joseph Sahaya Anand for his constant guidance and encouragement. He
always guides me and he is a very nice and helpful person. When I face problem on
doing project, he always guide me to the right way although he is very busy with his
work. I want to thanks to my fellow friends Kwan Wai Loon, Lim Kok Chin, and Pang
Chee Kong for helping me during the time difficulty.
iv
TABLE OF CONTENTS
TITLE
PAGE
Abstract
i
Abstrak
ii
Dedication
iii
Acknowledgement
iv
Table of Content
v
List of Tables
ix
List of Figures
xi
List Abbreviations
xii
1. INTRODUCTION
1
1.1
Introduction
1
1.2
Problem Statement
2
1.3
Objective
3
1.4
Scope of Study
3
1.5
Organization of Report
3
2. LITERATURE REVIEW
5
2.1.
Introduction
5
2.2.
Nickel
5
2.2.1. Commercially Pure Nickel
8
2.2.2. Corrosion properties of Pure Nickel
11
2.2.3. The applications of Nickel
11
2.2.4. Health Effects of Nickel
12
Current Automotive Body Material
13
2.3.1. Steel
15
2.3.
2.3.1.1. High Strength Steel
15
2.3.1.2. Stainless Steel
16
v
2.4.
Alternative Material for Automotive Body Materials
17
2.4.1. Aluminium
17
2.4.2. Magnesium and its Alloys
19
2.4.2.1.
Common Magnesium Alloys
2.4.3. Polymers and Composites
19
20
2.4.4. Comparison Cost and Hardness of Pure Nickel and Current
Automotive Body Materials
21
3.
METHODOLOGY
23
3.1.
Introduction
23
3.2.
Flow Chart of Methodology
24
3.3.
Material Preparation
25
3.3.1. Number of Samples
26
Heat Treatment (Annealing)
26
3.4.1. Test Specimen Condition
26
3.4.2. Procedure
27
Mechanical Testing
27
3.5.1. Tensile Test
28
3.4.
3.5.
3.6.
3.7.
3.5.1.1.
Test Machine
28
3.5.1.2.
Test Sample
29
3.5.1.3.
Test Method for Tensile Test
29
3.5.2. Hardness Test
30
3.5.2.1.
Test Machine
30
3.5.2.2.
Test Sample
31
3.5.2.3.
Test Procedure
32
Corrosion Test
32
3.6.1. Test Equipment and Specimen
32
3.6.2. Test Method
33
Crystallographic Analysis
33
3.7.1. X Ray diffraction
33
vi
3.8.
3.9.
Composition Analysis
34
3.8.1. Scanning Electron Microscope
34
Summary
35
4. RESULTS & DISCUSSIONS
36
4.1.
Introduction
36
4.2.
Mechanical Testing
36
4.2.1. Hardness Analysis
37
4.2.2. Tensile Analysis
38
4.3.
Corrosion Test
42
4.4.
Composition Analysis
45
4.4.1. Energy Dispersive X ray Analysis
45
Crystallographic Analysis
46
4.5.1. X-Ray Diffraction Analysis
46
4.5.
4.6.
Summary of Mechanical Properties and Chemical Properties of
Pure Nickel in Different Annealing Temperature
4.7.
51
Comparison mechanical properties of both of Annealed Pure Nickel
and Current Automotive Body Material.
52
4.7.1. Corrosion Resistance of Automotive Body Materials
52
5. CONCLUSION AND FUTURE WORK
54
5.1.
Conclusion
54
5.2.
