Unit 4

Ferrous materials

Palak Desai
Mechanical Engineering Department

C G Patel Institute of Technology

Uka Tarsadia University
Bardoli
 Ferrous is an adjective used to indicate the presence of
iron. The word is derived from the Latin word ferrum
(iron).
Ferrous metals include steel and pig iron (which contain
a few percent of carbon) and alloys of iron with other
metals (such as stainless steel.)
The term non-ferrous is used to indicate metals other
than iron and alloys that do not contain an appreciable
amount of iron
 Introduction
Iron is a very common element in the Earths
crust.

Iron is extracted from haematite, Fe2O3, by

reduction (i.e. removal of oxygen) in a blast
furnace
 What are the raw materials??

The raw materials are:

Iron Ore Coke

Limestone
 Coke
Solid residue product from the destructive
distillation of coal.
About 80 to 95% C.
Made by heating black coal in small ovens at 300
C for 24 hours in a coke plant.
 The iron ore
Consists of oxides in nature of iron and oxygen
Primarily magnetite (Fe3O4) or hematite
(Fe2O3)

The blast furnace basically separates the iron

from the oxygen in a reduction process
 The limestone
Acts as a flux converts impurities in the ore into
a slag
 Air
Preheated by fuel gas from the coke ovens to about
1000 C.
Delivered to the blast furnace at 6,000 m3/min
Passes through furnace and burns the coke to
produce heat required and also generates the
carbon monoxide.
 Typical blast furnace
1.6 tons of iron ore
0.18 tons of limestone
0.6 tons of coke
2 -3 tons of preheated air
The Blast Furnace
Stands 300 feet tall
Designed to run continuously for 4 -5 years before
being relined.
Heat generated by burning coke in the preheated
air.
Coke acts as reducing agent and changes to carbon
monoxide (the reducing agent) which removes the
oxygen from the iron oxide.
The Blast Furnace:
Four primary zones the bottom zone (zone 4)
reaches temperature of 1800 C this is where iron
is tapped off.
The top zone (zone 1) where coke is burned and
moisture driven off.
Zone 2 slag coagulates and is removed.
 Reducing the Iron Ore
to Iron
Hot air is blasted into the furnace making the
coke burn much faster than normal and the
temperature rises to about 1500oC.

The coke burns and produces carbon dioxide:

C + O2 CO2
Carbon Oxygen Carbon dioxide
 The CO2 then reacts with unburnt coke to form
CO:

CO2 + C 2CO
Carbon dioxide Carbon Carbon
monoxide
The carbon monoxide then reduces the iron ore
to iron:

3CO + Fe2O3 3CO2 + 2Fe

Carbon monoxide Iron(III) oxide Carbon dioxide
Iron
The iron is molten at this temperature and its very
dense, so it runs to the bottom of the furnace where its
tapped off..
 Removing the Impurities:
The limestone is decomposed by the heat into
calcium oxide and CO2:

CaCO3 CaO + CO2

The calcium oxide then reacts with the sand to

form calcium silicate or slag which is molten and
can be tapped off:

CaO + SiO2 CaSiO3

(molten slag)
Cupola Furnace

A cupola furnace is a
vertical cylindrical
furnace used for
melting only cast
iron. Although other
furnaces are capable
of melting cast iron,
the largest tonnage of
cast iron is melted in
Cupola furnace.

The cupola showing the general inputs and outputs.

Construction of Cupola Furnace

A coarse refractory sand and clay are rammed slightly on the bottom
doors of cupola furnace. The sand is rammed in a tapered manner to
allow the flow of molten metal easily through the tapping spout.

Opposite to the tapping spout and little higher is a slag hole through
which the slag is removed.

Slightly above the slag hole is the wind box and tuyeres. The tuyeres
are small openings (covered by wind box) through which air under
pressure is forced into the furnace from the wind box, via a pipe from
the blowing equipment.

