Mr. T.D.I.

Udayanga
Lecturer
Department of Engineering Technology
 Ferrous Metals
 Properties
 Application

 Types of Steel
 Properties
 Application

 Non-ferrous Metals
 Properties
 Application

 Important Alloys
 Properties
 Application

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 Engineering Manufacturing Process
Materials/ Raw Product/ Articles
Materials

 It is important to identify the available engineering materials and their properties such
as,
 Mechanical
 Thermal
 Electrical
 Chemical
 Etc
To select the suitable material for the desired end product or articles

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 Engineering
Materials

Metallic Non-metallic
Materials Materials

Ferrous Non-ferrous Organic Inorganic

Steels Cast Iron Aluminium Plastics Minerals

Plain Grey Copper Wood Cement

Carbon White Magnesium Paper Glass

Alloy Malleable Tin Rubber Ceramics

Ductile Zinc Leather Graphite

Nodular Lead Petroleum

Nickel and
their alloys

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 Ferrous metals are those which have iron as their main component such as,
 Pig iron
 Cast iron
 Steel
 Wrought iron

 All of these ferrous metals are obtained by smelting iron ore, coke and limestone.

Iron Ore Color Iron%

Haematite (FE3O4) Red 70%
Magnetite (Fe2O3) Black 72%
Limonite Brown 62.5%
Siderite Brown 48%

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 Pig iron is obtained by smelting iron ores ( chemically reducing iron ores in a blast
furnace)
 It acts as the raw material for the production of other ferrous metals such as cast
iron, steel, etc.
 In addition to iron pig iron contains various other constituents such as Carbon,
Silicon, Sulphur, Phosphorous, Manganese, etc
 According to the amount of Carbon exists and the form of Carbon, Pig Iron can be
classified as follows,
 Grey Pig Iron (Grades 1,2 and 3)
 White Pig Iron (Grades 4)
 Mottled Pig Iron (Grades 5)

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 Cast iron is an alloy of iron
 It is obtained by re-melting pig iron with coke, limestone and steel scraps in a
furnace named as cupola
 Carbon content of cast iron varies from 1.7% to 6.67%
 Other than Carbon, other impurities such as Silicon, Phosphorous, etc may present
in cast iron
 Properties of Cast Iron
 Weak in tension as it is a very brittle material
 Has good casting characteristics
 Has high compressive strength
 Has high wear resistance
 Has excellent machinability

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 Tensile strength of cast iron varies from 100 to 200 MPa
 Compressive strength varies from 400 to 1000 MPa
 Shear strength is 120 MPa
 Basically, cast iron is present in either free Carbon (graphite) or combined Carbon
(cementite) forms
 Cast iron is classified into seven major kinds as follows,
 Grey cast iron
 White cast iron
 Mottled cast iron
 Malleable cast iron
 Nodular cast iron
 Meehanite cast iron
 Alloy cast iron
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  In grey cast iron Carbon is principally in graphite form
Composition Properties Applications
C = 2.5% to 3.8% It can be easily cast Machine tool structures
Si = 1.1% to 2.8% It can be easily machined Household appliances
Mn = 0.4% to 1.0% It possesses lowest melting point Man holes covers
of ferrous alloys
P = less than 0.15% It possesses high vibration Piston rings
damping capacity
S = less than 0.1% It has high resistance to wear General machinery parts
Fe = Remaining It possesses high compressive Gas or water pipes for under
strength ground purposes
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  In white cast iron Carbon is in cementite form
Composition Properties Applications
C = 3.2% to 3.6% It is a very hard material For producing malleable iron
castings
Si = 0.4% to 1.1% It possesses excellent abrasive Railway brake blocks
wear resistance
Mg = 0.1% to 0.4% It is very difficult to machine Rim of a car
P = less than 0.3% It has high tensile strength Rolls crushing jaw
S = less than 0.2% It has low compressive strength Crusher plates
Fe = Remaining

