A REFRESHER ON
INDUSTRIAL & FERTILIZER MATERIALS
PRESENTED BY
NOOR-UL-HASSAN
MATERIAL CLASSIFICATION
MATERIALS
NON - FERROUS
METALS
FERROUS
NON - METALS
FERROUS METALS
ORIGINAL DEFINITION
- IRON CONTENTS GREATER THAN 50%.
Cr : 26 max. Mn : 02 max.
SS 310 Ni : 22 max. Si : 1.5 max.
Total : 51.5 max.
REVISED DEFINITION (1993)
- MATERIAL WHICH CONTAINS BY MASS MORE IRON THAN ANY
OTHER SINGLE ELEMENT.
CLASSIFICATION FERROUS METALS
FERROUS METALS
WROUGHT IRON
CARBON STEEL BASED ON “C” ADDITION
CAST IRON
ALLOY STEEL
EFFECT OF CARBON ON STEEL
Carbon
Hardness Strength Ductility Weldability
WROUGHT IRON
COMPOSITION
- CARBON CONTENTS LESS THAN 0.08 % CARBON
- CONTAINS SMALL AMOUNT OF SLAG (SiO2)
MECHANICAL PROPERTIES
- LOW STRENGTH , MALLEABLE AND DUCTILE
- EASILY WELDABLE
USES
- CURRENTLY WROUGHT IRON IS NOT PRODUCED DUE TO HIGH
MANUFACTURING COST
- MODERN WROUGHT IRON PRODUCTS ARE ACTUALLY MADE
FROM LOW CARBON STEEL
CARBON STEEL
TYPE OF STEEL FOR WHICH:
- NO ALLOYING ELEMENT IS ADDED EXCEPT CARBON
- CARBON CONTENTS ARE < 2%
CARBON STEEL IS CLASSIFIED ACCORDING TO:
ITS CARBON CONTENTS
ITS TREATMENT FOR DEOXIDIZATION
CARBON STEEL CLASSIFICATION
ACCORDING TO CARBON CONTENTS
CARBON STEEL
LOW CARBON STEEL CARBON CONTENTS < 0.3 %
MEDIUM CARBON STEEL CARBON CONTENTS BETWEEN 0.3 %
AND 0.6%
HIGH CARBON STEEL CARBON CONTENTS BETWEEN 0.6 %
AND 2.0%
LOW CARBON STEEL
COMPOSITION
- LESS THAN 0.3 % CARBON
MECHANICAL PROPERTIES
- EXCELLENT FORMABILITY AND WELDABILITY
- GRADES HAVING CARBON B/W 0.1 % TO 0.3 % ARE HEAT TREATABLE
GENERAL USES
- SHEETS MANUFACTURING, PIPING AND PRESSURE VESSEL
COMPONENTS
LOW CARBON STEEL
USED AT FERTILIZER PLANT
- PIPING, VALVES AND VESSELS FOR
- LOW, MEDIUM AND HIGH PRESSURE STEAM/CONDENSATE
- COOLING WATER, INSTRUMENT AIR, FUEL GAS, NATURAL GAS
- LIQUID AMMONIA (HIGH TEMPERATURE)
- LOAD BEARING STRUCTURES AND SHEETS
LOW CARBON STEEL GRADES
API 5L GRADE B
ASTM A - 105
ASTM A - 234
MEDIUM CARBON STEEL
COMPOSITION
- CARBON CONTENTS BETWEEN 0.3% TO 0.6%
MECHANICAL PROPERTIES
- GOOD BALANCE BETWEEN STRENGTH AND DUCTILITY
- HEAT TREATABLE
GENERAL USES
- MANUFACTURING OF GEARS, CRANKSHAFT ETC.
