Chapter 13: Properties and

Applications of Metal Alloys

ISSUES TO ADDRESS...
• How are metal alloys classified and what are their
common applications?

Chapter 11 - 1
Chapter 11 - 2
 MATERIAL SELECTION
• Need to select material that has the right
combination of characteristic for a specific
application.
• Need to have knowledge of the available
option.
• Selection decision may also be influence by
the ease with which metal alloys may be
formed or manufactured into useful
components.
• Alloy properties are altered by fabrication
processes and in addition, further property at
alteration may be induced by the employment
of appropriate heat treatment Chapter 11 - 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

1400 L
+L
1200
 1148ºC L +Fe3C
austenite Eutectic:
1000 4.30

+Fe3
C
+


800 727ºC Fe 3C


ferrite Eutectoid: cementite Adapted from Fig. 9.24,Callister &

600 0.76
+Fe3
C Rethwisch 8e. (Fig. 9.24 adapted from
Binary Alloy Phase Diagrams , 2nd ed.,
400
0 1 2 3 4 5 6 6.7 Vol. 1, T.B. Massalski (Ed.-in-Chief),
(Fe) ASM International, Materials Park, OH,
Co
,
wt
%C 1990.) Chapter 11 - 4
 FERROUS ALLOYS
• Iron is the prime constituent
• Are produced in larger quantities than any metal
type

• Al- Hadid/Iron Surah 57 Verse 25

We have already sent Our messengers with clear
evidences and sent down with them the Scripture
and the balance that the people may maintain
[their affairs] in justice. And We sent down iron,
wherein is great military might and benefits for
the people, and so that Allah may make evident
those who support Him and His messengers
unseen. Indeed, Allah is Powerful and Exalted in
Might Chapter 11 - 5
 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
Chapter 11 - 6
 FERROUS ALLOYS
Their widespread use is accounted for by three factors
• Iron containing compounds exist in abundant
quantities within the earth’s crust
• Metallic iron and steel alloy may be produced using
relatively economical extraction, refining, alloying and
fabrication technique
• Ferrous alloys are extremely versatile, in that they may
be tailored to have a wide rang of mechanical and
physical properties

Disadvantages
They are susceptible to corrosion

Chapter 11 - 7
 Steels
Low Alloy High Alloy
low carbon Med carbon high carbon
<0.25 wt% C 0.25-0.6 wt% C 0.6-1.4 wt% 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. Chapter 11 - 8
 STEEL
• Low Carbon Steel
• Contain less than 0.25% C
• Microstructures consist of ferrite and pearlite
• Relatively soft and weak but have outstanding ductility
and toughness, they are machinable, weldable and of all
steel are least expensive to produce
• Typical application include automobile body
components, structural shapes ( I beams, channels and
angle iron) an d sheet that are used in pipelines, building,
bridges and tin cans

Chapter 11 - 9
HIGH-STRENGTH, LOW ALLOY STEEL (HSLA)
• Contain other alloying elements such as cope,
vanadium, nickel and molybdenum in combined
concentrations as high as 10wt% and poses
higher strength than plain low-carbon steels
• Most may be strengthen by heat treatment,
giving tensile strength in excess of 480MPa
• They are ductile formable and machinable.
• In normal atmospheres, HSLA steels are more
resistance to corrosion than plain carbon steel
which they have replaced in many applications
where structural strength is critical (bridges,
towers, support column in high-rise buildings and
pressure vessels).

Chapter 11 - 10
 MEDIUM – CARBON STEELS (PLAIN & HEAT
TREATABLE
• Carbon between 0.2 to 0.6 wt%.
• These alloys may be heat treated by austenitizing,
quenching and then tempering to improve their
mechanical properties.
• Has low hardenabilities and can be successfully heat-
treated only in very thin sections and with very rapid
quenching rates.
• Heat treated alloys (Cr, Ni, Mo) are stronger that low
carbon steel but at a sacrifice of ductility and toughness.
• Application include railway wheels and tracks, gears,
crankshafts and other machine parts and high –strength
structural components calling for a combination of high
strength, wear resistance and toughness.
• Heat treatable – Piston, Gear, Wear application

Chapter 11 - 11
HIGH CARBON STEEL
• Having carbon content of 0.6 to 1.4 Wt%.
• Hardest, strongest but least ductile.
• Always used in a hardened and tempered
condition thus wear resistant and capable of
holding a sharp cutting edge.
• Usually contain chromium, vanadium,
tungsten and molybdenum
• Application : cutting tool and dies for forming
and shaping material as well as knives, razors,
backsaw blades, spring and high strength
wire.

