Carbon and Low-Alloy Steels

Carbon and Low-Alloy Steels
Presented by Weldon Mak Makela Senior Failure Analysis Engineer Materials Testing & Analysis Group, Element St. Paul
April 26, 2012
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Carbon and low-alloy steels

What is steel? Iron-carbon phase diagram. Carbon and low-alloy steel classifications. Mechanical properties. Microstructure. Application. Structural Steels. Specifications and selection of carbon and low-alloy steels. This presentation will not cover cast steels, coated products, forgings, cast irons, ultra-high strength or other specialty steels. Tool steels and stainless steels will be covered in separate presentations.
Source: Metals Handbooks, 10th Edition, ASM International.
What is steel?
Steel is iron with small amounts of carbon and other elements added to impart unique properties in the material. Pure iron is soft, ductile and has low strength. Steel is made by reducing iron ore to iron, which contains carbon and other impurities. Further refining reduces the impurities, controls carbon and other element content. Steels consist of iron with varying amounts of carbon:
Carbon content varies from 0.02-1.25%. Carbon is the primary elemental addition to increase strength. Carbon allows for heat treatment to increase strength.
Other elemental additions improve properties:

Manganese-up to 2.00%. Silicon-up to 1.0%. Chromium, nickel, molybdenum, and other elements in varying quantities.
Iron-Carbon Phase Diagram
Carbon Steels
The most common metal used to manufacture products.
Low-carbon steels: Carbon content varies from 0.05% to 0.30%. Medium-carbon steels: Carbon content varies from 0.30% to 0.60%. High-carbon steels: Carbon content varies from 0.60% to 0.95%.
Other elements commonly found in carbon steels:

Manganese is controlled to less than 2.0%. Sulfur is controlled to 0.35% maximum. Phosphorous is controlled to 0.12% maximum. Silicon is usually controlled to less than 0.60%. Lead, when added is controlled to less than 0.35%. Other elements are not controlled but are usually held to less than 2.0%.
Low-Alloy Steels
Elements are added to modify the basic carbon steel compositions to provide superior properties. Manganese, silicon, chromium, nickel and molybdenum are the most common additions to form low-alloy steels. Vanadium, niobium, aluminum, tungsten, copper and other elements are added to provide additional specific characteristics. Total elemental additions are less than 10%. Properties enhanced by alloying: Hardenability - the ability to be strengthened through heat treatment. Toughness - the ability to withstand impact loads. Environmental resistance - weathering and other corrosive environments. Elevated temperature resistance.
Classifications of Carbon and Low-Alloy Steels

Plain carbon Steels: Carbon, manganese, phosphorous and sulfur are controlled. Other elements are not controlled.
Resulfurized, rephosphorized or leaded steels: Sulfur, phosphorous or lead are intentionally added to improve machineability.
Low-alloy steels: Controlled additions of elements are utilized to enhance properties and to provide specific characteristics. Structural steels: All steels could be used as structural steels but we will focus on a group called the High-Strength Low-Alloy (HSLA) Steels.
Classification of Steels
Classification can depend on: Compositioncarbon, low-alloy, tool or stainless steels. Manufacturing methodopen hearth, basic oxygen, electric furnace, vacuum processed. Finishing methodhot or cold rolled, cold finished, cold drawn. Product formbar, plate, sheet, strip, wire, tubing, or structural shape. Deoxidation practicekilled, semikilled, capped or rimmed. Microstructureferritic, pearlitic, or martensitic. Strength levelspecified in ASTM or other standards. Heat treatmentannealed, normalized, spherodized or quenched and tempered. Quality descriptorscommercial, forging, drawing, or aircraft quality.
Carbon Steel Nomenclature

SAE-AISI: Four digit designation. First 2 digits define the alloy group. For example:
A 10 in the front indicates the group is a plain carbon steel. Resulfurized carbon steels start with 11, followed by the carbon content. Resulfurized and rephosphorized carbon steels will start with a 12, followed by the carbon content. High manganese carbon steels will start with a 15, followed by the carbon content for manganese contents between 1.00-1.65%.
Last 2 digits indicate the nominal carbon content.

