MATERIAL LOGAM

ISMOJO, ST.,MT

Penilaian
Ujian Tengah Semester (UTS) = 30% Ujian Akhir Semester (UAS) = 40% Tugas-tugas = 20% Kuis = 10% Yang berhak mengikuti ujian akhir semester: kehadiran 70%

Referensi

W.F. Smith, Principles of Materials Science and Engineering, McGraw-Hill, Singapore, 1990. S.H. Avner, Introduction to Physical Metallurgy, McGraw-Hill, Tokyo, 1974. D.S. Clark, W.R. Varney, Physical Metallurgy for Engineers, Van-Nostrand Reinhold Co., New York, 1952. B.J. Moniz, Metallurgy, 2nd edition, ATP, Homewood, Illinois, 1994. Reed-Hill, Robert E., Reza Abbaschian, and Lara Abbaschian. Physical Metallurgy Principles. 4th ed. Stamfor

Materials Sciences adalah suatu aspek yang mempelajari karakteristik material secara keilmuan dan teknologi yang dapat digunakan untuk membuat material atau bahan teknik.
Metallurgical Engineering Materials Engineering Ceramic Engineering

Materials Sciences

Composite Engineering

Polymer Engineering

1. Metallurgical Engineering Mempelajari karakteristik logam dan paduannya, merupakan ilmu tertua yang mempelajari material teknik. Perkembangan metalurgi selama 150 tahun terakhir membaginya menjadi 3 bagian utama, yaitu : a. Metalurgi Ekstraksi (mempelajari bagaimana mengekstraksi dan memurnikan suatu logam dari bijihnya). b. Metalurgi Fisik (mempelajari pengaruh struktur mikro terhadap sifat-sifat logam, memodifikasi struktur mikro). c. Metalurgi Mekanik (mempelajari teknik pembuatan dan gayagaya yang bekerja untuk membentuk suatu logam menjadi produk tertentu).

2. Ceramic Engineering Mempelajari perkembangan dan produksi suatu produk yang terbuat dari bahan non-metalik, inorganik dengan pembakaran pada temperatur tinggi.

3. Polymer Engineering Mempelajari perkembangan produk yang terbuat dari bahan sintetis organik. Polimer terdiri atas Thermosetting dan Thermoplastic. 4. Composite Engineering Mempelajari penerapan gabungan material untuk memperoleh sifatsifat yang tidak dimiliki oleh masing-masing bahan. Kombinasi yang dilakukan bisa logam, keramik, polimer (metal matrix composite/MMC; polymer matrix composite/PMC; ceramic matrix composite/CMC, dll). 5. Materials Engineering Mengevaluasi karakteristik sifat-sifat yang dimiliki oleh material. Ini berhubungan dengan penggantian material yang dapat memperbaiki kemampuan dan menurunkan harga komponen.

Spektrum pengetahuan material, penggabungan pengetahuan material dari ilmu material dan material teknik menjadikan rekasayawan dapat mengubah material menjadi produk yang berguna bagi masyarakat.

Diagram yang menggambarkan bagaimana ilmu dan teknik material terbentuk dari rangkaian pengetahuan dari ilmu-ilmu dasar dan berbagai disiplin ilmu pengetahuan.

Flow chart pembuatan suatu komponen

Gambar diatas mengkaitkan berbagai hal yang harus diperhatikan oleh seorang perancang dalam membuat suatu komponen atau konstruksi.

Contoh-contoh produk :
Early food containers of glass & steel use common ceramic and metal materials of the late 19th & early 20th centuries

The new containers are lightweight, will not break, and offer long shelf life for their contents

Advances in materials technology brought on new containers made of twopiece Al and steel cans and barrier packages made of laminated composites of plastics, aluminum, and paper.

Decorated Foil Pouches for Food and Drink

1XXX represents the commercially pure aluminum.

