Prof.

Anwar Kandil
Suez Canal University
Port Said

Materials Used in
Mechanical Design
 Prof. Anwar Kandil
Suez Canal University
Port Said

Materials Used in Mechanical Design

This chapter presents a brief review of some
basic metallurgical concepts and a short
summary of engineering material properties
to serve as background for what follows.
However, this chapter focuses on the use of
the material property data in design
decisions rather than the metallurgy of the
materials.
 Prof. Anwar Kandil
Suez Canal University
Port Said

Material Types
The material can be generally
classified into:

Ductile materials (such as mild steel)

Brittle Materials (such as cast iron)
 Prof. Anwar Kandil
Suez Canal University
Port Said

Tensile Test

Low-carbon steel Annealed high-carbon steel

 Prof. Anwar Kandil
Suez Canal University
Port Said

Stress and Strain

Stress (σ) Strain (ε)
is defined as load per unit is the change in length per unit
area (or unit load) and for the length and calculated from
tensile specimen is calculated
from
F ε=
(l − lo )
σ= lo
Ao
The stress units are psi The strain is unit-less, being
(pound per square inch) or Pa length divided by length.
(pascal).
 Prof. Anwar Kandil

Yield Strength Suez Canal University

Port Said

The yield strength (σy) is the stress on the stress-

strain curve where the test specimen experiences
a relatively large increase in deformation with
little or no increase in load
 Prof. Anwar Kandil

Proportional Limit Suez Canal University

Port Said

The proportional limit (σpl) is the stress at or

above which the stress is no longer proportional
to the strain.
Before the proportional limit, Hook’s law applies
(the stress is proportional to strain)
 Elastic Limit Prof. Anwar Kandil
Suez Canal University
Port Said

The elastic limit (σel) is the stress at or above

which the material will take a permanent set, or
plastic deformation.
The elastic limit marks the boundary between the
elastic behavior and plastic behavior regions of
the material.

٨
 Prof. Anwar Kandil
Suez Canal University
Ultimate Tensile Strength Port Said

The ultimate tensile strength (σu) is the largest tensile

stress the material can be sustain before breaking
 Prof. Anwar Kandil

Modulus of Elasticity Suez Canal University

Port Said

The modulus of Elasticity (E) is defined as the

slope of the stress-strain curve up to the
proportional limit, and is called also Young’s
modulus
 Prof. Anwar Kandil
Suez Canal University
Ductility Port Said

Ductility is the degree to which a material will

deform before ultimate fracture.
Ductility is measured by percent elongation (δ)

L f − Lo
(δ ) = .100%
Lo
 Prof. Anwar Kandil
Suez Canal University

Brittleness Port Said

Brittle materials do not

exhibit a clear yield point
 Prof. Anwar Kandil
Suez Canal University
Port Said

Compression Test

Ductile material Brittle material Stress-strain curve for

(Mild Steel) (Cast iron) brittle materials for
tension and compression
 Prof. Anwar Kandil
Suez Canal University
Port Said

Compression Test

Ductile material
(Mild Steel)

Brittle material
(Cast iron)

Stress-strain curve for brittle

materials for tension and
compression
 Prof. Anwar Kandil
Suez Canal University
Port Said

Bending Test

(a) Ductile steel (b) Brittle cast iron

 Prof. Anwar Kandil
Suez Canal University
Port Said

Torsion Test

(a) Ductile steel (b) Brittle cast iron

 Prof. Anwar Kandil
Suez Canal University
Port Said

Hardness

The hardness is the resistance of a

material to indentation by a penetrator

Brinell Hardness
Brinell hardness tester employs a
hardened steel ball 10 mm in
diameter as the penetrator under a
load of 3000-kg force, and the
resulting hardness is listed as BHN
Prof. Anwar Kandil
Suez Canal University
Port Said
Rockwell Hardness
Rockwell hardness tester uses a
hardened steel ball with a 1/16 inch
(≈ 3 mm) diameter under a load of
100-kg force for softer metals, and
the resulting hardness is listed as
Rockwell B, RB, or HRB
Hardness conversions Prof. Anwar Kandil
Suez Canal University
Port Said