At the top end of the shell, a charging door is provided through

which the charge is fed into the Cupola Furnace.
Construction of Cupola Furnace

A coarse refractory sand and clay are rammed slightly on the bottom
doors of cupola furnace. The sand is rammed in a tapered manner to
allow the flow of molten metal easily through the tapping spout.

Opposite to the tapping spout and little higher is a slag hole through
which the slag is removed.

Slightly above the slag hole is the wind box and tuyeres. The tuyeres
are small openings (covered by wind box) through which air under
pressure is forced into the furnace from the wind box, via a pipe from
the blowing equipment.

At the top end of the shell, a charging door is provided through

which the charge is fed into the Cupola Furnace.
Working of Cupola Furnace

1. Starting The Cupola Furnace

Initially, soft and dry wooden pieces are placed on the sand bottom after which
coke is charged up to the tuyeres lever. The wooden pieces are ignited through
the tap hole and sufficient air is passed through the tuyeres for proper
combustion of coke.

2. Charging Cupola Furnace

The charge used in cupola furnace consists of alternate layers of coke, flux
and metal (iron). These three components are continuously built into the
cupola furnace. The most commonly used iron - to - coke ratio is 8:1. The flux
may be limestone (CaCO3), fluorspar, sodium carbonate or calcium carbide.
Limestone is the commonly employed flux. The total weight of the flux will be
approximately 1/5th the weight of the coke chare.
3. Melting in Cupola Furnace

Cupola furnace works on the counter current principle. As the combustion

takes place, the charge materials (coke, flux and metal) will be descending
downwards, while the hot gases due to combustion will be ascending
upwards. Heat exchange takes place between the rising hot gases and the
descending charge thereby melting the metal. The liquid metal drops down,
while the coke floats up on top of it.

The flux also melts and reacts with the impurities of the molten metal forming
a slag. The slag floats on the surface of the molten metal thereby preventing
oxidation of the metal.

4. Tapping slag and molten metal in Cupola Furnace

When sufficient liquid metal is collected in the reservoir, the slag door is
opened and the slag floating on the surface of the molten metal is tapped and
disposed off. Immediately the tapping spout which was closed with a bott ( a
clay plug ) is opened and the liquid metal is tapped into ladles. The tapping
spout is again closed with the bott.
The liquid metal from the ladle is poured into the moulds.
5. Dropping Down The Bottom in Cupola Furnace

When melting is complete and no more liquid is required, the

charging of cupola furnace is stopped. The prop under the
bottom door is knocked down and the bottom door is swung out
of the way allowing the contents in the cupola to drop down.
The un-melted charge is collected and used during the next
melting.

Note:- The operation of dropping down the bottom is very

dangerous and has to be done by a trained person.
 Zones Of Cupola Furnace

1. Well zone in Cupola Furnace

2. Combustion Zone in Cupola Furnace

3. Reducing Zone in Cupola Furnace

4. Melting Zone in Cupola Furnace

5. Preheating zone in Cupola Furnace

1. Well zone in Cupola Furnace:-

Well zone in the portion situated between the rammed sand bottom and just below
the bottom edge of the tuyeres. The molten metal is occupied in this zone.
2. Combustion Zone in Cupola Furnace

The combustion zone or oxidizing zone is situated normally 15-30 cm from the
bottom edge of the tuyeres. It is in this zone where rapid combustion of coke takes
place due to which a lot of heat is generated in the furnace. The combustion is rapid
due to the supply of blast air through the tuyeres.
Oxidation of manganese and silicon evolve still more heat. The reactions which take
place in this zone are:

C+O2 (from air) CO2+heat

2Mn+O2 2 MnO + heat

Si+O2 SiO2 + heat
The temperature in this zone varies from 1550C - 1850C.
3. Reducing Zone in Cupola Furnace
Reducing zone or protection zone is the portion located from the top of the
combustion zone to the top of the coke bed. In this zone, some of the hot CO2 gas
moving upward through the hot coke gets reduced to CO. In other words, reduction of
CO2 to CO occurs in this zone. Due to the reducing atmosphere, the charge is protected
from oxidation. The reaction taking place in this zone is given by.

