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    Ferrous, Non-Ferrous Metals and Composite Materials

    Uploaded by

    Julius Andrew

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    © All Rights Reserved
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    & © » | Ferrous, Non-Ferrous Metals \ and Composite Materials AREPORT BY GROUP 8 M Contents What this report covers 01 Definition 02 History 03 Examples and Types GROUP 8 04 Application 05 Pros/Cons On Py-1ilalitconal ‘A ferrous metal is any metal that is primarily composed of iron and has A ferrous metal is or its hardness, durability and tensile strength, The term ferro which means “iron. -omes from the Latin word 7 Ferrous metals may include a lot of different ‘Some examples are chromium, nickel, molybdenum, vanadium, manganese, Those give ferrous steels material properties: + Durable + Great tensile strength Usually magnetic ‘ow resistance to corrosion like colour + Recyclable Good conduct 02 | History ‘The earliest surviving prehistoric iron artifacts were made from Iron was being produced from from Greece to India, and Sub-s The use of wrought iron (worked iron) and its spread 1 | defined the ‘Smiths in Europe found a way of producing wrought iron from or using finery forges. Ape Southern India had started exporting with a carbon content between pig iron and wrought iron) to ancient Chin, Afric, the Middle East and Europe. (| 02 | History New methods of producing it by carburizing bars of iron in the cementation process were devised, During the Industrial Revolution, new methods of producing bar iron by substituting coke for charc ‘emerged, and these were later applied to produce steel, ushering in a new era of greatly increased use of iron and steel that some contemporaries described as a co: DO Henry er invented a new steelmaking process which involved blowing air through molten pig-iron burn off carbon, and so producing mild steel. Steel-making processes have displaced wrought iron. Today, wrought iron is no longer produced on a commercial scale, having been displaced by the functionally equivalent mild or low-carbon steel 03 | Examples Non-alloy steels are also known as carbon steels because there, Although there are other elements also present, their content is 1 enough to nat make an impact on the material properties. Those elements are sulphur, phosphorus, silicon and manganese. Non-alloy steels are classified by their carbon content as Each has their ‘own uses and the characteristics vary. Also, different t methods are available accordingly. 03 | Non-Alloy Low carbon, oF mild steels contain of carbon. They are pretty st and very well suited for bending operations. The surface hardness can be increased through carburizing. The low cost and malleability low carbon steels are widely used. Some examples include i C10E/1.1121 C15E/1.1141 03 | Non-Alloy Medium carbon steels contain of carbon. The higher carbon content increases their strength and hardness compared to low carbon steels. At the same time, the ductility decreases. The increase of carbon and manganese allows tempering and quenching, Medium carbon steels are mainly used for making different automotive industry components like etc. Steels ranging from 0.4..0,6% are also suitable for everything. d to locomotives and rails. = ft _ [> seep CAOE/1.1186 C60E/1.1221 03 | Non-Alloy ‘The carbon content numbers for high carbon steels varying from i These are the strongest of this group, making it suitable for applications where resistance against mechanical material wear is needed. Another quality of high carbon steels is their tendency to keep a shape: As a downside, the weldability, ductility and impact toughness are all inferior to steels with less carbon. ‘The shape-keeping quality makes them useful as springs. Other use-cases include blades, rail wire rope, wear-resistant plates, all kinds of tools ete. MANY) * VT) * 70U/1.1520 C105U/1.1545 03.| Examples Cora) Alloy steels make up another sub-group of ferrous, metals. Steel's alloying elements are ie ‘etc, Each has their own effect on material properties. Of course, they are usually combined, so the end products has a bit of everything Chromium Manganese Nickel Silicon Titanium Vanadium Molybdenum Cast Iron en P es Corte) OG Chromium is the element responsible for creating stainless steel, Presence of chromium make a metal corrosion-resistant, As discussed in the material wear article, the protection takes place through creating an oxidised chromium layer on top of the metal. This means that the base metal does not get into contact with oxygen and the danger of corrosion is ty diminished. + Makes a metal corrosion-resistant * Increases tensile strength + Improves hardness + Enhances toughness + Makes resistance to wear Gea PV vast OG Manganese improves ductility, wear resistance and hardenability. The latter is done through quenching where manganese has a significant impact. It diminishes the danger of defect formation during the process by making it more stable. It also eliminates the formation of harmful iron sulfides, increasing strength at high temperatures. + Improves ductility + increases strength at high temperatures + Enhances hardenability + Makes