σu = 500 HB ± 30 HB psi

σu = 3,45 HB ± 0.2 HB MPa

 Prof. Anwar Kandil
Hardness Conversion Table Suez Canal University
Tensile strength (σu) Tensile strength (σu)
Brinell Rockwell Brinell Rockwell
(Approx) (Approx)

Indent dia.
Indent dia.
HB* RB RC ksi MPa (m HB RB RC ksi MPa
(mm)
m)
2.25 745 65.3 3.75 262 (103.0) 26.6 127 875

2.30 712 — 3.80 255 (102.0) 25.4 123 850

2.35 682 61.7 3.85 248 (101.0) 24.2 120 830

2.40 653 60.0 3.90 241 100.0 22.8 116 800

2.45 627 58.7 3.95 235 99.0 21.7 114 785

2.50 601 57.3 4.00 229 98.2 20.5 111 760

2.55 578 56.0 4.05 223 97.3 (18.8) — -

2.60 555 54.7 298 2055 4.10 217 96.4 (17.5) 105 725

2.65 534 53.5 288 1985 4.15 212 95.5 (16.0) 102 705

2.70 514 52.1 274 1890 4.20 207 94.6 (15.2) 100 690

2.75 495 51.6 269 1855 4.25 201 93.8 (13.8) 98 675

2.80 477 50.3 258 1780 4.30 197 92.8 (12.7) 95 655

2.85 461 48.8 244 1685 4.35 192 91.9 (11.5) 93 640

2.90 444 47.2 231 1595 4.40 187 90.7 (10.0) 90 620

2.95 429 45.7 219 1510 4.45 183 90.0 (9.0) 89 615

3.00 415 44.5 212 1460 4.50 179 89.0 (8.0) 87 600

3.05 401 43.1 202 1395 4.55 174 87.8 (6.4) 85 685

3.10 388 41.8 193 1330 4.60 170 86.8 (5.4) 83 570

3.15 375 40.4 184 1270 4.65 167 86.0 (4.4) 81 560

3.20 363 39.1 177 1220 4.70 163 85.0 (3.3) 79 545

3.25 352 (110.0) 37.9 171 1180 4.80 156 82.9 (0.9) 76 525

3.30 341 (109.0) 36.6 164 1130 4.90 149 80.8 73 503

3.35 331 (108.5) 35.5 159 1095 5.00 143 78.7 71 490

3.40 321 (108.0) 34.3 154 1060 5.10 137 76.4 67 460

3.45 311 (107.5) 33.1 149 1030 5.20 131 74.0 65 450

3.50 302 (107.0) 32.1 146 1005 5.30 126 72.0 63 435

3.55 293 (106.0) 30.9 141 970 5.40 121 69.8 60 415

3.60 285 (105.5) 29.9 138 950 5.50 116 67.6 58 400

3.65 277 (104.5) 28.8 134 925 5.60 111 65.7 56 385

3.70 269 (104.0) 27.6 130 895

 Prof. Anwar Kandil
Hardness conversion table Suez Canal University
Port Said

Tensile strength
Brinell Rockwell
(σu) (Approx)

Indent
dia. HB RB RC ksi MPa
(mm)
3.75 262 (103.0) 26.6 127 875
3.80 255 (102.0) 25.4 123 850
3.85 248 (101.0) 24.2 120 830
3.90 241 100.0 22.8 116 800
3.95 235 99.0 21.7 114 785
4.00 229 98.2 20.5 111 760
 Prof. Anwar Kandil
Modulus of Resilience Suez Canal University
Port Said

The ability of a material to absorb energy without

permanent deformation is called Resilience Ur (also called
Modulus of Resilience) and is proportional to the area
under the stress-strain curve up to the elastic limit,
σ el ε el σ elσ el σ y2
Ur = = ≈
2 2E 2E
 Prof. Anwar Kandil
Toughness Suez Canal University
Port Said

The ability of a material to absorb energy without

fracture is called its Toughness UT (also called Modulus
of Toughness) and is proportional to the area under the
stress-strain curve up to the fracture point
σu σ y +σu 
UT = ∫ σ dε ≅  ε f
0
 2 
 Prof. Anwar Kandil
Suez Canal University
Port Said

Engineering Materials
The engineering materials are mainly classified as:

Metals and their alloys, such as iron, steels,

copper, aluminum, etc.

