Introduction to metallic materials

MSE 301: Engineering Metallic Materials

First Semester 2022-2023 (221)
Instructor: Abduljabar AlsayoudRoom # 63-244 Phone: 2950

Office Hours: UTR: 10:10AM to 11:00 AM MW: 9:00 to 10:50 AM

Email: sayoudaq@kfupm.edu.sa

Course Description: Review of metallic bonding and crystal structures, dislocations and plastic deformation,
strengthening mechanisms. Solidification of metals. Heat treatment, properties and applications of ferrous alloys: steels,
cast irons, stainless steels, and non-ferrous alloys: Cu, Al, Ti, and Ni.

Textbook:

Engineering Materials Properties and Selection, Kenneth G. Budinski and Michael K. Budinski

References:

Modern Physical Metallurgy and Materials Engineering, 6th edition, 1997, Smallman and Bishop, Butterworth-Heinemann
Publishing.
 MSE 301: Engineering Metallic Materials
First Semester 2022-2023 (221)
Instructor: Abduljabar AlsayoudRoom # 63-244 Phone: 2950

Office Hours: UTR: 10:10AM to 11:00 AM MW: 9:00 to 10:00 AM

Email: sayoudaq@kfupm.edu.sa

Grading:
Homework assignments 15%
Quizzes 10%
Participation in classroom activities 15%
Mid Exam 20%
Project 15%
Final Exam 25%
Course Outline:

Chapter Topic
1 Introduction
2 Solidification of Metals and Alloys
3 Review of Fe-C phase diagram
4 HSLA, tool steels
5 Cast irons
6 Stainless steels (austenitic, ferritic, martensitic)
7 Weldability of steels
8 Corrosion of steels
Midterm exam
9 Aluminum alloys (precipitation hardening, solid solution)
10 Titanium alloys (alpha, Beta, Ti-6Al-4V)
11 Nickle alloys (Super-alloys)
12 Copper alloys (Brass, Bronze, Monel alloys)
Important of metallic materials
• Most elements are metals.

• Historically metals played important role in building civilizations (Bronze age, iron age and Copper

Age). (discovering, isolating alloying and processing)

• Up to now metals are used for most structural materials applications from construction to

transportation.

• Materials science was born from metallurgy in many universities.

Types of metallic materials
• Carbon and alloy steels

• Stainless steels

• Aluminum alloys

• Copper and copper alloys

• Titanium alloys

• Magnesium alloys

• Other important metals (gold, silver, zinc, chromium, nickel, uranium …)

• Superalloys

• Intermetallic compounds
Utilization of metallic materials
• Metals are used because of their high strength, hardness, toughness and melting point.

• Other metals are used due to their high electrical or thermal conductivity and some for their
magnetic properties.

• Cost of metals plays large role in their utilization.

• Some of the major contributions to the cost are:

• Availability

• Ease of extraction and isolation

• Disadvantages of most metals are their high density, susceptibility to corrosion, production energy
and pollution chemicals used for the extraction and isolation
Applications
• Oil and gas industry

• Construction

• Nuclear

• Aerospace

• Space shuttle

• Electronics

• Magnetic

• Optical

• Thermal
Topics for the projects
• Application
• Metallic vs nonmetallic
• Economy
• Availability
• Environmental impact
• Sustainability
• Circular economy
• Recyclability
• Corrosion
Topics to be covered for each alloy
• Introduction to the element and sources of extraction

• Alloying elements

• Phase diagrams, manufacturing methods, strengthening mechanisms, heat treatment, hardening

• Properties (mechanical, electrical, thermal, optical, chemical and magnetic)

• Applications (oil and gas ……)

• Locations of mines, countries production, companies

• KSA share and potential for expansion

Classification of Metal Alloys
Metal Alloys

Adapted from Fig.

Ferrous Nonferrous 11.1, Callister &
Rethwisch 9e.

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
δ
1400 L Fig. 9.24, Callister & Rethwisch 9e.
[Adapted from Binary Alloy Phase
γ+L Diagrams, 2nd edition, Vol. 1, T. B.
1200 γ 1148ºC L+ Fe3C Massalski (Editor-in-Chief), 1990.
austenite Eutectic: Reprinted by permission of ASM
1000 4.30 International, Materials Park, OH.]

γ + Fe3C
α+

α800 727ºC Fe3C

γ

ferrite Eutectoid: cementite

600 0.76 α + Fe3C
400
0 1 2 3 4 5 6 6.7
(Fe)
Co , wt% C
Chapter 11 - 11
 Classification of Metal Alloys
Adapted from Fig. 11.1,
Callister & Rethwisch 9e.