resistance to wear 03 | Alloy Steels Cora) Stainless steel cutlery helps us avoid the taste of rust Its main purpose is to increase ductility and corrosion resistance in combination with other elements, namely chromium. When chromium content is around 18% kel we get an extremely durable stainless and n steels. * Increase ductility + Makes a metal corrosion-re + Makes resistance to wear ap oy as OG Silicon is perhaps the most common alloying element in steel, as almost all steel requires silicon during the manufacturing process. Silicon helps to purify the iron ore during the smelting process by deoxidizing it and removing other impurities from it. Aside from its cleansing properties, silicon can also have an effect the mechanical properties of steel. It can be used to increase the strength and hardenability of certain steels, as well as magnetic properties. on + Improves strength + Enhances hardenability + Provides elasticity in springs Gives metal a very high tensile strength and toughness, They are light in weight, have extraordinary corrosion resistance and the ability to withstand extreme temperatures. 03 | Alloy Steels + Improves stengh Pudeearcr tt * Corrosion Resistance High Tensile Strength * Lightweight + Withstand extreme temperatures ERP NES: Corte) TA alloying element used in wrought metallurgy clure high strength low alloy (HSLA) materials, Vanadium provides improvement in strength ‘and wear resistance through grain refinement and precipitation of vanadium carbonitrides. The formation of vanadium carbides limits the grain size. This has an effect on increasing a material's ductility. Because of its effectivenes: must be held low. Otherwise, it can have a negative impact on material proper the amounts + Improves strength + Wear Resistance + Enhances hardness + Shock-impact resistance * Increase material's ductility Molybdenum has a large effect on steel alloys at high temperatures. It improves mechanical properties but also resistance to corrosion and acts as an amplifier for the effects of other alloying elements. DEEP Castle + ithstnd extreme temperatures Puaearctt * Corrosion resistance + Amplifies other alloy's effects 03 | Alloy | UTR) Cast iron is an alloy of iron and carbon, with a carbon content somewhere between 1.5 and 4 percent. There are also other elements present - namely silicon, manganese, sulphur and phosphorus. Although itis brittle, its hardness makes it resistant to wear. The final form of a cast iron product is gained through casting. This process only needs minor after treatment, making it possible to form a needed shape. * Great castability + Relatively cheap + High compressive strength * Good wear resistance + Low melting point 04 | Application Usually iron; however, it can be made tougher, ductile, stronger, harder, and more durable by adding copper, vanadium, tungsten, and manganese. It can be used for dies, tools, construction and machining equipment, 04 | Application Carbon steel, one of the most common ferrous metals, with over 90% iron c furniture, it ca components, nt. Besides structures and be used in automotive Carbon steel, often referred us shear resistant. It is used to primarily manufacture cutting tools such as saws, rotaries, and drill bits. 04 | Application Cast iron is made from pig is used for producing piston nd cylinder blocks. 04 | Application Wrought iron can withstand sudden shock, It is used for making gates, railings, chains, shackles, and couplings. This property is called Toughness and it is the opposite of brittleness, 04 | Application 04 | Application Cora) % recyclable materials, with a high amount of chromium that makes it more corrosion resistant than carbon steel. This mate be used to make appliances, pharmaceuticals, medical equipment, food-grade equipment, and knives. Stainless steel, made from 100% + High strength - weight ratio * Weighs more than Aluminum and Titanium Alloys ‘+ High quality and tough material + Recyclable and eco friendly Orem Meee. + Tends to corrode by rusting ‘* Machine ability is affected by the magnetic field + Requires more energy to form shapes or re-work Orem Meee. Cortes oe Py-1ilali acon) ‘The metals other than iron and alloys that in an appreciable amount of ferrous (iron) are known as non-ferrous metals, Non-ferrous metals’ advantages make them usable in many applications instead of iran and steel ‘The properties of non-ferrous metals: + High corrosion resistance (they do not rust Easy to fabricate - machinability, casting, welding ete + Great thermal conductivity + Great electrical conductivity * Low density (less mass) + Colourful + Non-magnetic Non-ferrous metals were the first metals used by humans for metallurgy. Gold, silver and copper exist in their native crystalline yet metallic form. + It develops between 6,500 and 2,500 B.C. Gold, siver and copper were the mast used metas in prehistoric times Metallurgy develo Agriculture and cattle breeding are developed. BD It takes place between 2,500 and 1,500 B.C. More complex societies are created than in Nealthic populations Bronze was found in india, Iran, Armenia, Egypt and Oana + The Aegean Sea is an exclusive space for bronze trade. Iron in this time was naturally abundant, but it was not moldable