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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

Classification of Metal Alloys

Metal Alloys

Adapted from Fig.

Ferrous Nonferrous 11.1, Callister &
Rethwisch 8e.

Steels
Steels Cast Irons
Cast Irons
<1.4 wt% C
<1.4wt%C 3-4.5
3-4.5 wt%C
wt% C

T(ºC) microstructure: ferrite,

1600 graphite/cementite

1400 L
+L Adapted from Fig. 9.24, Callister &
1200  1148ºC L+Fe3C Rethwisch 8e. (Fig. 9.24 adapted from
austenite Binary Alloy Phase Diagrams, 2nd ed.,
Eutectic: Vol. 1, T.B. Massalski (Ed.-in-Chief),
1000 4.30
ASM International, Materials Park, OH,
+Fe3C 1990.)
800 727ºC Fe3C
ferrite Eutectoid: cementite
600 0.76 +Fe3C
400
0 1 2 3 4 5 6 6.7
(Fe)
Co , wt% C Chapter 11 - 2

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Steels
Low Alloy High Alloy
low carbon Med carbon high carbon
<0.25 wt% C 0.25-0.6wt% C 0.6-1.4wt% 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 4340 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), 11.2(b), 11.3, and 11.4, Callister & Rethwisch 8e. Chapter 11 - 3

Refinement of Steel from Ore

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

Chapter 11 - 4

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Ferrous Alloys
Iron-based alloys
• Steels
• Cast Irons

Nomenclature for steels (AISI/SAE)

10xx Plain Carbon Steels
11xx Plain Carbon Steels (resulfurized for machinability)
15xx Mn (1.00 - 1.65%)
40xx Mo (0.20 ~ 0.30%)
43xx Ni (1.65 - 2.00%), Cr (0.40 - 0.90%), Mo (0.20 - 0.30%)
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
Chapter 11 - 5

Cast Irons
• Ferrous alloys with > 2.1 wt% C
– more commonly 3 - 4.5 wt% C
• Low melting – relatively easy to cast
• Generally brittle

• Cementite decomposes to ferrite + graphite

Fe3C  3 Fe () + C (graphite)

– generally a slow process

Chapter 11 - 6

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Fe-C True Equilibrium Diagram

T(ºC)
1600
Graphite formation
1400 L Liquid +
promoted by
 +L Graphite
• Si > 1 wt% 1200  1153ºC
Austenite 4.2 wt% C
• slow cooling
1000
  + Graphite
800
740ºC

0.65
600
Adapted from Fig. 11.2,
 + Graphite
Callister & Rethwisch 8e. 400
[Fig. 11.2 adapted from 0 1 2 3 4 90 100
Binary Alloy Phase (Fe) C, wt% C
Diagrams, 2nd ed.,
Vol. 1, T.B. Massalski (Ed.-
in-Chief), ASM International,
Materials Park, OH, 1990.]
Chapter 11 - 7

Types of Cast Iron

Adapted from Fig.
11.3(a) & (b),
Gray iron Callister &
Rethwisch 8e.
• graphite flakes
• weak & brittle in tension
• stronger in compression
• excellent vibrational dampening
• wear resistant

Ductile iron
• add Mg and/or Ce
• graphite as nodules not flakes
• matrix often pearlite – stronger
but less ductile
Chapter 11 - 8

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Types of Cast Iron (cont.)

Adapted from Fig.
11.3(c) & (d),
White iron Callister &
Rethwisch 8e.
• < 1 wt% Si
• pearlite + cementite
• very hard and brittle

Malleable iron
• heat treat white iron at 800-900ºC
• graphite in rosettes
• reasonably strong and ductile

Chapter 11 - 9

Types of Cast Iron (cont.)

Compacted graphite iron
• relatively high thermal conductivity
• good resistance to thermal shock
• lower oxidation at elevated
temperatures

Adapted from Fig. 11.3(e),

Callister & Rethwisch 8e.

Chapter 11 - 10

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Production of Cast Irons

Adapted from Fig.11.5,

Callister & Rethwisch 8e.

Chapter 11 - 11

Limitations of Ferrous Alloys

1) Relatively high densities

2) Relatively low electrical conductivities
3) Generally poor corrosion resistance

Chapter 11 - 12