Metal & Alloys: D. Navaja MSE101

METAL & ALLOYS

Part 2
D. Navaja
MSE101

1
TAXONOMY OF METALS

Adapted from
Fig. 11.1,
Callister 6e.
Adapted from Fig. 9.21,Callister 6e.

(Fig. 9.21 adapted from Binary Alloy
Phase Diagrams, 2nd ed.,
Vol. 1, T.B. Massalski (Ed.-in-Chief),
ASM International, Materials Park,
OH, 1990.)
D. Navaja MSE101 2
2
STEELS
D. Navaja MSE101 3
Based on data provided in Tables 11.1(b), 11.2(b), 11.3, and 11.4, Callister 6e. 3
Coke
Iron Ore Limestone
BLAST FURNACE
heat generation
gas C+O2 CO2
refractory
vessel reduction of iron ore to metal
layers of coke CO2 + C  2CO
and iron ore 3CO + Fe2O3 2Fe+3CO2
air purification
slag
Molten iron CaCO3  CaO+CO2
CaO + SiO2 + Al2O3  slag
Refinement of Steel from Ore

4
Iron containing – Steels - cast irons
Nomenclature AISI & SAE

10xx Plain Carbon Steels
11xx Plain Carbon Steels (resulfurized for machinability)
15xx Mn (10 ~ 20%)
40xx Mo (0.20 ~ 0.30%)
43xx Ni (1.65 - 2.00%), Cr (0.4 - 0.90%), Mo (0.2 - 0.3%)
44xx Mo (0.5%)
where xx is wt% C x 100

example: 1060 steel – plain carbon steel with 0.60 wt% C
Stainless Steel -- >11% Cr
Ferrous Alloys D. Navaja MSE101 5

1) Relatively high density
2) Relatively low conductivity
3) Poor corrosion resistance
Limitations of Ferrous Alloys

D. Navaja MSE101 6
d Liquid
g+ L
L + Fe3C
Austenite
Carbon
Cast Iron
910˚C Steel g + Fe3C
a+g
723˚C
a a + Fe3C
0% 1.4% ~1.7% ~3% ~4.5%

7
Iron-Carbon Phase diagram D. Navaja MSE101

 Iron with 1.7 to 4.5% carbon and 0.5 to 3%
silicon
 Lower melting point and more fluid than steel
(easiest to cast)
 Low cost material usually produced by sand
casting
 A wide range of properties, depending on
composition & cooling rate
◦ Strength
◦ Hardness
◦ Ductility
◦ Thermal conductivity
◦ Damping capacity
Cast Iron D. Navaja MSE101 8

Adapted from Fig.11.5,
Callister 7e.
Production of Cast Iron D. Navaja MSE101 9

 Slow cooling favours the formation of graphite &
low hardness
 Rapid cooling promotes carbides with high
hardness
 Thick sections cool slowly, while thin sections
cool quickly
 Sand moulds cool slowly, but metal chills can be
used to increase cooling rate & promote white
iron
Effect of cooling rate

10 D. Navaja MSE101
Type Structure Property Microstructure
Grey Cast Iron • Carbon as graphite – • Low ductility
flakes • Good machinability
• Produced by slow • Damping capacity
cooling. high
• High Si or carbon • Thermal conductivity
high
Ductile Cast Iron • Nodular, Spheroidal • better ductility than

graphite grey cast iron
• Addition of Ce and • Strength higher
Mg than grey cast iron
• Low cost
Malleable Cast Iron • Graphite nodules are • better ductility than
irregular clusters grey cast iron
• Produced by heat • Strength higher
treatment of white than grey cast iron
cast iron • Good shock
resistance
White Cast Iron • No graphite, • Abrasion resistant
because carbon • lack of impact
forms Fe3C or more resistance
complex carbides • Hard and brittle
Types of cast iron 11 D. Navaja MSE101

D. Navaja MSE101 12
 Automotive parts
◦ Engine blocks
 Furnace parts
 Pipe fittings
Applications of Ductile Cast Iron

13 D. Navaja MSE101
 Automotive industry 55% of ductile iron in
USA
◦ Crankshafts, steering knuckles, disc brake
callipers
 Pipe and pipe fittings (joined by welding)
Applications of Ductile Cast Iron

14 D. Navaja MSE101
 Similar applications to ductile iron
 Malleable iron is better for thinner castings
 Ductile iron better for thicker castings >40mm
 Vehicle components
◦ Power trains, frames, suspensions and wheels
◦ Steering components, transmission and differential parts,
connecting rods
 Railway components
 Pipe fittings AS3673
Applications of Malleable Iron

15 D. Navaja MSE101
 Stair cases
 Tools and Utensils
Application of White Cast iron

D. Navaja MSE101 16
 White cast iron - not weldable
◦ Small attachments only
 Grey cast iron - low weldability
◦ Welding largely restricted to salvage and repair
 Ductile and malleable irons - good
weldability (inferior to structural steel)
◦ Welding increasingly used during manufacture
Weldability
17 D. Navaja MSE101
 Promote graphite (Si, Ni)
 Promote carbides (Cr)
 Affect matrix microstructure
◦ Ferrite, pearlite, martensite or austenite
 Corrosion resistance (Cr)
Effects of alloy elements