High formability, resistance and conductivity

corrosion electrical

Electrical, chemical applications

The 1XXX series would not be used where strength is a prime consideration. For the applications where extremely high corrosion resistance, formability and/or electrical conductivity are required (foil and strip for packaging)

1060 or 1110

Jembatan

Pipeline

Dumptruck

Pesawat terbang

Jaringan listrik

Rodagigi
Peralatan dapur

Kereta listrik

Baut dan mur Elektro nik Pembuatan Pesawat terbang

Komponen mesin

Sudu turbin

Komponen mesin hasil coran

Pembuatan mobil

Komponen mesin

Patung tembaga paduan

Pakaian perang

Bronze Mask

Mobil masa depan

Ford contour dengan bahan dari aluminium ekstrusi

16

Komponen produk pengecoran

Material Properties
Chemical Composition Microstructure Phases Grain size Corrosion resistance Inclusions Physical Mechanical Tensile/compressive properties Toughness Ductility Fatigue Hardness Creep resistance Shear strength Melting point Glass transition (polymers/glasses) Magnetic Electrical Optical Acoustic Gravimetric Color Tensile/compressive properties Heat distortion Pressure-velocity limit Toughness Stress rupture resistance Creep resistance Tensile/compressive properties Fracture toughness Transverse rupture Hardness Manufacturing considerations Available shapes Available sizes Available surface texture Manufacturing tolerances

Metals

Plastics

Composition Fillers/additives Crystallinity Molecular weight Flammability Spatial configuration Chemical resistance Composition Porosity Grain size Crystal structure Corrosion resistance Phases

Manufacturing tolerances Stability Available sizes

Ceramics

Available shapes Available sizes Available surface texture Manufacturing tolerances

Composites

Composition matrix:filler Matrix/filler bond Volume fraction of fillers Reinforcement type Chemical resistance

Tensile/compressive properties Fracture toughness Creep resistance Reinforcement orientation

Available shapes Available sizes Manufacturing tolerances Stability

Diktator material = SOLVENT

Material terlarut = SOLUTE

Pada logam berlaku larutan padat (solid solution). Dengan demikian solvent dan solute keduanya adalah padatan.

Pelarutan terjadi pada temperatur tinggi, dimana kedua padatan berubah menjadi cair. Untuk baja, pada temperatur tinggi, besi (Fe) dapat melarutkan banyak unsurunsur khususnya karbon. Fe menjadi diktator. Sejumlah kecil C, S atau Mn menjadi unsur yang terlarut.

19

Struktur partikel atom mirip dengan sistim tata surya

Secara umum struktur atom terdiri dari inti atau nucleus (proton dan neutron) yang dikelilingi oleh elektron.

Proton = partikel bermuatan positif

Neutron = netral Elektron = bermuatan negatif Jumlah proton = jumlah elektron Setiap kulit pada orbit elektron mengandung sejumlah elektron, misalnya pada kulit pertama (terdekat dengan inti) = 2 elektron, kedua = 8 elektron, ketiga = 18 elektron, keempat = 32 elektron
kusharjanto, metalurgi-unjani 20

Jika kulit terluar telah terpenuhi jumlah elektronnya, maka unsur akan menjadi stabil dan tidak akan bereaksi dengan unsur lain membentuk senyawa atau molekul. Contoh: gas inert argon dan helium digunakan sebagai gas pelindung dalam proses pengelasan, karena tidak bereaksi dengan logam untuk membentuk senyawa intermetalik yang tidak diinginkan. Jika kulit terluar belum terpenuhi jumlah elektronnya, maka akan berikatan dengan unsur lain untuk membentuk senyawa atau molekul.

Salah satu dasar untuk mengklasifikasi material adalah ikatan kimia. Dua jenis ikatan kimia:
1.Ikatan kuat (primary bonding): melibatkan pembagian elektron (ikatan ion, kovalen dan logam). 2.Ikatan sekunder (secondary bonding): melibatkan tarik menarik atom-atom yang relatif lemah dan tidak ada pembagian atau pertukaran elektron (ikatan van der waals).

Ikatan (Bonding)
Jika atom-atom mempunyai jarak yang cukup jauh, maka akan terjadi interaksi yang lemah.
Menurunnya jarak antar atom, energi-pun akan turun dan sistem menjadi lebih stabil. Atom-atom akan mencapai jarak optimal pada level energi terendah. Ikatan terjadi jika jarak antar atom cukup untuk menghasilkan tarik menarik.