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 Steel is an alloy of Iron and Carbon with
Carbon content maximum up to 1.7%
 Carbon occurs in the form of Iron Carbide
 It has the ability to increase the hardness
and strength of the steel
 Mechanical properties of the steel varies
with the amount of Carbon present
 Other than Carbon there may be other
elements present in steel as impurities
 Amount of these element present import
certain desired properties to steel

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 Effect of impurities on Steel
 Silicon - prevent steel becoming porous by making steel tougher and harder
 Sulphur – increase brittleness of steel
 Manganese – increases wear resistance, hardness and strength. But decreases
machinability
 Phosphorus – induces brittleness in steel. But improves the resistant to atmospheric
corrosion
 Depending on the Carbon content steel can be divided as follows,
 Dead Carbon Steel – up to 0.15% Carbon
 Low Carbon or Mild Steel – 0.15% to 0.45% Carbon
 Medium Carbon Steel – 0.45% to 0.8% Carbon
 High Carbon Steel – 0.8% to 1.5% Carbon

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 Properties
 Has tensile strength of 555 N/mm2
 Has hardness of 140 BHN
 Melting point is about 1410 0C
 It is a low cost material that is easy to shape

 Applications
 Mild steel containing 0.15 to 0.20% carbon
 It is used in structure steels, universal beams, screws, drop forgings, case hardening
steel, bars, rods, tubes, angles and channels etc.
 Mild steel containing 0.20-0.30% carbon
 It is used in making machine structure, gears, free cutting steels, shafts and forged
components etc.

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 Properties
 It is harder than mild steel
 It is ductile and strong
 It has good malleability
 Tensile strength is better than cast iron and wrought iron
 Compressive strength is better than wrought iron but lesser than cast iron

 Applications
 Plain carbon steels having carbon % 0.30 to 0.45. Axles, special duty shafts, connecting
rods, forgings, machinery steel, spring clips, turbine, rotors, gear shafts, key stock, forks
and bolts.
 Plain carbon steels having carbon % 0.45 to 0.60. Railway coach axles, crank pins,
crankshafts, axles, spline shafts, loco tyres.
 Plain carbon steels having carbon % 0.60 to 0.80. Drop forging dies, die blocks, bolt
heading dies, self-tapping screws, valve spring, lock washers, hammers, cold chisels,
hacksaws, jaws for vices etc.
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 Properties
 Extremely strong material comparing with other Carbon Steel
 Has very high brittleness. So need special handling of this material

 Applications
 HCS containing 0.7 to 0.8% carbon possesses hardness of 450-500 BHN. It has application for making
cold chisels, drill bits, wrenches, wheels for railway service, jaws for vises, structural wires, shear
blades, automatic clutch discs, hacksaws etc.64 Introduction to Basic Manufacturing Processes and
Workshop Technology
 HCS containing 0.8 to 0.9% C possesses hardness of 500 to 600 BHN. This steel is used for making
rock drills, punches, dies, railway rails clutch discs, circular saws, leaf springs, machine chisels, music
wires,
 HCS containing 0.90 to 1.00% carbon is also known as high carbon tool steel and it possesses
hardness of 550-600 BHN. Such steel is used for making punches, dies, springs keys and shear
blades.
 HCS containing 1.0 to 1.1 % C is used for making railway springs, mandrels, taps, balls, pins, tools,
thread metal dies.
 HCS containing 1.1 to 1.2% C is used for making taps, twist drills, thread dies, knives.
 HCS containing 1.2 to 1.3% carbon is used for making files, reamers Files, dies for wire drawing,
broaches, saws for cutting steel, tools for turning chilled iron.

