20CYT22-CHEMISTRY FOR MECHANICAL SYSTEMS�UNIT - I�
Dr.A.Geetha
Associate Professor
Department of Chemistry
Kongu Engineering College
20CYT22-CHEMISTRY FOR MECHANICAL SYSTEMS
UNIT - I
Lubricants - functions – requirements - classification with examples –properties: viscosity, viscosity index, flash and fire point, cloud and pour point, oiliness, aniline point and carbon residue – Explosives – requirements – classification – manufacture of important explosives (TNT, GTN and RDX) – Rocket propellants – properties and classification – Refractory bricks – criteria of a good refractory material – classification – properties: refractories, RUL, porosity, thermal spalling, thermal conductivity and dimension stability – general method of manufacturing of refractories – Insulators – classification with examples, thermal insulators and electrical insulators – characteristics of insulating materials.
Lubricants
Lubricants – A substance, which when applied between two moving parts reduces friction by introducing a slippery film between the two surfaces.
Lubrication - process of reducing friction and wear between two moving surfaces by applying lubricant in between the moving parts.
Characteristics of Good Lubricant
Functions of Lubricants
Functions of Lubricants
thermal stress.
generated debris and contaminants introduced into it.
Classification of Lubricants - classified based on their physical state as
1.Gaseous Lubricants
2.Liquid Lubricants
oil-palm, castor, sunflower oil & whale oil.
3.Solid Lubricants
For good lubrication water vapour is necessary & not effective in vacuum.
effective in vacuum. It oxidizes beyond 400°C hence it can be used up to 400°C.
high temperatures up to 1200°C and in oxidizing atm.
and sintered ceramic powders is called Self lubricating composites.
4. Semisolid Lubricants
Ex. Greases- 80% mineral oil + 10% soaps + 10% additives (inhibitors, antioxidants, antiwear)
used up to 120°C.
5. Metals/Alloys Lubricants
Properties of Lubricants
1.Viscosity
is low, excessive wear takes place. If viscosity is too high, friction between layer increases.
2.Viscosity Index (VI)
3. Flash and Fire Point
operating conditions. Flash point is important in determining shipping, storage and safety.
not burn when small flame is brought near to it.
when flame is brought near to it. Good lubricant should have flash point above the temp at which it is to be used. Fire points are 8-10% higher than the flash point.
4.Cloud and Pour Points
5. Oiliness
good oiliness stay on between the lubricated surfaces.
6. Aniline Point
and a lower percentage of aromatic hydrocarbons. Aromatic hydrocarbons have a tendency
to dissolve certain types of rubber hence their low level is desirable in lubricants.
7. Carbon Residue
carbon residue.
EXPLOSIVES
Classifications of Explosives
Explosives are classified on the basis of their sensitivity, velocity & physical forms
1. Classification based on sensitivity
b. Secondary explosives
c.Tertiary explosives (blasting agents)
secondary explosives for detonation.
2. Classification based on velocity
a. Low explosives(propellants)
i. Gun powder(black powder)- mixture of 75% KNO3, 15% charcoal & 10% Sulphur. During ignition
decomposes into
10 KNO3 + 3S + 8C 3K2SO4 + 2K2CO3 + 5N2
ii. Nitro Cellulose (smokeless powder)
ether + alcohol + solvent. Stabilizer diphenylamine is added to prevent further reaction.
b. High Explosives
pure explosive with non-explosive materials.
High explosives are further classified into
i. Single compound explosives- contain only one chemical compound.
Ex. Ammonium nitrate- stable, non-toxic & cheap.
Picric acid- used as a booster to detonate another less sensitive explosive like TNT
ii. Binary explosives- it is a mixture of TNT with other explosive. It is heated to liquid state and poured
into the container then allowed to solidify. Ex. Pentotile- mixture of 50% TNT and 50% PETN.
iii. Plastic explosives- combination of explosives in plastic state and are hand-moulded or
press-loaded Into various shapes. Ex.PETN
iv. Dynamites- Contains nitroglycerine. It is an oily liquid, which detonates by pressure, shock,
temp above 50°C. Different types of dynamites are
used for blasting hard rocks, coal and mineral demolitions
explodes rapidly when exposed to fire.