Non-metals, such as plastic, rubber, glass, etc.

 Prof. Anwar Kandil

Ferrous Metals Suez Canal University

Port Said

Steel Cast Iron

Plain Carbon Steel
Gray Cast Iron

Cast Steel
Ductile Cast Iron

Case Hardening Steel
Malleable Cast Iron
• White Malleable Cast Iron

Heat Treatable Steel • Black Malleable Cast Irion

Alloy Steel
Cast Iron with Spheriodal Graphite

 Prof. Anwar Kandil

Ferrous Metals Suez Canal University

Port Said

Steel

Plain Carbon Steel

Cast Steel

Case Hardening Steel

Heat Treatable Steel

Alloy Steel
 Prof. Anwar Kandil

Ferrous Metals Suez Canal University

Port Said

Cast Iron

Gray Cast Iron

Ductile Cast Iron

Malleable Cast Iron
• White Malleable Cast Iron
• Black Malleable Cast Irion

Cast Iron with Spheriodal Graphite

 Prof. Anwar Kandil
Suez Canal University
Port Said

Material Designation Systems

American Organization

American Iron and Steel Institute (AISI)

Society of Automotive Engineers (SAE)

American Society for Testing and Materials
(ASTM)

German Organization

Deutsche Industrie Norm (DIN)
i.,e. : German industrial Standardization
 Prof. Anwar Kandil
American Iron and Steel Institute (AISI) Suez Canal University
Port Said
 Prof. Anwar Kandil
Suez Canal University
Port Said

German Organization

Deutsche Industrie Norm (DIN)

i.,e. : German Industrial Standardization
 Prof. Anwar Kandil
Suez Canal University
Port Said
Steels
Plain Carbon Steels (DIN 1611 & 1612)

St 50

σu = 500 MPa
Stahl; i.e. Steel
 Prof. Anwar Kandil
Suez Canal University
Port Said
Mechanical Properties of Plain Carbon Steel According to
DIN 1611 & 1612
Carbon Tensile Yield Elongation
% Reduction Hardness
Designation Content strength strength Uses and application
In area % (HB)
% MPa MPa δ5 δ10
Steel sections, Plates, Wire
St 34 0.12 340 190 30 25 70 - 50 95 - 120 for general purposes, Bolts
and nuts for light loads.

St 37 <0.1 370 200 25 20 65 - 45 100 -130 Suitable for forged parts.

Suitable for parts subjected

to dynamic loading, e.g.
St 42 0.25 420 220 25 20 60 - 40 115 - 145 Rotating parts, Shafts, Axles,
Gears.
As for St42, but for highly
stressed parts, e.g. Crank
shafts Transmission shafts,
St 50 0.35 500 250 22 18 50 - 28 135 - 170 Turbine shafts, High speed
shafts, Suitable for parts with
specified hardness.
As for St50, but for still more
highly stressed parts,
St 60 0.45 600 300 17 14 38 - 20 165 - 200 Suitable for keys, Feathers,
Cotters.
Suitable for parts with high
St 70 0.60 700 350 12 10 28 – 1- 195 - 250 hardness
 Prof. Anwar Kandil
Suez Canal University
Port Said
Steels
Cast Steels (DIN 1681 & 17245)

GS 45

σu = 450 MPa
Stahlguβ ; i.e. Cast Steel
 Prof. Anwar Kandil
Suez Canal University
Port Said
Chemical Composition and Mechanical Properties of Cast Steels

According to DIN 1681 & 17245

Chemical
composition Strength properties
Designation (Average values %) Applications
σu σy
C Si Mn δ5 %
(MPa) (MPa)

GS 38 0.15 380 180 20

GS 45 0.25 450 220 16

0.3 0.4
General steel
GS 52 0.35 to To 520 250 12
castings
0.5 0.7
GS 60 0.45 600 300 8

