Engineering

Drawing and Design

Seventh Edition

Chapter 12

Cast Irons & Ferrous Metals

Ferrous Metals: Iron and the large family of iron alloys called STEEL are the most frequently specified metals. Cast Iron: Low cost but its properties can vary greatly depending on how it is manufactured (rate of cooling, thickness of casting, how long it remains in mold)
Ductile (nodular) iron is used when higher ductility or strength is required than is available in gray iron. (crank shafts, heavy-duty gears, automobile door hinges) Grey iron is a supersaturated solution of carbon in an iron matrix and is widely available. (automotive blocks, flywheels, brake disks & drums, machine bases, gears) White iron is produced by chilling which prevents the graphite carbon from precipitating out. Wear resistant(mill liners, shot-blasting nozzles)

Cast iron continued

High-Alloy irons: ductile, gray or white iron that contain over 3%alloy content Malleable iron (ferric and pearlitic) is produced by a 2-stage heating process and is strong and ductile, has good impact and fatigue properties, and excellent machining characteristics

Carbon Steel is an iron-carbon alloy with small amount of other elements

Cast or wrought into different mill forms Wrought steel is either poured into ingots or sand-cast Carbon and low-alloy cast steels lend themselves to the formation of streamlined, intricate parts with high strength & rigidity High-alloy cast steel (minimum 8% nickel and/or chromium)

Carbon steels account for over 90% of total steel production

The conditions under which the steel solidifies have a significant effect on its properties Steel specification: chemical or mechanical properties, by its ability to meet a standard specification, or by its ability to be fabricated into an identified part.

Chemical Composition of steel

Carbon: the principal hardening element in steel (.85% gives greater hardness, less ductility) Manganese: increasing manganese increases the rate of carbon penetrations during carburizing but decreases weldability Phosphorus Silicon Sulfur Copper Lead

MANUFACTURING MATERIAL

SCHEMATIC DIAGRAM OF A BLAST FURNACE

MANUFACTURING MATERIAL

FLOWCHART FOR STEELMAKING

MANUFACTURING MATERIAL

FLOWCHART FOR STEELMAKING

Classification Bodies
SAE: Society of Automotive Engineers AISI: American Iron and Steel Institute ASTM: American Society for Testing & Materials ASME: American Society of Mechanical Engineers

SAE and AISI System of steel identification

Four numbered code First number: major class of steel Second number: subdivision of major class Third & Fourth numbers: Carbon content (hundredths of one percent) Example: SAE 2335 is a nickel steel containing 3.5 % nickel and .35 of 1% carbon

MANUFACTURING MATERIAL
CARBON STEEL DESIGNATIONS
TYPE OF CARBON STEEL Plain carbon Low-carbon steel (0.06 to 0.20% carbon) Medium-carbon steel (0.20 to 0.50% carbon) High-carbon steel NUMBER SYMBOL 10XX 1006 to 1020 Toughness and less strength Toughness and strength Less toughness and greater hardness Improves machinability Increases strength and hardness but reduces ductility Improves surface finish Chains, rivets, shafts, and pressed steel products Gears, axles, machine parts forgings, bolts and nuts Saws, drills, knives, razors, finishing tools and music wire Threads, splines, and machined parts PRINCIPAL PROPERTIES COMMON USES

1020 to 1050

1050 and over

Sulfurized (free-cutting) Phosphorized

11XX 12XX

Manganese steels

13XX

MANUFACTURING MATERIAL
AISI DESIGNATION SYSTEM FOR ALLOY STEEL
TYPE OF STEEL Manganese Steel Molybdenum Steels ALLOY SERIES 13xx 40xx 41xx 43xx 44xx 46xx 47xx 48xx 50xx 51xx E51100 E52100 61xx 86xx 87xx 88xx 92xx APPROXIMATE ALLOY CONTENT (%) Mn 1.6 - 1.9 Mo 0.15-0.3 Cr 0.4-1.1; Mo 0.08 - 0.35 Ni 1.65-2; Cr0.4-0.9;Mo 0.2-0.3 Mo 0.45 - 0.6 Ni 0.7-2; Mo 0.15-0.3 Ni 0.9-1.2;Cr0..35-0.55;Mo0.15-0.4 Ni3.25-3.75;Mo 0.2-0.3 Cr 0.3--0.5 Cr 0.7-1.15 C 1.0;Cr 0.9-1.15 C 1.0; Cr 0.9 1.15 Cr 0.5 - 1.1; V0.1-0.15 Ni Ni Ni Si PRINCIPAL PROPERTIES Improve surface finish High Strength COMMON USES Axles, forgings, gears Cams, mechanical parts