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 To improve the properties of ordinary steel, sufficient amount of
alloying elements are added
 Some of the most common alloying elements are Nickel, Manganese,
Silicon, Chromium, etc
 These alloying elements used separately or in combination to get
desired properties out of alloy steels
 Each alloying element improves properties of alloys such as
machinability, hardness, toughness, wear resistance, corrosion
resistance, elasticity and soon

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 Nickel - Steels contain 2 to 5% nickel and from 0.1 to 0.5% carbon increase its strength
and toughness. In this range, nickel contributes great tensile strength, yield strength,
toughness and forming properties and hardness with high elastic limit, good ductility
and good resistance to corrosion.
 Chromium - It improves corrosion resistance (about 12 to 18% addition). It increases
tensile strength, hardness, wear resistance and heat resistance. It provides stainless
property in steel. It decreases malleability of steel. It is used in steels as an alloying
element to combine hardness with high strength and high elastic limit. It also imparts
corrosion resisting properties to steel.
 Silicon - It improves magnetic permeability and decreases hysteresis losses. It
decreases weldability and forgeability. It is also added as a deoxidizer during casting
of ingots. It takes care of oxygen present in steel by forming SiO2. Silicon steels behave
like nickel steels. These steels have a high elastic limit as compared to ordinary carbon
steel.
 Manganese - It improves the strength of the steel in both the hot rolled and heat
treated condition.
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 Stainless steel contains Chromium together with Nickel as alloy and rest is Iron.
 When correctly heat treated, stainless steel has resistance to oxidation and corrosion.
 Addition of other alloying elements may increase its corrosive resistance such as Nickel,
Molybdenum
 General Properties
 Has wide range of strength and hardness
 Has high ductility, formability, corrosion resistance
 Has good thermal conductivity, creep resistance

 Classification of Stainless Steel

 Martensitic Stainless Steel – used as springs, ball bearing, valves, knife blades, etc
 Ferritic Stainless Steel – used of kitchen equipment, automobile trimmings, sinks, etc
 Austenitic Stainless Steel – used for conveyor chains, furnaces, spokes, industrial components, etc
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 This name is given because, these steel is used for cutting tools which operates
at much higher speeds
 These steels have the property of retaining their hardness even at elevated
temperatures
 By adding elements such as tungsten, chromium, vanadium these steels are
produced
 Classification of HSS
 High Speed Steel – used to produce lathe, planer and shaper tools, drills, punches, etc
 Molybdenum based HSS – used for rough cutting tools, drilling and tapping tools, milling
cutters, etc
 Cobalt based HSS – used to make high production tools for high production lather, planer,
shaper, milling and boring machines
 Vanadium HSS – used to make tools for machining materials which are difficult to machine
by conventional means

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Department of Engieering Technology, Facutly of Technology, University of Sri
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 Study about different cast irons (their composition, properties and applications)
 Malleable Cast Iron
 Ductile Cast Iron
 Wrought Iron

 Study about different alloy steels (their Properties and applications)

 Vanadium Steel
 Manganese Steel
 Tungsten Steel
 Spring Steel
 Structural Steel

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 Non-Ferrous metals contain metals other than iron as their main
constituents such as, Aluminium, Copper, Zinc, Magnesium, Lead, Tin,
Nickel and their alloys
 These non-ferrous metals are used due to various reasons including
the following,
 Resistance to corrosion
 Their special electrical and magnetic properties
 Ease of casting
 Good formability
 Low density
 Attractive colors

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 Aluminium is a white metal which is produced by electrical processes from the oxide
(alumina)
 Properties
 It is ductile, malleable and very good conductor of heat and electricity
 Has very high resistance to corrosion
 In proportion to its weight it is quite strong

 Applications
 Mainly used in aircraft and automobile parts
 used for reflectors, mirrors and telescopes
 Used in making furniture, doors and window components, kitchen utensils, collapsible tubes