Jika jarak atom terlalu dekat terjadi tolak menolak.

unstable

Repulsive energy
Separated atoms

System Energy
Stable

Bond Energy

Distance between atoms metalurgi-unjani kusharjanto,

23

Ikatan logam (metallic Bonding)

Terjadi ketika valensi elektron meninggalkan masing-masing atom dan digunakan bersama di antara semua atom dalam bentuk awan elektron bebas. Terdapat pada unsur-unsur logam yang hanya mempunyai 1, 2 atau 3 elektron dikulit terluarnya. Melimpahnya proton, atom-atom bermuatan ion-ion positif. Elektron-elektron yang mengambang membentuk awan-awan elektron, sehingga elektron mudah bergerak. Adanya elektron-elektron bebas menyebabkan konduktivitas panas dan listriknya tinggi.

What is a metal?

Metals
Metals: combination of metallic elements (free electrons)
good conductors of electricity and heat not transparent to visible light strong and ductile

A metal is defined as an opaque, lustrous elemental

chemical substance that is a good conductor of heat and electricity, and when polished, a good reflector of light. (ASM Definition)

The Periodic Table

Metals

Transition Metals

Metal Alloys

Metal Alloys
Ferrous Alloys Classification of Steels Designation of Steels Nonferrous Alloys Aluminum Copper Magnesium Titanium Refractory metals Superalloys Noble metals

Classification of Ferrous Alloys

Metal Alloys

Ferrous

Nonferrous

Steels

Cast Irons

Low Alloy

Gray Ductile White Malleable iron iron iron iron

High Alloy
Low-carbon Medium-carbon High-carbon

High Plain strength, low alloy

Plain

Heat treatable Plain Tool

Stainless

Classification of Ferrous Alloys

Based on carbon content Pure iron (< 0.008wt% C)

From the phase diagram, it is composed almost exclusively of the ferrite phase at room temperature.

Steels (0.008 ~ 2.14wt% C)

In most steels the microstructure consists of both a and Fe3C phases.

Carbon concentrations in commercial steels rarely exceed 1.0 wt%.

Cast irons (2.14 ~ 6.70 wt% C)

Commercial cast irons normally contain less than 4.5wt% C

P
x

E 2.14

F
L + Fe3C

4.30

O
0.76 0.022

Cementite Fe3C
C
x The ironiron carbide phase diagram.

6.70

Ferrous Alloys Steels

The carbon content is normally less than 1.0 wt%.

Plain carbon steels: containing only residual

concentrations of impurities other than carbon and a little manganese About 90% of all steel made is carbon steel.

Alloy steels: more alloying elements are

intentionally added in specific concentrations.

Stainless steels

Standar material (materials standards)

Standar material dikembangkan oleh pemerintah, industri, baik secara nasional maupun internasional.
Standar adalah dokumen kesepakatan yang merupakan piranti/perangkat tolok ukur sifat-sifat, karakteristik atau suatu prosedur yang telah berjalan. Standar biasanya dikembangkan oleh suatu komite yang terdiri dari para profesional dibidangnya.

Langkah pertama dalam pengembangan suatu standar adalah membuat suatu draft yang dibahas oleh sebuah komite yang nantinya akan disahkan menjadi suatu standar yang berlaku secara nasional maupun internasional. Pengembangan proses membutuhkan waktu yang lama, tetapi dokumen akhir yang telah selesai dibahas merepresentasikan suatu konsensus dari opini komite dan memperhatikan kenyataan diindustri saat itu.

Suatu standar harus ditinjau secara berkala (minimum sekali dalam lima tahun) untuk menentukan apakah dipertahankan atau diperbaiki. Jika suatu standar ditetapkan sudah tidak relevan lagi, maka standar tersebut harus dihapus. Ada tiga kelas standar:

1. Spesifikasi (specification)
2. Metoda pengujian (test method) 3. Rekomendasi penggunaan (recommended practice) Sebuah kode berisi ketiga kelas standar dan mengikat secara hukum. 1. Spesifikasi

Merupakan pernyataan bahwa suatu produk harus sesuai antara keperluan teknis dan komersial. Contohnya baja paduan dan baja tahan karat untuk baut yang bekerja pada operasi temperatur tinggi mengikuti ASTM A 193.