HIGH CARBON STEEL
COMPOSITION
- CARBON CONTENTS BETWEEN 0.6% TO 2.0%
MECHANICAL PROPERTIES
- HIGH STRENGTH
- LOW DUCTILITY
- POOR WELDABILITY AND FORMABILITY
GENERAL USES
- HIGH STRENGTH WIRES AND SPRINGS
CAST IRON
COMPOSITION
- CARBON CONTENTS BETWEEN 2% AND 5%
- SILICON INCLUSION BETWEEN 1% AND 3%
MECHANICAL PROPERTIES
- MELTING TEMPERATURE BELOW CARBON STEEL
- EXCELLENT FLUIDITY (REQUIRED FOR CASTING PURPOSE)
- POOR WELDABILITY AND DUCTILITY
GENERAL USES
- MANUFACTURING OF PUMPS, TURBINES, COMPRESSORS AND GEAR BOX
CASINGS
CLASSIFICATION FERROUS METALS
FERROUS METALS
WROUGHT IRON
CARBON STEEL BASED ON “C” ADDITION
CAST IRON
ALLOY STEEL
ALLOY STEELS
ALLOY STEEL Cr-Mo Alloy
LOW ALLOY STEEL CORROSION RESISTANT
ALLOYING ELEMENT UP TO 8.0%
HEAT RESISTANT
HIGH ALLOY STEEL WEAR RESISTANT
ALLOYING ELEMENT GREATER THAN 8.0%
Cr – Mo STEELS
COMPOSITION
- Cr UPTO 2.25% AND Mo UP TO 1.25%
ALLOYING EFFECT
- Cr INCREASES CORROSION RESISTANCE
- Mo ADDS ELEVATED TEMPERATURE STRENGTH
MECHANICAL PROPERTIES
- HIGH STRENGTH AT TEMPERATURES UP TO 650 0C
- DIFFICULT WELDING AS HEAT TREATMENT IS INVOLVED
GENERAL USES
- PRESSURE VESSEL, PIPING AT HIGH TEMPERATURE
Cr – Mo STEELS
USES AT FERTILIZER PLANT
- PIPING, VALVES AND VESSELS FOR VER HIGH PRESSURE STEAM (KS)
Cr - Mo STEEL GRADES
A-335 GRADE P11 (PLANT-I KS)
A-335 GRADE P22 (PLANT-I KS)
STAINLESS STEEL
WHEN Cr CONTENTS ARE GREATER THAN 11.5 %, Cr REACTS WITH ATMOSPHERIC
O2 AND FORM THIN PASSIVE Cr-O2 LAYER ON STEEL SURFACE PREVENTING
OXIDATION OF Fe CONTENTS
Cr–O2 LAYER
STEEL
EFFECT OF CHROMIUM
STAINLESS STEEL
STAINLESS STEEL
AUSTENITIC
FERRITIC
MARTENSITIC
DUPLEX
SCHAFFLER DIAGRAM
AUSTENITIC STAINLESS STEEL
COMPOSITION Cr UP TO 30%
Ni UP TO 30%
C 0.3%
MECHANICAL PROPERTIES
- EXCELLENT CORROSION RESISTANT
- GOOD WELDABILITY
- CAN BE USED AT LOW AND HIGH TEMPERATURE (UP TO 900 0C)
- CANNOT BE HARDENED BY HEAT TREATMENT
GENERAL USES
- FOOD PROCESSING, CORROSIVE SERVICES e.g. UREA, ACID etc.