CO2+C (coke) = 2CO - Heat

Due to the reduction, the temperature reduces to around 1200 C in this zone.
4. Melting Zone in Cupola Furnace

The portion located just above the coke bed to the top of the metal (iron) is called the
melting zone. The metal starts melting in this zone and trickles down through the coke
bed to the well zone. The molten iron while passing down through the reducing zone
picks up carbon and the reaction is given by:

3Fe + 2CO = Fe3C+ CO2

5. Preheating zone in Cupola Furnace

The portion occupied from the top surface of the melting zone to the charging
door is called Preheating zone. The hot gases rising upwards from the combustion
and reducing zone gives its heat to the charge before passing out of the furnace.
Thus, the charge is preheated before descending downwards
Steel making
 Basic Oxygen Furnace
The basic oxygen converter steel making process,
originally know as the LD process, has revolutionized steel
making technology in the world.
LD stands for Linz and Donawitz, towns in Austria where
the process was developed. The process is also known as
BOf.
The BOF process was introduced in india in the Rourkela
steel plants in late 50s. Later almost all the major
integrated steel plants in India adopted this steel making
technology.
Fluxes and coolants
Fumes to cleaning
plant

Water-cooled fume
Moveable seal hood

Water-cooled
Tap Hole lance

Steel shell Refractory lining

(Dolomite)
The Sequence
1. Charging

Scrap Iron and Steel

form 30% of the charge
Molten Iron from the
blast furnace makes up
the rest
Blowing

A water cooled pipe carries

oxygen to the surface of the
hot metal
Oxygen blows at high
pressure which increases
temperature and burns off
impurities
 Sampling

Samples are taken to check

the composition of the steel
 Tapping

Once chemical analysis

indicates correct composition,
lance is lifted out
Molten steel is poured through
Tap Hole
Removing Slag

Once chemical analysis

indicates correct composition,
lance is lifted out
Molten steel is poured
through TapHole
Electric Arc Furnace
 The Electric Arc Furnace
Carbon electrodes
Power Cables

Swivel Roof Refractory lining

Water cooled
panels
Tapping Spout
Furnace Door

Steel Scrap

The Electric Arc furnace is a circular vessel that sits on a set of

rollers which allow it to be tipped for Tapping and Slagging
The Sequence
Charging
The charge consists solely of Scrap Iron
Melting
The electrodes are lowered, and the arc is started, by
raising the electrodes a little above the surface of the
scrap
Slagging
The furnace is first tilted on rollers to allow Slag to be
raked off or poured into slag ladles.
Tapping
The furnace is then titled in the other direction and
then the molten steel is poured out through a spout
into the pouring ladle.
 White CI

