8

Ferrous and

Nonferrous Alloys
1302 212 Engineering Materials
.

Engineering Materials


2
(Ferrous metals)

(base metal)

2. (Nonferrous
metals)


(base
metal)
2

1.

Engineering Materials

Ferrous metals

1.
2.

3.

Engineering Materials

(Fe2O3)

1538 C

Engineering Materials

Engineering Materials

Timeline
1.
2.
3.
4.

2900 B.C.

2000 B.C.
1350
1000 B.C.
200
B.C
Engineering Materials

2. Steel Making

1. Reduction of iron compounds to
molten iron
2.
Process Steelmaking
3.
Casting
4.
Rolling
5.
Heat treatment
Engineering Materials

1.

(Float)
(Magnetic separation)

(Agglomeration) 1

Engineering Materials

Agglomeration of iron ore

Engineering Materials

 ()

, ,

Magnetite (Fe3O4) 70%
Hematite (Fe3O3)
70%
Siderite (FeCO3)
60%
Pyrite (FeS2)

45%
Limonite (HFeO2) 35%

10

Engineering Materials

http://www.soes.soton.ac.uk/resources/collection/minerals/minerals/

Magnetite

Magnetite
(Fe3O4)

70%

Pyrite

Pyrite (FeS2)

45%

Hematite

Hematite
(Fe3O3)

70%
11

Engineering Materials

http://www.musee.ensmp.fr/mineral//11087x.jpg
http://www.gc.maricopa.edu/earthsci/imagearchive/limonite.htm

Siderite
Siderite (FeCO3)

Limonite
Limonite (HFeO2)
Engineering Materials

12

2. Process Steelmaking

(%
)


Blast
furnace

flux CaO CaCO3

13

Engineering Materials

3.5%

2%,
1.5%,
1%
1%
2

14

Engineering Materials

3.

(Pig iron)

1600 C


Oxidation

Slag

90%Fe


Mn, Cr, Mo, Ni V

15

Engineering Materials

:Furnace

1. The basic open-hearth

furnace

16

Engineering Materials

www.key-to-steel
Engineering Materials.com

17

2. The Basic oxygen furnace

oxygen

http://www.bluescopesteel.com/corp/navajo/display.cfm
Student information

18

Engineering Materials

19

Engineering Materials

20

Engineering Materials

3. The electric arc furnace

Radiation

21

Engineering Materials

22

Engineering Materials

23

Engineering Materials

3.

Casting ()

2
1.
2.

Continuous Casting
Ingot Casting

24

Engineering Materials

3.1 Continuous Casting

Billet, Bloom, Slab

3.2 Ingot Casting
(mould)
Ingot

25

Engineering Materials

4. Rolling () and Mechanical

treatment (hot rolling, cold rolling,
forging, extruding ect.)
Ingot

hot rolled

5. Heat treatment ()


26

Engineering Materials

3.1
3

3.2

27

Engineering Materials

Steel process animation

http://www.sidmar.be/CONTENT/2c.htm

28

Engineering Materials

3.

Low
alloy
C

High
alloy

HSL
Plain
Pla
Pla

A
Heat
in
in
Treata

29

Engineering Materials



2
1. (Steels) C
2.

2wt%

(Cast Irons)
C 2wt%

30

Engineering Materials

Yieldstrength

n
Si

Ni

, 0.25%


, ,

Engineering Materials
31

S
Sn
Al
Cu

(Toughness)
(Cracking) Casting (S)
Mn , S (Fe) FeS

Hot shortness
(Cracking)


Inclusion
(Castability)

(Edge cracks)

32

Engineering Materials

P
b
N
b
V

33

Engineering Materials


1.
2.
3.
4.