Suggestion for Future Work
55
REFERENCES
56
APPENDICES
61
A. Gantt Chart PSM I
61
B. Gantt Chart PSM II
62
vii
C. Yield Strength Finding
63
D. Image of Necking Forming during Tensile Test
65
viii
LIST OF TABLES
TITLE
PAGE
Table 2.1
Chemical, Mechanical and Thermal Properties of Nickel
7
Table 2.2
Chemical Composition of Nickel Alloy
8
Table 2.3
Room Temperature Mechanical Properties and Physical
9
Properties of Commercially Pure Nickel and Low Alloy
Nickel
Table 2.4
Description and Major Applications of Commercially Pure
10
Nickel
Table 2.5
Results Of Atmospheric Corrosion And Pitting Of Nickel-
12
Base Alloy of 20-Year Exposure 24.4m From Ocean At
Kure Beach, NC
Table 2.6
Main Criteria and Ratings for Realistic Selection of
14
Automotive Body Materials
Table 2.7
Material Properties of Various Steels
16
Table 2.8
Automotive Aluminium alloys in Current Use
18
Table 2.9
Common Automotive Magnesium Alloys
19
Table 3.1
Number of Samples
26
Table 3.2
Annealing Condition of Pure Nickel
27
Table 3.3
The Dimensions of the Specimen
29
Table 4.1
Hardness Result of Pure Nickel with Different Annealing
37
Temperature
Table 4.2
Ultimate Tensile Strength, Young Modulus and Yield
39
Strength of Pure Nickel in Different Annealed Temperature
Table 4.3
Results of Corrosion Analysis by using Tafel Extrapolation
Technique
ix
44
Table 4.4
Theoretical XRD Lattice Parameter of Pure Nickel
47
Table 4.5
Comparison between Theoretical and Experimental of
47
Interplanar Spacing of Non-heat treated Pure Nickel.
Table 4.6
XRD Lattice Parameters Comparison
48
Table 4.7
The Grain Size Range of Non- heat Treated and Annealed
48
Pure Nickel
Table 4.8
Mechanical and Chemical Properties of Pure Nickel at
Different Annealed Temperature for 1 Hour
x
51
LIST OF FIGURE
TITLE
PAGE
Figure 2.1
Nickel in Various Form
6
Figure 2.2
The Galvanic Series of Metals
11
Figure 2.3
Graph of Price Against Hardness Between Pure Nickel
21
and Current Automotive Materials
Figure 3.1
Flow Chart of Methodology
24
Figure 3.2
Image of diamond cutter
25
Figure 3.3
Image of horizontal band saw
25
Figure 3.4
Image of CWF-1300 Furnace
27
Figure 3.5
Image of Universal Testing Machine
28
Figure 3.6
Image of tensile testing specimens dimension and shape
29
Figure 3.7
Micro Vickers Hardness Testing Machine
30
Figure 3.8
Image of Metkon FinoPress Automatic Mounting Press
31
Figure 3.9
Buehler Grinder and Polisher
31
Figure 3.10
Buehler grinder polisher
31
Figure 3.11
The EuroCell
32
Figure 3.12
Image of X-Ray X-Ray Diffractormeters
33
Figure 3.13
Image of Scanning Electron Microscopy
34
Figure 4.1
Indentation of Diamond Pyramid Indenter with A 90°
37
Angle Between Opposite Faces. Image Is Magnified At
50x
Figure 4.2
Graph of Hardness against Annealing Temperature
38
Figure 4.3
Graph of Ultimate Tensile Strength against Different
39
Annealing
Figure 4.4
Graph of Yield Strength against Different Annealing
Temperature of Pure Nickel
xi
40
Figure 4.5
Graph of Young’s Modulus in Different Annealing
40
Temperature of Pure Nickel
Figure 4.6
Graph of Tensile Stress against Elongation of Pure
41
Nickel In Different Annealing Temperature
Figure 4.7
Tafel graph for non- heat treated and 300°C pure nickel
42
Figure 4.8
Tafel graph for 500°C and 700°C annealed pure nickel
43
Figure 4.9
Graph of Corrosion Rate against the Different Annealing
44
Temperature
Figure 4.10
Data Obtained from EDX for Non Heat Treated and
45
Annealed Pure Nickel
Figure 4.11
Results Obtained from X -Ray Diffraction
46
Figure 4.12
Intensity of Non- heat Treated and Different Annealed
50
Temperature of Pure Nickel
xii
LIST OF ABBREVIATIONS
ASTM
-
American Society for Testing Material
CFRP
-
Carbon Fiber Reinforce Polymer
ECAP
-
Equal- Channel Angular Pressing
EDX
-
Energy Dispersive X-Ray
FCC
-
Face Centered Cubic
FKP
-
Falkuti Kejuruteraan Pembuatan
GMT
-
Glass Mat Thermoplastic
HSS
-
High Strength Steel
HV
-
Vickers Hardness
SEM
-
Scanning Electron Microscopy
UTEM
-
Universiti Technikal Malaysia Melaka
UTM
-
Universal Testing Machine
UTS
-
Ultimate Tensile Strength
XRD
-
X-Ray Diffraction
xiii
CHAPTER 1
INTRODUCTION
1.1
Introduction
The main purpose of this project is to study the mechanical properties and thermal
properties of pure Nickel as an alternative of automotive body.