 Aluminium can be easily alloyed with other elements to improve various properties
 Such Aluminium alloys includes Duralumin, Y-alloy, Magnalium
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Alloy Composition Properties
Duralumin Copper = 3.5-4.5% • Can be easily forged and
Manganese = 0.4-0.7% casted
Magnesium = 0.4-0.7% • Possesses low melting
Aluminium = 94% point
• Has high tensile strength
compared to mild steel
• Possesses low corrosion
resistance and high
electrical conductivity
Y-alloy Copper = 3.5-4.5% • Has higher strength and
Manganese = 1.2-1.7% machinability than
Nickel = 1.8-2.3% Aluminium
Aluminium = 92.5% • Can be easily cast and
hot worked
Magnalium Copper = 0-25% • Light weight and brittle
Magnesium = 1-5% • Possesses poor
Nickel = 0-12% castability and good
Aluminiuim = 85-95% machinability
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Applications
Automobile and aircraft
components
Surgical and orthopedic
work
Measuring instrument parts
construction
Mainly used for cast
purposes
Used in aircraft engines for
cylinder heads, pistons, etc.
Used for making aircraft and
automobile components
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 Copper is the most widely used non-ferrous metal in industry which is extracted from
copper ores such as copper glance, copper pyrites, malachite and azurite.
 Properties
 It is a good conductor of electricity
 Non-corrosive under ordinary conditions and resist weather
 It is one of the best conductor of heat
 Can withstand severe bending and forging without failure

 Applications
 Making electric cables and wires
 Tubes for heat transfer work
 Household utensils

 Copper is used for making alloys with other metals such as Copper-Zinc alloys(Brasses)
and Copper-Tin alloys (Bronzes)
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 Brasses are widely used alloy of Copper
 The fundamental a binary alloy comprises of 50% Copper and 50% Zinc
 Addition of other elements may greatly change the properties of brass
 Following are the types of brass available
 Red Brass
 Yellow Brass or Muntz Metal
 Cartridge Brass
 Admiralty Brass
 Naval Brass
 Manganese Brass
 Iron Brass or Delta Metal
 Gliding Brass
 Free Cutting Brass
 Lead Brass
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Brass Type Composition Properties Applications
Red Brass Cu = 85% Has excellent corrosion Making of heat exchanger
Zn = 15% resistance and workability tubes, condenser, radiator
cores, plumbing pipes
Yellow Brass or Muntz Metal Cu = 60% Has high strength and high Used in making bolts, rods,
Zn = 40% hot workability tubes, valves and fuses
Pump parts, condenser
tubes
Admiralty Brass Cu = 71% • Has high resistance to Plates used for ship
Zn = 29% corrosion (specially for building
Sn = 1% sea water) Condenser tubes in marine
• Can be cold worked installations
Naval Brass Cu = 59% • Similar to Muntz metal Used for making marine
Zn = 40% • Has high resistance to hardware casting, piston
Sn =1% corrosion due to sea rods, propeller shafts,
water welding rods, etc.

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 Bronze is a alloy of Copper and Tin
 Properties
 Has higher strength, better corrosion resistance
 Can be shaped or rolled into wire
 It has antifriction or bearing properties
 It is costlier than brass

 Following are the types of bronzes available;

 Phosphor Bronze
 Silicon Bronze
 Beryllium Bronze
 Manganese Bronze
 Aluminium Bronze
 Bell Metal
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Type of Bronze Composition Properties Application
Phosphor Bronze Cu = 89 – 94% • Possesses good Used making of bolts,
Sn = 6 – 10% corrosion resistance electric contact springs,
P = 0.1 – 0.3% • Mechanical properties bearings, bushes, gears,
increases with the ship sheathing, valve parts,
increase of Phosphor propeller blades, etc.

Silicon Bronze Cu = 96% • Has good general Used for making boilers,
Si = 3% corrosion resistance tanks, stoves, screws,
Mn or Zn = 1% • Has higher strength tubing’s, pumps, etc.
Manganese Bronze Cu = 60% • It is highly resistance to Used for bushes, plungers,
Zn = 35% corrosion feed pumps, rods, worm
Mn = 5% • Stronger and harder than gears, etc
phosphor bronze
Bell Metal Cu = 66.7% • It is a very strong metal Used to make bells
Sn = 33.3% • Possesses resistance to
corrosion water and
atmosphere
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 Nickel is a sliver shining metal which is extracted from Iron Sulphides which
contains about 3% of Nickel
 Properties
 It is as hard as steel and possesses good heat resistance
 It is tough and have good corrosion resistance
 It is paramagnetic

 Applications
 Kitchen utensils and appliances
 Laundry and dairy machines
 Electroplating to protect iron and brass surfaces
 Making stainless steel

