Ch. 2 - Metal Mat

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)
- UNIVERSITI KUALA LUMPUR : MALAYSIAN INSTITUTE OF MARINE ENGINEERING TECHNOLOGY

( UNIKL MIMET )
CHAPTER 2
METALLIC MATERIALS
SHIP MATERIALS / LGB 21203

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CONTENT:
1. Introduction
1.1 Metallic materials
1.2 Ferrous and Non ferrous alloy
2. Production of iron and steel.
3. Low alloy steels, Stainless Steel and Cast Iron.
4. Aluminium alloy
4.1 Joining of aluminium and steel
5. Copper alloy, Magnesium alloy, Titanium alloy and
Nickel alloy.
6.
Metallic materials suited to marine environment.

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INTRODUCTION: METALLIC MATERIAL

These materials are composed of one or more metallic
elements and may also contain some nonmetallic elements.
Metals have a crystalline structure in which the atoms are
arranged in an orderly manner.
Metals are relatively strong and ductile at room temperature
and maintain good strength even at high temperature. It also
good thermal and electrical conductors.

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INTRODUCTION: FERROUS & NONFERROUS ALLOY

Those with iron as prime constituent (except for high alloy steel)
Important as engineering construction material (especially steel
Fe-C)
They are important because:
Abundant within the earth-crust low cost
Easier to be produced
Good strength toughness and ductility
Versatile wide range of mechanical and physical properties
Can be alloyed and heat treated to get desired mechanical
properties
Alloying is combining or mixing other material like carbon or
other metals to iron
Heat treatment is a process of heating and cooling a metal to
achieve specific microstructure which in turns display specific
mechanical properties (e.g. Quenching austenite
gives

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METAL ALLOYS
FERROUS
STEEL
LOW ALLOY
CAST IRON
HIGH ALLOY
NON-FERROUS
Cu
Mg
Al
Ti

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PRODUCTION OF IRON AND STEEL

Production of Pig Iron in a Blast Furnace:
Iron extracted from iron ores in large blast

furnaces
Coke (carbon) acts as a reducing agent to

reduce iron oxides (Fe22O33) to produce raw pig
iron (contain 4% carbon w impurities)
Fe22O33 + 3CO 2Fe + 3CO22
Pig iron from the blast furnace usually

transferred in the liquid state to a steelmaking
furnace.
Cross-section of
Blast Furnace

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Steelmaking an Processing:
Plain carbon steel essentially alloys of iron and carbon with up to

about 1.2% carbon, but majority of steels contain less than 0.5%
carbon.
Steel is made by oxidizing the carbon and other impurities in the
pig iron until the carbon content of the iron reduced to the required
level.
Commonly process for converting pig iron into steel is the basicoxygen process.
Cross section of
basic oxygen
furnace

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Pig iron and up to 30% steel scrap are charged into a barrelshaped refractory line converter into which an oxygen lance is
inserted. Pure oxygen from the lance reacts with the liquid bath
to form iron oxide. Carbon in the steel then reacts with the iron
oxide to form carbon monoxide.
FeO + C Fe +CO
Before the oxygen reaction starts, slag-forming fluxes (lime)
are added in controlled amounts. The carbon content of the
steel can be drastically lowered with a reduction in the
concentration of impurities such as sulfur and phosphorus.
The molten steel from the converter is either cast in stationary
molds or continuously cast into long slabs.

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Steel are iron-carbon alloys.

Mechanical properties are a function of carbon content and other alloying elements.

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LOW ALLOY STEELS, STAINLESS STEEL & CAST IRON

NOMENCLATURE OF FERROUS ALLOY
Nomenclature: AISI (American Iron & Steel Institute)
and SAE (Society of Automotive Engineer.
10xx Plain carbon steels
11xx Plain carbon steels (resulfurized for machinability)
15xx Mn (10 20%)
40xx Mo (0.20 0.30%)
43xx Ni (1.65 2.0%), Cr (0.4 0.9%), Mo (0.2 0.3%)
where xx is wt% C x 100
Example: 1060 steel plain carbon steel with 0.60wt% C

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LOW ALLOY STEELS, STAINLESS STEEL & CAST IRON

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LOW ALLOY STEELS

Alloys of low carbon steel being produced in the greatest quantity <
0.25wt %C
Consists of ferrites and pearlites hence soft and weak but can be
treated to achieve high strength.
Machinable, weldable and cheaper to be produced
Types:
i. Plain low carbon steel - no alloying elements, variable tensile
strength (TS) (415-550MPa and Yield Strength (YS)= 275MPa
Applications crankshafts, bolts, hammers, hand tools, gears,
knives
ii. High strength low allow steel (HSLA) with alloying, higher TS and
YS
Applications automobiles opines, nails, wire, pipe structural
SHIP MATERIALS and
/ LGB 21203