Nickel is the
chemical element with the symbol, Ni which discovered in 1751 by Baron Axel
Frederik Cronstedt. Nickel is categorized as a transition metal in periodic table.
Nickel is a lustrous material which in silvery- white colour. Pure nickel is good in
electrical conductivity, thermal conductivity, and strength and corrosion resistance. It
is a reactive element but slow reacting with air at normal temperatures and pressures
due to the formation of a protective oxide surface. Nickel is used in coin ad also
plating for brass and iron element. The thermal properties of pure nickel can be
obtained by do annealing in different temperature for pure nickel. Various tests had
been conducted to obtain mechanical properties of pure nickel. The testing includes
tensile test, microhardness test, corrosion test and morphology study by using XRay Diffraction and Energy-dispersive X-ray spectroscopy. This research is to
compare the mechanical properties of pure nickel with others automotive body
material. Current automotive body materials include high strength steel, aluminium,
and composite materials. Researchers have done in finding the alternative materials
which can achieve the optimal production efficiencies in automotive body.
1
1.2
Problem Statement
Due to the increasing demand of high quality exterior panels, better functional
properties and lower weight in the automotive industry, the researches on different
materials have been conducted to alternate the existing automotive body material.
One of the changes is due to the weight deduction. Therefore, automotive body
materials change from steel to aluminium. The weight of the steel is higher than
aluminium but the cost of the steel is lower than aluminium. This is due to the weight
of the automotive body will affect the energy consumption of the automotive.
Therefore, researches on lightweight material have been conducted to achieve fuel
efficiency. Cui, X.T.et al, (2007) stated that approximately 40% of the weights of the
automotive are from automotive body and interior account. Every 56.69kg weight
reduction results in a gain of 0.09-0.21 km per liter fuel economy. Besides the weight
of the material, the mechanical properties of the material in automotive body also
important in order to increase the performance of the automotive. Edwards, K .L.
(2004) stated that materials with high specific stiffness and strength properties for
example allow highly efficient lightweight load bearing structures to be produced.
High strength and strain alloy steel sheets with transformation-induced plasticity are
used for body panel. The properties of alloy steel allow deep drawing; provide
resistance to denting, and opportunity to use a lighter gauge to reduce vehicle weight.
The material used in automotive body should have the properties of high fracture
toughness due to the ability to absorb energy in case of high speed crashes.
Klarstrom, D.L. (2001) stated that nickel and nickel base alloys are important to
modern industry due to the ability to withstand a wide variety of severe operating
conditions involving corrosive environments, high temperatures and high stress.
Nickel is widely used in variety applications of food processing equipment, chemical
shipping drums, aircraft gas turbine, caustic, handling equipment and piping. For this
project, pure nickel have been use to compare the mechanical properties and thermal
properties in automotive body material.
2
1.3
Objectives
The objectives of this project are:
To study the mechanical properties and corrosion test of pure nickel at
different annealing temperature.
To compare the mechanical properties of pure nickel as an alternative for
automotive body material.
1.4
Scope of Study
This project involves the study of different annealing conditions for pure nickel of
their mechanical properties and thermal properties. Apply pure nickel as an
alternative automotive body by study the mechanical and chemical properties of pure
nickel at different annealing temperature .This project consists of the comparison
between pure nickel and current automotive body material. An experiment on
mechanical and chemical studies with thermal effect of pure nickel has to be
conducted. Thermal properties will be studied by doing annealing in different
temperature. Mechanical studies include tensile and hardness test. Chemical study
include corrosion test was carried out to obtain the corrosion rate of pure nickel in
different annealing temperature.