on its own and it’s melting point (1,650 °F) was higher than any kiln at the time could reach, 03 | Examples rae Copper is pretty widely spread in the industrial sphere, ‘Add the alloys brass (copper and zinc) and bronze (copper and tin), and you may already see the many ses of copper. For mechanical engineers, slide bearings and bushings may be the most known uses. ‘+ High thermal conductivity ~ heat exchangers, heating vessels and appliances etc + High electrical conductivity - used as an electrical conductor in wiring and motors * Good corrosion resistance - beautiful but expensive roofing ‘+ High ductility ~ makes the material very easily formable and suitable for making statues o Ithas a silvery color, Without the addition of alloying elements, itis more ductile and not quite as strong as many steels. However, through the addition of alloying elements and heat treating or work hardening, aluminum can achieve very high strengths. Aluminum is, lighter than steel. It forms a protective oxide layer that helps it reduce the risk of detrimental corrosion, 03 | Examples * Corrosion resistant * Good conductor of heat and electricity (but less than copper) ~ in combination with ductility and malleability replaces copper in some instances + High ductility and lightweight Corio) + Becomes hard after cold working, so needs annealing %e For the average person, lead may ring a bell related with bullets (which are now without lead) and gas (which has a sign "unleaded"). Although at first added to fuel to decrease motor knocks, it turned out to be heavily unhealthy when vaporised into the atmosphere The same goes for bullets and shooting range employees who got health problems because of it. But 03 | eal) (at) why add it in the first place? Because lead is the 4 heaviest common metal. As it doesn’t react easily with ‘ther substances, they are stil used in batteries and power cables, acid tanks and water pipes + Very heavy + Resistant to corrosion - doesn’t react with many chemicals * Soft and malleable Cora) %e For the average person, lead may ring a bell related with bullets (which are now without lead) and gas (which has a sign "unleaded"). Although at first added to fuel to decrease motor knocks, it turned out to be heavily unhealthy when vaporised into the atmosphere The same goes for bullets and shooting range employees who got health problems because of it. But 03 | eal) (at) why add it in the first place? Because lead is the 4 heaviest common metal. As it doesn’t react easily with ‘ther substances, they are stil used in batteries and power cables, acid tanks and water pipes + Very heavy + Resistant to corrosion - doesn’t react with many chemicals * Soft and malleable Cora) 04 | Application Lightweight, durable, strong and extremely flexible, aluminum has proven to be the best material for the construction of heavier-than-air aircraft. By weight, 80 percent of all aircraft is now made of aluminum parts, The fuselage, wings and rudder, doors and floors, frames of seats, fuel nozzles, hydraulic systems, bal bearings, engine turbines—are made of aluminum. In ‘ther words, it’s found throughout the entire aircraft and its frame, Developments in aircraft technology are directly linked to the advancement and production of aluminum alloys, Aluminum casting technology offers lower costs to manufacturers, but also allows engineers to incorporate innovative designs and concepts. 04 | Application Magnesium ci parts are the choice of the industry because the metal is 75% lighter than steel, 33% lighter than aluminum, has a high strength to weight ratio, high impact resistance, has an excellent dimensional stability, and can be cast to just about any shape The application of magnesium cast alloys is also compatible with commercial automatic transmission fluids. In laboratory studies, the effects of high temperature, presence of condensation or water, and the galvanic coupling with steel caused no significant corrosion of magnesium under any of the test conditions, Overall, magnesium cast parts offer a lightweight, component and feature integration that’s proven to be durable and highly effective. 04 | Application The use 0 titanium and titanium alloys in the manufacturing of golf equipment was first introduced to the game in the 1970s, but it took another twenty years to perfect the design before the widespread use Of the club took off in the 1990s. Club designers realized titanium is an amazingly strong, yet lightweight metal, It’s 45 percent lighter than steel. Titanium’s light-weight material allowed for a la sweet spot on the club head, resulting in a fas F swing, which optimized the launch, flight, and trajectory of the ball. Distance was increased on average by 20 percent. Titanium is also the strongest and most durable of the metals, and is impervious to the elements and any weather conditions, 04 | Application Bronze gears are integral part in a variety of gear-drive systems. Gears cast with bronze are found in power transmission systems, jack screws, landing gears, and pumps, among other gear-drive systems, and are used in industries ranging from automative and aviation to machine tooling, marine, and oil production, The main reason bronze casting has gained so much popularity is because the metal has unique properti that contribute to minimal wear, The metal has low coefficients of friction compared to other ferrous and nonferrous metals, such as steel or aluminum. Lower friction means higher efficiency and less wear, whi makes a good bearing material Other factors that make bronze gears a good bearing material is its corrosion resistance, its resistance to high temperatures, and itis easily machined, welded, brazed and soldered. 