CHAPTER 5

Ferrous Metals and Alloys: Production,

General Properties, and Applications

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 Blast Furnace
Figure 5.1
Schematic
illustration of a
blast furnace.
Source: Courtesy
of American Iron
and Steel Institute.

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 Electric Furnaces

Figure 5.2 Schematic illustration of types of electric furnaces: (a) direct arc, (b) indirect arc, and (c) induction.

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 Basic-Oxygen Process
Figure 5.3 Schematic
illustrations showing
(a) charging, (b)
melting, and (c)
pouring of molten iron
in a basic-oxygen
process. Source:
Inland Steel Company

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 Figure 5.4 The
continuous-casting
process for steel.
Typically, the solidified
metal descends at a speed
of 25 mm/s (1 in./s). Note
that the platform is about
20 m (65 ft) above ground
level. Source:
Metalcaster's Reference
and Guide, American
Foundrymen's Society.
Continuous
Casting

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 Typical Selection of Carbon and Alloy Steels for
Various Applications
TABLE 5.1
Product Steel Product Steel
Aircraft forgings, 4140, 8740 Differential gears 4023
tubing, fittings Gears (car and truck) 4027, 4032
Automobile bodies 1010 Landing gear 4140, 4340, 8740
Axles 1040, 4140 Lock washers 1060
Ball bearings and races 52100 Nuts 3130
Bolts 1035, 4042, 4815 Railroad rails and wheels 1080
Camshafts 1020, 1040 Springs (coil) 1095, 4063, 6150
Chains (transmission) 3135, 3140 Springs (leaf) 1085, 4063, 9260, 6150
Coil springs 4063 Tubing 1040
Connecting rods 1040, 3141, 4340 Wire 1045, 1055
Crankshafts (forged) 1045, 1145, 3135, 3140 Wire (music) 1085

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 Mechanical Properties of Selected Carbon and
Alloy Steels in Various Conditions
TABLE 5.2 Typical Mechanical Properties of Selected Carbon and Alloy Steels in the Hot-Rolled,
Normalized, and Annealed Condition
AISI Condition Ultimate Yield Elongation in Reduction of Hardness
tensile Strength 50 mm (%) area (%) (HB)
strength (MPa)
(MPa)
1020 As-rolled 448 346 36 59 143
Normalized 441 330 35 67 131
Annealed 393 294 36 66 111
1080 As-rolled 1010 586 12 17 293
Normalized 965 524 11 20 293
Annealed 615 375 24 45 174
3140 Normalized 891 599 19 57 262
Annealed 689 422 24 50 197
4340 Normalized 1279 861 12 36 363
Annealed 744 472 22 49 217
8620 Normalized 632 385 26 59 183
Annealed 536 357 31 62 149

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 AISI Designation for High-Strength Sheet
Steel
TABLE 5.3
Yield Strength Chemical Deoxidation
Composition Practice
3
psi x 10 MPa
35 240 S = structural alloy F = killed plus sulfide inclusion control
40 275
45 310
50 350 X = low alloy
60 415 K = killed
70 485 W = weathering
80 550 O = nonkilled
100 690 D = dual phase
120 830
140 970

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 Room-Temperature Mechanical Properties and
Applications of Annealed Stainless Steels
TABLE 5.4 Room-Temperature Mechanical Properties and Typical Applications of Selected Annealed
Stainless Steels
Ultimate
tensile Yield Elongation
AISI strength strength in 50 mm
(UNS) (MPa) (MPa) (%) Characteristics and typical applications
303 550–620 240–260 53–50 Screw machine products, shafts, valves, bolts,
(S30300) bushings, and nuts; aircraft fittings; bolts; nuts;
rivets; screws; studs.
304 565–620 240–290 60–55 Chemical and food processing equipment,
(S30400) brewing equipment, cryogenic vessels, gutters,
downspouts, and flashings.
316 550–590 210–290 60–55 High corrosion resistance and high creep strength.
(S31600) Chemical and pulp handling equipment,
photographic equipment, brandy vats, fertilizer
parts, ketchup cooking kettles, and yeast tubs.

410 480–520 240–310 35–25 Machine parts, pump shafts, bolts, bushings, coal
(S41000) chutes, cutlery, tackle, hardware, jet engine parts,
mining machinery, rifle barrels, screws, and
valves.
416 480–520 275 30–20 Aircraft fittings, bolts, nuts, fire extinguisher
(S41600) inserts, rivets, and screws.

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 Basic Types of Tool and Die Steels

TABLE 5.5
Type AISI
High speed M (molybdenum base)
T (tungsten base)
Hot work H1 to H19 (chromium base)
H20 to H39 (tungsten base)
H40 to H59 (molybdenum base)
Cold work D (high carbon, high chromium)
A (medium alloy, air hardening)
Shock resisting O (oil hardening)
S
Mold steels P1 to P19 (low carbon)
P20 to P39 (others)
Special purpose L (low alloy)
F (carbon-tungsten)
Water hardening W

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 Processing and Service Characteristics of
Common Tool and Die Steels
TABLE 5.6 Processing and Service Characteristics of Common Tool and Die Steels
Approximate
AISI Resistance to Resistance to hardness Resistance to Resistance to
designation decarburization cracking (HRC) Machinability Toughness softening wear
M2 Medium Medium 60–65 Medium Low Very high Very high
T1 High High 60–65 Medium Low Very high Very high
T5 Low Medium 60–65 Medium Low Highest Very high
H11, 12, 13 Medium Highest 38–55 Medium to high Very high High Medium
A2 Medium Highest 57–62 Medium Medium High High
A9 Medium Highest 35–56 Medium High High Medium to
high
D2 Medium Highest 54–61 Low Low High High to very
high
D3 Medium High 54–61 Low Low High Very high
H21 Medium High 36–54 Medium High High Medium to
high
H26 Medium High 43–58 Medium Medium Very high High
P20 High High 28–37 Medium to high High Low Low to
medium
P21 High Highest 30–40 Medium Medium Medium Medium
W1, W2 Highest Medium 50–64 Highest High Low Low to
medium
Source: Adapted from Tool Steels, American Iron and Steel Institute, 1978.

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