1.5
Organization of the Report
The whole report is divided into six major parts, which is known as Introduction,
Literature Review, Methodology, Results, Discussion, and Conclusion and future
work.
Basically, each of the content of each chapter is;
Chapter 1 : Introduction
This chapter contains the background of the problem statement generally and
includes the objectives and the scope of the study. This chapter summarizes
3
the project with material properties and techniques involved to study the
suitable alternative material for automotive body.
Chapter 2: Literature Review
In this chapter, any information which is related to the project is studied and
summarized. The source of the information can be from journals, books,
internet, articles and etc. Based on the information from past studies and
research, it will guide a correct path for the success of the project.
Chapter 3 : Methodology
It describes overview of the research methods to conduct the various
experiments. It provide the details of introduce the test to be conduct; the
function of the machine and the details of the specimens and the parameter to
be used for the experiments.
Chapter 4: Results
It states all the results such as tables, figures and graphs when research
carrying out. All the important findings will be presented in a comprehensive
way. It also analyzes the results statistically.
Chapter 5: Discussion
Discuss the results obtain and compare with the current automotive body
material. Besides, comparison of finding between theoretically and
practically practices.
Chapter 6 : Conclusion
It summarizes the main findings and how the scope is covered fully and brief
recommendation for further study.
4
CHAPTER 2
LITERATURE REVIEW
2.1.
Introduction
This chapter consists of information related to the study of pure nickel, current
automotive body materials and comparison properties between pure nickel and
current automotive body material. This chapter introduces the history of current
automotive materials and the changes occurring. Besides, this chapter discuss about
the mechanical and chemical properties of pure nickel with respect to thermal effect.
Also the possibility of replacing the current automotive body materials proposed
based on the work done by others.
2.2.
Nickel
Nickel was first found by the Swedish chemist Axel Cronstedt in 1751. The name of
Nickel comes from the German word “kupfernickel”. It is occur in white colour
metal. The sulfide ores were found contain nickel, copper, cobalt, iron, and precious
metals (gold, silver, and the platinum-group metals). Researchers are finding the way
to separate nickel from copper. Mankins, W.L and Lamb, S., (1990) mentioned that
Pyrometallurgical, Hydrometallurgy, and vapometallurgy processes have been used
to separate the metallic ores and rock. Nickel is a metallic element which occurs in
group VIII of the periodic table. According to Klarstrom, D.L. (2001), pure nickel is
a ductile and tough due to it possesses a face-centered cubic crystal structure up to its
melting point. Nickel is a transition metal. The appearance of Nickel is silvery- white
metal; it looks lustrous, malleable and highly reflective. The compounds of the
nickel are in green or blue colour. Nickel is the metal which good in corrosion
5
resistance. Nickel is reacting with all acids except concentrated nitric acid. Nickel is
not influenced by alkaline. It is a conductor of heat and electricity. The chemical,
mechanical and thermal properties of nickel are shown in Table 2.1. Figure 2.1 show
the difference size and various forms of nickel.
Figure 2.1: Nickel in various forms
6
Table 2.1: Chemical, mechanical and thermal properties of nickel CES EduPack, (2009).
Values (S.I.)
Property
0.0065-0.0067
Atomic Volume (average)
8.83-8.95
Density
162-200
Bulk Modulus
70-1000
Compressive Strength
80-110
Fracture Toughness
Units (S.I.)
m3/kmol
g/cm3
GPa
MPa
MPa.m1/2
0.305-0.315
Poisson's Ratio
72-86
Shear Modulus
345-1000
Tensile Strength
190-220
Young's Modulus
70-900
Yield Strength (elastic limit)
2-60
Elongation
135-500
Fatigue strength at 107 cycles
80-300
Hardness -Vickers
1716-1743
Melting Point
452-460
Specific Heat
67-91
Thermal Conductivity
12-13.5
Thermal Expansion
8-10
Resistivity
7
GPa
MPa
GPa
Mpa
%
MPa
HV
K
J/kg.K
W/m.K
10-6/K
10-8 ohm.m