ENR116 – Mod. 3- Slide No.

Types of alloy
 ENR116 – Mod. 3- Slide No. 2

Intended Learning Outcomes

At the end of this section, students will be able

to:-

• Classify the technologically important metal types.

• Identify the typical applications of these metal

classes.
 ENR116 – Mod. 3- Slide No. 3

Classification of metal alloys

Metal Alloys

Adapted from Fig.

Ferrous Nonferrous 11.1, Callister &
Rethwisch 8e.

Steels
Steels Cast Irons
Cast Irons
<1.4 wt% C
<1.4wt%C 3-4.5 wt%C
3-4.5 wt% C

T(ºC) microstructure: ferrite,

1600 graphite/cementite
d
1400 L
g+L Adapted from Fig. 9.24, Callister &
1200 g 1148ºC L+Fe3C Rethwisch 8e. (Fig. 9.24 adapted from
austenite Binary Alloy Phase Diagrams, 2nd ed.,
Eutectic: Vol. 1, T.B. Massalski (Ed.-in-Chief), ASM
1000 4.30
International, Materials Park, OH, 1990.)
g+Fe3C
a+

a800 727ºC Fe3C

g

ferrite Eutectoid: cementite

600 0.76 a+Fe3C
400
0 1 2 3 4 5 6 6.7
(Fe)
Co , wt% C
 ENR116 – Mod. 3- Slide No. 4

Steels

Low Alloy High Alloy

low carbon Med carbon high carbon
<0.25wt%C 0.25-0.6wt%C 0.6-1.4wt%C

heat
Name plain HSLA plain
plain tool stainless
treatable
Cr,V Cr, Ni Cr, V,
Additions none none none Cr, Ni, Mo
Ni, Mo Mo Mo, W
Example 1010 4310 1040 4340 1095 4190 304, 409
Hardenability 0 + + ++ ++ +++ varies
TS - 0 + ++ + ++ varies
EL + + 0 - - -- ++
Uses auto bridges crank pistons wear drills high T
struc. towers shafts gears applic. saws applic.
sheet press. bolts wear dies turbines
vessels hammers applic. furnaces
blades Very corros.
resistant
increasing strength, cost, decreasing ductility

Based on data provided in Tables 11.1(b), 11.2(b), 11.3, and 11.4, Callister & Rethwisch 8e.
 ENR116 – Mod. 3- Slide No. 5

Refinement of steel from ore

The Basic Oxygen Steel (BOS) Process:

 ENR116 – Mod. 3- Slide No. 6

Ferrous alloys

Iron-based alloys:
Steels
Cast Irons
Nomenclature for steels (AISI/SAE)
10xx Plain Carbon Steels
11xx Plain Carbon Steels (resulfurized for machinability)
15xx Mn (1.00 - 1.65%)
40xx Mo (0.20 ~ 0.30%)
43xx Ni (1.65 - 2.00%), Cr (0.40 - 0.90%), Mo (0.20 - 0.30%)
44xx Mo (0.5%)
where xx is wt% C x 100
example: 1060 steel – plain carbon steel with 0.60 wt% C

Stainless Steel: >11% Cr

 ENR116 – Mod. 3- Slide No. 7

Cast irons

Ferrous alloys: with > 2.1 wt% C (generally 3 - 4.5 wt% C)

• Low melting – relatively easy to cast

• Generally brittle

http://www.newtonforge.co.uk
• Metastable
• Cementite decomposes to ferrite + graphite (a slow
process)

Fe3C  3 Fe () + C (graphite)

 ENR116 – Mod. 3- Slide No. 8

Fe-C true equilibrium diagram

Graphite formation T(ºC)

1600
promoted by:
1400 L Liquid +
Si > 1 wt%
g +L Graphite
Slow cooling 1200 g 1153ºC
Austenite 4.2 wt% C
1000
a+g  + Graphite
800
740ºC
0.65
600
Adapted from Fig. 11.2,
 + Graphite
Callister & Rethwisch 8e. 400
[Fig. 11.2 adapted from 0 1 2 3 4 90 100
Binary Alloy Phase (Fe) C, wt% C
Diagrams, 2nd ed.,
Vol. 1, T.B. Massalski (Ed.-
in-Chief), ASM International,
Materials Park, OH, 1990.]
 ENR116 – Mod. 3- Slide No. 9

Types of cast iron

Gray iron: Adapted from Fig.

11.3(a) & (b),
Callister &

• graphite flakes Rethwisch 8e.

• weak & brittle in tension, stronger in

compression
• excellent vibrational dampening and
wear resistance

Ductile iron:
• add Mg and/or Ce
• graphite as nodules not flakes
• matrix often pearlite –
stronger but less ductile
 ENR116 – Mod. 3- Slide No. 10

Types of cast iron

White iron:
• < 1 wt% Si
• pearlite + cementite
• very hard and brittle
Adapted from Fig.
11.3(c) & (d),
Callister &
Rethwisch 8e.
Malleable iron:
• heat treat white iron at 800-900ºC
• graphite in rosettes
• reasonably strong and ductile
 ENR116 – Mod. 3- Slide No. 11

Types of cast iron

Compacted graphite iron:

• relatively high thermal conductivity

• good resistance to thermal
shock
• lower oxidation at elevated
temperatures
Adapted from Fig.
11.3(e), Callister &
Rethwisch 8e.
 ENR116 – Mod. 3- Slide No. 12

Production of cast irons

Adapted from Fig.11.5,

Callister & Rethwisch 8e.
 ENR116 – Mod. 3- Slide No. 13

Limitations of ferrous alloys

I. Relatively high densities

II. Relatively low electrical conductivities

III. Generally poor corrosion resistance

 ENR116 – Mod. 3- Slide No. 14

Nonferrous alloys

Based on • Cu Alloys • Al Alloys

discussion
and data Brass: Zn is subst. impurity -low r: 2.7 g/cm3
provided in
Section
(costume jewelry, coins, -Cu, Mg, Si, Mn, Zn additions
11.3, corrosion resistant) -solid sol. or precip.
Callister &
Rethwisch Bronze : Sn, Al, Si, Ni are strengthened (struct.
3e.
subst. impurities aircraft parts
(bushings, landing & packaging)
gear) Nonferrous • Mg Alloys
Cu-Be: -very low r: 1.7g/cm3
precip. hardened Alloys -ignites easily
for strength -aircraft, missiles
• Ti Alloys
-relatively low r: 4.5 g/cm3 • Refractory metals
-high melting T’s
vs 7.9 for steel • Noble metals -Nb, Mo, W, Ta
-reactive at high T’s -Ag, Au, Pt
-space applic. -oxid./corr. resistant
 ENR116 – Mod. 3- Slide No. 15

Summary

• Steels and cast irons are ferrous alloys – a

large range of steels can be produced by
alloying with additional metals.

• The limitations of ferrous alloys (high density, low

conductivity, poor corrosion resistance) can be
addressed with nonferrous alloys.