CHAPTER 5

Ferrous Metals and Alloys: Production, General Properties, and Applications

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Blast Furnace
Figure 5.1 Schematic illustration of a blast furnace. Source: Courtesy of American Iron and Steel Institute.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Electric Furnaces

Figure 5.2 Schematic illustration of types of electric furnaces: (a) direct arc, (b) indirect arc, and (c) induction.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Basic-Oxygen Process
Figure 5.3 Schematic illustrations showing (a) charging, (b) melting, and (c) pouring of molten iron in a basic-oxygen process. Source: Inland Steel Company

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Continuous Casting

Figure 5.4 The continuous-casting process for steel. Typically, the solidified metal descends at a speed of 25 mm/s (1 in./s). Note that the platform is about 20 m (65 ft) above ground level. Source: Metalcaster's Reference and Guide, American Foundrymen's Society.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Typical Selection of Carbon and Alloy Steels for Various Applications

TABLE 5.1 Product
Aircraft forgings, tubing, fittings Automobile bodies Axles Ball bearings and races Bolts Camshafts Chains (transmission) Coil springs Connecting rods Crankshafts (forged)

Steel
4140, 8740 1010 1040, 4140 52100 1035, 4042, 4815 1020, 1040 3135, 3140 4063 1040, 3141, 4340 1045, 1145, 3135, 3140

Product
Differential gears Gears (car and truck) Landing gear Lock washers Nuts Railroad rails and wheels Springs (coil) Springs (leaf) Tubing Wire Wire (music)

Steel
4023 4027, 4140, 1060 3130 1080 1095, 1085, 1040 1045, 1085 4032 4340, 8740

4063, 6150 4063, 9260, 6150 1055

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Mechanical Properties of Selected Carbon and Alloy Steels in Various Conditions

TABLE 5.2 Typical Mechanical Properties of Selected Carbon and Alloy Steels in the Hot-Rolled, Normalized, and Annealed Condition
AISI Condition Ultimate tensile strength (MPa) 448 441 393 1010 965 615 891 689 1279 744 632 536 Yield Strength (MPa) 346 330 294 586 524 375 599 422 861 472 385 357 Elongation in 50 mm (%) Reduction of area (%) Hardness (HB)

1020

1080

3140 4340 8620

As-rolled Normalized Annealed As-rolled Normalized Annealed Normalized Annealed Normalized Annealed Normalized Annealed

36 35 36 12 11 24 19 24 12 22 26 31

59 67 66 17 20 45 57 50 36 49 59 62

143 131 111 293 293 174 262 197 363 217 183 149

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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AISI Designation for High-Strength Sheet Steel

TABLE 5.3 Yield Strength psi x 10 35 40 45 50 60 70 80 100 120 140
3

Chemical Composition S = structural alloy

Deoxidation Practice F = killed plus sulfide inclusion control

MPa 240 275 310 350 415 485 550 690 830 970

X = low alloy K = killed W = weathering O = nonkilled D = dual phase

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Room-Temperature Mechanical Properties and Applications of Annealed Stainless Steels

TABLE 5.4 Room-Temperature Mechanical Properties and Typical Applications of Selected Annealed Stainless Steels Ultimate tensile Yield Elongation AISI strength strength in 50 mm (UNS) (MPa) (MPa) (%) Characteristics and typical applications 303 550620 240260 5350 Screw machine products, shafts, valves, bolts, (S30300) bushings, and nuts; aircraft fittings; bolts; nuts; rivets; screws; studs. 304 (S30400) 316 (S31600) 565620 240290 6055 Chemical and food processing equipment, brewing equipment, cryogenic vessels, gutters, downspouts, and flashings. High corrosion resistance and high creep strength. Chemical and pulp handling equipment, photographic equipment, brandy vats, fertilizer parts, ketchup cooking kettles, and yeast tubs. Machine parts, pump shafts, bolts, bushings, coal chutes, cutlery, tackle, hardware, jet engine parts, mining machinery, rifle barrels, screws, and valves. Aircraft fittings, bolts, nuts, fire extinguisher inserts, rivets, and screws.

550590

210290

6055

410 (S41000)

480520

240310

3525

416 (S41600)

480520

275

3020

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Basic Types of Tool and Die Steels

TABLE 5.5 Type High speed Hot work AISI M (molybdenum base) T (tungsten base) H1 to H19 (chromium base) H20 to H39 (tungsten base) H40 to H59 (molybdenum base) D (high carbon, high chromium) A (medium alloy, air hardening) O (oil hardening) S P1 to P19 (low carbon) P20 to P39 (others) L (low alloy) F (carbon-tungsten) W

Cold work Shock resisting Mold steels Special purpose Water hardening

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Processing and Service Characteristics of Common Tool and Die Steels

TABLE 5.6 Processing and Service Characteristics of Common Tool and Die Steels
AISI designation M2 T1 T5 H11, 12, 13 A2 A9 D2 D3 H21 H26 P20 P21 W1, W2 Resistance to decarburization Medium High Low Medium Medium Medium Medium Medium Medium Medium High High Highest Resistance to cracking Medium High Medium Highest Highest Highest Highest High High High High Highest Medium Approximate hardness (HRC) 6065 6065 6065 3855 5762 3556 5461 5461 3654 4358 2837 3040 5064 Machinability Medium Medium Medium Medium to high Medium Medium Low Low Medium Medium Medium to high Medium Highest Toughness Low Low Low Very high Medium High Low Low High Medium High Medium High Resistance to softening Very high Very high Highest High High High High High High Very high Low Medium Low Resistance to wear Very high Very high Very high Medium High Medium to high High to very high Very high Medium to high High Low to medium Medium Low to medium

Source: Adapted from Tool Steels, American Iron and Steel Institute, 1978.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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