04 | Application Zinc casting and electroplating in the manufacturing of electrical components and parts has proven to be the most effective application in combating the effects of corrosion and chemicals in harsh industrial environments. Zinc is a hard metal, dimensionally stable and self-lubricating, and its properties make it ideal for electrical and thermal conductivity. (One of the strongest and toughest metals there is for the casting of parts, zinc creates a formidable barrier in protecting metal surfaces. It’s an abundant, low-cost material and, as its casting is done at a moderate temperature, it’s energy efficient. Today, itis used extensively in the manufacturing of electrical hardware. + Easy to fabricate, i.e., machining, casting, welding forging and rolling. + High corrosion resistance and low density. + Possess very good thermal and electrical conductivity Orem Mdcey Aero) Cora) Orem dco A ere) Cora) + No Magnetic Attraction- Unlike ferrous metals, nonferrous metals are not magnetically attractive, This can be a disadvantage since it excludes this metal from any application where magnetism is ssary or is an advantage. «+ Light-weight Nonferrous metals typically are light-weight and have limited strength capabilities. This prevents these metals from being used in any application where strength or heft is necessary + High cost- On average, nonferrous metals cost more than ferrous metals, although the price can vary according to the metal. Industries or companies needing nonferrous metals for applications face a disadvantage compared to those companies using ferrous metals, because the cost is higher Oey Py 1ilalitceyal A composite material is a combination of two materials. with different physical and chemical properties. Depends on materials used but generally speaking, + The tensile strength of composite materials is 4-6 times higher than conventional materials such as stel laminum, ete + They have better torsion and stiffness properties. ‘+ Ithas a high fatigue endurance limit (ultimate tensile strength of up to 60% + They are 30-45% lighter than alurninum structur designed for the same functional requirements low embedded energy + Composites make less noise during operation and provide + Also h iss vibration Composite materials are additional versatile 02 | History Humans have used composites for thousands of years. In 3400 B.C the first man made composites were engineered by the Mesopotamians in Iraq. The ancient society glued wood strips on top of each other at different angles to create plywood ‘The Egyptians started to make death masks out of linen or papyrus soaked in plaster. Later on, both of these societies started to reinforce their materials with straw to strengthen mud bricks, pottery and boats. ‘The Mongols began to engineer composite bows which were incredibly effective at the time. These were made out of wood, bamboo, bone, cattle tendons, horn and silk bonded with pine resin, 02 | History = S| Synthetic resins started to take a solid form by using polymerisation. In the 1900s this new-found knowledge about chemicals led to the creation of various plastics such as polyester, phenolic and vinyl Synthetics then started to be developed, as created by the chemist Leo Baekeland. The fact that it did not conduct electricity and was heat resistant meant it could be widely used across many industries. soho Glass fibre was introduced by Owens Corning who also started the first fibre reinforced polymer (FRP) industry. The resins engineered during this era are still used to this day and, in 1936, unsaturated polyester resins were patented. Two years later, higher performance resin systems became accessible, PC) a 1961 ‘The first carbon fiber was patented in 1961 and then became commercially available Mid-1990s Composites were starting to become increasingly ‘common for manufacturing processes and construction due to their relatively cheap cost compared to materials that had Mid-2000s The composites on a Boeing 787 Dreamliner in the mid-2000s substantiated their use for high strength applications, ~ 1 used previously. | Examples Ceramic Matrix Composite Ceramic spread out in a ceramic matrix, These are better than normal ceramics as they are thermal shock and ff resistant. Properties * Thermal Shock Resistant + Fracture Resistant Metal Matrix Composite ‘ead throughout a matrix Properties | Examples Concrete strengthened by a materi with high tensile strength such as steel reinforcing + Durable ‘+ High tensile strength 03 | Examples Concrete which is poured into a glass fiber structure with high zirconia content than traditional reinforced concrete -ompressive, flexural, & tensile strength « Lighter Orem

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