CHAPTER 11: METAL ALLOYS

APPLICATIONS AND PROCESSING

ISSUES TO ADDRESS...
• How are metal alloys classified and how are they used?
• What are some of the common fabrication techniques?
• How do properties vary throughout a piece of material
that has been quenched, for example?
• How can properties be modified by post heat treatment?

Chapter 11- 1
TAXONOMY OF METALS

Adapted from
Fig. 11.1,
Callister 7e.

Chapter 11- 2
STEELS

Chapter 11- 3
 CAST IRON
• Ferrous alloys with 2.5 < wt% C < 4.5
• Gray, Ductile (Nodular), white, malleable cast iron.
• Si (> 1wt%) and slow cooling promote graphite formation.

Chapter 11-
 CAST IRON
• Gray cast iron with 2.5<wt% C<4.0; 1.0<wt% Si< 3.0
– Weak and brittle in tension
– Base structures for machines and heavy equipments that are exposed to vibrations are
constructed by this material due to better damping capacities
– Graphite exist in the form of flakes within the ferrite matrix.

• Ductile (Nodular) cast iron

– Forms by adding a small amount of Mg/ Ce
– Graphite in sphere-like particles

• White Cast Iron

– Low- Silicon content (< 1 wt% Si) and rapid cooling rates
– Carbon exists as cementite
– Very hard and brittle, unmachinable

• Malleable Cast Iron

– Forms by heating white iron 800 <T < 900C for a long time (30+ h) in nonoxidizing ambient.
– Cementite decomposes into graphite and exists in the form of clusters in ferrite

Chapter 11-
CAST IRON

Chapter 11-
CAST IRON

Chapter 11-
 NONFERROUS ALLOYS
• Cu Alloys • Al Alloys
Brass: Zn is subst. impurity -lower : 2.7g/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. impurity aircraft parts
(bushings, landing & packaging)
gear)
Cu-Be:
NonFerrous • Mg Alloys
-very low : 1.7g/cm3
precip. hardened Alloys -ignites easily
for strength -aircraft, missles
• Ti Alloys
-lower : 4.5g/cm3 • Refractory metals
-high melting T
vs 7.9 for steel • Noble metals -Nb, Mo, W, Ta
-reactive at high T -Ag, Au, Pt
-space applic. -oxid./corr. resistant
Based on discussion and data provided in Section 11.3, Callister 7e. Chapter 11- 4
 METAL FABRICATION METHODS-I

FORMING
• Forging • Rolling
(wrenches, crankshafts) (I-beams, rails)
force
die
Ao blank Ad often at
elev. T
Adapted from
force Fig. 11.8,
• Drawing Callister 7e.
(rods, wire, tubing)
die Ad
Ao tensile
force
die

Chapter 11- 6
METAL FABRICATION METHODS-II

CASTING
• Sand Casting • Die Casting
(large parts, e.g., (high volume, low T alloys)
auto engine blocks)

• Continuous Casting
• Investment Casting (simple slab shapes)
(low volume, complex shapes
e.g., jewelry, turbine blades)
plaster
die formed
around wax
prototype
Chapter 11- 8
METAL FABRICATION METHODS-III

FORMING CASTING JOINING

• Powder Processing
(materials w/low ductility)

Chapter 11- 9
METAL FABRICATION METHODS-III

FORMING CASTING JOINING

• Welding
• Heat affected zone:
(when one large part is
(region in which the
impractical)
microstructure has been
changed).
Figure 11. 9

Chapter 11- 9