Chapter 11 - 12
 STAINLESS STEEL
• Highly resistant to corrosion in a variety of
environment
• Predominant alloying element is chromium – 11%
• Enhanced by nickel and molybdenum
• Divided into 3 classes on the basis of the
predominant phase constituent of the
microstructure : Martensitic, ferritic and autenitic
• Frequently used at elevated temperature and in
severe environments because they resist
oxidation and maintain their mechanical integrity
under such conditions
• Use in gas turbines, high temp steam boiler, heat
treating furnace, aircraft, missile and nuclear
power generating units
Chapter 11 - 13
 Cast Irons
• Ferrous alloys with > 2.1 wt% C
– more commonly 3 - 4.5 wt% C
• Low melting – relatively easy to melt and cast
• Generally brittle and casting is the most
convenient fabrication technique
• Cementite decomposes to ferrite + graphite
Fe3C  3 F e ( ) C (
g raph i
te )
– Slower cooling rates during solidification
favor graphitization process
– Mechanical behavior depend on
composition and heat treatment Chapter 11 - 14
 Fe-C True Equilibrium Diagram
T (ºC)
1600
Graphite formation
1400 L Liquid +
promoted by
 +L Graphite
• Si > 1 wt% 1200  1153ºC

• slow cooling Austenite 4.2 wt% C

1000

+  + 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
Diagrams , 2nd ed.,
(Fe) C , wt% C
Vol. 1, T.B. Massalski (Ed.-in-
Chief), ASM International,
Materials Park, OH, 1990.]
Chapter 11 - 15
 Types of Cast Iron Adapted from Fig.
11.3(a) & (b),
Gray iron Callister &
• Carbon content: 2.5 – 4 wt% Rethwisch 8e.

• Silicon content: 1 – 3 wt%

• graphite flakes surrounded by ferrite or pearlite
matrix (the fractured surface appeared gray).
• weak & brittle in tension
• stronger in compression
• excellent vibrational dampening
• wear resistant
Ductile iron
• add Mg and/or Ce (cerium) to gray iron before
casting.
• graphite as nodules not flakes
• matrix often pearlite – stronger and more ductile
than gray iron
• Use as valve, pump bodies, crankshaft, gears

Chapter 11 - 16
Types of Cast Iron (cont.)
White iron Adapted from Fig.
11.3(c) & (d),
•  1 wt% Si, rapid cooling. Callister &
Rethwisch 8e.
• pearlite  cementite
• very hard and brittle
• Unmachinable
• Use for wear resistant surface eg
rollers in rolling machine

Malleable iron
• heat treat white iron at 800-900ºC
• graphite in rosettes
• reasonably strong and ductile
• Application: connecting rod,
transmission gear, flanges, pipe
fittings, valve Chapter 11 - 17
Types of Cast Iron (cont.)
Compacted graphite iron
• Graphite formation is promoted by
the presence of silicon
• Silicon content 1.7-3.0wt%
• Graphite has a wormlike shape
• Intermediate between gray and
ductile iron.
• relatively high thermal conductivity Adapted from Fig. 11.3(e),
Callister & Rethwisch 8e.
• good resistance to thermal shock
• lower oxidation at elevated
temperatures
• Use as diesel engine block, exhaust
msanifolds, gearbox housing, brake
disk for high speed train and
flywheels Chapter 11 - 18
 Limitations of Ferrous Alloys

1) Relatively high densities

2) Relatively low electrical conductivities
3) Generally poor corrosion resistance

Chapter 11 - 19
 Nonferrous Alloys
• Cu Alloys • Al Alloys
Brass: Zn is subst. impurity -low : 2.7 g/cm3,
(costume jewelry, coins, -Cu, Mg, Si, Mn, Zn additions
corrosion resistant)
Bronze : Sn, Al, Si, Ni are - Struct aircraft parts ,
subst. impurities beverage cans, core
(bushings, landing power cables.
gear) NonFerrous • Mg Alloys
-very low : 1.7g/cm 3

- Electrical wire, Alloys -ignites easily
- missiles, handheld device
aircraft,
• Ti Alloys
-relatively low : 4.5 g/cm3 • Refractory metals
-high meltingT’s
vs 7.9 for steel • Noble metals -Nb, Mo, W, Ta
-reactive at highT’s -Ag, Au, Pt
-space applic. -oxid./corr. resistant
Based on discussion and data provided in Section 11.3,Callister & Rethwisch 3e. Chapter 11 - 20
 Assignment 3
1. A three-point bending test was performed on an
aluminum oxide specimen having a circular cross
section of radius 3.8 mm; the specimen fractured at a
load of 445 N when the distance between the support
points was 50.8 mm.
(a) Compute the flexural strength.
(b) The point of maximum deflection Δy occurs at the
center of the specimen where modulus of elasticity 393
GPa .Compute Δy.
• Name metals that being employed in the latest
Malaysians coinages.
• Explain the reason why those metals are being used
(relate with properties of the metals).

Chapter 11 - 21
 Summary

• Ferrous alloys: steels and cast irons

• Non-ferrous alloys:
-- Cu, Al, Ti, and Mg alloys; refractory alloys; and noble metals.
• Metal fabrication techniques:
-- forming, casting, miscellaneous.
•

Chapter 11 - 22
 Homework
11.1 (a) List the four classifications of steels. (b) For
• each, briefly describe the properties and typical
applications.
11.2(a) Cite three reasons why ferrous alloys are
used so extensively. (b) Cite three characteristics of
ferrous alloys that limit their utilization.

Chapter 11 - 23
 ANNOUNCEMENTS
Reading:

Core Problems:

Self-help Problems:

Chapter 11 - 24