6 Steel

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Module 6
Steel and Iron: Production and Properties
Prof. Bondan T. Sofyan
Dept. Metallurgy and Materials Engineering University of Indonesia
Steel: Production and Properties

1. 2. 3. 4. Classification of Metals Steel Iron Steelmaking a. Indirect Reduction b. Direct Reduction
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Classification of Metal Alloys

Metal Alloys Ferrous Steel Cast Iron Non Ferrous
Low Alloy
High Alloy Grey Cast Iron Nodular Cast Iron Malleable Cast Iron White Cast Iron
Low Carbon Steel
Medium Carbon Steel
High Carbon Steel
Stainless Steel
Tool Steel
Steel and Iron

Iron and steel alloy is the most widely used metals in engineering application, because:
It is abundantly available in the earth crust. Economical: low processing and refining cost. Can be produced in a vast range of properties, to meet design requirement.
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Steel vs Iron
C<2% High pitch sound when hit Bounded C a or Fe3C lamella Tmelting > 1550OC High strength and ductility (200-500 MPa, 18-35 %) Malleable Long machinary chips Low yellowish spark C>2% Low pitch sound when hit Free C as graphite Tmelting 13001400 OC Low strength and ductility (150300 MPa) Not malleable Short machinary chips High red spark
Steel
Steel : material which consists of Fe as the base metal with C addition up to 2 %. Carbon is the most important alloying element in steel. Other alloying elements:
Impurities: Si, P, S, Mn cant be removed from steel. Alloying: Cr, Ni, Mo, etc intentionally added.
Prof. Bondan T. Sofyan Dept. Metallurgy and Materials Engineering University of Indonesia
10/1/2012
Classification of Metal Alloys

Metal Alloys Ferrous Steel Cast Iron Non Ferrous
Low Alloy
High Alloy Grey Cast Iron Nodular Cast Iron Malleable Cast Iron White Cast Iron
Low Carbon Steel
Medium Carbon Steel
High Carbon Steel
Stainless Steel
Tool Steel
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Low Carbon Steel

C 0,25 %. Microstructure consists of ferrite and pearlite soft, ductile and relatively tough. Not responsive to heat treatment. Application: automobile body, pipe, sheet, etc.
Low Carbon Steel
Symbol
ASTM ASTM A366-72 ASTM A619-82 ASTM A620-82
Class
Si
Mn 0.50 max 0.45 max 0.40 max
P 0.040 max 0.035 max 0.030 max
S 0.045 max 0.035 max 0.030 max
UTS 270 min 270 min 270 min
0.2% 32 min
HRB 60 max 50
SPCC
CR-CQ
0.12 max
SPCD
CR-DQ CRDQSK
0.10 max
34 min
SPCE
0.08 max
36 min
50
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Low Carbon Steel

Posco Steel
Steel with the same composition, may have different microstructures and different properties.
Nippon Steel
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Medium Carbon Steel

C: 0.25 0.6 % Lower ductility, higher strength and toughness compared to low carbon steel. Responsive to heat treatment. Application: gears, railways, cranckshaft, etc.
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High Carbon Steel

C: 0.6 1.2 wt. % High strength, high hardness and low ductility is heat treated (hardening + temper) to increase toughness while keeping the high strength. Microstructure: pearlite + cementite (Fe3C). Application: tool steel, die, cutting blade.
SKD 11 = D2 Composition: 1.4-1.6 C; 0.6 Mn max; 0.6 Si max; 11.00-13.00 Cr; 0.3 Ni max; 1.10 V max; 0.7 1.2 Mo High C, high Cr, V, Mo. Hardness 54-61 HRC. Coeff. Thermal expansion: 10.4 12.2 mm/mK Depth hardening: deep Air-hardening alloy tool steel, high wear resistance, high surface hardness, good dimensional stability
Tool Steel
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Cast Iron
Cast iron is Fe with C > 2,14 %, with the microstructure that consists of free carbon as graphite in pearlitic, ferritic, austenitic, martensitic or bainitic matrix. Other elements: Si, Mn, P and S (trace elements) Alloying elements: Cr, Mo, Cu, Sn, etc to improve particular properties.
Types of Cast Iron
1. Grey Cast Iron (FC) 2. White Cast Iron 3. Malleable Cast Iron 4. Ductile Cast Iron (FCD) 5. Austempered Ductile Iron (ADI) Matrix: Ferritic, pearlitic, austenitic, martensitic, bainitic (austempered).
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Graphite Morphology
a) Flakes b) Spheroidal c) Mallaeble
Besi Tuang Kelabu (Grey Cast Iron)

(FC/Grey Cast Iron) Grafit flakes/serpihan (dua dimensi) Eutektik sell berbentuk KOL (tiga dimensi) max = 10 - 30 kg/mm2 < 1,0% Mikrostruktur :matriks ferrite dan flake grafit
Struktur mikro FC
Eutektik Cell Besi FC

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Bentuk Grafit Pada Grey Cast Iron

Type B Type A
Type D Type C
Type E
Sifat Grey Cast Iron

Mekanik:
Elongasi (%) Kekerasan Kekuatan bentur Mampu mesin 0.3 1.2 130 270 brinell Getas dan lemah Sangat baik
Fisik dan Kimia:

Berat jenis: Temperatur kamar Cair Pemuaian panas 7.1 7.3 6.75 6.95 10 x 106/0C
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Besi Tuang Nodular (FCD) 1948

Mg : 0,040 0,080 % menyebabkan grafit berubah menjadi bulat S < 0,010 %, diatas nilai ini akan bereaksi dulu dengan Mg, kemudian baru berfungsi sebagai noduliser.
Penemu : Henton Morrogh, BCIRA, Inggris dan Team INCO USA s = 45 - 55 kg/mm 2 e = 3 20 % Tergantung : 1. Nodularity grafit 2. Jumlah nodul/mm2 3. Komposisi Matriks (ferrite/pearlite) 4. Adanya paduan (Cu, Ni, Mo, dll.)
Austempered Ductile Iron (ADI)

Besi Cor Austemper (FCA) 1970an Besi cor grafit bulat dengan matriks ausferit (ferit + austenit). ferit berbentuk jarum kekuatan a u s t e n i t keuletan mencapai > 100kg/mm2 : ferit jarum = 4 7 % : austenit Aplikasi : pengganti komponen baja cor/tempa
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Besi Tuang Mallable (Mampu Tempa)

Grafit berbentuk kapas / aggregat. Hasil temper besi cor putih (waktu lama = 50 jam) Fe3C 3 Fe + C grafit pada 950 oC Temper grafit hasil cor (merubah struktur Fe3C = temper grafit) Kadar Si rendah, cegah timbul grafit UTS : 40 47 Kg/mm2 Yield : 28 30 Kg/mm2 Regangan : 15 20 % Kekerasan : 135 155 HB
Sifat Mekanik Berbagai Besi Tuang

UTS (Kg/mm2) Grey Cast Iron(FC) Mallable Cast Iron Nodular Cast Iron (FCD) Austempered Ductile Iron (ADI) Vermicular Cast Iron
Elongasi (%) <1 15 20 3 20 47 2-5

10 35 40 47 45 55 > 100 30 - 40
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Ref: kawasakisteel.org
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EAF & LADLE FURNACE
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RH DEGASSING - CONCAST
Reheating Furnace & Sizing Press

5) Sizing
Press
7)
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Hot Rolling Facilities
Cold Roll Facilities
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10/1/2012

Steel and Iron: Production and Properties

Prof. Bondan T. Sofyan

Dept. Metallurgy and Materials Engineering University of Indonesia

Steel: Production and Properties

Prof. Bondan T. Sofyan

Dept. Metallurgy and Materials Engineering University of Indonesia

Classification of Metal Alloys

Low Carbon Steel

Medium Carbon Steel

High Carbon Steel

Prof. Bondan T. Sofyan

Dept. Metallurgy and Materials Engineering University of Indonesia

Steel and Iron

Prof. Bondan T. Sofyan

Dept. Metallurgy and Materials Engineering University of Indonesia

Prof. Bondan T. Sofyan

Dept. Metallurgy and Materials Engineering University of Indonesia

Prof. Bondan T. Sofyan

Dept. Metallurgy and Materials Engineering University of Indonesia

Classification of Metal Alloys

Low Carbon Steel

Medium Carbon Steel

High Carbon Steel

Prof. Bondan T. Sofyan

Dept. Metallurgy and Materials Engineering University of Indonesia

Low Carbon Steel

Prof. Bondan T. Sofyan

Dept. Metallurgy and Materials Engineering University of Indonesia

Low Carbon Steel

ASTM ASTM A366-72 ASTM A619-82 ASTM A620-82

Mn 0.50 max 0.45 max 0.40 max

P 0.040 max 0.035 max 0.030 max

S 0.045 max 0.035 max 0.030 max

UTS 270 min 270 min 270 min

Prof. Bondan T. Sofyan

Dept. Metallurgy and Materials Engineering University of Indonesia

Prof. Bondan T. Sofyan

Dept. Metallurgy and Materials Engineering University of Indonesia

Low Carbon Steel

Prof. Bondan T. Sofyan

Dept. Metallurgy and Materials Engineering University of Indonesia

Medium Carbon Steel

Prof. Bondan T. Sofyan

Dept. Metallurgy and Materials Engineering University of Indonesia

High Carbon Steel

Prof. Bondan T. Sofyan

Dept. Metallurgy and Materials Engineering University of Indonesia

Prof. Bondan T. Sofyan

Dept. Metallurgy and Materials Engineering University of Indonesia

Prof. Bondan T. Sofyan

Dept. Metallurgy and Materials Engineering University of Indonesia

Types of Cast Iron

Prof. Bondan T. Sofyan

Dept. Metallurgy and Materials Engineering University of Indonesia

Besi Tuang Kelabu (Grey Cast Iron)

Eutektik Cell Besi FC

Bentuk Grafit Pada Grey Cast Iron

Prof. Bondan T. Sofyan

Dept. Metallurgy and Materials Engineering University of Indonesia

Sifat Grey Cast Iron

Fisik dan Kimia:

Prof. Bondan T. Sofyan

Dept. Metallurgy and Materials Engineering University of Indonesia