34

Engineering Materials

Steels

C 2wt% ,

C
Mn Si, P S

35

Engineering Materials

1.Carbon Steels

0
0.25
0.60
1.Low
Carbon
Steels

910
C

1.0
wt%C

2.Medium
Carbon Steels

0.025

3.High Carbon Steels

0.8

+
Pearlite

36

Engineering Materials

1.1 Low Carbon Steels

steels C 0.25 %
(Plain
carbon steel) , HSLA : high strength low
alloy Cu, V, Ni,
Mo

,
, (channels)

37
Engineering Materials

Ferrite
Pearlite

Low Carbon steel 0.2%C

38

Engineering Materials

1.2 Medium Carbon Steels

steels C 0.25 0.6 %

Cr, Ni

low carbon steels

wheels , screw, gear, die
39

Engineering Materials

Ferrite

Pearlite

Carbon steel 0.6%C

40

Engineering Materials

1.3 High Carbon Steels

steels C 0.6 1.0 %

(Tool steel)
Cr, V, W, Mo carbide
strength
knives, ball bearing, springs,
tool bits
41

Engineering Materials



AISI - American Iron and Steel Institute
SAE - Society for Automotive Engineers
ASTM - American Society for Testing
and Materials
UNS - Universal Numbering System
42

Engineering Materials

 Plain carbon or alloy steels 4

2
2

Carbon Steels
1001 Plain Carbon Steel, Mn
1.00%Mn
Nickel Steels
23XX Carbon Steel 3.50%Ni
25XX Carbon Steel 5.00%Ni
43

Engineering Materials

High strength low alloy

(HSLA)

1.

2.
3.
4.
5.

strength 695 MPa

oxidation

44

Engineering Materials

 High

strength Low Alloy Steels

0.3%



intermetallic compound

45

Engineering Materials

2. High alloy steels

2.1 Stainless Steels

Cr >
11wt%Cr
Ni , Mn, C,
Mo
Cr
chromium oxide
film

46

Engineering Materials

 stainless
steel

1. Ferritic
2. Austenitic
3. Martensitic
4. Precipitation Hardening
5. Duplex
47

Engineering Materials

2.1.1 Ferritic Stainless Steel

Cr 12-17wt %
(BCC)

Yield strength Tensile strength


Elongation


48

Engineering Materials

Stainless steel 430 ferritic

Ferrite
Carbides

49

Engineering Materials

2.1.2 Austenitic stainless steel

17 Cr wt % 6-22

Ni wt %
(FCC)

Ni Ferritic

Yield strength Ferritic
Tensile Strength Elongation

304 18/8

50

Engineering Materials

Stainless steel 316 Austenitic

Austenite grains

51

Engineering Materials

2.1.3 Martensitic stainless steel

Cr 11.5-18 wt%

C 0.1-1 wt%

Austenitic and Ferritic

52

Engineering Materials

Stainless steel 440 Martensitic

carbide

Stainless steel
15-5PH low carbon
martensitic

53

Engineering Materials

2.1.4 Precipitation Hardening stainless

steel

Cr 15-18 wt% Ni 38wt% and Mo

precipitation hardening Cu, Al,
Ti

PH13-9Mo, AM-350
54

Engineering Materials

2.2 Tool Steels

C , W ,
Mo , Cr , Co , Ni , Mn , Si , Ti , V

55

Engineering Materials


/





Hardenability

56

Engineering Materials

 Tool Steels
1.
2.

3.
4.
5.
6.

(High Speed
Steel, HSS)
(Hot Work)

Forging Cr, W, Mo

(Cold Work)

( )
( Low alloys)

57

Engineering Materials

Cast Irons

2 %

Si

Steels

58

Engineering Materials

L +
1532
C

+
910

Engineering cast iron, Melting

point ~1140-1200 C

L+

910 austenite
+ C
ferrite
-ferrite +

Pearlite

Pearlite

0.
0.025
8

Ste

1148
+
C
727 Fe3C
C

Pearlite +
Fe3C

2.
08

Cast

L+
Fe3C

Fe3C

6. %C
4.
67
3
Tensile
Elongati
strength
59
on
Engineering Materials

(Gray cast iron)

2. (White cast iron)
(Ductile cast iron)
(Malleable cast
iron)
5.
(Alloys or Special cast iron)
1.

3.
4.