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MEDIUM ALLOY STEELS

0.25 0.6 wt %C
Heat treated to achieve good mechanical
properties
Used in tampered condition (tampered
martensitic)
Strength -ductility combination can be tailored by
heat treatment and alloying (with Ni, Cr and Mo)
Applications: high strength structural components
railway wheels, tracks, crankshafts

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HIGH ALLOY STEELS

0.6 1.4 wt %C
Hardest, strongest and least ductile carbon
steel
Used in harden and tempered conditions
Can be alloyed with carbon and other metals to
form vary hard and wear resistance material
(e.g. C, Cr, Ni, W, Mo and V)
Applications:
embossing
cutting
dies,
tools,
cutlery,
drills,
paper
saws,
cutters,
concrete drill, blacksmith tools

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STAINLESS STEELS
Highly resistance alloy to corrosion (rusting) in a
variety
of
environment.
Mechanical
integrity
maintains.
Consisting of iron-carbon and chromium (> 12 wt
% Cr needed)
Add nickel and molybdenum as well
Example 0.08 C, 11.0 Cr, 1.Mn, 0.50 Ni, 0.75 Ti :
S40900
Examples of use of stainless-steel:

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STAINLESS STEELS
In general there are three main types of stainless steel;
Martensi
tic
Ferritic
Austenit
ic
STAINLESS STEEL

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FERRITIC STAINLESS STEELS

Essentially iron-chromium binary alloys containing about 12 30%
Cr. Chromium (Cr) has the same BCC crystal structure as ferrite,
extends the phase region and suppresses the phase region.
Ferritic stainless steels, since they contain more than 12% Cr, do
not undergo the FCC-BCC transformation and cool from high
temperatures as solid solutions of chromium in iron.
Relatively low in cost since they do not contain nickel.
They are used mainly as general construction materials in which
their
special corrosion and heat resistance required.

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FERRITIC STAINLESS STEELS
Duplex Microstructure with ferrite and autenite grains. (ASM Metals

handbook)
Microstructure in weld, HAZ and base

metal of duplex stainless steel
(Austenite is in white and ferrite in
dark) (Source: ArcelorMittal Industry)

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MARTENSITIC STAINLESS STEELS

Essentially Fe-Cr alloys containing 12 to 17% Cr with sufficient
carbon (0.15 to 1.0% C) so that a martensitic structure can be
produced by quenching from the austenitic phase region.
Capable to develop martensitic structure after an austenizing
and quenching heat treatment.
Corrosion resistance relatively poor compared to the ferritic and
austenitic type

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Microstructure of martensite formed

by quenching steel from the
austenite region: very hard and
brittle: magnification, 300x (in the
book Alexander, et al)
Microstructure image
of a
martensitic stainless
steel

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AUSTENITIC STAINLESS STEELS

Essentially iron-chromium-nickel ternary alloys containing about
16 to 25% Cr and 7 to 20% Ni.
Structure remains austenitic (FCC, iron type) at all normal heat
treating temperatures.
Austenitic stainless steels normally have better corrosion

resistance than ferritic and martensitic because the carbides can
be retained in solid solution by rapid cooling from high
temperature.

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The image shows the microstructure of an austenitic

stainless steel.

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CAST IRON
Family of ferrous alloys with a wide range of properties. They are
intended to be cast into the desired shape instead of being worked
in the solid state.
Normally contain 2 to 4 % carbon and 1 to 3% silicon. Other
alloying elements may also be present to control or vary certain
properties.
Excellent casting since they are easily melted, very fluid in the
liquid state, and do not form undesirable surface films when
poured.
Relatively low impact resistance and ductility, and this limits their
use for some applications.

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CAST IRON
Gray Cast
Iron
Ductile Cast
Iron
Cast Iron
Malleable
Cast Iron
White Cast
Iron
Type of cast
iron

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WHITE CAST IRON

Is formed when much of the carbon in a molten cast iron forms
iron carbide instead of graphite upon solidification.
To retain the carbon in the form of iron carbide in white cast irons,
their carbon and silicon contents must be kept relatively low (2.53.0%C and 0.5-1.5% Si) and the solidification rate high.
Often used for their excellent resistance to wear and abrasion.
White cast iron serves as the raw materials for malleable cast
iron.

