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CHAPTER
9
Engineering
Alloys
9-1
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Blast Furnace
Figure 9.1
9-2 After A. G. Guy,”Elements of Physical Metallurgy,”2nd ed., !959, Addision-Wesley, Fig. 2-5, p.21.
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Steel Making
• Pig iron and 30% steel crap is fed into refractory
furnace to which oxygen lane is inserted.
• Oxygen reacts with liquid bath to form iron oxide.
• FeO + C Fe + CO
• Slag forming fluxes
are added.
• Carbon content and
other impurities are
lowered.
• Molten steel is
continuously cast and Figure 9.2
formed into shapes.
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Invariant reactions
• Peritectic reaction:
14950C
Liquid (0.53%C) + δ (0.09% C) γ (0.17% C)
• Eutectic reaction:
0
Liquid (4.3% C) 1148 C γ austenite (2.08%C) + Fe3C ( 6.67%C)
• Eutectoid reaction:
0
γ Austenite (0.8%C) 723 C α Ferrite(0.02%C) + Fe3C ( 6.67%C)
9-5
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Figure 9.11
9-8 After W. F. Smith, “The Structure and Properties of Engineering Alloys,” 2nd ed.,McGraw-Hill, 1981, p.12.
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9-9
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Microstructure of Fe – C Martensites
• Lath martensite: Less than 0.6% C and consists of
domains of lathe of different orientation.
• Plate martensite: More than 0.6% C and have fine
structure of parallel twins.
Figure 9.13
9-10 After A. R. Marder and G. Krauss, as presented in “Hardenebility Concepts with Applications to Steel,” AIME, 1978, p. 238.
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Martensite (Cont..)
Figure 9.17
9-11After E. R. Parker and V. F. Zackay Strong and Ductile Steels, Sci.Am.,November 1968, p.36; Copyright by Scientific
American, Inc; all rights reserved.
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Repeat
procedure
at
Figure 9.22
Figure 9.21
9-12 After W. F. Smith, “The Structure and Properties of Engineering Alloys,” McGraw-Hill, 1981, p.14
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9-13 After H. E. McGannon(ed.), “The Making Shaping and Treating of Steel,” 9th ed., United States Steel Corp., 1971
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Figure 9.25
9-14 After R. A. Grange, V. E. Lambert, and J. J. Harrington, Trans, ASM, 51:377(1959)
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Figure 9.27
Figure 9.26
9-15 After R. A. Grange and J. M. Kiefer, “Alloying Elements in Steel,” ASM 2nd ed., 1966, p.254.
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9-16 After T. G. Diggers et al., “ Heat Treatment and Properties of Iron and Steel,” NBS Monograph 88, 1966, p. 10
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Figure 9.31
9-17 From “ Suiting the heat Treatment to the job,” United States Steel Corp., 1968, p.34.
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Effects of Tempering
Figure 9.32
9-18 After JE. C. Bain, and H. W. Paxton, “Alloying Elements in Steel, “ 2nd ed., American Society for Metals, 1996 p.38.
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9-19 Source: “Metals Handbook,” vol. 2, 8th ed., American Society for Metals, 1964.
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9-20
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9-21
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9-22 Source: “Alooy Steel: Semifinished; Hot-Rolled and Cold-Finished Bars,” American Iron and Steel Institute, 1970.
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9-23 After JE. C. Bain, and H. W. Paxton, “Alloying Elements in Steel, “ 2nd ed., American Society for Metals, 1996
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Figure 9.35
9-24 Source: “Metals Handbook,” vol. 2, 9th ed., American Society for Metals, 1973.
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Hardenability
• Hardenability determines the depth and distribution of
hardness induced by quenching.
• Hardenability depends on
Composition
Austenitic grain size
Structure before
quenching
• Joming hardenability test:
Cylindrical bar (1 inch dia and 4
inch length with 1/16 in flange
at one end is austenitized and one
end is quenched.
