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Chapter 11: Applications and Processing of Metal Alloys
Chapter 11: Applications and Processing of Metal Alloys
ISSUES TO ADDRESS...
• How are metal alloys classified and what are their
common applications?
• What are some of the common fabrication techniques
for metals?
• What heat treatment procedures are used to improve the
mechanical properties of both ferrous and nonferrous alloys?
Chapter 11 - 1
_____
Steels _________
_________
<1.4wt%C __________
3-4.5 wt%C
γ + Fe3C
α+
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
Name plain HSLA plain plain tool stainless
treatable
Cr,V Cr, Ni Cr, V,
Additions none none none Cr, Ni, Mo
Ni, Mo Mo Mo, W
Example 1010 4310 1040 43 40 1095 4190 304, 409
Hardenability 0 + + ++ ++ +++ varies
TS - 0 + ++ + ++ varies
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 Very corros.
resistant
increasing strength, cost, decreasing ductility
Based on data provided in Tables 11.1(b), 11.3, and 11.4, Callister & Rethwisch 10e.
Chapter 11 - 3
1
Chapter 11: Applications and Processing of Metal Alloys
BLAST FURNACE
heat generation
gas C + O2 →CO2
refractory
vessel reduction of iron ore to metal
layers of _____ CO2 + C → 2CO
and _________ _______________________
air purification
slag
Molten iron CaCO3 → CaO+CO2
CaO + SiO2 + Al2O3 → slag
Chapter 11 - 4
Ferrous Alloys
Iron-based alloys
• Steels
• Cast Irons
Chapter 11 - 5
Cast Irons
• Ferrous alloys with > ____________more
commonly
__________________________Low melting
– relatively easy to cast
• Generally brittle
Chapter 11 - 6
2
Chapter 11: Applications and Processing of Metal Alloys
600
Fig. 11.2, Callister & Rethwisch 10e.
α + Graphite
[Adapted from Binary Alloy Phase Diagrams,
T. B. Massalski (Editor-in-Chief), 1990.
400
Reprinted by permission of ASM International, 0 1 2 3 4 90 100
Materials Park, OH.] (Fe) C, wt% C
Chapter 11 - 7
_______ iron
• add Mg and/or Ce
• graphite as ________ not flakes
• matrix often pearlite – stronger
but less ductile
Chapter 11 - 8
Callister &
White iron Rethwisch 10e.
• < 1 wt% Si
• pearlite + _________
• very hard and ________
__________ iron
Iron Castings Society, Des Plaines, IL
Reprinted with permission of the
Chapter 11 - 9
3
Chapter 11: Applications and Processing of Metal Alloys
Chapter 11 - 10
Chapter 11 - 11
Chapter 11 - 12
4
Chapter 11: Applications and Processing of Metal Alloys
Nonferrous Alloys
• Cu Alloys • Al Alloys
Brass: Zn is subst. impurity -low ρ: 2.7 g/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. impurities aircraft parts
(bushings, landing & packaging)
gear) NonFerrous • Mg Alloys
Cu-Be : -very low ρ: 1.7 g/cm3
precip. hardened Alloys -ignites easily
for strength -aircraft, missiles
• Ti Alloys
-relatively low ρ: 4.5 g/cm3 • Refractory metals
-high melting T’s
vs 7.9 for steel • Noble metals -Nb, Mo, W, Ta
-reactive at high T’s -Ag, Au, Pt
-space applic. -oxid./corr. resistant
Based on discussion and data provided in Section 11.3, Callister & Rethwisch 10e.
Chapter 11 - 13
Metal Fabrication
• How do we fabricate metals?
– ___________ - hammer (forged)
– Cast molten metal into mold
• ____________________
– Rough stock formed to final shape
Chapter 11 - 14
5
Chapter 11: Applications and Processing of Metal Alloys
Chapter 11 - 16
Chapter 11 - 17
Chapter 11 - 18
6
Chapter 11: Applications and Processing of Metal Alloys
molten
solidified
Chapter 11 - 19
7
Chapter 11: Applications and Processing of Metal Alloys
a) _____________ A
b) __________ P
c) ___
Tempering
(Tempered
Martensite) A
B
10
0%
50
0% %
Hardenability -- Steels
• ___________ – measure of the ability to form martensite
• Jominy end quench test used to measure _____________.
Fig. 11.15, Callister &
flat ground Rethwisch 10e.
specimen (Adapted from A.G. Guy,
Essentials of Materials Science,
(heated to γ McGraw-Hill Book Company,
New York, 1978.)
phase field) Rockwell C
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 ar
Chapter 11 - 24
8
Chapter 11: Applications and Processing of Metal Alloys
Hardness, HRC
five alloys each with, 100
80 %M
C = _____________ 4340
50
40 4140
10
(Adapted from figure furnished courtesy
40
Republic Steel Corporation.) 5140
20
0 10 20 30 40 50
Distance from quenched end (mm)
Chapter 11 - 26
Precipitation Hardening
• Particles impede _________ motion.
• Ex: Al-Cu system 700
T(ºC) L CuAl2
• Procedure: 600
-- Pt A: _______________
α+L θ+L α
A
(get α solid solution) 500 θ
-- Pt B: _______ to room temp. α + θ
400 C
(retain α solid solution)
-- Pt C: _______ to nucleate 300
small θ _________ within (Al) 0 B 10 20 30 40 50 wt% Cu
α phase. composition range
available for precipitation hardening
• Other alloys that precipitation
Fig. 11.29, Callister & Rethwisch 10e.
harden: Temp. (Adapted from J.L. Murray, International
Metals Review 30, p.5, 1985. Reprinted by
• Cu-Be Pt A (sol’n heat treat) permission of ASM International.)
• Cu-Sn
• Mg-Al Pt C (precipitate θ)
9
Chapter 11: Applications and Processing of Metal Alloys
p re n y s
ge
io
so il.
it
rag ate ge
lut
u
ed s
so n-eq
ma
“o reci r lar
30
tensile strength (MPa)
%EL (2 in sample)
”
lid
p we
ve pit
no
400
fe
20
300
149ºC 10
200 204ºC 149ºC
204ºC
100 0
1min 1h 1day 1mo 1yr 1min 1h 1day 1mo 1yr
precipitation heat treat time precipitation heat treat time
Fig. 11.32, Callister & Rethwisch 10e. [Adapted from Metals Handbook: Properties and Selection: Nonferrous
Alloys and Pure Metals, Vol. 2, 9th ed., H. Baker (Managing Ed.), 1979. Reproduced by permission of ASM International,
Materials Park, OH.] Chapter 11 - 28
Summary
Chapter 11 - 29
10