Grey CI
CAST IRONS
Ductile CI

Good castability C > 2.4% Malleable CI

Alloy CI
 Gray cast iron
It contains :
C = 2.5 to 3.8%.
Si = 1.1 to 2.8 %
Mn = 0.4 to 1.0%
P = less than 0.15%
S = less than 0.1%
Fe = Remaining
 Gray cast iron
Properties
i. When fractured it gives grey color
ii. It can be easily cast.
iii. It is marked by presence of flakes of graphite in a matrix of ferrite and
pearlite or austenite; graphite flakes occupy 10% of metal volume.
iv. It can be easily machined and possesses machinability better than steel.
v. It possesses lowest melting of ferrous alloys.
vi. It possesses high vibration damping capacity
vii. It has high resistance to wear.
viii. It possesses high fluidity and hence can be cast into complex shapes and
thin sections.
ix. It possesses high compressive strength and has a low tensile strength.
x. It has very low ductility and low impact strength as compared with steel.
Applications
Gray cast iron
The grey iron castings are mainly used for machine tool
bodies, automotive cylinder blocks, pipes and pipe fittings and
agricultural implements. The other applications involved are
i. Machine tool structures such as bed, frames, column etc.
ii. Household appliances etc.
iii. Gas or water pipes for under ground purposes.
iv. Piston rings.
v. Rolling mill and general machinery parts.
vi. Cylinder blocks and heads for I.C. engines.
vii.Frames of electric motor.
viii.General machinery parts.
Gray cast iron
 White cast iron
The white color is due to the fact that the carbon is this
iron is in combined form as iron carbide which is
commonly specified as cementite. It is the hardest
constituent of iron.
The chemical composition of white cast iron is given as
under.
C = 3.2 to 3.6%
Si = 0.4 to 1.1 %
Mg = 0.1 to 0.4%
P = less than 0.3%
S = less than 0.2%
Fe = Remaining
 White cast iron
Properties
i. Its name is due to the fact that its freshly broken surface
shows a bright white fracture.
ii. It is very hard due to carbon chemically bonded with iron as
iron carbide , which is brittle also.
iii. It possesses excellent abrasive wear resistance.
iv. Since it is extremely hard, therefore it is very difficult to
machine.
v. Its solidification range is 2650-2065F.
vi. Shrinkage is 1/8 inch per foot.
vii. The white cast iron has a high tensile strength and a low
compressive strength.
 White cast iron
Applications
i. For manufacturing those component or
parts which require a hard, and abrasion
resistant surface such as rim of car
ii. Railway brake blocks.
White cast iron
 Ductile cast iron
Small quantities of magnesium or cerium is added to cast iron,
Graphite content is converted into nodular or spheroidal form
and it is well dispersed throughout the material.
Resulting structure possesses properties more like cast steel than
like the other grades of cast iron.
Compositions of ductile cast iron are as follows:
Carbon = 3.2 to 4.2%
Silicon = 1.0 to 4.0 %
Magnesium = 0.1 to 0.8%
Nickel = 0.0 to 3.5%
Manganese = 0.5 to 0.1%
Iron = Remaining
 Ductile cast iron
Ductile cast iron has
High fluidity
Excellent castability
Strength
High toughness
Excellent wear resistance,
Weldability
Higher machinability in comparison to grey cast
iron.
Ductile iron used in drain grids
 Ductile Iron/Nodular Iron

Ferrite (White)
Graphite (black)

Bulls Eye

Ferrite

5 m

Pearlite (grey)
 Malleable cast iron
Malleable cast iron is unsuitable for articles which are thin, light
and subjected to shock.
It can be flattened under pressure by forging and rolling.
It is an alloy in which all combined carbon changed to free form
by suitable heat treatment.
Graphite originally present in iron in the form of flakes which is
the source of weakness and brittleness.
Carbon in this cast iron is dispersed as tiny specks instead of
being flaky or in combined form.
The tiny specks have not such weakening effect and casting
would not break when dropped.
The tensile strength of this cast iron is usually higher than that
of grey cast iron.
 Malleable cast iron
It has excellent machining quality and is used for
making machine parts for which the steel forging
and in which the metal should have a fair degree of
machining accuracy.
Hubs of wagon
Heels small fittings for railway rolling brake supports
Parts of agricultural machinery
Pipe fittings
Hinges
Locks
 Malleable Iron
Pearlitic Matrix Ferrite (White)

Graphite (black)

Pearlite (grey)

Partially Malleabilized Iron Ferritic Matrix

Incomplete Ferritizing Anneal

Ferrite (White)

Graphite (black)

