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Basic Metals Notes PDF
Basic Metals Notes PDF
Chapter 11 - 1
Chapter 11 - 2
1
Taxonomy of Metals
Metal Alloys
Adapted from
Ferrous Nonferrous Fig. 11.1,
Callister 7e.
Steels
Steels Cast Irons
Cast Irons
Cu Al Mg Ti
<1.4 wt% C
<1.4wt%C 3-4.5 wt%C
3-4.5 wt% C
T(°C) microstructure:
1600 ferrite, graphite
d
cementite
1400 L
g+L
1200 g 1148°C L+Fe3C
austenite Eutectic:
1000 4.30
g+Fe3C
a+
Carbon steel
Chapter 11 - 4
2
Chapter 11 - 5
t11_01b_pg361
Chapter 11 - 6
3
AISI: the American Iron and Steel Institute
SAE: the Sociaty of Automotive and Engineering
ASTM: the American Society for Testing and
Materials
UNS: the Uniform Numbering System
Chapter 11 - 7
High alloys:
Chapter 11 - 8
4
Chapter 11 - 9
Chapter 11 - 10
5
Chapter 11 - 11
Chapter 11 - 12
6
Chapter 11 - 13
Chapter 11 - 14
7
Stainless steels
Chapter 11 - 15
Stainless steels
Chapter 11 - 16
8
Chapter 11 - 17
Chapter 11 - 18
9
Steels
Low Alloy High Alloy
low carbon Med carbon high carbon
<0.25 wt% C 0.25-0.6 wt% C 0.6-1.4 wt% C
heat austenitic
Name plain HSLA plain
plain tool
treatable stainless
Cr,V Cr, Ni Cr, V,
Additions none none none Cr, Ni, Mo
Ni, Mo Mo Mo, W
Example 1010 4310 1040 4340 1095 4190 304
Hardenability 0 + + ++ ++ +++ 0
TS - 0 + ++ + ++ 0
EL + + 0 - - -- ++
Uses auto bridges crank pistons wear drills high T
struc. towers shafts gears applic. saws applic.
sheet press. bolts wear dies turbines
vessels hammers applic. furnaces
blades V. corros.
resistant
increasing strength, cost, decreasing ductility
Based on data provided in Tables 11.1(b), 11.2(b), 11.3, and 11.4, Callister 7e. Chapter 11 - 19
Ferrous Alloys
Iron containing – Steels - cast irons
Chapter 11 - 20
10
Cast Iron
• Ferrous alloys with > 2.1 wt% C
– more commonly 3 - 4.5 wt%C
• low melting (also brittle) so easiest to cast
Chapter 11 - 21
600
Cast iron a + Graphite
1. Gray iron
400
2. Nodular (ductile) iron 0 1 2 3 4 90 100
(Fe) Co , wt% C
3. White iron
4. Malleable iron
5. Compacted graphite iron
Chapter 11 - 22
(CGI)
11
Types of Cast Iron
Gray iron
– 1 - 3 % Si, 2.5 – 4% C
– graphite flakes plus ferrite/pearlite
– brittleness due to the flake-like graphite
• weak & brittle under tension
• stronger under compression
• excellent vibrational dampening
• wear resistant
Chapter 11 - 23
Microstructure of pearlite in
the grey iron (Fe-3.3C-2.1Si-
0.5Cr-0.5Mo-1.0Cu). TEM.
Chapter 11 - 24
12
(a) steel; (b) grey cast iron
Chapter 11 - 25
Malleable iron
Chapter 11 - 26
13
Types of Cast Iron
Chapter 11 - 27
Chapter 11 - 28
14
Cast iron
Chapter 11 - 29
Chapter 11 - 30
15
Limitations of Ferrous Alloys
Chapter 11 - 31
Metal Fabrication
• How do we fabricate metals?
– Blacksmith - hammer (forged)
– Molding - cast
• Forming Operations
– Rough stock formed to final shape
Chapter 11 - 32
16
Metal Fabrication Methods - I
Chapter 11 - 34
17
Metal Fabrication Methods - II
Chapter 11 - 35
18
Metal Fabrication Methods - II
Sand Sand
molten metal
• Continuous Casting
• Investment Casting (simple slab shapes)
(low volume, complex shapes
molten
e.g., jewelry, turbine blades)
plaster solidified
die formed
around wax wax
prototype
Chapter 11 - 37
19
Thermal Processing of Metals
Annealing: Heat to Tanneal, then cool slowly.
• Stress Relief: Reduce • Spheroidize (steels):
stress caused by: Make very soft steels for
-plastic deformation good machining. Heat just
-nonuniform cooling below TE & hold for
-phase transform. 15-25 h.
Heat Treatments
800
Austenite (stable)
a) Annealing T(°C) TE
A
b) Quenching P
600
c) Tempered
Martensite
B
400 A
10
0%
Adapted from Fig. 10.22, Callister 7e. 50
0% %
0%
200 M+A
50%
M+A
90%
b) a)
10
-1
10 10
3
10
5 c)
time (s) Chapter 11 - 40
20
f11_10_pg389
Chapter 11 - 41
Chapter 11 - 42
21
Hardenability--Steels
• Ability to form martensite
• Jominy end quench test to measure hardenability.
Adapted from Fig. 11.11,
flat ground Callister 7e. (Fig. 11.11
specimen adapted from A.G. Guy,
Essentials of Materials
(heated to g Science, McGraw-Hill Book
phase field) Rockwell C Company, New York,
1978.)
24°C water hardness tests
60
40
0 M(finish)
ar P ite
M
M ens
lite ea +
ar
ar ite
t
t
rli Pe
te a
Chapter 11 - 44
22
Hardenability vs Alloy Composition
100 10 3 2 Cooling rate (°C/s)
• Jominy end quench
60
Hardness, HRC
results, C = 0.4 wt% C 100
(table 11.2a p363) 4340 80 %M
50
40 4140
10
40
(Fig. 11.14 adapted from figure furnished 5140
courtesy Republic Steel Corporation.) 20
0 10 20 30 40 50
Distance from quenched end (mm)
Chapter 11 - 46
23
Summary
Chapter 11 - 47
24