MatE 443 Ferrous MetallurgyR.E. NapolitanoMaterials Science & EngineeringIowa State University

What is Ferrous Metallurgy?

What is Ferrous Metallurgy?

What is Ferrous Metallurgy?

What is Ferrous Metallurgy?Historically, ferrous metallurgy is the foundation for virtually everything we know about the structure and properties of metals. Process Metallurgy Extraction and Refinement Physical Metallurgy Thermodynamics and kinetics of microstructural transformations Mechanical Metallurgy Deformation behavior and failure mechanisms

Ferrous Metallurgy Course OutlineThe Manufacture of Iron and SteelPhysical Metallurgy of Ferrous AlloysProperties of Steels and Cast IronsThe Heat Treatment of Steels and Cast Irons

I. The Manufacture of Iron and Steel Iron Ores Recovery of Iron Steelmaking Processes Control of Ingot/CC Structure Melt Chemistry & Alloying

Thermomechanical Processing Standard Product Forms Classification of Steels & Irons

II. Physical Metallurgy of Ferrous Alloys Phases and Microstructures Phase diagrams Stable/metastable phases Fe, Fe-C, Alloys Phase Transformations Nucleation and growth Austenite decomposition Martensitic transformation Interface driven processes

Transformation Kinetics Kinetics of diffusion Competitive nucleation kinetics Growth morphologies TTT and CC diagrams JMA/K kinetics

III. The Heat Treatment of Steel and Cast Iron Hardness and Hardenability Composition and size effects Hardenability curves Critical diameter Grossman Number Tempering of Steel Composition and size effects Hardenability curves Critical diameter Grossman Number Specialized Heat Treatments Martempering Austempering Patenting Ausforming Spheroidizing Surface Treatments Carburization and case hardening Induction hardening Flame Hardening Nitriding and carbonitriding Heat Treatment Equipment Batch and continuous furnaces Heat treating environments Surface treatments Basic Heat Treatments Annealing Normalizing Quenching Tempering

IV. Properties of Steels and Cast Irons Mechanical Properties General flow behavior Strength & toughness Fracture toughness Fatigue and wear Chemical Properties Corrosion resistance High temperature behavior Alloying effects Coatings Physical Properties Thermal properties Electrical properties Magnetic properties Classes of Specialized Steels Stainless steels Tool Steels HSLA Steels High Temperature Steels Etc.

What should I already be familiar with?Thermodynamics of Materials Phase diagrams Gibbs free energy Physical chemistry Kinetics of Phase Transformations Thermal activation Diffusive processes Nucleation and growth Mechanical Metallurgy Plastic deformation Elementary dislocation theory Strengthening mechanisms Characterization Methods Optical Microscopy Scanning electron microscopy X-ray diffractionMatE 212

D.R.Gaskell, Introduction to Metallurgical Thermodynamics, Chapters 10, 11, and 12.MatE 315

D.A. Porter and K.E. Easterling, Phase Transformations in Metals and Alloys, Chapters 2.1-2.3, 3.4, 5.1-5.4.MatE 318 and 342

G.E. Dieter, Mechanical Metallurgy, Chapters 5 and 6.MatE 214

Richardson, Optical Microscopy for the Materials Sciences; Goldstein et al., SEM and X-Ray Microanalysis; Cullity, Elements of X-ray Diffraction.

What should I gain from this course?A general knowledge of the various methods available for the production of ferrous materials and their associated characteristics with respect to engineering properties.

Practical capabilities with respect to the identification and control of microstructures in steels and cast irons.

An understanding of the relationships between microstructure, chemistry, processing, and properties in ferrous alloys.

A general appreciation for the wide variety of microstructures and properties available in ferrous alloys.

The ability to assess, select, and specify ferrous alloys and processing routes for particular design applications.

The ability to apply basic metallurgical principles to engineering problems related to the design, production, and application of ferrous alloys.

MatE 443 Course StructureHomework & Quizzes15%Lab Reports20%Lab Project10%Exam I15/10/10%Exam II15/10/10%Exam III15/10/10%Comprehensive Final Exam20%

Text: Krauss, Steels: Processing, Structure, and Performance

Other Refs:

Website: http://www.mse.iastate.edu/solidification/Courses/MatE443-Website/index.htm

Leslie, The Physical Metallurgy of SteelsHoneycombe & Bhadeshia, Steels, Microstructure and PropertiesSamuels, Light Microscopy of Carbon SteelsSee syllabus