 By alloying nickel with other elements nickel alloys can be obtained such as haste
alloy, monel metal, Inconel, nomonic and ni-chrome
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Nickel Alloy Composition Properties Applications

Haste Alloy or Ni = 45% • Can be hot and cold worked, casted and Used in components of
high temperature Cr = 22% welded nuclear plants, jet and rocket
alloy Mo = 9% • Has high corrosion resistance engines
Co = 1.5% • Can be machined
W = 0.5%
C = 0.15% and Fe
remaining
Monel Metal Ni = 68% • Corrosion resistance is superior than Used for pump fittings,
Cu = 30% brass and bronze condenser tubes, sea water
Fe = 1% • Can retain strength at high temperatures exposed parts
• Has good mechanical properties Used for make turbine
blades, containers,
machinery parts, evaporators,
etc.
Inconel Ni = 80% • Has high resistance to corrosion and Used for making springs,
Cr = 14% oxidation at elevated temperatures exhaust manifold of aircraft
Fe = 6% • Can be casted, forged, cold and hot engines, machinery for food
worked
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 Lead is a bluish grey metal which is a very durable and versatile material
 Properties
 It has high density
 It has a very good resistance to corrosion
 It has properties of easy workability
 It is the softest and heaviest of all the common metals

 Applications
 Used in safety plug in boilers, fire door releases, fuses
 Sheaths for electric cables
 Produce alloys such as brass and bronze
 Lead sheets are used for making roofs and gutters

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 Zinc is a bluish grey in colour and obtained from common Zinc ores such as Zinc
blende, Zincite, Calamine.
 Properties
 This material becomes brittle at 200 0C and can be powdered at this temperature.
 It possesses high resistance to corrosion
 It can be readily worked and rolled

 Applications
 Commonly used as a protective coating on iron and steel ( galvanizing)
 Also used for generating electric shells
 Used for producing alloys such as brass
 Zinc oxides are used as pigments in paint

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 Tin is a brightly shining white metal which is obtained from tin ores such as
tinstone.
 Properties
 It does not corrode in wet and dry conditions
 Considered as a soft and ductile material
 It possesses very good malleability

 Applications
 Commonly used to make bearings which are subjected to high pressure and load
 Used as coating on other metals
 Tin cans are used for storing food and food items

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  A bearing alloy commonly possess good wearing quality, low co-efficient of
friction, high thermal conductivity, good casting qualities, non-corrosive properties,
ability to withstand high pressure and impact, low shrinkage and low cost.

Bearing alloy Compositio Properties Applications

n
Admiralty Gun Metal Cu = 88% Tensile strength = 270 MPa Used for bearings where
Sn = 10% Hardness = 65 BHN lubrication is needed and oiling is
Pb = 2% difficult
Lead Bronze Cu = 80% Tensile strength = 230 MPa Generally used for bearings where
Sn = 10% Hardness = 65 BHN lubrication is doubtful
Pb = 10% Has antifriction property
Hard Bearing Bronze Cu = 85% Tensile strength = 220 Mpa Used for bearings where high
Sn = 15% Hardness = 100 BHN compressive loads apply
(locomotive slide valves, etc.)
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 What is it meant by heat treating a metal?
 Following are the main constituents of Iron
 Austenite
 Ferrite
 Cementite
 Pearlite,
Study about these constituents of Iron

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 Title: Introduction to Basic Manufacturing Processes and Workshop Technology
Author Rajender Singh, Publisher: NEW AGE INTERNATIONAL (P) LIMITED,
PUBLISHERS, ISBN: (10) : 81-224-2316-7 ISBN (13) : 978-81-224-2316-7
 Title Workshop Technology: Manufacturing Process (3rd Revised edition), Author
S.K. Garg, Publisher: Laxmi Publications, ISBN: 8131806979, ISBN-
13: 9788131806975
 Title A TEXTBOOK OF WORKSHOP TECHNOLOGY : MANUFACTURING
PROCESSES (English) 6th Edition, Author J. K. GUPTA , R. S. KHURMI , Publisher: S
Chand, ISBN-13 9788121908689

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