Chapter 11 - 12
World Iron Mine Production and Reserves

(thousand metric tons)

https://www.mining-technology.com/comment/new-projects-growth-australia-iron-ore/#:~:text=Overall%2C
https://pubs.usgs.gov/periodicals/mcs2022/mcs2022.pdf %20Australia%20produced%20922.6Mt,increase%20of%200.5%25%20over%202020.
 Iron ore producing companies
World’s top five iron ore producing companies (2020)

1. Vale – 300 million tonnes (Brazil)

2. Rio Tinto – 286 million tonnes (Australia)

3. BHP – 248 million tonnes (Australia)

4. Fortescue Metals Group – 204 million tonnes (Australia)

5. Anglo American – 61 million tonnes (British listed multinational company)

https://www.nsenergybusiness.com/features/top-five-iron-ore-producing-companies-world/
 Saudi Arabia Iron mines
1. Wadi Al-Sawawin iron ore mine
• Al Madinah Province (estimated reserves of 429 million mt)

• One of the largest iron reserve in Saudi Arabia

2. Wadi Fatima (50 million mt)

3. Jabal Idsas (306 million mt)

https://www.steelbb.spglobal.com/?PageID=157&article_id=182866
Iron and Steel Production

(million metric tons)

https://pubs.usgs.gov/periodicals/mcs2022/mcs2022.pdf
 Saudi Arabia steel production
As of 2020, Saudi Arabia produced approximately 7.8 million metric tons of steel, an increase from around 4.8 million

metric tons in 2017. The total crude steel production worldwide in 2020 was 1.88 billion metric tons. (

https://www.statista.com/statistics/718271/saudi-arabia-crude-steel-production/#:~:text=As%20of%202020%2C%20Saudi%20Arabia,was%201.88%20billion%20metric%20tons )
HADEED (4.6 Million MT in 2021) from scrap United Sulb Company

Al-Ittefaq Steel Products Company TenarisSaudiSteelPipes

Rajhi Steel Industries Company Ltd Jubail Energy Services Company (JESCO)

Solb Steel Watania Steel Factory Corporation

Al Yamamah Company for Reinforcing Steel Bars Saad Bin Dajam Steel Plant

Al Qaryan Steel Company Arabian Refractory Factory Co

ArcelorMittal Gulf Ferro Alloys Company (SABAYEK)

https://www.ncsi.org.sa/
 Recycled iron and steel scrap
• Scraps are very important for the production of new

steel and cast iron.

• Recycling 1 ton of steel conserves 1.1 tons of iron

ore, 0.6 ton of coking coal and and 0.05 ton of
limestone.

• Also conserves energy because the remelting of

scrap requires much less energy than the production
of iron or steel products from iron ore.

https://pubs.usgs.gov/periodicals/mcs2022/mcs2022.pdf
Iron-Carbon (Fe-C) Phase Diagram
• 2 important T(°C)
1600
points d
-Eutectic (A): 1400 L
L Þ g + Fe3C g g +L
1200 1148°C
A L+Fe3C
-Eutectoid (B): (austenite)

Fe3C (cementite)
R S
g Þ a + Fe3C 1000 g g
g g g +Fe3C

a+
800
a B 727°C = T eutectoid

g
R S
600
a+Fe3C
400
0 1 2 3 4 5 6 6.7
(Fe) 0.76 4.30 Co, wt% C
120 mm C eutectoid
Result: Pearlite = Fe3C (cementite-hard)
alternating layers of a (ferrite-soft)
a and Fe3C phases
(Adapted from Fig. 9.27, Callister 7e.) Adapted from Fig. 9.24,Callister 7e.
19
Isolation of metals from Ores (Iron)
• The 4th most abundant element in earth crust.

• Extraction of the metal from ores dates from about 2000 bc.

• Some of the main sources of iron are hematite (Fe2O3), magnetite (Fe3O4), titanomagnetite.

• Isolation of the metal include reduction of the ore (oxide to remove the oxygen).

• Until late 1700 this was done by using charcoal (from pyrolysis of wood)
• Charcoal: black powder, consisting of carbon obtained by removing water and other volatile constituents from
animal and vegetation substances.

• Pyrolysis: the heating of an organic material, such as biomass, in the absence of oxygen.
Isolation of metals from Ores (Iron)
• Industrial revolution started after replacing that with coke (from coal)
• Coke: a solid fuel made by heating coal in the absence of air

• This made the process more environmentally friendly and reduced the cost by fivefold.

• The oxide reduction takes place in the blast furnace

• The iron ore + limestone (calcium carbonate) + coke are fed from the top of the furnace.

• limestone act as a lux or purifying agent to remove other impurities.

• Oxygen (air) is forced into the base.

• Carbon monoxide and carbon from the coke are the reagents that changes the iron oxide to metallic iron.

• The metallic iron tapped at the bottom of the furnace is called pig iron