metal alloys formation 1 wec objective to have an understanding of manufacturing of steels &...
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Metal Alloys Formation
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Objective
To have an understanding of
• Manufacturing of steels & their products,
• Alloy designation,
• Classification,
• Properties & uses of various types …..Plain/ alloy/tool etc,
• Effects of common alloying elements
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Metal Alloys• Most engineering metallic materials are alloys.
• Elemental metals are generally very soft and not very usable.
• Metals are alloyed to enhance their properties, such asstrength,hardness or corrosion resistance,
and to create new properties, such assuperconductivity and shape memory effect.
• Engineering metal alloys can be broadly divided into
–Ferrous alloys and
–Non-ferrous alloys
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Engineering Materials
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Metal
Non-ferrousFerrous
Carbon Low Alloy High Alloy
Cast ironsCast ironsSteelsSteels
Low-C
Medium-C
High-C
Tool (Mo,V,W,Cr, Ni)
Stainless (Cr, Ni)
……
High-strength low-alloy……
Grey iron
Nodular iron
White iron
Malleable iron
Alloy cast irons
Classes of Metals
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Steel
Structural framing
Roofing / Cladding
Interior products
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The Whole Spectrum of Steel Products!
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Alloy Designation
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AISI - SAE Classification System AISI XXXX
American Iron and Steel Institute (AISI)
• classifies alloys by chemistry
• 4 digit number– 1st number is the major alloying element
– 2nd number designates the subgroup alloying element OR the relative percent of primary alloying element.
– last two numbers approximate amount of carbon (expresses in 0.01%)
http://www.steelnumber.com/en/number_en10027_eu.php
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• Alloy Designation Alloy Designation– AISI: American Iron and Steel Institute– SAE: Society of Automotive Engineers– ASTM: American Society for Testing and Materials– UNS: Unified Numbering System
AISI Grade X1X2X3X4
Carbon Steels and Low Alloy Steels
Older, but still widely
used
Primary alloying elements
Carbon content
10, 11, 12 plain C steel13 Mn steel2x Ni steel, x=%Ni3x Ni-Cr Steel, x=%Ni+Cr4x Mo Steel, x=%Mo5x Cr steels, x=%Cr6x Cr-V Steels, x=%Cr+V7x W-Cr Steels, x=%W+C9x Si-Mn Steels, x=%Si+Mn
X1X2
eg. 15 = 0.15%C5195 =?
1040Fe-0.4%C
2520Fe-5%Ni-0.2%C
Fe-1%Cr-0.95%C10WEC
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What is a steel and alloy of?
Iron (Fe) and Carbon (C)
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Plain Carbon Steels
An alloy of Fe & C
whose properties depends
only upon the %age of
Carbon present in it.
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Metal Alloys
Non-ferrousFerrous
Carbon Low Alloy High Alloy
Cast ironsCast ironsSteelsSteels
Low-C
Medium-C
High-C
Tool (Mo,V,W,Cr, Ni)
Stainless (Cr, Ni)……
High-strength low-alloy……
Grey iron
Nodular iron
White iron
Malleable iron
Alloy cast irons
Classes of Metals
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Plain Carbon Steel vs. Alloy Steel
Lowest cost
Should be considered first in most application
Classifications
• Low Carbon Steel
• Medium Carbon Steel
• High Carbon Steel
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Plain Carbon Steels: General Properties
• Yield strength: 300MPa (mild steels) - 700MPa (high C steels)
• Tensile strength: 400-1000 MPa
• Ductility: EL% 15-30
• Young’s modulus: 210 MPa.
• Divided into
– low (<0.3%C),
– medium (0.3-0.6%C) and
– high (0.6-1.2% C) carbon levels
• Increasing C content increases strength & hardness, but decreases ductility
& toughness
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Low Carbon Steel
• Carbon < 0.3wt%• Used wherever soft,
deformable materials are needed
• E.g., structural sections, rivets, nails, wire, pipe.
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Medium Carbon Steels
• Carbon = 0.3 - 0.6wt%
• Used where higher strength is required
• E.g., gears, shafts, axles, rods, etc.
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High Carbon Steels
• Carbon = 0.6 - 1.2wt%
• used where high hardness is required
• E.g. hammers, chisels, drill, springs.