GS 70 0.55 700 360 6

 Prof. Anwar Kandil
Suez Canal University
Port Said
Steels
Case Hardening Steels (DIN 17210)

C 15
Carbon content = 0.15 %
Carbon

CK 15
Carbon content = 0.15 %

Carbon mit kleinem Phosphor (P) und/oder Sulfer (S)

i.e.: with low P and/or S
 Prof. Anwar Kandil
Suez Canal University
Port Said
Chemical Composition and Mechanical Properties of
Case Hardening Steels According to DIN 17210
(Unalloyed Steels)
Strength properties
Chemical composition
(Average values %) Soft
annealed
After case hardening
Designation Applications

C Si Mn P S HB σu σy δ5 %
(MPa) (MPa)

420 Small machine

< <
C 10 0.10 0.25 0.37 131 to 250 19 parts
0.045 0.045
520 (Fine mechanics)
Quality
steels
500 Levers, Pins,
< <
C 15 0.15 0.25 0.37 140 to 300 16 Links, Bolts,
0.045 0.045
650 Buches, etc.

High < < Same as above,

quality CK 10 Same as for C 10 Same as for C10 but for higher
0.035 0.035
steels stressing.
Suitable for
< < grinding m/c,
CK15 Same as for C15 Same as for C 15 spindles, came
0.035 0.035
shafts, gears, etc
 Chemical Composition and Mechanical Properties Prof. Anwar Kandil
Suez Canal University
of Heat Treatable Steels According to DIN 17200 Port Said
(Unalloyed Steels)
Strength properties
Chemical composition
(Average values %) Soft
annealed
After case hardening
Designation Applications
σu σy
C Si Mn P S HB δ5 %
(MPa) (MPa)
500
C 22 0.22 0.25 0.45 0.045 0.045 155 to 300 22 Shafts)
600
600 Levers, Flanges, Screws,
C 35 0.35 0.25 0.55 0.045 0.045 172 to 370 18 Nuts, Parts with
hardened surfaces
720
650 Parts subjected to
Quality compression and wear,
steels C 45 0.45 0.25 0.65 0.045 0.045 206 to 400 16 Parts with hardened
800 surfaces

750
Extension springs,
C 60 0.60 0.25 0.65 0.045 0.045 243 to 490 14 Frames for springs
900
C 67 0.67 0.37 0.70 0.05 0.05 240 - - -
Wheel rims
C 70 0.70 0.32 0.60 0.05 0.05 180 - - -
CK 22 Same as for C 10 0.035 0.035 Same as for C10 Uniform metal structure
and good surface quality
– Suitable for lightly
High CK35 Same as for C15 0.035 0.035 Same as for C 15 loaded machine and
automobile parts
quality
Parts for power
steels CK 45 Same as for C45 0.035 0.035 Same as for C 45 transmission
Crankpins, Gearwheels,
CK 60 Same as for C60 0.035 0.035 Same as for C 60 Couplings
 Prof. Anwar Kandil

Alloy Steels Suez Canal University

Port Said

Effect of the Main Alloying Elements on the Properties of Alloy Steels

Mechanical properties Physical properties Manufacturing properties

Mail alloying elements Yiel Redu Resist Resista Stabili Abilit

Elo Machi
Streng d ction Elast Impac Hardn ance nce to ty to Sealin Forga y to
nga corros nabilit
th Poi of icity t value ess to high g bility Nitridi
tion ion y
nt area wear temp. ng

Aluminum AL - - - D - D - - - - DD - DD III
Chromium Cr II II D D I D II I III I DDD - D II
Cobalt Co I I D D - D I III - II D C D -
Copper Cu I II C C - C I - I I C C DDD -

Manganese
Ma I I C C I C I DD - C C D I C
(in pearlitic steels)

Manganese
(in austenitic Mn I D III C - - DDD - - - DD DDD DDD -
steels)
Molybdenum Mo I I D D - I I II - II II D D II

Nickel
Ni I I C C - C I DD - I D D D -
(in pearlitic steels)