2. Metoda pengujian Sekumpulan/seperangkat perintah atau cara-cara untuk mengidentifikasi, melakukan pengukuran atau mengevaluasi sifatsifat material. Contohnya pengujian impak untuk material logam menggunakan ASTM E 23.

3. Rekomendasi penggunaan/aplikasi
Sekumpulan/seperangkat perintah atau cara-cara dalam melaksanakan satu atau lebih pengoperasian atau fungsi selain dari identifikasi, pengukuran atau mengevaluasi material. Contohnya rekomendasi penggunaan untuk persiapan permukaan baja atau material keras yang lainnya dengan menggunakan penyemprotan air sebelum dilapis atau lapis ulang mengikuti NACE RP-01-72. 4. Kode

Sekumpulan standar atau seperangkat peraturan yang harus ditaati. Contohnya ASME Boiler and Pressure Vessel Code, dimana didalamnya terdapat peraturan untuk proses perlakuan panas setelah pengelasan dari bejana tekan yang berkaitan dengan jenis dan ketebalan material.

Contoh-contoh standar:

ASTM A 193
SPECIFICATION
FOR ALLOY STEEL AND STAINLESS STEEL BOLTING MATERIAL FOR HIGH-TEMPERATURE SERVICE

ASTM E 23
TEST METHOD
NOCTHED BAR IMPACT TESTING OF METALLIC MATERILAS

NACE RP-01-72
RECOMMENDED PRACTICE
SURFACE PREPARATION OF STEEL AND OTHER HARD MATERIALS

ASME Boiler and Pressure Vessel Code CODE

SECTION VIII, DIVISION 1, PARAGRAPH UCS-56 POST-WELD HEAT TREATMENT OF CARBON STEEL PRESSURE VESSELS

Organisasi-organisasi Profesional
1. AISI (American Iron and Steel Institute)

2. SAE (Society of Automotive Engineers)

3. ASTM (American Society for Testing and Materials) 4. UNS (Unified Numbering System) 5. NACE (National Association of Corrosion Engineers) 6. AWS (American Welding Society) 7. AA (Aluminum Association) 8. API (American Petroleum Institute) 9. ASME (American Society of Mechanical Engineers) Kesemuanya berada dibawah National Standards Institute) naungan ANSI (American

Standar setiap negara:

Negara Austria Belgia Bulgaria Canada Czechoslovakia Perancis Jerman Jepang Inggris Indonesia Polandia Italia Rumania Spanyol Swedia Rusia Eropa bersatu Hungaria Singkatan ONORM NBN BDS CSA CSN AFNOR DIN JIS BS SNI PN UNI STAS UNE SS GOST EURONORM MSZ

The Designation of Steels

A four-digit number: the first two digits indicate
the alloy content; the last two, the carbon concentration

For plain carbon steels, the first two digits are 1

and 0; alloy steels are designated by other initial two-digit combinations (e.g., 13, 41, 43)

The third and fourth digits represent the weight

percent carbon multiplied by 100

For example, a 1040 steel is a plain carbon steel containing 0.40 wt% C.

The Designation of Steels

A four-digit number: the first two digits indicate
the alloy content; the last two, the carbon concentration

41 40
Identifies major alloying element(s) Percentage of carbon

Steel Alloys
Steel Numerical Nam e 10XX, 11 XX 13XX 23XX, 25 XX 31XX, 33XX, 303XX 40XX 41XX 43XX & 47XX 44XX 48XX 50XX, 51XX, 501XX, 61XX 515XX 521XX, 514XX, 81XX, 86XX, 87XX, 88XX 92XX 93XX, 98XX 94XX XXBXX XXLXX
94XX Ni-

Key Alloys Carbon only Manganese Nickel Nickel-Chromium Mo Cr-Mo Ni-Cr-Mo Mn-Mo Ni-Mo Cr Cr-V Ni-Cr-Mo Si-Mn Ni-Cr-Mo Ni-Cr-Mo-Mn Boron Lead

Sistem kodifikasi baja (lanjutan)

AISI/SAE and UNS Designation Systems and Composition Ranges for Plain Carbon Steel and Various Low-Alloy Steels

Classification of Steels
Low-carbon steels Less than 0.25 wt%C
Medium-carbon steels 0.25 ~ 0.60 wt%C High-carbon steels 0.60 ~ 1.4 wt%C

P
x

E 2.14

F
L + Fe3C

4.30

O
0.76 0.022

Cementite Fe3C
C
x The ironiron carbide phase diagram.