Classification based on physical form
based on physical form explosives classified as
e. Extrudable, f. Binary, g. Slurries & gels, h. Blasting agents
Preparation of 2,4,6-trinitrotoluene (TNT)
TNT is synthesized in a three-step process. First toluene is nitrated using mixture of acids to mono-
nitrotoluene. Then its re-nitrated to trinitrotoluene using anhydrous mixture of nitric acid and oleum.
Preparation of Glyceryl Trinitrate (GTN) or nitro glycerin
Rocket Propellants
an oxidizer is an agent that releases oxygen for combination with a fuel).
Properties of a good propellant
Classifications propellants
Propellants are classified into solid, liquid, gaseous and hybrid
Solid rocket propellant
and nitroglycerine mixture.
Heterogeneous solid propellants – dispersion of oxidizing agent in a fuel mass. Ex. Gun powder
Liquid rocket propellants
Gaseous rocket propellants
Hybrid rocket propellants
Few rocket propellants currently used are
REFRACTORIES
Definition:
Refractories are inorganic materials which can withstand at high temperatures without getting softened or deformed in shape.
Objectives:
loss during the process.
and gases at high temperatures without getting softened or distorted in
shape.
Applications:
Ceramics Refractories
Crucible
Refractories
Criteria Of a Good Refractory Material
Classification of Refractories
1.Acidic refractories: These are made up of acidic materials like alumina (Al2O3) and silica (SiO2). They are not attacked by acidic materials but can be easily attacked by basic material. Examples: Alumina, silica and fireclay.
2. Basic refractories: These are made up of basic materials, like CaO, Mg, etc. They are not attacked by basic materials, but can be attacked by acidic materials. Examples: Magnesite, and dolomite refractories.
3. Neutral refractories: These are made from weakly acidic / basic materials, like carbon, chromite, zirconia, etc., are used to prepare neutral refractories.
Examples: Graphite, chromite, zirconia and carborundum refractories.
Properties of Refractories
1.Refractoriness 4. Thermal Conductivity
2.Refractoriness-under load 5. Thermal Spalling
3. Porosity 6. Dimensional Stability
REFRACTORINESS
Definition: It is the ability of a material to withstand at very high temperatures without appreciable softening or deformation under a particular service condition. Most of the refractories are made up of a mixture of several metallic oxides. They do not have a sharp melting point.
The refractoriness of a refractory material is generally measured as the softening temperature and it is expressed in terms of Pyrometric Cone Equivalent (PCE). It is determined by using the pyrometric cone test.
Determination of Refractoriness
REFRACTORINESS UNDER LOAD (RUL) (or) STRENGTH
RUL Test
POROSITY
Porosity (P) = (W – D / W – A) × 100
where
W = Weight of saturated specimen (with water) in air.
D = Weight of dry specimen.
A = Weight of saturated specimen (with water) in water.
THERMAL CONDUCTIVITY
THERMAL SPALLING
Thermal spalling of any refractory material is defined as the property of breaking, cracking, fracturing or peeling off the material under high temperature.
(i) Rapid change in temperature (ii) Slag penetration.
Spalling can be decreased by
DIMENSIONAL STABILITY
It is the resistance of a refractory material to any volume changes, when exposed to high temperature over prolonged time.
The dimensional changes are of two types.
1.Reversible
2.Irreversible
Reversible Dimensional Changes
This may result due to the uniform expansion and contraction of a refractory material. So, the dimensional changes of a good refractory must be reversible.
Irreversible Dimensional Changes
This is due to the formation of increasing amounts of liquid from low fusible constituent of the refractory bricks, when it is subjected to long periods of soaking at high temperature.
.
Example: Magnesite bricks shrink in service.
The conversion of amorphous nature of Magnesite (specific gravity is 3.05) into more dense crystalline form of Periclase (specific gravity is 3.54) on heating.
Magnesite → Periclase
(Amorphous) (Crystalline)
Spe.Gra= 3.05 Spe.Gra= 3.54
A good refractory should
have high dimensional stability.
General method of manufacturing of refractories
Raw material processing
This consists of crushing, grinding clay and then sieving to get the raw material of correct size. The materials is further purified to remove unwanted material by processes such as (a) froth floatation (b) magnetic separation (C) Chemical Methods .The raw materials are then dried and calcined at 1200-15000 C to remove volatile impurities.
Blending and mixing
The two or more powdered raw material with equal size is thoroughly mixed with a suitable binding material and thus, it forms homogeneous mixture which makes moulding easier.