Nickel
(in austenitic Ni I D III II - III DD - II III DD DDD DDD -
steels)
Phosphorous P I I D D - DDD I - - - - II D -
Silicon Si I II D C III D I DDD - I D D D D
Sulphur S - - D D - D - - D - - III DDD -
Tungsten
W I I D D - C I III - III DD DD DD I
(Wolfram)
Vanedium V I I c C I I I II I II D - i I
 Prof. Anwar Kandil
Suez Canal University
Port Said

Alloy Steel
Average Content of Alloying Elements

30 Cr Ni Mo 8

Molybdenum 8/10 = 0.8 %

Nickel 8/4 = 2%
Chromium = 8/4 = 2%
Carbon content = 0.30 %
 Prof. Anwar Kandil
Alloy Steel (Mechanical Properties) Suez Canal University
Port Said
Material Material Properlies (MPa)
Designation
Annealed Heat Treated
σ0.2 σu σ0.2 σu
Heat treatable steel (DIN 17200)
40 Mn 4 ca. 350 600 – 750 450 – 650 700 – 1050
30 Mn 5 400 – 500 600 – 700 420 – 550 650 – 950
25 Cr Mo 4 400 – 500 700 max 420 - 650 650 –1050

37 Mn Si 5 400 – 500 650 – 750 450 – 800 700 – 1200

34 Cr 4 350 – 450 550 – 650 550 – 800 800 – 1200
41 Gr 4 ca. 400 600 – 750 550 – 800 800 – 1200
34 Cr Mo 4 500 – 600 750 max. 450 – 800 700 – 1200

42 Mn V 7 350 – 450 600 – 750 700 – 900 900 – 1300

42 Cr Mo 4 500 – 600 750 max. 550 – 900 750 – 1300
36 Cr Ni Mo 4 450 – 550 750 max. 550 – 900 750 – 1300

50 Cr Mo 4 500 – 600 750 max. 600 – 900 800 – 1300

34 Cr Ni Mo 6 450 – 550 650 – 800 600 – 900 800 – 1300

30 Cr Mo V 9 450 – 550 750 max 700 – 1050 900 – 1450

30 Cr Ni Mo 8 400 - 450 750 – 850 700 – 1050 900 – 1450

Case-Hardening Steels (DIN 17210)

15 Cr 3 400 650 – 850
16 Mn Cr 5 600 800 – 1100
20 Mn Cr 5 700 1000-1300

15 Cr Ni 6 650 900 – 1200

18 Cr Ni 8 800 1200-1450

Stainless Steel (DIN 17440)

X 5 Cr Ni 18 9 190 500 – 700
X 5 Cr Ni Mo 18 10 210 500 – 700
X10 Cr Ni Ti 18 9 210 500 – 750

X 10 CrNiMoTi 18 10 270 450 – 600 230 500 – 750

X 8 Cr Ti 17 950 max. 600 800 - 950
X 22 Cr Ni 17

DIN Material Designation

Preceding number indicates average Carbon Content * 100.
Figure following symbols of alloying elements indicates average content of alloying element multiplied by following factors:
For Co , Cr , Mn, Ni , Si and W : * 4
For Al , Cu , Mo, Ti and V : * 10
For C , N , P and S : * 100
 Prof. Anwar Kandil
Suez Canal University

Cast Iron Port Said

Gray Cast Iron (DIN 1691)

GG 18

σu= 180 MPa

Grauguss ; i.e. : Gray Cast iron
 Prof. Anwar Kandil
Suez Canal University
Port Said
Cast Iron
Chemical Compositions of Gray Cast Iron (DIN 1691)

Chemical composition %
Designation Applications
C Si Mn P S
GG 12 3.3 – 3.6 1.5 – 2.5 0.4 – 0.6 0.5 – 1.0 < 0.12 Commercial Castings
Normal
grey cast GG 14 3.3 – 3.6 1.8 – 2.4 0.5 – 0.7 0.5 – 0.8 < 0.12 Light Machine Castings
iron Medium Machine
GG 18 3.3 – 3.5 1.8 – 2.0 0.6 – 0.8 < 0.5 < 0.12
Castings