6.70

Low-Carbon Steels
Less than 0.25 wt%C Unresponsive to heat treatments intended to form
martensite; strengthening is accomplished by cold work Microstructures: ferrite and pearlite Relatively soft and weak, but having outstanding ductility and toughness ductility = 25%EL Machinable, weldable, and, of all steels, are the least expensive to produce structural shapes, and sheets used in pipelines, buildings, bridges, etc.

Typically, sy = 275 MPa, sUT = 415~550 MPa, and

Applications: automobile body components,

Composition of Five Plain Low-Carbon Steels

Mechanical Characteristics of Hot-Rolled Material and Typical Applications for Various Plain Low-Carbon Steels

Medium-Carbon Steels
0.25 ~ 0.60 wt%C

May be heat treated by austenitizing, quenching,

and then tempering to improve their mechanical properties

Microstructure: tempered martensite Stronger than low-carbon steels Applications: railway wheels and tracks, gears,
crankshafts, and other machine parts

Typical Applications and Mechanical Property Ranges for Oil-Quenched and Tempered Plain Carbon

Classified as high-carbon steels

High-Carbon Steels
0.60 ~ 1.4 wt%C Used in a hardened and tempered condition Hardest, strongest, and yet least ductile; especially
wear resistant and capable of holding a sharp cutting edge

Containing Cr, V, W, and Mo; these alloying

elements combine with carbon to form very hard and wear-resistant carbide compounds (e.g., Cr23C6, V4C3, and WC)

Applications: cutting tools and dies for forming and

shaping materials, knives, razors, hacksaw blades, springs, and high-strength wire

Designations, Compositions, and Applications for Six Tool Steels

High-Strength, Low-Alloy Steels

Alloying elements: Cu, V, Ni, & Mo (total ~10wt%)
Higher strength than low-carbon steels Most may be strengthened by heat treatments

Ductile, fomable, machinable

Tensile strength: > 480 MPa

A Comparison of the Advantages Offered by Carbon Steel and Alloy Steel

Carbon Steel Lower cost Greater availability Alloy Steel Higher strength Better wear Toughness Special high temperature behavior Better corrosion resistance Special electrical properties
94XX Ni-

Alloy steel is more expensive than carbon steel; it

should be used only when a special property is needed.

What makes stainless steels stainless?

Stainless Steels

Stainless steels are selected for their

excellent resistance to corrosion.

Stainless steels are divided into three

classes: martensitic, ferritic, or austenitic

The predominant alloying element is

chromium; a concentration of at least 11 wt% Cr is required It permits a thin, protective surface layer of
chromium oxide to form when the steel is exposed to oxygen.

The chromium is what makes stainless steel

stainless!

Ferrous Alloys Their Limitations

1) 2) 3) Relatively high density Comparatively low electrical conductivity Susceptibility to corrosion in some common environments

Cast alloys alloys that are so brittle that forming or shaping by appreciable deformation is not possible
Wrought alloys alloys that are amenable to mechanical deformation

Aluminum and its Alloys

Aluminum and aluminum alloys are the most widely
used nonferrous metals.