60

Engineering Materials

1. Gray Cast Iron

(Pig Iron) (Blast furnace)

C 2 4 wt%


(Graphite
Flake)

61

Engineering Materials

200-250 MPa
62

Engineering Materials

Graphite flake

Ferrite

Gray Cast Iron

ASTM type A

63
Engineering Materials

2.White Cast Iron

1.7-3 wt%, 1%Si, 0.5%Mn P<0.1%,

S<0.2%

C solid
solution

C
(Fe3C)

64

Engineering Materials


Pearlite Cementite
(Fe3C)
(Ledebulite) Cementite

Fe3C

Pearlite

65

Engineering Materials

3.Malleable Cast Iron

1600 F
24 - 48
Carbon atom
graphite

Ferrite Pearlite

66

Engineering Materials

Rosette graphite

Ferrite grain

ferrite matrix

67

Engineering Materials

4. Ductile Iron

4.2-4.6 wt%
Eutectic


ferrite, pearlite graphite graphite
(Nodular)
Nodular graphite Mg

Modulus of elasticity 68
Engineering Materials

Ferrite
grain

Nodular Graphite
69

Engineering Materials

5. Alloys or Special Cast Iron

Cr , Si , Ni,
Cu 1



matrix

Ni-Resist

70

Engineering Materials

 Wear resistant Hi-Cr cast iron

(Fe-2.6C-17Cr-2Mo-2Ni wt%)
Chromium Carbide (M7C3)
71

Engineering Materials


AST

Cast

Microstructu UTS,

iron
Gray

re
Ferrite

YS, %Elongat

ksi
18

ksi
-

+Pearlite

30

Pearlite

40
80

55

Ductile Ferrite
Fine Pearlite
+Pearlite
Mallea Ferrite +
50/54 32/3

ion

10/18

72

Engineering Materials

Cast

Process

Graphit

Matrix

Ductil

iron
White

e
Rapid cooling Carbide Ferrite

ity
No

Gray

rates
Slow cooling

No

Flake

Ferrite/Pe

rates
arlite
Mallea White+anneal Flake to Ferrite/Pe

Good

ble
ing
Nodula Mg +slow

Good

r
Alloy

cooling
alloying

element

nodule arlite
Nodular Ferrite/Pe
arlite
Carbide Ferrite/Pe
arlite

Good
73

Engineering Materials

1.

2.

3.
4.
5.

Cr and Mn Cementite stabilizers

Si, Al and Ni graphite formers

graphite ferrite
matrix
graphite pearlite
Engineering Materials
74
matrix

1.

a)

b)
c)

2.

3.

a.

Mg

b. Carbon 2-4wt%

Engineering Materials
75
c.

Non-Ferrous Metals

76

Engineering Materials


1. (Heavy Metals)

4 g/cm3
1.

(Light Metals)

1.74 4.5 g/cm3

77

Engineering Materials

Only a small number are used in

quantity as the basis for engineering
materials, there are
1. Copper
2. Nickel
Heavy metal
3. Zinc
4. Aluminium
5. Magnesium
Light metal
6. Titanium
Many others are used as alloying
elements or special purpose.

78

Engineering Materials

 (Copper, Cu)
1.
2.
3.
4.
5.
6.

8.9 g/cm3

1,073- 1,093 oC



(Patina)

79

Engineering Materials

 (Copper)

copper sulphide, Cu2S

Cu2S FeS2

(Roasting), oxidation
flux

80

Engineering Materials

www.fcx.com/envir/wtsd/2004/copper.htm

81

Engineering Materials

Website:www.copper.org

82

Engineering Materials

 (Brasses)

Zn 35%
Zn 20% Red brass

Zn 20-35% Yellow brass
Red
brass

83

Engineering Materials

 , ,

, , , ,

84

Engineering Materials

 (Bronzes)

(60-98
wt%) 1


1. (Cu+Sn+Zn)

85

Engineering Materials

2. (Cu+(5-9%)Al)

, , ,

3. (Cu+Pb+Zn)

4. (Cu+Be+Zn)

86

Engineering Materials

Zinc and Zinc alloys

1.

2.
3.
4.

Zn 7.1 g/cm3
419 oC

3-4
87

Engineering Materials

Zinc die cast

88

Engineering Materials

www.zinccoaters.com.au/

89

Engineering Materials

Nickel and Nickel alloys

1.
2.
3.
4.

5.