18 D. Navaja MSE101
 12 to 28% chromium
 Less effect on hardenability than in steels
 Mo, Ni, Mn, and Cu also added for
hardenability to give martensite
High chromium irons

19 D. Navaja MSE101
• Cu Alloys • Al Alloys
Brass: Zn is subst. impurity -lower r: 2.7g/cm3
(costume jewelry, coins, -Cu, Mg, Si, Mn, Zn additions
corrosion resistant) -solid sol. or precip.
Bronze : Sn, Al, Si, Ni are strengthened (struct.
subst. impurity aircraft parts
(bushings, landing & packaging)
gear) NonFerrous • Mg Alloys
Cu-Be: -very low r: 1.7g/cm3
precip. hardened Alloys -ignites easily
for strength -aircraft, missiles
• Ti Alloys
-lower r: 4.5g/cm3 • Refractory metals
-high melting T
vs 7.9 for steel • Noble metals -Nb, Mo, W, Ta
-reactive at high T -Ag, Au, Pt
-space applic. -oxid./corr. resistant
Nonferrous Alloys D. Navaja MSE101 20

Based on discussion and data provided in Section 11.3, Callister 7e.
 Duralumin is a strong, lightweight alloy of
aluminium that is comprised of approx.
4% copper and small amounts of
manganese, magnesium and silicon.
 This alloy is widely used in aircraft
construction because of its strength and
light weight.
Adv. Materials: Duralumin D. Navaja MSE101 21

• Ferrous alloys (steels and cast irons) are those in which iron is the prime
constituent.
• Most steels contain less than 1.0 wt% C, and, in addition, other alloying
elements, which render them susceptible to heat treatment (and an
enhancement of mechanical properties) and/or more corrosion resistant.
• Ferrous alloys are used extensively as engineering materials because:
• Iron-bearing compounds are abundant.
• Economical extraction, refining, and fabrication techniques are
available.
• They may be tailored to have a wide variety of mechanical and
physical properties.
• Limitations of ferrous alloys include the following:
• Relatively high densities
• Comparatively low electrical conductivities
• Susceptibility to corrosion in common environments
SUMMARY
D. Navaja MSE101 22
20
• The most common types of steels are plain low-carbon, high-strength low-
alloy, medium-carbon, tool, and stainless.
• Plain carbon steels contain (in addition to carbon) a little manganese and
only residual concentrations of other impurities.
• Stainless steels are classified according to the main microstructural
constituent.
• The three classes are ferritic, austenitic, and martensitic.
• Cast irons contain higher carbon contents than steels—normally between
3.0 and 4.5 wt% C—as well as other alloying elements, notably silicon.
• For these materials, most of the carbon exists in graphite form rather than
combined with iron as cementite.
• Gray, ductile (or nodular), malleable, and compacted graphite irons are the
four most widely used cast irons; the latter three are reasonably ductile.
SUMMARY
D. Navaja MSE101 23
Gray iron
 graphite flakes
 weak & brittle under tension
 stronger under compression
 excellent vibrational
dampening
 wear resistant
Ductile iron
 add Mg or Ce
 graphite in nodules not
flakes
 matrix often pearlite - better
ductility
D. Navaja MSE101 24
White iron
 <1wt% Si so harder but
brittle
 more cementite
Malleable iron
 heat treat at 800-900ºC
 graphite in rosettes
 more ductile
D. Navaja MSE101 25
Nonferrous Alloys
 All other alloys fall within the nonferrous category, which is further
subdivided according to base metal or some distinctive characteristic that
is shared by a group of alloys.
 Nonferrous alloys may be further subclassified as either wrought or cast.
 Alloys that are amenable to forming by deformation are classified as
wrought.
 Cast alloys are relatively brittle, and therefore fabrication by casting is
most expedient.
 Seven classifications of nonferrous alloys were discussed—copper,
aluminum, magnesium, titanium, the refractory metals, the superalloys,
and the noble metals, as well as miscellaneous (nickel, lead, tin, zinc, and
zirconium).
SUMMARY
D. Navaja MSE101 26
QUESTIONS?
Next Topic: Metal Heat Treatment

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METAL & ALLOYS

Adapted from Fig. 9.21,Callister 6e.

Refinement of Steel from Ore

Nomenclature AISI & SAE

where xx is wt% C x 100

Stainless Steel -- >11% Cr

Ferrous Alloys D. Navaja MSE101 5

Limitations of Ferrous Alloys

0% 1.4% ~1.7% ~3% ~4.5%

Iron-Carbon Phase diagram D. Navaja MSE101

Cast Iron D. Navaja MSE101 8

Production of Cast Iron D. Navaja MSE101 9

Effect of cooling rate

Ductile Cast Iron • Nodular, Spheroidal • better ductility than

Types of cast iron 11 D. Navaja MSE101

Applications of Ductile Cast Iron

Applications of Ductile Cast Iron

Applications of Malleable Iron

Application of White Cast iron

Effects of alloy elements

High chromium irons

Nonferrous Alloys D. Navaja MSE101 20

Adv. Materials: Duralumin D. Navaja MSE101 21

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