AUSTENITIC STAINLESS STEEL
USED AT FERTILIZER PLANT
- PIPING, VALVES AND VESSELS FOR
- ALL PRESSURE UREA SERVICE AND UREA FLUSHING CIRCUIT
- MDEA, PROCESS GAS, DEMIN WATER
AUSTENITIC GRADES
SS- 304
SS- 316
SS- 316L Modified
25 Cr – 22Ni – 02 Mo
SS- 321
CONCEPT OF SENSITIZATION IN STAINLESS STEEL
AT HIGH TEMPERATURE (> 750 0C) Cr REACTS WITH C AND FORMS CrC
TO PREVENT SENSITIZATION Ti OR Nb IS ADDED TO FORM TiC OR NbC
GRAIN BOUNDARIES
CHROMIUMCARBIDE
(Cr23 C6)
CHROMIUM
MARTENSITIC STAINLESS STEEL
COMPOSITION Cr UP TO 17%
Ni 0%
C 1.2%
MECHANICAL PROPERTIES
- MODERATE CORROSION RESISTANT
- POOR WELDABILITY
- CAN BE HARDENED BY HEAT TREATMENT
GENERAL USES
- SHAFTS, SURGICAL INSTRUMENTS, FASTENERS
MARTENSITIC STAINLESS STEEL
USED AT FERTILIZER PLANT
- PUMP SHAFTS, IMPELLERS FOR CORROSIVE SERVICE
MARTENSITIC GRADES
SS- 410
SS- 416
SS- 420
SS- 440
FERRITIC STAINLESS STEEL
COMPOSITION Cr UP TO 30%
Ni 0%
C .3%
MECHANICAL PROPERTIES
- MODERATE TO GOOD CORROSION RESISTANT
- POOR WELDABILITY
- CANNOT BE HARDENED BY HEAT TREATMENT
GENERAL USES
- DOMESTIC EQUIPMENTS
DUPLEX STAINLESS STEEL
COMPOSITION Cr UP TO 30%
Ni UP TO 8%
C .3%
MECHANICAL PROPERTIES
- GOOD CORROSION RESISTANCE
- GOOD STRENGTH : GREATER THAN AUSTENITIC AND OTHER GRADES
- GOOD WELDABILITY
GENERAL USES
- OFF-SHORE APPLICATIONS, HIGH PRESSURE UREA
DUPLEX STAINLESS STEEL
USED AT FERTILIZER PLANT
- UREA REACTOR (STAMI CARBON PLANTS)
- STEMS FOR HIGH PRESSURE UREA VALVES
DUPLEX GRADES
HVD-1
FERRALIUM ALLOY
MARTENSITIC
STEEL
SS - 317
INCREASE C
LOWER Cr ADD MORE Mo (4%)
FOR PITTING RESISTANCE
FERRITIC
SS - 317L
STEEL
LOWER C SS - 316L
SS - 316
NO Ni SS - 304L
ADD Mo (2%)
FOR PITTING RESISTANCE
SS - 347
SS – 304
ADD Nb + Ta 18 Cr – 8 Ni
TO REDUCE SENSITIZATION
ADD Ti ADD Cr & Ni SS – 310
SS - 321 STRENGTH & CORROSION RESIST. SS - 309
TO REDUCE SENSITIZATION
DUPLEX REDUCE Ni
STEEL TO REDUCE AUSTENITIC STRUCTURE
MATERIAL DESIGNATION SYSTEM
ASTM - American Society for Testing Materials
AISI - American Iron and Steel Institute
SAE - Society of Automotive Engineers
UNS - Unified Numbering System
DIN - German Standards
BS - British Standards
JS - Japanese Standards
AISI/SAE DESIGNATION SYSTEM
CLASSIFY MATERIAL ON THE BASIS OF COMPOSITION
CARBON AND ALLOY STEEL (EXCEPT STAINLESS STEEL)
ADDITION OF ELEMENTS
10 - Carbon Steel
41 - 1% Cr & 0.3% Mo Steel
PREFIX M OR E SUFFIX H
M - Merchant Quality Steel
E - Electric Furnace Steel
X 13 Y 12 Z
B - Boron
L - Lead
CARBON %AGE
H - Hardenability
MATERIAL TYPE
AISI/SAE DESIGNATION SYSTEM
STAINLESS STEEL
2 - Austenitic Stainless Steel