Rockwell C hardness is measured Figure 9.36b
up to 2.5 inch from quenched end.
9-25 After H. E. McGannon(ed.), “The Making Shaping and Treating of Steel,” 9th ed., United States Steel Corp., 1971, p.1099
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Hardenability (cont..)
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4820
9-27
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Stainless Steel
• Excellent corrosion resistance in stainless steel is due
to high (at least 12%) Chromium forming chromium
oxide on surface.
• Ferrite stainless steel :
12-30% Cr
Structure is mainly
ferritic (BCC α ).
Cr extends α region
and suppresses γ region
forming γ loop.
Figure 9.55
Low cost high strength (517 MPa) and hence used
in construction materials.
9-45 After “Metals Handbook,” vol. 8, 8th ed., American Society for Metals, 1973, p.291.
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9-46
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Austenitic Region
9-47
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Cast Iron
9-48
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Pearlite
Figure 9.59
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Graphite
Flakes
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Figure 9.63
9-51 After “Metals Handbook,” vol. 7, 8th ed., American Society for Metals, 1972, p.88.
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Figure 9.65
9-52 After “Metals Handbook,” vol. 7, 8th ed., American Society for Metals, 1972, p.95.
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Heat Treatment
9-53
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Aluminum Alloys
9-28
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9-29
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Figure 9.43
9-30
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Example - Al 4% Cu Alloy
9-31
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Figure 9.47
9-32 After J. M. Silcock, T. J. Heal, and H. K. Hardy “Alluminium,” 1, American society of Metals, 1967,p.123.
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• Aluminum hydroxide is
precipitated from aluminum
solution.
• Aluminum hydroxide is
thickened and calcined to
Al2O3 which is dissolve in
cryolite and electrolyzed. Figure 9.48
• Metallic aluminum sinks to bottom and is tapped out.
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• Classification: According to
major alloying elements.
• Four digits: First digit -
major group of alloying
elements.
• Second digit: Impurity limits.
• Last 2 digits: Identify
aluminum alloy.
9-34
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Temper Designations
T1 – Naturally aged
T3 – Solution heat treated.
F – as fabricated H1 – Strain hardened T4 – Solution heat treated
O – Annealed alloy. and naturally aged.
H – Strain hardened. H2 – Strain hardened T5 - Cooled and artificially
T – Heat treated to and partially aged.
T6 - Solution heat treated
produce stable annealed.
and artificially aged.
temper H3 - Strain hardened T7 - Solution heat treated
an annealed and stabilized.
T8 - Solution heat treated,
cold worked and then
artificially aged.
9-35
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9-36
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9-37
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Aluminum Casting
• Sand Casting: Simple and used for small
quantities and complex jobs.
• Permanent mold casting: Molten metal is
poured into permanent metal mold.
Finer grain structure and strength due to fast cooling.
Less shrinkage and porosity.
More shrinkage and simple parts only.
• Die casting: Molten metal forced into molds
under pressure.
Almost finished parts, automatic.
Good tolerance and surface finish.
Fine grain structure.
9-38
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Copper Alloys
9-40
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9-41
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Unalloyed Copper
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Alpha
Beta
Figure 9.53
• Zinc (0.5 to 3%) is always added to copper to increase
machinability.
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9-44
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• Magnesium Alloys:
Low density metal, high cost, low castability, low
strength, poor creep, fatigue and wear resistance.
Two types: wrought alloys (sheet, plate, extrusion)
and casting alloys (casting).
Designated by two capital letters and two or three
numbers.
First two letters indicate two major alloying
elements.
The numbers indicate wt% of alloying elements.
9-54
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9-55
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Titanium Alloys
9-56
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Nickel Alloys
9-57
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Intermetallics
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Ni
N
Ti
iT
Deformed i
Cooled (Martensite)
Heated (Martensite) Heated
(Austenite) (Austenite)
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SMA - Hysterisis
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Amorphous Metals
crystalline Amorphous
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Bone plate
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Titanium Alloys
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