TAXONOMY OF METALS

Ferrous alloys
def: those of which iron is the prime constituent. Application: as engineering construction materials

Widespread use because of 3 factors.

1. 2.

Abundant quantities within the earths crust Produced from economical process
Extraction, refining, alloying and fabrication

3.

Versatile material : wide range of mech. & phys. Props

Disadvantage: corrode.

STEELS

Steels
Carbon content: < 1.4wt% Classification by carbon content

Low , medium and high carbon type

Subclasses by concentration of other alloying elements

Plain carbon steel Alloy steel

Low carbon steel

carbon content: < 0.25wt% 2 types : Low plain carbon steel and High strength low alloy

m/structure: ferrite and pearlite

Props : relatively soft and weak, outstanding ductility and toughness, machinable and weldable Strengthening accomplished by cold work Typical application: automobile body components, structural shapes ( I beam, channel ), sheets for pipelines, building, bridges, tin cans

High Strength Low Alloy (HSLA)

+ alloying element i.e Cu, V, Ni and Mo with total concentration as high as 10wt%. Props ductile, formable and machinable, corrosion resistant > than plain carbon. Strength : > plain carbon low carbon steel

Strengthening by heat treatment.

Typical application : bridges, towers, support columns in high rise building, pressure vessels.

Medium carbon steels

Carbon concentration: 0.25 and 0.60wt%C 2 types: plain medium carbon steel and heat treatable steels

Plain medium carbon steel; low hardenabilities

heat treatment: quenching and tempering Heat treatable steel containing Cr, Ni and Mo Heat treated alloy stronger than L. Carbon steel , lower ductility and toughness than L. Carbon steel

High Carbon Steels

carbon content: 0.60 1.4 wt% C Prop: hardest, strongest, least ductile of the carbon steel Application:

used for withstanding wear A holder for a sharp cutting edge i.e drills, woodworking tools, axes, turning and planning tools, milling cutters, knives, high strength wire

Tool steel and die steels

High carbon alloy containing Cr, V, W and Mo. Props : hard and wear resistance bcoz of carbide compounds. Higher hardness and Tm difficult to fabricate by traditional methods i.e tungsten carbide Tm = 2600

Stainless steel
Resistant to corrosion At least 11 wt% Cr Ni & Mo will enhance corrosion resistance 3 classes for stainless steel Austenitic Ferritic Martensitic

Austenitic stainless steel 18 Cr, 8 Ni, < 0.15 wt% C

Non magnetic props Hardened and strengthened by cold work Shock resistant

Highly corrosion resistant coz high Cr and + Ni

Ferritic

12-25% Cr, < 0.1% C Magnetic props Hardened and strengthened by cold work High resistance to corrosion but low impact

Martesitic

Hardened, tempered by heat treatment

Magnetic props

Application of stainless steel

cookware, chemical and food processing equipment Decorative trim, nozzles Turbine blades, steam boilers, parts in heating furnaces springs, pump rings, aircraft fittings

Cast Iron
Carbon contents above 2.14wt%

Si content : 0.5-3wt%Si
Commercial range : 3.0-4.5 wt% C + other alloying elements Props: easily melted, some cast iron are brittle Microstructure : most commonly graphite (C) & ferrite. Graphite: grey, soft

Factors that influencing the character of the carbon:

Composition and rate of cooling The presence of other substance (i.e: Si, Al , S and Mn)

The diff. between cast iron and steels

Carbon content Silicon content Carbon microstructure ( stable form and unstable form)

TYPES OF CAST IRON

gray cast iron Ductile / nodular cast iron White cast iron Malleable cast iron

Gray cast iron

Carbon content: 2.54.0 wt% C Silicon content: 1.03.0wt% Si Microstructure: graphite flakes in ferrite or pearlite matrix

Props :

Cheap and ease of machining Low melting temperature (1140-1200C) Ability to take good casting impressions Wear resistance High damping capacity A reasonable tensile strength of 108.340 N/mm2 High compressive strength Fracture surface: gray appearance Good thermal conductivity

Disadvantage Weak and brittle in tension

Ductile/ nodular cast iron

Nodular cast iron = grey cast iron + cerium/magnesium Microstructure: graphite (nodular/spherelike particles) in pearlite or ferrite matrix. Props:

tensile strength > grey cast iron. Others mech props steel

Application: valves, pump bodies, gear and other automotive and machine components.

White cast iron

Silicon content: <1.0 wt%Si

Microstructure: cementite and pearlite

High rate of cooling prevent graphite Intermediate metal for produce malleable cast iron.