Ni 8-8.9 g/cm3
1,450 oC



30

stainless steel
90

Engineering Materials

Alloys of Ni
Ni-Co is heat resistant, used in the chemical
industry
Ni-Mn has resistant to oxidation used in spark
plugs
Ni-Al has high strength as well as resistant to
corrosion, used in springs and shafts
Ni-Cu (Monel Metals) high corrosion resistance
and high strength. When Si is added, monel will
has good wear resistance. It use to resist
corrosion due to sulfuric acid, caustic soda or
salt water in the chemical, electrical, textile
Engineering Materials
91
laundry marine industries.

Ni-Cr-Fe (Inconel metals)

Have good strength and high resistance
to corrosion by chemical at high temp.
Used in airplane exhaust systems, heattreating container, food-processing
equipment

92

Engineering Materials

Website:
1. http://www.key-tometals.com/Article9.htm
2.

93

Engineering Materials

Website:
1. http://www.key-tometals.com/Article9.htm
2.

94

Engineering Materials

(Tin)

Cassiterite,
SnO3

Cassiterite

95

Engineering Materials

SnO3



1200 C

(
affinity
)

99%
SnO2 + 2C Sn + 2CO
Engineering Materials
96

http://www.thaitambon.com/SPK/Pewter1.htm

97

Engineering Materials

(Lead)

Galena, (PbS) ,
, ,

Galena

98

Engineering Materials

( Pb
PbS) FeS2

blast
furnace 900 C



400 C

99

Engineering Materials

2. (Light Metals)

1.74 4.5
g/cm3
1.
(Aluminium, Al)
2. (Magnesium, Mg)
3. (Titanium, Ti)
4. (Beryllium, Be)
100

Engineering Materials


strength to
weight ratio

10 kg

7kg in titanium, 4.9
kg in aluminium, 3.8 kg in magnesium
and only 2.2 kg in beryllium

101

Engineering Materials

 (Aluminium, Al)
1.
2.
3.
4.
5.

2.7 g/cm3

658 oC

102

Engineering Materials

6.
7.
8.

103

Engineering Materials

 Bauxite
(Hydrated aluminium oxide, Al2O3.H2O)
, , ,
, ,

104

Engineering Materials

Bayer Process

Pure aluminium oxide
99.4%

105

Engineering Materials

Hall Process

99.5-99.9%

106

Engineering Materials

Aluminium can be divided into two main

groups including:
(1) Wrought aluminium
Copper, Magnesium, Zinc, Silicon,
Chromium and Manganese are element
usually alloyed with Al. Examples of
precipitates are Al2Cu, AlMgZn and
Mg2Si.
(2) Cast aluminium
For cast aluminium, Silicon Magnesium
and Copper are used.

107

Engineering Materials

www.aluminiumlearning.com

108

Engineering Materials

 (Magnesium, Mg)
1.
2.
3.
4.
5.

6.

1.74 g/cm3
650 oC
25%
Youngs modulus 5
HCP
BCC

109

Engineering Materials

8.
9. Zn

10. Al and Zn
solid solution strengthening
7.

110

Engineering Materials



magnesite,
dolomite, brucite, carnallite
magnesite
(MgCO3),

brucite
(MgO.H2O),

carnallite
(MgCl2.KCl.6H2O)

Dolomite
(MgCO3),

111

Engineering Materials

Dow chemical
electrolytic process


99.9%

680 750 C

112

Engineering Materials

Silicotermic process
magnesite (MgCO3)
dolomite (MgCO3)
magnesia
anhydrous magnesium
chloride

113

Engineering Materials

i-mobile 318 magnesium design

114

Engineering Materials

 (Titanium and its

alloys
3
1.
2.
3.
4.
5.

4.5 g/cm
1,700 oC
hcp

400oC

Austenitic stainless steel
Ti alloys Ti-Al, Ti-Cr, Ti-Fe

Website: http://www.titanium.org/

115

Engineering Materials

aircraft tailpipe, aircraft
frame, gas turbine, compressor

gas turbine blade

Stream turbine blade

116

Engineering Materials

http://www.absolutetitanium.com

117

Engineering Materials

Cu

Al

118

Engineering Materials