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Mild steel panels for easy shaping
Medium-carbon steel chassis for strength and toughness
high-carbon steel springs
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Low-C
Medium-C
High-C
Tool
Tool (Mo,V,W,Cr, Ni)
Stainless (Cr, Ni)
……
High-strength low-alloy……
Metal Alloys
Non-ferrousFerrous
Carbon Low Alloy High Alloy
Cast ironsCast ironsSteelsSteels
Grey iron
Nodular iron
White iron
Malleable iron
Alloy cast irons
Classes of Metals
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Alloy Steel
Alloy steel may be defined as one whose characteristics
properties are due to some elements other than Carbon.
Although all Plain-Carbon steels contain moderate
amounts of Mn & Si, but they are not considered alloy
steels because the principal function of Mn & Si is to act
as de-oxidizer during steel manufacturing process.
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Why alloying is necessary?
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Why alloying is necessary?Many purposes, some of the most important are:-
i. increase harden-ability,
ii. reduce danger of warpage,
iii. improve strength & toughness at high & low
temperatures,
iv. resist grain growth at elevated temperature,
v. improve wear, corrosion, fatigue & creep
resistance.
vi. improve machine-ability,
vii. improve magnetic properties.23WEC
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Alloying Elements used in Steel
• 2% to 5%
• Increases toughness
• Increases impact resistance• 12% to 20% with low amounts of C possess great
corrosion / scaling resistance• universal grain refiner in alloy steels • unfortunately is a powerful graphitiser. • Invar
– contains 36% Ni– virtually no thermal expansion– used for sensitive measuring devices
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Alloying Elements used in Steel
• Usually < 2%
• increases hardenability and strength
• 5 % Cr steels used for making forging dies
• typically used in combination with Ni and Mo
• 10.5% < Cr < 27% = stainless steel –– used for corrosion resistance
• Improves non-scaling properties
• Causes grain growth
• Reduces toughness
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Alloying Elements used in Steel
• Usually < 0.3%
• has strong carbide stabilizing influence
• increases hardenability and strength
• Mo-carbides help increase creep resistance at elevated temps
• imparts some sluggishness to tempering influences
• improves the tensile strength & sp. heat resistance
• has favorable influence on the welding properties.
• Steel with higher contents tend to be difficult to forge
• typical application is hot working tools26WEC
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Alloying Elements used in Steel
• acts as de-oxidizer during steel manufacturing • combines with sulfur (MnS) to prevent brittleness & improves
machining • forms stable Carbides• >1%
– increases hardenability• improves strength, wear resistance of steel• 11% to 14%
– increases hardness– good ductility– high strain hardening capacity– excellent wear resistance
• Ideal for impact resisting tools27WEC
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Alloying Elements used in Steel
• Usually 0.03% to 0.25%
• has strong carbide-forming tendency.
• stabilities martensite and increases hardenability.
• induces resistance to softening at high temperatures once the steel is hardened
• increases hot hardness properties in High Speed & Tool steels by increasing cutting properties.
• increases strength without loss of ductility
• Like Nickel it restrains grain growth
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Alloying Elements used in Steel
• helps to form stable carbides
• renders transformations very sluggish - hence, once
hardened, a steel resists tempering influences.
• increases hot hardness
– used as cutting tool steels
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Alloying Elements used in Steel
• Imparts brittleness
– Okay if combined with Mn
• Improves machining
• Some free-machining steels contain 0.08% to
0.15% S
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Alloying Elements used in Steel
• for low carbon steels, can drastically increase
hardenability
• improves machinablity and cold forming capacity
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• deoxidizer
• 0.95% to 1.30%
• produce Al-nitrides during nitriding
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Alloying Elements used in Steel
• 0.10% to 0.50%
• increases corrosion resistance
• Reduces surface quality and hot-working ability
• used in low carbon sheet steel and structural steels
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• About 2%• increases strength without loss of ductility
• enhances magnetic properties
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Alloy Steel
• >Most common alloy elements:
– Chromium, nickel, molybdenum, vanadium,
tungsten, cobalt, boron, and copper.
• Added in small percents (<5%)
– increase strength and hardenability
• Added in large percents (>20%)
– improve corrosion resistance or stability at
high or low temps
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High Strength Low Alloy SteelsLow alloy = alloying elements <10%
• Yield strength : 800-1100 MPa
• Tensile strength: 950-1300MPa
• Ductility : EL% 15-20
• Young’s modulus: 200 MPa (alloying generally reduces Young’s Modulus)
Uses
• Used where high strength or hardness is needed – eg high strength bolts, connecting rods, springs, torsion bars, ball bearings.
