UNIT III FERROUS AND NONFERROUS METALS

FERROUS METALS

Effect of alloying additions on steel

and stabilisers

Stainless steels

Tool steels

HSLA,

Maraging steels

Cast Iron

NON FERROUS METALS

Copper and copper alloys Brass, Bronze and Cupronickel

Aluminium and Al-Cu

Precipitation strengthening treatment

Bearing alloys,

Mg-alloys,

Ni-based super alloys

Titanium alloys

One question from Ferrous and one from Non Ferrous for
semester Exam

Big Picture

c13f01

ALLOY STEELS
An alloy steel may be defined as one whose
characteristic properties are due to some element
other than carbon.
Although all plain-carbon steels contain moderate
amounts of manganese (up to about 0.90
percent) and silicon (up to about 0.30 percent),
they are not considered alloy steels because the
principal function of the manganese and silicon is
to act as deoxidizers. They combine with oxygen
and sulfur to reduce the harmful effect of those
elements

Purpose of Alloying
(Alloying elements are added to steels for many purposes)

Increase hardenability
Improve strength at ordinary temperatures
Improve mechanical properties at either high or low
temperatures
Improve toughness at any minimum hardness or
strength
Increase wear resistance
Increase corrosion resistance
Improve magnetic properties
Improve machiniability

General Effects of Alloying Elements

When selecting a steel for a particular job, plain
carbon steels are preferable over alloy steels are
expensive.
On other hand, an alloy steel can be used to
desired properties throughout the heavy section
and wherever the service conditions demand the
enhanced properties which are unattainable with
a plain steel.
in some instances, use of alloy steel may
intensify the problem rather than reducing them.
Designer recognize the situation in which alloy
steels are preferable

Classification of alloying Elements

Solid Solution Formation
Carbide formation
Shifting of critical temperature
Solid Solution Formation
Alloying elements dissolve in Ferrite and form solid
solution when added to steel. Increases the strength
and hardness of steel by solid solution
strengthening .
Small loss in ductility.
Ex: Ni, Si, Al, & Mg,

 Carbide formation
Some alloying elements are combined
with carbon and form stable carbides.
Extensively hard and they increase wear
resistance.
Increase resistance to softening at
elevated temperature and prevent grain
coarsening.
Ex: Niobium, Titanium, vanadium,
molybdenum, tungsten and chromium.

 Shifting of Critical Temperature

Alloying elements could lower or raise the critical
temperature of steel.
Some alloying elements like manganese and nickel
lower the critical temperature (Enlarges Austentite
region and stable at room temperature ) so these
elements are called as austenite stabilizers.
Chromium, tungsten, Vanadium, Molybdenum,
silicon and titanium shift the critical temperature
to higher values and these alloys reduce the
autentite region and if elements are added more
quantity austenite region may not appear.
Also it shift of this type tends to merge ferrite and
delta iron together to give a continuous ferrite
from the room temperature to the melting point.
Ferrite Stabilizer

Behavior of the Individual Elements

Effects of Alloying Elements on Steel

Manganesecontributes to strength and hardness; dependent upon the

carbon content. Increasing the manganese content decreases ductility
and weldability. Manganese has a significant effect on the hardenability
of steel.
Phosphorus increases strength and hardness and decreases ductility
and notch impact toughness of steel. The adverse effects on ductility
and toughness are greater in quenched and tempered higher-carbon
steels.
Sulfur decreases ductility and notch impact toughness especially in the
transverse direction. Weldability decreases with increasing sulfur
content. Sulfur is found primarily in the form of sulfide inclusions.
Siliconis one of the principal deoxidizers used in steelmaking. Silicon is
less effective than manganese in increasing as-rolled strength and
hardness. In low-carbon steels, silicon is generally detrimental to
surface quality.
Copper in significant amounts is detrimental to hot-working steels.
Copper can be detrimental to surface quality. Copper is beneficial to
atmospheric corrosion resistance when present in amounts exceeding
0.20%.
Nickel is a ferrite strengthener. Nickel does not form 12
carbides in steel.
It remains in solution in ferrite, strengthening and toughening the

Probable
hardening
effect ot
the various
elements

Stainless Steels
Inmetallurgy,stainless steel, also known
asinox steelorinox, means"inoxydable", is
steelalloywith a minimum of 10.5% or11%
chromiumcontent by mass.
Stainless steel does not readilycorrode,rustor
stain with water as ordinary steel does.
However, it is not fully stain-proof in lowoxygen, high-salinity, or poor air-circulation
environments.
There are different grades and surface finishes of
stainless steel to suit the environment the alloy
must endure.
Stainless steel is used where both the properties
of steel andcorrosion resistanceapplication.

Contd.
Stainless steel differs from carbon steel by the
amount of chromium present. Unprotected carbon
steelrustsreadily when exposed to air and moisture.
Thisiron oxide film (the rust) is active and
accelerates corrosion by forming more iron oxide;
and, because of the greater volume of the iron oxide,
this tends to flake and fall away.
Stainless steels contain sufficient chromium to form
apassivefilm of chromium oxide, which prevents
further surface corrosion by blocking oxygen
diffusion to the steel surface and blocks corrosion
from spreading into the metal's internal structure,
and, due to the similar size of the steel andoxide
ions, they bond very strongly and remain attached to
the surface.