Props

Brittle Not easily machinable Fracture surface: white appearance

Malleable cast iron

Form by the heat treatment of white cast iron.

Heating temp : 800C - 900 C Duration : 2/3 days Heating environment : neutral atmosphere

Microstructure: a clumps of graphite (rossette) in ferrite or pearlite matrix Props:

i.e .pipe fittings, valve parts for railroad, marine and other heavy duty. ferrite malleable good toughness

Application: general engineering services at normal and elevated temperature

NONFERROUS ALLOYS
Brass : Zn is subst. impurity -lower : 2.7g/cm 3 (costume jewelry, coins, -Cu, Mg, Si, Mn, Zn additions corrosion resistant) -solid sol. or precip. Bronze : Sn, Al, Si, Ni are strengthened (struct. subst. impurity aircraft parts (bushings, landing & packaging) gear) Mg Alloys NonFerrous Cu-Be : -very low : 1.7g/cm 3 Alloys precip. hardened -ignites easily for strength -aircraft, missles

Cu Alloys

Al Alloys

Ti Alloys

-lower : 4.5g/cm 3 vs 7.9 for steel -reactive at high T -space applic. -Ag, Au, Pt -oxid./corr. resistant

Refractory metals

Noble metals

-high melting T -Nb, Mo, W, Ta

Non ferrous alloys

Advantages:

Lower density Comparatively high electrical conductivity Good corrosion resistance Mostly lower melting points (casting)

These alloys can be divided into four class

Cast alloys alloys that are so brittle that forming or shaping by deformation is not possible. Wrought alloys: alloys that amenable to mechanical deformation

Heat treatable: an alloy whose mechanical strength is improved by precipitation hardening/ martensitic transformation Non-heat treatable: an alloy can not be improve with heat treatment.

Aluminum and its alloys

Characteristic:

Abundant metal Tm= 660C Crystal structure: FCC Tensile strength= 45 MPa Density : 2.70 x 10g/cm3 E : 7.5 GPa Resistant to corrosion Nonmagnetic and non toxic

Aluminum alloys group

1.

Wrought aluminum alloys

i. Heat treatable ii. Nonheat-treatable

2.

Cast aluminum alloys

i. Heat treatable ii. Nonheat-treatable

Designation for alloy Groups

Aluminium Association No. Aluminium, 99.00% and greater , major alloying element Copper 1xxx 2xxx

Manganese Silicon Magnesium Magnesium and silicon Zinc Other element Unused series

3xxx 4xxx 5xxx 6xxx 7xxx 8xxx 9xxx

Common heat treatment of aluminum alloys

Age or precipitation hardening Accomplished by two sub-heat treatment
1.

Solution heat treatment

All solute atoms are dissolved to form a singlephase solid solution Then rapid cooling ( mainly to Tr) to prevent and extent diffusion Thus, a nonequilbrium of phase solid solution supersaturated with atom

2.

Precipitation hardening
The supersaturated solid solution is heated to intermediate temp. (within + two phase region) phase begins to form as finely dispersed particles
T To SOLUTION HEAT TREATMENT Quench

T2

PRECIPITATION HEAT TREATMENT

T1

time

Aluminum Alloys
Aluminum Copper Alloys (2xxx series) Aluminum Manganese Alloy (3xxx series) Aluminum-Silicon Alloys (4xxx series) Aluminum-Magnesium Alloys (5xxx series) Aluminum-Silicon Magnesium Alloys (6xxx) Aluminum-Zinc Alloys (7xxx series) Aluminum-lithium (8xxx series)

Wrought alloys-nonheat- treatable

For stress bearing panels used for bodies in land and air transport Stronger than pure aluminum High resistance to sea water and marine atmosphere.

Wrought alloys heat treatable

Aluminium-magnesium-silicide alloys
Medium strength, good formability, satisfactory corrosion resistance, adequate weldability. Most commonly used. Not suitable at elevated temperature. Application: containers body, roadway balustrading, overhead electrical conductors

Aluminum zinc-magnesium-copper alloys

Highest strength of all aluminium alloys Mainly for aircraft structure

Aluminum-copper-magnesium-silicon alloys (duralumin)

For many general engineering and aircraft structural purpose. Higher strength than aluminium-mangnesium silicide alloys but lower corrosion resistance Good fracture toughness, service temp. up to 120oC

Aluminium casting alloys

Aluminium-silicon and aluminium-silicon copper alloys

Excellent fluidity and castability. Lighter than Al-Cu alloys Widely used for automobile casting- water-cooled manifolds, jackets, motor housing Pump parts in chemical and dye industries. Addition of copper increase strength and machinability but lowers castability, corrosion resistance and ductility.