Plain carbon steels will have the designation of: SAE 1005 SAE 1095. This indicates the nominal carbon content will vary from 0.05%-0.95%.
AISI American Iron and Steel Institute designation is slowly disappearing. SAE Society of Automotive Engineers is more common. UNS Unified Numbering System is a worldwide designation for composition of metals and alloys. For example: UNS G10200 is the designation for SAE 1020 carbon steel.
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SAE-AISI Carbon & Low-Alloy Steel Nomenclature

Type of Carbon/Alloy Steel Group Carbon Steels Numeral and Digital Designation 10xx 11xx 12xx 15xx 13xx 23xx 25xx 31xx 32xx 33xx 34xx 40xx 44xx 41xx 43xx 43BVxx 47xx 81xx 86xx 87xx 88xx 93xx 94xx 97xx 98xx C=0.05-0.95% S<0.33% S<0.35, P=0.12% 1.00<Mn<1.65% 1.60<Mn<1.90% Ni=3.50% Ni=5.00% Ni=1.25, Cr=0.65 & 0.80 Ni=1.75, Cr=1.07 Ni=3.50, Cr=1.50 & 1.57 Ni=3.00, Cr=0.77 Mo=0.20 & 0.25 Mo=0.40 & 0.52 Cr=0.50, 0.80, 0.95, Mo=0.12, 0.20, 0.25, 0.30 Ni=1.82, Cr=0.50 & 0.80, Mo=0.25 Ni=1.82, Cr=0.50, Mo=0.12 & 0.25, V=0.03 Min. Ni=1.05, Cr=0.45, Mo=0.20 & 0.35 Ni=0.30, Cr=0.040, Mo=0.12 Ni=0.55, Cr=0.50, Mo=0.20 Ni=0.55, Cr=0.50, Mo=0.25 Ni=0.55, Cr=0.50, Mo=0.35 Ni=3.25, Cr=1.20, Mo=0.12 Ni=0.45, Cr=0.40, Mo=0.12 Ni=0.55, Cr=0.20, Mo=0.20 Ni=1.00, Cr=0.80, Mo=0.25 Nominal Alloy Content, %
Manganese Steels Nickel Steels
Nickel-Chromium Steels
Molybdenum Steels
Cr-Mo Steels Ni-Cr-Mo Steels
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SAE-AISI Carbon & Alloy Steel Nomenclature, continued

Type of Carbon/Alloy Steel Group Ni-Mo Steels Numeral and Digital Designation 46xx 48xx Nominal Alloy Content, % Ni=0.85 & 1.82, Mo=0.20 & 0.25 Ni=3.50, Mo=0.25
Cr Steels
50xx 51xx
50xxx 51xxx 52xxx 61xx 72xx
Cr=0.27, 0.40, 0.50, 0.65 Cr=0.80, 0.87, 0.92, 0.95, 1.00, 1.05
C=1.0% Min., Cr=0.50 C=1.0% Min., Cr=1.02 C=1.0% Min., Cr=1.45 Cr=0.60, 0.80, 0.95, V=0.10 %, 0.15 % Min. W=1.75, Cr=0.75
Cr - Bearing Steels
Cr - Vanadium Steels Tungsten-Cr Steels
Si-Mn Steels
92xx
Si=1.40 & 2.00, Mn=0.65, 0.82, 0.85, Cr=0 and 0.65 %
High-Strength Low-Alloy Steels Boron Steels Leaded Steels
9xx xxBxx xxLxx
Various SAE Grades B denotes boron steel L denotes leaded steel
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Mechanical Properties of Carbon and Low-Alloy Steels

Mechanical properties vs. carbon content. Mechanical properties vs. manganese content. Mechanical properties vs. cold work. Mechanical properties vs. heat treatment. Impact properties. Fatigue properties.
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Typical Stress/Strain Curve for Steel
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Mechanical Properties vs. Carbon Content