10 m
Fully Malleabilized Iron
Complete Ferritizing Anneal
 Alloy cast iron
The alloy cast iron is produced by adding alloying
elements like nickel, chromium, molybdenum, copper and
manganese in sufficient quantities in the molten metal
collected in ladles from cupola furnace.
These alloying elements give more strength and result in
improvement of properties.
The alloy cast iron has special properties like increased
strength, high wear resistance, corrosion resistance or heat
resistance.
The alloy cast irons are extensively used for automobile
parts like cylinders, pistons, piston rings, crank cases,
brake drums, parts of .crushing and grinding machinery
etc.
 Effect of impurities on cast iron
Carbon:
Carbon is one of the important elements in cast iron.
It reduces melting point of iron. Pure iron has a melting point of about
1500C but iron with 3.50% C has melting point of about 1350C.
Silicon:
Presence of silicon in cast iron promotes the decomposition of cementite
into graphite.
It also helps to reduce the shrinkage in cast iron when carbon is changed to
graphite forms.
Sulphur:
It makes the cast iron hard and brittle.
Since too much sulphur gives unsound casting, therefore, it should be kept
below 0.1% for most casting purposes.
It will make cast iron hard thereby counteracting the softening influences of
silicon.
It also promotes oxidation of cast iron. Hence, it is kept as low as possible
in cast iron.
 Effect of impurities on cast iron
Manganese:
It makes cast iron white and hard.
It is often kept below 0.75%.
It reduces the harmful effects of the sulphur by forming the
manganese sulphide which is not soluble in cast iron.
Phosphorus:
It increases fusibility and fluidity in cast iron but induces
brittleness.
It is rarely allowed to exceed 1 %.
Phosphorus in irons is useful for casting of intricate shapes
and for producing very cheap and light engineering castings.
Phosphorus has no effect on the carbon as well as on
shrinkage in the cast iron.
Comparison among grey, white and spheroidal cast iron
 Carbon and Alloying Steels
Carbon and alloying steels are the most
commonly used metals
The structural makeup and controlled processing
of these steels make them suitable for many
different functions.
Basic product shapes include plate, sheet, bar,
wire, tube, castings, and forgings.
Increasing the percentages of these elements in
steels, increases the properties they impart.
 Effects of Elements in Steels
Different elements are added to steels to
given the steel different properties.

The elements pass on properties such as

harden- ability, strength, hardness,
toughness, wear resistance, etc.

Some properties are beneficial while others

are detrimental.
 Effects of Elements in Steels
Boron: Improves hardenability without the loss of (or even with some
improvement in) machinability and formability.
Calcium: Deoxidizes steels, improves toughness, and may improve
formability and machinability.
Carbon: improves hardenability, strength, hardness, and wear resistance;
it reduces ductility, weldability, and toughness.
Cerium: controls the shape of inclusions and improves toughness in high-
strength low alloy steels; it deoxidizes steels.
Chromium: improves toughness, hardenability, wear and corrosion
resistance, and high-temperature strength; it increases the depth of the
hardness penetration resulting from heat treatment by promoting
carburization.
Cobalt: improves strength and hardness at elevated temperatures.
 Effects of Elements in Steels
Copper: improves resistance to atmospheric corrosion and, to a
lesser extent, increases strength with little loss in ductility; it
adversely affects the hot-working characteristics and surface
quality.
Lead: improves machinability; it causes liquid-metal
embrittlement.
Magnesium: has the same effects as cerium.
Manganese: improves hardenability, strength, abrasion
resistance, and machinability; it deoxidizes the molten steel,
reduce shot shortness, and decreases weldability.
Molybdenum: improves hardenability, wear resistance,
toughness, elevated-temperature strength, creep resistance, and
hardness; it minimizes temper embrittlement.
 Effects of Elements in Steels
Nickel: improves strength, toughness, and corrosion resistance; it
improves hardenability.

Niobium (columbium): imparts fineness of grain size and improves

strength and impact toughness; it lowers transition temperature and may
decrease hardenability.

Phosphorus: improves strength, hardenability, corrosion resistance, and

machinability; it severely reduces ductility and toughness.

Selenium: improves machinability.

Silicon: improves strength, hardness, corrosion resistance, and electrical

conductivity; it decreases magnetic-hysteresis loss, machinability, and
cold formability.
 Effects of Elements in Steels
Sulfur: Improves machinability when combined with manganese; it
lowers impact strength and ductility and impairs surface quality and
weldability.

Tantalum: has effects similar to those of niobium.