High duty GG 22 3.2 – 3.4 1.6 – 1.8 0.6 – 0.8 < 0.4 < 0.12 Heavy Machine Castings
cast iron GG 26 2.8 – 3.2 1.2 – 1.6 0.7 – 0.9 < 0.3 < 0.12 Dense Castings
Special
GG 30 2.6 – 3.0 1.2 – 1.8 0.8 – 1.2 < 0.2 < 0.12 High Stressed Parts
cast iron
 Prof. Anwar Kandil
Suez Canal University
Port Said

Cast Iron
Mechanical properties of Gray Cast Iron (DIN 1691)

Designation Ultimate Ultimate Bending Modulus of Modulus of

tensile Compression Strength elasticity rigidity
strength strength σub (MPa E (MPa) G (MPa)
σut (MPa) σuc (MPa)
GG 12 120 550 250 88000 34000
GG 14 140 620 300 95000 37000
GG 18 180 690 340 105000 40000
GG 22 220 800 400 115000 44000
GG 26 260 880 440 120000 46000
GG 30 300 1000 480 125000 48000
 Prof. Anwar Kandil
Suez Canal University
Port Said

Cast Iron
White Malleable Cast Iron (DIN 1692)

GTW 40
σu= 400 MPa
Weisser Temperguss; i.e. White malleable
cast iron
 Prof. Anwar Kandil
Cast Iron Suez Canal University
Port Said
Mechanical properties of White malleable Cast Iron (DIN 1692)
Tensile
Diameter of Elongation
Material strength Offset stress Brinell
test Specimen (minimum )
Designation (minimum) σ0.2 (Mpa) hardness
(d mm) %
(MPa)
9 340 - 6
GTW — 35 12 350 - 4 220
15 360 - 3
9 360 200 10
GTW — 40 12 400 220 5 220
15 420 230 3
9 400 230 12
GTW — 45 12 450 260 7 200
15 400 200 5
9 520 340 7
GTW - 55 12 550 360 5 240
15 570 370 4
9 620 410 4
CTW --65 12 650 430 3 270
15 670 410 2
9 320 170 15
CTW-S38' 12 300 200 12 200
15 400 210 8
 Prof. Anwar Kandil
Suez Canal University
Port Said

Cast Iron
Black Malleable Cast Iron (DIN 1692)

GTS 45
σu= 450 MPa
Schwarzer Temperguss; i.e. Black malleable
cast iron
 Prof. Anwar Kandil
Suez Canal University
Cast Iron Port Said
Mechanical properties of Black malleable Cast Iron (DIN 1692)

Tensile
Diameter of Elongation
Material strength Offset stress Brinell
test Specimen (minimum )
Designation (minimum) σ0.2 (Mpa) hardness
(d mm) %
(MPa)

12
GTS — 35 350 200 12 up to 150
15

12
GTS — 45 450 300 7 160 – 200
15

12
GTS — 55 550 360 5 180 – 220
15

12
GTS - 65 650 430 3 210 – 250
15

12
GTS - 70 700 550 2 240 – 270
15
 Prof. Anwar Kandil
Suez Canal University
Port Said

Cast Iron
Cast Iron with Spheriodal Graphite (DIN 1693)

GGG 50
σu= 500 MPa
Gusseisen mit Kugelgraphit;
i.e.: Cast iron with sphriodal graphite
 Cast Iron Prof. Anwar Kandil
Suez Canal University
Port Said

Mechanical Properties of Cast Iron with Spheriodal Graphite (DIN 1693)

Tensile
Elongation
Material strength Offset stress Brinell
(minimum )
Designation (minimum) σ0.2 (Mpa) hardness
%
(MPa)

GGG - 40 400 250 15 150 – 180

GGG - 50 500 320 7 160 – 240

GGG - 60 600 380 3 175 – 290

GGG – 70 700 440 2 210 – 320

GGG – 80 800 500 2 230 – 360

 Prof. Anwar Kandil
Suez Canal University
Port Said