HOT ROLLED CARBON STEEL BARS, MANGANESE <1.0%
140
120
100
80 KSI
Tensile Strength
60 Yield Strength
40
20
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 NOMINAL CARBON CONTENT, %
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Mechanical Properties vs. Manganese Content

HOT ROLLED CARBON STEEL BARS, MANGANESE >1.0%
120
100
80
KSI
60
Tensile Strength
Yield Strength
40
20
0 0.25 0.36 0.41 0.48 0.52 NOMINAL CARBON CONTENT, %
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Tensile Strength vs. Manganese Content

EFFECT OF MANGANESE CONTENT ON TENSILE STRENGTH
140 120 100 80 KSI 60 40 20 0 0 0.2 0.4 0.6 0.8 1 NOMINAL CARBON CONTENT, % Mn <1.0% Mn >1.0%
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Yield Strength vs. Manganese Content

EFFECT OF MANGANESE CONTENT ON YIELD STRENGTH
80 70 60 50 KSI 40
Mn <1.0%
30
20 10 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 NOMINAL CARBON CONTENT, %
Mn >1.0%
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Mechanical Properties vs. Cold Work

COLD DRAWN CARBON STEEL BARS
120
100
KSI
80
60
Tensile Strength Yield Strength
40
20
0 0.1 0.2 0.3 0.4 0.5 NOMINAL CARBON CONTENT, %
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Tensile Strength vs. Cold Work

EFFECT OF COLD WORK ON TENSILE STRENGTH
140
120
100
80 KSI
60
Hot Rolled
Cold Drawn
40
20
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
NOMINAL CARBON CONTENT, %
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Yield Strength vs. Cold Work

EFFECT OF COLD WORK ON YIELD STRENGTH
90
80 70 60 50 KSI 40 30 20 10 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 NOMINAL CARBON CONTENT, %
Hot Rolled
Cold Drawn
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Quenched & Tempered Hardness vs. Carbon Content
Rockwell C Ultimate Tensile Hardness, HRC Strength, ksi. 55 50 45 40 35 30 25 20 301 255 214 182 157 136 120 108
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General Comments on Impact Properties of Carbon and Low-Alloy Steels

1. Carbon and low-alloy steels have a ductile-to-brittle transition temperature: - Above the DBTT the material will fail in a ductile manner and the absorbed impact energy is high. - Below the DBTT the material will fail in a brittle manner (cleavage) with low absorbed energy.
2. The transition temperature can be shifted by alloy additions: - Manganese and silicon will lower the DBTT. - Sulfur and phosphorous will raise the DBTT.
3. The energy absorbed can be altered by alloy additions: - Nickel will increase the toughness at low temperatures. - Chromium, molybdenum and copper indirectly increase absorbed energy through hardenability enhancement.
Carbon and Low-Alloy Steels 23
Impact Properties vs. Carbon Content
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General Statements about Fatigue

Fatigue is a progressive, localized and permanent change in a material subjected to fluctuating strains, at stresses with maximum values less than the ultimate tensile strength of the material. 1. The stress can be substantially less than the ultimate tensile strength. 2. The alternating strains can lead to crack initiation and propagation. 3. As the crack grows in size, final failure can occur catastrophically when the remaining cross section can no longer support the applied load. 4. Steels have a fatigue limit, which is approximately 50% of the ultimate tensile strength. 5. The following variables will affect the fatigue limit: - Surface roughness - Temperature - Decarburization, carburizing, nitriding - Designs that create stress risers - Microstructure and grain size - Material discontinuities - Processing discontinuities - Residual stress - Corrosion or erosion - Service-induced nicks or gouges - Material properties, carbon content
Typical S-N Curve for Steel
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SAE 1005 Low Carbon Steel
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SAE 1018 Low Carbon Steel
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SAE 8620 Low Carbon Alloy Steel
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SAE 1045 Medium Carbon Steel
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SAE 1144 Resulfurized Steel
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SAE 1060 Medium Carbon Steel
32
SAE 5150 Alloy Steel
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Applications for Low-Carbon Steels