Tellurium: improves machinability, formability, and toughness.

Titanium: improves hardenability; it deoxidizes steels.

Tungsten: has the same effects as cobalt.

Vanadium: improves strength, toughness, abrasion resistance, and

hardness at elevated temperatures; it inhibits grain growth during heat
treatment.

Zirconium: has the same effects as cerium

 Carbon Steels
Carbon steels are group by
their percentage of carbon
content per weight. The higher
the carbon content the greater
the hardness, strength and wear
resistance after heat treatment.

Low-carbon steel, also called

mild steels, has less than 0.30%
carbon. Used in everyday
industrial products like bolts,
nuts, sheet, plate and tubes. High Carbon Steel Nails
 Carbon Steels
Medium-carbon steel has 0.30% to 0.60%
carbon. Used for jobs requiring higher
strength such as machinery, automotive
equipment parts, and metalworking
equipment.

High-carbon steel has more than 0.60%

carbon. Used parts that require the highest
strength, hardness, and wear resistance.
Once manufactured they are heat treated
 Alloy Steels
Alloy steels are steels that contain
significant amounts of alloying elements.

High strength low alloy steels

Microalloyed steels
Nanoalloyed steels
 Alloy Steels

High-strength, low- Microalloyed steels

alloy steels (HSLA) Provide superior
steels were developed to properties without the
improve the ratio of use of heat treating.
strength to weight. When cooled
Commonly used in carefully these steels
automobile bodies and in develop enhanced and
the transportation consistent strength.
industry (the reduced
weight makes for better
fuel economy ).
 Stainless Steels

Stainless steels are

primarily know for their
corrosion resistance, high
strength, and ductility
and chromium content.
 Stainless Steels

The reason for the name stainless is due to the fact

that in the presence of oxygen, the steel develops a
thin, hard, adherent film of chromium.
Even if the surface is scratched, the protective film is
rebuilt through passivation.
For passivation to occur there needs to be a minimum chromium
content of 10% to 12% by weight.
 Stainless Steels
Stainless steels tend to have lower carbon content
since increased carbon content lowers the
corrosion resistance of stainless steels.

Since the carbon reacts with chromium it

decreases the available chromium content which is
needed for developing the protective film.
 Stainless Steels
Using stainless steels as reinforcing bars, has become a new
trend, in concrete structures such as highways buildings and
bridges.
It is more beneficial than carbon steels because it is resistant to
corrosion from road salts and the concrete itself.

corrosion in
concrete
 Tool and Die Steels
Tool and die steels are alloyed steels
design for high strength, impact toughness,
and wear resistance at normal and elevated
temperatures.

High-speed steels Maintain their hardness

and strength at elevated operating
temperatures. There are two basic types the
M-series and T-series
 Tool and Die Steels
M-series contain 10 %
molybdenum and have
higher abrasion resistance
than T- series
T- Series contain 12 % to
18 % tungsten. They
undergo less distortion in
heat treatment and are less
expensive than the M-
series. M- series steel drill bits coated
with titanium
 Tool and Die Steels
Dies are tools used for drawing wire, and
for blanking, bending, cutting, machine
forging, and embossing. .
H-series (Hot-working steels) for use at
elevated temperatures. They have high
toughness and high resistance to wear and
cracking.
S-series (shock resisting steels) designed for
impact toughness.
 Steels
Low Alloy High Alloy
low carbon Med carbon high carbon
<0.25wt%C 0.25-0.6wt%C 0.6-1.4wt%C