Properties Low density (2.7 g/cm3), as compared to 7.9 g/cm3

for steel

High electrical and thermal conductivity Resistant to corrosion in some common

environments

Easily formed and thin Al foil sheet may be rolled Al has an FCC crystal structure; its ductility is
retained even at very low temperatures

Limitation: low melting temperature (660C)

Aluminum and its Alloys (Contd)

Aluminum alloys: strengthened by cold working and
alloying (Cu, Mg, Si, Mn, and Zn)

Nonheat-treatable: single phase, solid solution

strengthening

Heat treatable: precipitation hardening (MgZn2) Applications: aircraft structural parts, beverage
cans, bus bodies, and automotive parts (engine blocks, pistons, and manifolds)

Engineering materials for transportation to

effectively reduce fuel consumption

Specific strength: the tensile strength-specific

gravity ratio

Aluminum Alloy Desginations

Material Al (99.00% minimum and greater) Al alloys are grouped by major alloying elements Copper Manganese Silicon Magnesium Magnesium and Silicon
94XX Ni-

Number 1XXX

2XXX 3XXX 4XXX 5XXX 6XXX

Aluminums use in vehicles is rapidly increasing due to a heightened need for fuel efficient, environmentally friendly vehicles
Aluminum can provide a
weight savings of up to 55 percent compared to an equivalent steel structure, while matching or exceeding crashworthiness standards of similarly sized steel structures.

The Ford Motor Company

now has aluminum-intensive test vehicles on the road, providing 46% weight savings in the structure, with no loss in crash protection.

Aluminum plate is used in the manufacture of aircraft and for fuel tanks in spacecraft

Aircraft manufacturers use high-strength alloys (principally

alloy 7075) to strengthen aluminum aircraft structures.

Alloy 7075 has zinc and copper added for ultimate strength,
but because of the copper it is very difficult to weld.

7075 has the best machinability and results in the finest

finish.

Lightweight aluminum is a good material for conductor cables

Electrical transmission
lines are the largest users of aluminum rod/bar/wire products.

In fact, this is the one

market in which aluminum has virtually no competition from other metals.

Aluminum is simply the

most economical way to deliver electrical power.

Compositions, Mechanical Properties, and Typical Applications for Some Aluminum Alloys

Copper and its Alloys

Unalloyed copper:
So soft and ductile that it is difficult to machine Unlimited capacity to be cold worked

Highly resistant to corrosion in diverse environments

Copper alloys: strengthened by cold working and/or

solid-solution alloying.

Bronze and brass are two common copper alloys.

Applications: costume jewelry, cartridge casings,
automotive radiators, musical instruments, electronic packaging, and coins

Bronze and Brass

Bronze is an alloy of
copper and tin.

The first metal

purposely alloyed by the smith

May contain up to 25%

tin

Brass is an alloy of copper

and zinc.

Bronze Mask

Contain 5-30% zinc The zinc increases the strength of the copper. Ductility and formability are also increased.

Cu-Zn Phase Diagram

Magnesium and its Alloys

Properties Lowest density (1.7 g/cm3) of all the structural metals Mg has a HCP crystal structure; relatively soft and has
a low elastic modulus (45 GPa)

At room temperature difficult to deform; only small

degrees of cold work may be imposed without annealing

Most fabrication is by casting or hot working at

temperatures between 200 and 350C

Low melting temperature (651C) Relatively unstable and especially susceptible to

corrosion in marine environments

Applications: aircraft and missile application, automobiles,

and in audio-video-computer-communications equipment

Titanium and its Alloys

Relatively new engineering materials that possess an
extraordinary combination of properties

Low density (4.5 g/cm3) High melting temperature (1668C), high elastic
modulus (107 GPa)

Extremely strong: 1400 MPa tensile strength at room

temperature, highly ductile and easily forged and machined

Limitations
Chemical reactivity with other materials at elevated
temperatures

Cost

Applications: airplane structures, space vehicles, and

in the petroleum and chemical industries

Compositions, Mechanical Properties, and Typical Applications for Some Titanium Alloys
Common Tensile Yield A llo y Name Composition Ductility Condition Strength Strength (UNS T ype (wt%) (%EL) (MPa) (MPa) Numbser)

a
94XX Ni-

Ti-6Al-4V (R564000)

6Al, 4V, balance Ti

Annealed

947

877

14

Typical Applications: High-strength prosthetic

implants, chemical-processing equipment, airframe structural components

Titanium Biomaterials (e.g. Ti-6Al-4V)

Titanium has become the leading structural metallic
biomaterial and 50 years of clinical performance has proven its value.