Aluminium-magnesium alloy
Highly resistant to corrosion, higher machinability , Superior alloy for marine environment marine craft fittings

Aluminium-copper alloy
Mainly used for aircraft casting part Good mechanical props and shock resistance Moderate corrosion resistance

Props High electrical and thermal conductivity Good corrosion resistance Good machinability and strength Ease of fabrication Non-magnetic A pleasing color Can be welded, brazed and soldered

Copper

Copper Alloys
Most common alloying element: Zn, Al, Sn and Ni Further addition of the 2nd element: hardness and brittleness increase, reduce the toughness Ex: Brasses, Bronzes, copper-nickel, copper-zinc-nickel, aluminium bronze

Brasses
Cu-Zn alloys ( wt%Zn: 0-50%) Important:

Wide range of mechanical props Ease of working Colour Resistance to atmospheric and marine corrosion

used for electrical fittings, ammunition cases, screws, household fittings, and ornaments.

Copper-Zinc-nickel
Form 2 classes of material:
1.

The alloys (7-30% Ni, 63% Cu)

Good resistance corrosion Application ;

Basis of silver and chromium electroplated goods In telephone and wireless industries (contactors and springs) In form tape or wire for electrical resistance Fittings for ships

2.

The alloys (10% Ni, 45% Cu, 45% Zn)

a.k.a nickel brass for architectural and ornamental purpose

Copper nickel alloys

a.k.a cupronickels Good resistance to sea, alkalies, sulphric acids and alkaline solution. Poor resistance to nitric acids, cyanide solution Application: turbine blade, valve parts, pump rod liners and impellers

Bronzes
Cu-Ti alloys Softer and weaker than steels It resists corrosion (especially seawater corrosion) widely used for springs, bearings, bushings and similar fittings

bushings

Aluminium Bronze
Copper rich aluminium alloys Props

High strength Resistance to corrosion and wear High resistance to fatigue Fine golden colour Possibility of heat treatment in manner similar to steel Application: heat exchanger tubes

Titanium
Low density :4.51 g/cm3 Non-magnetic Electrical and thermal conductivity steel high strength-to-weight ratio, excellent mechanical properties, and corrosion resistance Good strength Resistance to erosion and erosion-corrosion Very thin, conductive oxide surface film Hard, smooth surface that limits adhesion of foreign materials

Titanium alloys
Titanium alloys are designed for particular application areas. For example: Alloys Ti-5Al-2Sn-2Zr-4Mo-4Cr (commonly called Ti-17) and Ti-6Al-2Sn-4Zr-6Mo for high strength in heavy sections at elevated temperatures. Alloys Ti-6242 (Ti-6Al-2Sn-4Zr-2Mo) for creep resistance

Alloy Ti-5Al-2,5Sn is designed for weldability Alloys Ti-6Al-6V-2Sn, Ti-6Al-4V and Ti10V-2Fe-3Al for high strength at low-tomoderate temperatures.

application
as static and rotating gas turbine engine components. applications in nuclear power plants, food processing plants, oil refinery heat exchangers, marine components and medical prostheses

aircraft engine discs, blades, shafts and casings from the front fan to the last stage

TITANIUM IMPELLER FORGING Titanium Integrally Bladed Rotor Fan Disc

Titanium Rotor Compressor

Structural Airframe Component

Magnesium
Light weights : 1.74g/cm3 Ease of machinability

High strength to weight ratio

Crystal structure: HCP

Good high temperature mechanical properties

Good to excellent corrosion resistance Used as alloying element in Al, Zn, Pb and other nonferrous metal. Application as magnesium anodes: effective corrosion protection for water heaters, underground pipelines, ship hulls

automotive applications include clutch and brake pedal support brackets, steering column lock housings .
hand-held tools, luggage, computer housings, and ladders. Magnesium alloys are valuable for aerospace applications because they are lightweight and exhibit good strength and stiffness at both room and elevated temperatures

Magnesium Clutch Side Casing

Small Magnesium Covers for a Helicopter Transmission Case. Shown with Tagnite and Paint over Tagnite.

Two Views of a Magnesium Transmission Case for a Helicopter Shown with Paint over Tagnite.

Two views of a Magnesium Intake Manifold. Shown with Paint over Tagnite