heat austenitic
Name plain HSLA plain plain tool
treatable stainless
Cr,V Cr, Ni Cr, V,
Additions none none none Cr, Ni, Mo
Ni, Mo Mo Mo, W
Example 1010 4310 1040 43 40 1095 4190 304
Hardenability 0 + + ++ ++ +++ 0
TS - 0 + ++ + ++ 0
EL + + 0 - - -- ++
Uses auto bridges crank pistons wear drills high T
struc. towers shafts gears applic. saws applic.
sheet press. bolts wear dies turbines
vessels hammers applic. furnaces
blades V. corros.
resistant
increasing strength, cost, decreasing ductility
Based on data provided in Tables 11.1(b), 11.2(b), 11.3, and 11.4, Callister 7e.
 Nomenclature of Steels
Historically, many methods for identifying alloys
by their composition have been developed
The commonly used schemes in this country are
those developed by AISI/SAE and ASTM
The American Iron and Steel Institute (AISI) and the
Society of Automotive Engineers (SAE)
American Society for Testing and Materials (ASTM)
European countries, Japan, Russia etc. developed
their own schemes
In order to avoid confusion, the Universal/Unified
Numbering System (UNS) was developed
 AISI/SAE Classification of
Steels
A four digit description
First two digits identify the alloy type
Last two digits indicate the carbon content
For example
AISI/SAE 1020 steel is a plain carbon steel (10xx) which has
0.20 wt.% carbon (xx20)
Plain carbon steel (10xx) are inexpensive, but have several limitations
including:
Poor hardenability because the critical cooling rate is very high
Rapid cooling leads to distortion and cracking
Poor corrosion resistance
Poor impact resistance at low temperature
Alloy steels were developed to address these issues
Alloying changes the eutectoid composition, the eutectoid carbon
content and the critical cooling rate
These alloys are more expensive, but a better combination of
properties is obtained
 AISI/SAE Classification of Steels

UNS uses the AISI/SAE designation with a letter before and a 0 after the 4 digits
The letter identifies the alloy group
 Overview of UNS

Axxxxx - Aluminum Alloys

Cxxxxx - Copper Alloys, including Brass and Bronze
Fxxxxx - Iron, including Ductile Irons and Cast Irons
Gxxxxx - Carbon and Alloy Steels
Hxxxxx - Steels - AISI H Steels
Jxxxxx - Steels - Cast
Kxxxxx - Steels, including Maraging, Stainless, HSLA, Iron-Base Superalloys
L5xxxx - Lead Alloys, including Babbit Alloys and Solders
M1xxxx - Magnesium Alloys
Nxxxxx - Nickel Alloys
Rxxxxx - Refractory Alloys
R03xxx- Molybdenum Alloys
R04xxx- Niobium (Columbium) Alloys
R05xxx- Tantalum Alloys
R3xxxx- Cobalt Alloys
R5xxxx- Titanium Alloys
R6xxxx- Zirconium Alloys
Sxxxxx - Stainless Steels, including Precipitation Hardening and Iron-Based Superalloys
Txxxxx - Tool Steels
Zxxxxx - Zinc Alloys
 AISI/SAE, ASTM, UNS
ASTM developed a parallel classification, starting with a
letter A followed by numbers and other descriptors
 Tool Steels

AISI designation has a letter and a number.

The letter describes the application
M (high speed machine tool), H (hot working)
The letter describes the heat treatment
A (air hardening), O (oil quenching), W (water quenching)

UNS designation all tool steels start with a T

 Stainless Steels
Excellent corrosion resistance
Contain 12 to 30% Chromium
Cr oxidizes easily and forms a thin continuous layer of oxide that
prevents further oxidation of the metal
Cr is a ferrite stabilizer

Ferritic Stainless Steels are

essentially Fe-Cr Alloys
Ferrite phase (bcc structure)
Inexpensive, high strength

Austenite is restricted to a small

region of the phase diagram
 Stainless Steels

Austenitic Stainless Steels

Nickel is an austenite stabilizer. The addition of both
Cr and Ni results in the austenite (g, fcc) phase being
retained to room temperature
The austenite phase is very formable (fcc structure)
Ni makes these alloys expensive
Martensitic Stainless Steels
Have both Cr and C
There is more Cr than in ferritic SS since Cr tends to
form Cr23C6, which removes available Cr for corrosion
protection
Can be heat treated to high strength
UNS letter S indicates stainless steel