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Low-C
Medium-C
High-C
Tool
Tool (Mo,V,W,Cr, Ni)
Stainless (Cr, Ni)
……
High-strength low-alloy……
Metal Alloys
Non-ferrousFerrous
Carbon Low Alloy High Alloy
Cast ironsCast ironsSteelsSteels
Grey iron
Nodular iron
White iron
Malleable iron
Alloy cast irons
Classes of Metals
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Tool Steels
A class of (usually) highly alloyed steels designed
for use as industrial cutting tools, dies, and molds
• To perform in these applications, they must
possess
– high strength, hardness, hot hardness, wear resistance,
and toughness under impact
• Tool steels are heat treated
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AISI Classification of Tools Steels
T, M High‑speed tool steels ‑ cutting tools in machining
H Hot‑working tool steels ‑ hot‑working dies for
forging, extrusion, and die‑casting
D Cold‑work tool steels ‑ cold working dies for
sheet metal press-working, cold extrusion, and forging
W Water‑hardening tool steels
S Shock‑resistant tool steels ‑ tools needing high toughness, as in sheet metal punching and bending
P Mold steels ‑ molds for molding plastics and rubber
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Tool Steels• Carbon tool steels: 0.8~1.2%C• High alloy tool steels are often
alloyed with Mo, V, W, Cr and/or Ni
• E.g., HSS, W-Cr-V (18-4-1)• Yield strength: 1000-1500 MPa• Tensile strength: up to 2000MPa• Ductility: EL% 5-15• Young’s modulus: 200 MPa
(alloying generally reduces Young’s Modulus)
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Tool Steels
Uses• Used where extreme
hardness is required.• Ductility/toughness usually
sacrificed• E.g. Moulds and dies, saws,
cutting tools, punches
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Stainless Steel (SS)Highly alloyed steels designed for corrosion
resistance
• Principal alloying element is chromium, usually greater than 11.5%
– Cr forms a thin impervious oxide film that protects surface from corrosion
– “Stainless-ness” comes from the formation of a self-repairing Cr2O3 thin, adherent &
impervious oxide film that protects or passivates the underlying steel.
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Stainless Steel (SS)
• Nickel (Ni) is another alloying ingredient in certain SS to increase corrosion protection
• Carbon is used to strengthen and harden SS, but high C content reduces corrosion protection since chromium carbide forms to reduce available free Cr, therefore Carbon content is kept very low - < 0.1% to avoid Cr3C2
formation
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Properties of Stainless Steels
• In addition to corrosion resistance, stainless steels
are noted for their combination of strength and
ductility
– While desirable in many applications, these
properties generally make SS difficult to work
in manufacturing
• Significantly more expensive than plain C or low
alloy steels
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Types of Stainless Steel
• Classified according to the predominant phase
present at ambient temperature:
1. Austenitic stainless ‑ typical composition
18% Cr and 8% Ni
2. Ferritic stainless ‑ about 11.5% to 27% Cr,
low C (0.25% max), and no Ni
3. Martensitic stainless ‑ as much as 18% Cr
but no Ni, higher C content (0.15-0.75%) than
ferritic stainless
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Additional Stainless Steels
• Traditional stainless steels developed in early 1900s
• Several additional high alloy steels have been developed and are also classified as stainless steels:
4. Precipitation hardening stainless ‑ typical composition = 17% Cr and 7%Ni, with additional small amounts of alloying elements such as Al, Cu, Ti, and Mo
5. Duplex stainless ‑ mixture of austenite and ferrite in roughly equal amounts
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Stainless Steels - Typical Mechanical Properties
• Yield strength : 200-1600 MPa
• Tensile strength : 300-1800MPa
• Ductility : EL% 2-20
• Young’s modulus:~170 MPa (alloying
reduces Young’s Modulus)
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Designation Scheme for Stainless Steels
• Three‑digit AISI numbering scheme
• First digit indicates general type, and last two
digits give specific grade within type
– Examples:
Type 302 – Austenitic SS18% Cr, 8% Ni, 2% Mn, 0.15% C
Type 430 – Ferritic SS 17% Cr, 0% Ni, 1% Mn, 0.12% C
Type 440 – Martensitic SS 17% Cr, 0% Ni, 1% Mn, 0.65% C
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Assignment
Alloy steels•Cr steels•Ni steels•Ni-Cr steels•Mn steels•Mo- steels•V-steels
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Thanks
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