Chromium Steels

Hardness Great Strength and toughness Hardness and Strength

Gears, Shafts, bearings springs, connecting rods

Chromium - vanadium steel Nickel-ChromiumMolybdenum Steels Silicon-managanese steel

Punches and Dies, Pistons Rods, Gears, Axles 0.4-0.7;Cr 0.4-0.6;Mo 0.15-0.25 Rust resistance, hardness Food Containers 0.4-0.7;Cr 0.4-0.6;Mo 0.2-0.3 and strength Surgical equipment 0.4-0.7;Cr 0.4-0.6;Mo 0.3-0.4 1.8 - 2.2 Springiness and elasticity Springs

Steel forms
Carbon-steel sheets: flat rolled sheets made from heated slabs that are progressively reduced in size as they move through a series of rollers Hot-Rolled Sheets Cold-Rolled Sheets Carbon-Steel plates Hot-rolled bars Cold-finished bars Steel Wire Pipe : specified by OD and wall thickness Tubing: specified by OD, ID or wall thickness

Structural-Steel shapes
Beams & channels: specified by depth and weight per length (lb/ft) Angles: specified by length of legs & thickness (or lb/ft) Tees Zees Wide-flange sections: specified by depth, width across flange, lb/ft

More types of Steel

High-Strength Low- Alloy (HSLA) Low and Medium- Alloy steels Stainless steels: corrosion resistance Free-Machining

MANUFACTURING MATERIAL
COMMON METHODS OF FORMING METALS
METAL FORMING METHOD

MOLYBDENUM COPPER, TANTALUM, TUNGSTEN

SILVER,GOLD, PLANTINUM

MAGNESIUM

ALUMINUM

TITSNIUM

COPPER

STEEL

LEAD

IRON

CASTING CENTRIFUGAL CONTINUOUS CERAMIC MOLD INVESTMENT PERMANENT MOLD SAND SHELL MOLD DIE CASTING COLD HEADING DEEP DRAWING EXTRUDING FORGING MACHINING PM COMPACTING STAMPING AND FORMING X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

ZINC

TIN

Nonferrous Metals
Aluminum: 1/3 density of steel, but some alloys are stronger than steel & corrosion resistant Copper: good conductor, corrosion resistant Nickel Magnesium Zinc Titanium Beryllium Refractory metals Precious metals

MANUFACTURING MATERIAL
WROUGHT ALUMINUM ALLOY DESIGNATIONS
MAJOR ALLOYING ELEMENT Aluminum (99% or more) Copper Manganese DESIGNATION 1xxx 2xxx 3xxx

Silicon
Magnesium Magnesium and silicon Zinc Other elements Unused series

4xxx
5xxx 6xxx 7xxx 8xxx 9xxx

Plastics: nonmetallic materials capable of being formed or

molded with heat, pressure, chemical reactions, or combination

Disadvantages of metals: corrode or rust, need lubrication, working surfaces wear readily, cant be used as electrical or thermal insulators, opaque & noisy, when they flex they fatigue rapidly Plastics (many) are chemical resistant, corrosion resistant, need no lubrication, quiet running, light weight, range of colors, adaptable to mass production methods, low cost Thermoplastics soften or liquefy and flow when heat is applied Thermosetting Plastics undergo an irreversible chemical change when heat is applied or a catalyst or reactant added Can be machined

MANUFACTURING MATERIAL
COMMON TERMS
FAMILY OF PLASTICS THERMOSETTING Alkyds THERMOPLASTICS ABS

Allylics
Amino (Melamine and Urea) Casein Epoxy Phenolics Polyesters (fiberglass) Silicones

Acetal Resin
Acrylics Cellulosics Fluorocarbons Nylon Polycarbonate Polyethylene Polystyrene Polypropylenes Urethanes

Vinyls

Rubber
Elastomers are derived from either natural or synthetic sources Has Elastic properties. Withstands large deformations and quickly recovers shape Mechanical rubber (tires, belts, bumpers) Cellular rubber (pads, weather stripping, foam rubber)