Low-carbon steels: Carbon content less than 0.30%. Products are sheet, strip, plate, wire, bar, tubing and structural shapes. Can be purchased in hot or cold-rolled, cold-finished, annealed, cold drawn condition. Typical applications: - Body panels for vehicles, appliances, etc. - Coated products such as galvanized sheet, strip or wire. - Low strength wire products. - Structural shapes. - Chain Weldable, formable, heat treatable to moderate strength levels. Note: Low-carbon steels are often referred to as mild steels.
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Applications for Medium-Carbon Steels

Medium-carbon steels-carbon content between 0.30-0.60%. Increased carbon and manganese allow the medium-carbon steels to be quenched and tempered to high strength levels. Purchased in many forms. Typical uses: - Shafts, couplings, crankshafts, gears and other high-strength applications. - Rails, railway wheels, rail axles. - Forgings, castings. Can be welded if properly pre-heated and post-heated.
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Applications for High-Carbon Steels

High-carbon steels: Carbon content between 0.60-1.00%. High carbon allows heat treatment to very high strength levels. Cold working produces products with very high strength levels. Typical uses: - Springs. - High strength wire such as music wire. - Tool applications-water hardening tool steels are commonly high carbon steels. - Other products requiring high strength with a minimum of processing. Normally not weldable because of high-carbon content.
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Applications for Low-Alloy Steels

Low-alloy steels: Carbon varies from 0.10-1.00%. Elements are added to produce unique capabilities. Heat-treatable to high strength and toughness. Elemental additions can improve environmental degradation under certain conditions. Elemental additions up to 10% can improve oxidation and corrosion resistance at elevated temperatures. Common uses: - Bearings and bearing races. - Weathering steels. - A myriad of parts and products that must be heat-treated to highstrength or high-toughness. Note: Low-alloy steels gain strength through heat treatment.
Structural Steels
High-strength carbon and low-alloy steels having yield strengths greater than 275 MPa (40 ksi) and can be classified as follows: As-rolled carbon-manganese steels (13XX and 15XX). Heat-treated carbon steels.* Heat-treated low-alloy steels.* As-rolled high-strength low-alloy (HSLA) steels, also know as microalloyed steels. *Notice that we have been talking about carbon and low-alloy steels, but now they are heat treated for use as high-strength structural steel.
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High-Strength Low-Alloy Steels (HSLA)

Primarily utilized for structural applications requiring: High strength: HSLA steels utilize low carbon content with small amounts of alloying elements and a variety of controlled processing parameters to obtain high yield strengths, greater than 275 MPa (40 ksi.). Good toughness, weldability, formability and atmospheric and other corrosion resistance. Availability as hot-rolled sheet, strip, and plate; hot-rolled and cold-finished bar; tubing, pipe and structural shapes. Can also be furnished as coldrolled sheet and forgings. Applications include construction of bridges, buildings, drilling rigs, vehicle parts, piling, ships, etc. Described in at least 18 ASTM specifications, which provide chemical composition, mechanical properties, forms available and intended uses. Many of these specs list several grades with different strength levels.
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Specifications for HSLA Steels

ASTM Specification A242 A572 A588 A606 A607 A618 A633 A656 A690 A709, Gr 50 & 50W A714 A715 A808 A812 A841 A847 A860 A871 Available Forms Plate, Bar, Shapes 4 in. Plate, Bar, Shapes 6 in. Plate, Bar, Shapes 8 in. HR & CR Sheet and Strip HR & CR Sheet and Strip Welded and Seamless Tubing Plate, Bar, Shapes 6 in. Plate 5/8 in. Piling Plate, Shapes 4 in. Pipe, welded and seamless HR Sheet, Strip HR Plate 2 1/2 in. Coiled sheet Plate 4 in. Welded and Seamless Tubing Welded fittings Plate 1 3/8 in. Special Characteristics Atmospheric weathering 6 grades with YS 42 ksi Atmospheric weathering, YS 50 ksi Atmospheric weathering 6 grades with YS 45 ksi 3 grades with different characteristics 5 grades with YS 42 ksi YS 80 ksi Corrosion resistance Minimum YS = 50 ksi 1/2 to 26 in. Pipe 4 grades, YS = 50-80 ksi CVN 30-45 ft-lb @ -50F YS = 65-85 ksi YS = 45-50 ksi YS 50 ksi YS 70 ksi Atmospheric weathering Intended Uses Welded, bolted or riveted construction Bridges and buildings Welded bridges and buildings Weight savings and durability Weight savings and durability Welded, bolted or riveted construction Service down to -50F Truck, crane, railroad car frames Sea water exposure applications Bridges Piping Structural, formability & weldability Railway tank cars Welded pressure vessels Welded pressure vessels Bridges and buildings Gas, oil transmission lines Tubular structures and poles
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Specifications for Carbon & Low-Alloy Steels