Element addition
3 - Austenitic Stainless Steel
4 - Martensitic & Ferritic
3 16 Z
L - Low Carbon (<0.03%)
H - High Carbon Contents
No Specific Interpretation
N - Added Nitrogen
MATERIAL TYPE Cu - Added Copper
ASTM STANDARDS
DESIGNATION SYSTEM
CLASSIFY PRODUCTS ON THE BASIS OF MANUFACTURING METHOD
MOST WIDELY USED SYSTEM – COVERS ALL DETAILS REQUIRED FOR MATERIAL
PROCUREMENT
Grade
ASTM A 182 / 182 M - 93b F 304L
Ferrous Metals AISI NO
Arbitrary Number Year of Revision
Metric System
ASTM STANDARDS
DESIGNATION SYSTEM
C - Corrosion Resistant
H - Heat Resistant EXAMPLES
M - Addition of Molybdenum
A 403/A 403M -93 WP304L
Digital No. - Carbon Percentage
A 351 Grade HK40
P - Pipe
T - Tube A 336/A 336M-89 Class F22
TP - Tube and Pipe
A 351 Grade CF8M
F - Forging
W - Wrought
UNIFIED NUMBERING SYSTEM (UNS)
JOINT VENTURE AS ASTM AND SAE TO GENERATE UNIFIED COMPUTER FRIENDLY
SYSTEM
AISI/SAE NUMBER
1 - Boron
4 - Lead
TYPE OF STEEL
6 - Electric Furnace Steel
G - Carbon and Alloy steels
X 1040 1
F - Cast Irons
H - Heat and Corrosion
ELEMENT ADDITION Resistant Steels
MATERIAL COMPOSITION
WHERE TO FIND
BLACK BOOK BY CASTII PUBLISHING (PDF FORMAT)
KEY TO STEEL (SOFTWARE)
ASTM STANDARDS
THE END
Cr – Mo STEELS
Cr UP TO 30% Cr UP TO 30%
Ni UP TO 30% Ni UP TO 8%
C 0.3%
C .3%
Cr UP TO 30% Cr UP TO 17%
Ni 0% Ni 0%
C 0.3% C 1.2%
STAINLESS STEEL
CONCEPT OF SENSITIZATION
CHROMIUM CARBIDE (Cr23 C6)
CHROMIUM DEPLETED LAYER
MATERIAL CLASSIFICATION
FERROUS METALS LOW CARBON
CARBON STEEL HIGH CARBON
MEDIUM CARBON
CAST IRON
LOW ALLOY STEEL
HIGH ALLOY STEEL
STAINLESS STEEL
Ni UP TO 30%
Cr
UP TO 30%
Cr UP TO 30% Cr UP TO 30%
Cr UP TO 17%
Ni 0% Ni 0%
Ni UP TO 8%
C 1.2%
C .3% C .3% C .3%
AUSTENITIC DUPLEX FERRITIC MARTENSITIC
STAINLESS STEEL STAINLESS STEEL STAINLESS STEEL STAINLESS STEEL
AUSTENITIC STAINLESS STEEL
UN-STABILIZED GRADE STABILIZED GRADE
Cannot Be Used for High Can Be Used for High
Temperature Temperature
- SS 304 - SS 321
- SS 316 - SS 347
- 316L + G510
- 25 Cr – 22 Ni – 2 Mo
AUSTENITIC STAINLESS STEEL
SS - 317
ADD MORE Mo (4%)
FOR PITTING RESISTANCE
SS - 317L
LOWER C SS - 316L
SS - 316
SS - 304L
ADD Mo (2%)
FOR PITTING RESISTANCE
SS - 347
SS – 304
ADD Nb 18 Cr – 8 Ni
TO REDUCE SENSITIZATION
ADD Ti ADD Cr & Ni SS – 310
SS - 321 STRENGTH & CORROSION RESIST. SS - 309
TO REDUCE SENSITIZATION
CARBON STEEL
CARBON STEEL
LOW CARBON STEEL CARBON CONTENTS < 0.3 %
MEDIUM CARBON STEEL
CARBON CONTENTS BETWEEN
0.3 % AND 0.6%
HIGH CARBON STEEL
CARBON CONTENTS BETWEEN
0.6 % AND 2.0%
OBJECTIVE
CARBON STEEL CLASSIFICATION
ACCORDING TO CARBON CONTENTS
SHAEFFLER DIAGRAM