Moulding
Moulding can be done either manually or mechanically by the application of high pressure. Low strength and low density refractories are produced by hand moulding, whereas high strength and high density refractories are made by mechanical moulding.
Drying
The drying process enables the removal of moisture from refractories and to prevent development of internal stressor cracks during use.
Firing
The refractories are fired to stabilize and strengthen their structure. This process is done at high temperatures or the temperature higher than the service temperature. Firing is carried out in chamber at the temperature ranging from 1400°C to 2000°C, depending on the composition and properties desired.
INSULATORS
Definition:
The substances which are capable of retarding or stop the flow of heat or electricity or sound through them are known as insulators.
Classification of Insulators
Thermal Insulators
Sound Insulators
Electrical Insulators
Characteristic of Insulating Material
1. Electrical conductivity
The ability of material to conduct the electricity is called as an electrical conductivity. Resistivity is the reciprocal of electrical conductivity.
A good insulating material should possess low conductivity or high resistivity.
2. Dielectric constant
It is a quantitative measure of the ability of the material to store electric charges. It is expressed as the ratio of the capacitance of a capacitor containing the dielectric material under study to the capacitance of the same capacitor with vacuum as the dielectric.
A good insulating material should possess low dielectric constant.
3. Dielectric losses
It is caused by the absorption of electrical energy and by leakage of current through the material. Dielectric losses should be minimal for an ideal insulator.
4. Porosity
This increases the moisture-holding capacity and thus adversely affects
the electrical properties of an insulator. So dielectrics of high porosity are not used.
5. Thermal expansion and contraction
This should be least for a good insulator.
6. Resistance to external chemical effects
Insulators should be inert to chemical such as oils, solvents, acids and
alkalis.
7. Chemical alteration in the insulating material
In some materials, chemical alteration takes place during use. However such changes should not deteriorate their properties.
Classification of Insulators
Thermal Insulators
Sound Insulators
Electrical Insulators
Examples for different kinds of insulating materials
ELECTRICAL INSULATORS
The material which does not allow the electricity to pass through them is known as an electrical insulating material or dielectrics. A good insulating material should possess low dielectric constant.
Insulator | Remarks | Applications |
Simple Gases | ||
Air | Most important dielectric gas | It provides insulation b/w the overhead transmission lines |
Nitrogen | Chemically inert dielectric | It is used in transformers to replace the harmful oxidizing atmosphere. Under high pressure, it is also used as dielectric in certain capacitors. |
Insulator | Remarks | Applications |
Liquid insulating materials | ||
Mineral oils | Used in the temperature range of -50 to 1100C. The non-hydrocarbon cpds, Oxygen, Sulphur etc, are influenced the electrical properties and resist to thermal expansion. | In transformers, light fraction oil like transil oil is used to allow convecting cooling. |
Silicone fluids | Used in the temperature range of -90 to 2200C. They are stable at high temperatures, are non corrosive to metals up to 2000 C. | Used as coolants in radio pulse, aircraft and radio transformers. |
Insulator | Remarks | Applications |
Solid insulating materials | ||
Paper and press boards (low density) | Less dielectric loss and discharge current | Used in high frequency capacitors and cables. |
Butyl rubbers | Possess very good dielectric properties | Used for insulation of industrial flexible cables, domestic cables and wires. |
Thermal Insulators
The materials having extremely low thermal conductivities are known as thermal insulators.
Thermal properties of an insulator depend upon
1. Pores
2. Moisture in the pores
Characteristic of thermal Insulating Material
1. It should have low conductivity
2. It should be fire proof
3. It should be chemically stable
4. Its cost should be low
5. It is more stable physically and mechanically.
6. It should have low density.
Classification Of Thermal Insulating Material
1. Organic thermal Insulating Material
These materials possess very large number of fine pores scattered throughout them. These materials have low specific gravities and also naturally occurring.
Example: Wool------ 0.11 g/cm3
2. Inorganic thermal Insulating Material
These materials are preferred as high temperature insulating material.
Example: Asbestos ---- 1500 C
Sound Insulator
Soundproofing insulation is used in buildings and homes to reduce the amount of sound transmitted to other parts of the building. Mineral wool and fiberglass are the most common materials. It’s a relatively easy and cost-effective way to improve the soundproofing of a room.
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