Types of SS
Classified into 5 types:
1.
2.
3.
4.
5.

Ferritic SS
Martensitic SS
Austenitic SS
Precipitation Hardening (PH) SS
Duplex Stainless Steel

Ferritic SS
The steels containing greater amount of chromium (from
10.5 to 27%) and about 0.12% carbon are called ferritic
stainless steels.
They are Ferro-magnetic, high cold formability usually
undergo excessive grain growth during prolonged exposure
to elevated temperatures.
These stainless steels remain ferritic at all temperatures
below solidification become chromium is ferrite stabilizer.
These steels cannot be hardened by martensitic
transformation because there is no possibility of forming
austenite.
Annealing is only HT applied to relieve cold working stress
and hardened by cold working.
These steels have lower strength at elevated temperatures.
Corrosion and oxidation resistance and less expensive.
Applications: Vessels for chemical and food industries,
automotive and architeture and household application
Common ferritic grades include 18Cr-2Mo, 26Cr-1Mo, 29Cr-4Mo, and
29Cr-4Mo-2Ni

Martensitic SS
Martensitic stainless steel contains chromium (1214%)
and molybdenum (0.21%), nickel (less than 2%), and
carbon (about 0.11%) - first stainless steels.
Since these steels possess martensitic structure,
therefore, they are called martensitic stainless steels.
These steels are magnetic and cold workedwith low
carbon. They may be hardened by suitable heat
treatment and the hardness obtainable depends upon
the carbon content.
These steels can be easily welded and machined.
When formability, softness, etc. are required in
fabrication, steel having 0.12 per cent maximum carbon
is often used in soft condition.
With increasing carbon, it is possible by hardening and
tempering to obtain tensile strength.

Martensitic SS -1
In this condition, these steels find many useful general
applications where mild corrosion resistance is required.
Also, with the higher carbon range in the hardened and
lightly tempered condition, tensile strength may be
developed with lowered ductility.
These steels may be used where the corrosion conditions
are not too severe, such as for hydraulic, steam and oil
pumps, valves and other engineering components.
However, these steels are not suitable for shafts and
parts working in contact with non-ferrous metals (i.e.
brass, bronze or gun metal bearings) and with graphite
packings, because electrolytic corrosion is likely to occur.
After hardening and light tempering, these steels develop
good cutting properties. Therefore, they are used for
cutlery,springs, surgical and dental instruments.

Austenitic SS
They contain a maximum of 0.15% carbon, a
minimum of 16% chromium and sufficient nickel
and/or manganese to retain an austenitic
structure
at
all
temperatures
from
thecryogenicregion to the melting point of the
alloy. Here nickel is austenite stabiliser.
These steels cannot be hardened by quenching,
in fact they are softened by rapid cooling from
about 1000C. They are nonmagnetic and
possess greatest resistance to corrosion (than
ferritic and martensitic) in media except
hydrochloric acid and other halide acids and salt.
These steels are very tough and can be forged
and rolled but offer great difficulty in machining.

Austenitic SS-1

They can be easily welded, but after welding, it is

susceptible to corrosive attack in an area adjacent to the
weld.
This susceptibility to corrosion (called intercrystalline
corrosion or weld decay) may be removed by softening
after welding by heating to about 1100C and cooling
rapidly.
If Cr is decrease by below 12% there is a sharp decrease
in corriosion resistance this is known as sensitising.
Carbide formation are to be prevented in this steel thats
why the carbon is0.15%. Other elements are also have
strong affinity for carbon (titanium, niobium, tantalum or
columbium)
The most widely used steel contain 18 per cent chromium
and 8 per cent nickel with carbon content as low as
possible. Such a steel is commonly known as 18/8 steel.

Application of austenite SS
These steels are
used in the manufacture of pump shafts, rail road
car frames and sheathing, screws, nuts and bolts
and small springs.
Since 18/8 steel provide excellent resistance to
attack by many chemicals, therefore, it is
extensively used in chemical, food, paper making
and dyeing industries.
Grades:
200 Seriesaustenitic chromium-nickel-manganese
alloys.
300 SeriesThe most widely used austenite steel is

Precipitation Hardening SS
Precipitation-hardening SS have a matrix
structure of either austenite or martensite.
Austenite PH SS are magnetic and contains
atleast 10% Ni in order to reamin austenitic.
They strengthening elements are Mo,Nb,Cu,
or Ti. These steels are used succesfully upto
about 650oC.
Martensitic PH SS usually contains 17% Cr and
are alloyed with small amounts of Cu, Mo, Al, Ti,
or Nb. These steels are more common in use than
those with austenitic matrix.
PH SS have good corrosion resistance and
ductility. They have high strength at elevated
temp. These are the most expensive SS.

Duplex SS
Carbon content very low (0.03%)
with additions of Ti or Mo. They have
a microstructure of ferrite grains in
austenite or vice-versa. Their yield
strength is twice as that of austenitic
SS. The other advantages are high
corrosion resistance , greater
resistance to stress- corrosion
cracking and good weldability.
Application: Water Treatment plants,
heat exchanger components, off

Microstructure of SS

Austenite

PH

Ferrite
Martensite