There are a few generic characteristics that

biomaterials need to possess for applications as longterm implantable devices.

must have the appropriate mechanical properties,

taking into account the stress levels and frequencies that will be encountered and the expectations of stress transfer within the relevant part of the body

must be sufficiently corrosion resistant, taking into

account the duration of implantation and the consequences of any corrosion should it take place

should have adequate biological safety

Superalloys
Superlative combinations of properties Nickel-based alloys Other alloying elements: Nb, Mo, W, Ta, Cr, and Ti
e.g. IN792: Ni-12Cr-10Co-2Mo-4W-3.5Al-4Ti-4Ta0.01B-0.09Zr-0.1C-0.5Hf

Applications: aircraft turbine components Turbine blades and discs, high creep and oxidation
resistance at elevated temperatures (1000C)

Must withstand exposure to severely oxidizing

environments and high temperatures for reasonable time periods

Density is an important consideration because

centrifugal stresses are diminished in rotating parts when the density is reduced.

Modern Civil Aircraft Engines

Turbine blades in a jet engine
experience:

Mechanical forces:
Creep Fatigue Thermomechanical fatigue

High temperature
environment

Oxidation Hot corrosion

Material Strength with Increased Temperature

Titanium Alloy

Nickel Alloy

Steel Aluminum Alloy

Ni-based superalloys are used for turbine blades

Modern aeroengine design constantly seeks to increase the engine

operating temperature to improve overall efficiency.

The materials for turbine blades are required to perform at higher

and higher temperatures.

The use of advanced nickel-based alloys, together with innovative

cooling design

Improvement in High-Temperature Creep Resistance of Turbine Blades

Polycrystalline turbine blade Columnar grain structure produced by a directional solidification technique Creep resistance is further enhanced with single-crystal blades.

Thermal Barrier Coatings (TBCs)

Demands for higher efficiency and lower

emission require higher operating temperatures in both

aircraft engines land-base power-generation gas

turbines

The typical melting points of the superalloys

used for the turbine components range from 1230 ~ 1315C

The temperature in a combustion gas

environment is > 1370C

Thermal Barrier Coatings (TBCs)

The superalloy technology alone cannot provide
new metals with the improved high-temperature performance.

Composition & microstructure evolutions Cooling strategy

The key to meeting these new demanding goals
lies in providing an insulating ceramic thermal barrier coating (TBC) to lower the surface temperature of the superalloy underneath

TBCs offer an increase in operating temperature greater than what superalloys achieved over 25 years

Equivalent Metal Temperature

167C (300F) Ceramic

83C (150F) Metal

Durham et al., 1993

1965

1976

1985

TBCs comprise metal & ceramic multilayers

Hot Gases

Ceramic Top Coat (100-400mm) (Y2O3-Stabilized ZrO2) Bond Coat (~100mm)

Thermally Grown Oxide (TGO) (1-10mm)

Substrate

Cooling Air

A complex interplay occurs in TBCs

Diffusion Oxidation Phase
transformation

Elastic
deformation

Thermal expansion Thermal conduction Radiation

Fracture
Fatigue Sintering

Plastic
deformation

Creep
deformation

Understanding and improving scale-metal adhesion are critical for design of TBCs
EB-PVD YSZ

Alumina Scale

Spallation Zone

(Ni,Pt)Al Bond Coat

10 m

Picture Courtesy of GEAE

Refractory Metals
Melting temperatures range between 2468C for
niobium (Nb) and 3410C for tungsten (W)

Interatomic bonding is extremely strong. Large elastic moduli and high strength and
hardness at ambient and elevated temperatures

Applications: Ta and Mo are alloyed with stainless steel to

improve its corrosion resistance.

Molybdenum alloys: extrusion dies and structural

parts in space vehicles

Tungsten alloys: filaments, X-ray tubes, welding

electrodes

Noble Metals
Expensive (precious) and superior or notable (noble)
in properties

Soft, ductile, and heat resistant

Silver, gold, platinum, palladium, rhodium,
ruthenium, iridium, and osmium

Silver and gold may be strengthened by solidsolution alloying with copper

Sterling silver: Ag-Cu (~7.5 wt% Cu) Applications: Jewelry, integrated circuit electrical contacts,
chemical laboratory equipment (Pt), catalyst, thermo-couples