Basic Metallurgy

Learning Objectives

Describe Structure of Metals

Describe Mechanical Properties of Metals
Define Carbon Steels, Alloy Steels, Cast Irons
and Stainless Steels
Become Familiar with Most Common Oilfield
Nickel-Base and Titanium Alloys

Structure of Metals

Atoms form regular pattern Crystal Lattice

Unit Cell
Face-Centered Cubic - FCC
Body-Centered Cubic BCC
Hexagonal Close Packed HCP

Unit Cells - FCC, BCC & HCP

Crystal Structure & Grains

Allotrope More than one crystal structure in metal

depending on temperature
Mechanical Properties Strength, Ductility & Toughness
- dependant on crystal structure
Grains nucleate & grow during solidification
Grain Boundary Interface of two or more grains
ordered structure disrupted
Fine Grain size generally increases both strength &
toughness

Relationship Between
Grain Size & Yield Strength

Metallography & Microstructure

Alloys

Solid Solutions of two or

more elements
Substitutional
Interstitial

Tensile Test Specimen

Tensile Test Stress & Strain

Common Hardness Tests

Hardness & Tensile

Impact Toughness

BCC Temperature Dependence

& Transition
Charpy Impact Test
Microstructure & Grain Size
Effects
Alloy Elements & Heat
Treatment Effects

Charpy V-Notch Impact

Test Specimen

Impact
Effect of Carbon

Effect of Grain Size

Fatigue

Stress Number of Cycles

Welded Steel in Seawater

Fatigue Fracture Surface with Beach

Marks

Steel Iron + Manganese + Carbon

Manganese Substitutional in Iron

Carbon Interstitial in Iron
Allotropic Transformations on Cooling after liquid
solidifies as BCC
BCC to FCC
FCC to BCC

Phase Diagram Equilibrium Phases

Temperature Composition Dependant

Single Phase Two Phase
Hypoeutectic Eutectic - Hypereutectic
Hypoeutectoid Eutectoid - Hypereutectoid

Iron-Carbon Phase Diagram

Pearlite Microstructure

Bainite & Martensite

Alloy Steels

Impurities Oxygen, Sulfur & Phosphorus

Deoxidizers Silicon, Aluminum & Titanium
Manganese Hardenability & MnS
Molybdenum Hardenability & Hot Strength
Nickel Hardenability & Toughness
Chromium Hardenability, Corrosion & Oxidation
Resistance, Hot Strength
Tungsten Hardenability & Hot Strength
Columbium & Vanadium Grain Refinement,
Hardenability & Hot Strength

AISI & SAE Steels

ASTM Unified Numbering System

Time-Temperature-Transformation

Continuous Cooling Transformation

H-Band & Standard AISI Steels

Hardness & Yield vs Tempering Temperature

Tempered Martensite 300oC & 700oC

Cast Irons

Iron + Carbon (greater than 2.0%) & Silicon

Alloys Manganese, Phosphorus, Nickel, Chromium
Classes
Gray Flakes of Carbon (graphite) in Ferrite Matrix
White No Free Carbon Iron Carbides
Malleable Heat White Iron & Slow Cool

Ferritic - Ferrite Matrix w/ Carbon (graphite) Nodules

Pearlitic Carbon (graphite) in Nodules + Carbides or Martensite
Alloy Carbon (graphite) in Nodules

Ductile Mg or Ce Added to Spherodize Carbon (graphite)

Gray Cast Iron

Gray Cast Iron
Carbon as graphite flakes in a ferrite matrix.
High silicon (~2%) and carbon (~3%).
Classified by two digit tensile strength levels 20, 30, etc
in ksi.
Low fracture elongation <1%.
Good vibration resistance, high heat transfer, thermal
cycling resistance.
Modulus varies with strength levels usually use secant
modulus rather than tangent modulus at origin. Secant
modulus about 75% of tangent modulus.

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White Cast Iron

White Cast Iron
Carbon as carbides iron and alloy (Cr, Mo, Ni {heat
treat})
Silicon low (<1%) and carbon varies from ~2% to over
3.5% depending on desired hardness.
Alloyed and heat treated to achieve high hardness
levels. Matrix varies from pearlite to tempered
martensite.
Wear applications almost exclusively.
Malleable Cast Iron
Heat treat white iron at 1,500 to 1,750F for long times (day or

so) to produce graphite nodules. Stronger & tougher than gray.

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Ductile Cast Iron

Ductile Cast Iron

Carbon as graphite spheres in ferrite matrix.
Composition similar to gray cast iron Si & C.
Small additions of Mg, Ce, etc during casting
process promote formation of graphite spheres.
Classified by three two-digit numbers tensile in
ksi - yield in ksi elongation in %. i.e. 60-40-18
High strength and toughness compared to other
cast irons even better than malleable cast iron.
Mg or Ce additions add cost and raw materials
are higher purity than for gray but no heat treat.
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Stainless Steels

Chromium > 12.0%

Nickel May be Added to Improve Corrosion Resistance &
Mechanical Properties
Molybdenum Improves Pitting Resistance & Hot Strength
AISI Grades
Austenitic
Ferritic
Martensitic
Precipitation Hardening
Duplex Austenite & Ferrite
Cold Work of Austenitic Stainless for strengthening
Cold Work of Ferritic Stainless for strengthening
Heat Treatment of Martensitic and Precipitation Hardening
stainless steels for strengthening

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Table 1-3 Compositions of AISI standard grades of stainless steels - continued

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Table 1-3 Compositions of AISI standard grades of stainless steels - continued

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Duplex Stainless

Austenite + Ferrite
Low carbon
Cr 22-25% Ni 5+% Mo 3+%
Some with additional alloying
Nitrogen added to Improve Pitting Resistance
Excellent Corrosion Resistance

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Nickel-Base Alloys

Nickel, Chromium, Molybdenum, Iron, Copper,

Aluminum & Titanium
Incoloys: Nickel - Iron - Chromium
Inconels: Nickel - Chromium
Monels: Nickel - Copper
Hastelloys: Nickel Chromium - Molybdenum
Cold Work for Strengthening
Some Age Hardenable

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Titanium Alloys

Superior Corrosion Resistance from TiO2

High Temp BCC Beta
Low Temp HCP Alpha
Categories
Alpha
Near Alpha
Alpha + Beta
Near Beta
Beta
Alloys Aluminum, Nickel, Vanadium, Molybdenum, Chromium, Palladium,
Platinum & Tin
Alpha & Near Alpha not Heat Treatable
Alpha + Beta, Near Beta & Beta Solutionize Plus Aging Heat Treatment

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 QUESTIONS?

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