Specifications are written statements defining product requirements. Describes both technical and commercial requirements. Controls procurement. May cover any or all of the following parameters: - Scope defines product classification, size range, processing, or other information deemed useful to both supplier and user. - Chemical composition of the carbon or low-alloy steel. - Quality statement describes special requirements such as steel quality, type and processing methods. - Quantitative requirements identify chemical composition ranges, mechanical and physical properties and test methods germane to the application. - Additional requirements may include such items as size and straightness tolerances, surface and edge finish, packaging and loading instructions.
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Specifications, continued
Most existing specifications have been prepared by engineering societies, associations, and institutions whose members make, specify, purchase and/or use steel products. Some common ones are listed below: Association of American Railroads AAR American Bureau of Shipbuilding ABS American Railway Engineering Association AREA American Society of Mechanical Engineers ASME American Petroleum Institute API American Society for Testing and Materials ASTM Society of Automotive Engineers SAE Aerospace Material Specifications (of SAE) AMS Federal and Military Specifications FED and MIL
Foreign countries have their own material and process specification systems, such as the DIN, JIS, BS, AFNOR, UNI, etc. Many of these specifications reference some ASTM specifications.
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Specifications, continued
ASTM is the most widely used specification system because they are complete for procurement purposes. Most ASTM specs include composition, mechanical, dimensional, quality and testing requirements, or reference other ASTM specs that cover specific aspects of a material. ASTM specifications are used worldwide. Some federal and military procurements are gradually transitioning to ASTM specifications. Material descriptions use common SAE-AISI designations but also include the UNS system to identify a material composition. A common ASME specification is referred to as the Boiler and Pressure Vessel Code. This code is the authority for any application involving the design and construction of boilers, pressure vessels and associated piping, including nuclear applications. Many ASME material specifications closely parallel ASTM.
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Carbon and Low-Alloy Steel Selection

Material and process selection should always be based on the following considerations: Material strength with reference to operational loads, vibration, temperature and environmental exposures. Processing parameters such as formability, weldability, machineability and other fabrication considerations to produce the product. Form of material to most economically fabricate the product whether it be sheet, strip, plate, bar, or structural shape. Availability of the material in the required form, quantity and price. Finishing processes such as painting, plating, heat treatment, etc. Always use a material and/or process specification to procure or finish a product.
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Some General Comments

1. Resulfurized, rephosphorized or leaded steels are not generally weldable or heat treatable. 2. The above materials should not be used in dynamic or cyclical applications, especially in cold weather environments. 3. When designing products, ensure the maximum load is no greater than 1/3 of the yield strength of the material and well below the fatigue limit. 4. Never use a steel in the as quenched condition. Always temper the steel. 5. When welding, always use pre-heat and/or post-heating when the carbon content is more than 0.30%. 6. A low-alloy steel is not significantly stronger than a plain carbon steel with the same carbon content, in the same condition. Low-alloy steels provide high-strength, only after heat treating. Save money if you dont need high-strength.
Contact us for further information
Weldon Mak Makela Senior Failure Analyst 651 659 7275 weldon.makela@element.com
Josh Schwantes Metallurgical Engineering Manager 651 659 7205 joshua.schwantes@element.com
Craig Stolpestad Sales Manager 651 659 7206 craig.stolpestad@element.com
Mark Eggers Inside Sales, NDT & Metals 651 659 7349 mark.eggers@element.com
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April 26, 2012