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WHITE CAST IRON
Microstructure of White cast iron

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GRAY CAST IRON

Formed when the carbon in the alloy exceeds the amount that
can dissolve in the austenite and precipitates as graphite
flakes.
Unalloyed gray cast irons usually contain 2.5 to 4% C and 1 to
3% Si. Since silicon is a graphite stabilizing element in cast
irons, high silicon content is used to promote the formation of
graphite.
The solidification rate is also an important factor that

determines the extent to which graphite forms.
Moderate and slow cooling rates favor the formation of

graphite.

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GRAY CAST IRON
Grey Iron Microstructure
Microstructure of a grey cast iron with

a carbon content of 3.2% and a silicon
content of 2.2% by weight.
Gray
Cast
Iron
typical
microstructure of gray iron is a
matrix of pearlite with graphite
flakes dispersed throughout.

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DUCTILE CAST IRON

Sometimes called nodular or spherulitic graphite cast iron.
Similar properties to those steel such as high strength, toughness,
ductility, hot workability, and hardenability.
Composition of unalloyed ductile iron is similar to that of gray iron
with respect to carbon ad silicon contents. Carbon content of
unalloyed ductile iron ranges from 3.0 to 4.0%C and the silicon
content from 1.8 to 2.8%. The sulphur and phosphorus levels of
high-quality ductile iron must be kept very low at 0.03%S and
0.1%P.
The spherical nodules in ductile cast iron are formed during the
solidification of the molten iron, because the sulphur and oxygen
levels in the iron are reduced to very low levels by adding

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DUCTILE CAST IRON
Microstructure of a ductile cast iron with a carbon content of 3.6% and

a silicon content of 2.6% by weight.

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MALLEABLE CAST IRON

Is a first cast as white cast irons which contain large amounts of iron
carbides and no graphite.
Carbon and silicon contents of malleable irons are in the 2.0% to
2.6%C and 1.1 to 1.6% Si ranges.
Advantages:
Excellent machinability
Significant ductility
Good shock resistance properties
Disadvantages: The major disadvantage is shrinkage.
To produce a malleable iron structure, cold white iron castings are
heated in a malleablizing furnace to dissociate the iron carbide of
the white iron to graphite and iron.

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MALLEABLE CAST IRON
Microstructure of a malleable cast iron

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METALLIC MATERIAL SUITED TO MARINE ENVIRONMENT

Ordinary-Strength Hull Structural Steels
For steel hull construction Ordinary-strength Hull Structural
Steels are recommended for plates and wide flats up to and
including 100mm (4 ins), and for sections and bars up to and
including 50mm (2 ins).
Higher Strength Hull Structural Steels
Higher-strength hull structural steels may be specified for boats
and ships larger than 30m in length, requiring construction using
plates and wide flats with the following markings:

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Anchor may be:

forged or cast from
steel
plate or bar
fabricated steel
anchors

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Chain Shackles:
~ Should be made of
materials proved suitable
for the type of service
that will be used

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Outfitting material
Use
Stainless steel
Hardware, door handles, ships fittings, water holding tanks, Galley fittings,
cooking ovens, stoves, gas jets, utensils, general outfitting requirements,
balastrading, steps, ladders, hatches, lift rings, door latches, pipes, stairs, fan
blades, sprinklers, fire alarms, valves, springs, cogs, gears, vents, drainage pipes
and grates, guard rails, louvers, fasteners, bolts, screws, rivets, eye bolts, u-bolts,
miscellaneous hardware, couplings, blocks and swivels, hand and power tools,
hooks and shackles, manholes, doors, sinks, food preparation counters and
serving bars, storage racks, wash basins, refrigerators, racks for pots, dishes,
cups, glasses, rigging hardware, overhead cabinets for general storage, bathroom
and laundry services.
Copper and copper

alloys
Aluminium bronze, manganese bronze, aluminium brass, gunmetal, cupro-nickel

and monel are traditional shipbuilding materials that make up 2 3 % of
deadweight of all new constructions for items such as:
Pipes and piping, radiators, steam lines, cooking utensils, linings, heating
elements, coils and systems, cladding, sheathing, miscellaneous fasteners and
hardware, instrument casings, feedwater, fresh- water, salt water cooling
systems, pumps, evaporators, steam lines, heaters, valves, coolers, lighting,
electrical cables, generators, electric motors, electrical contacts, fittings and
switches, communications equipment/systems, control room equipment/systems,
propellers (high tensile brass or aluminium bronze), heavy tailshafts, rudder
stocks, propeller cone nuts (Admiralty gunmetal or manganese bronze), condenser
tubes (cupro-nickel or aluminium brass), tube plates and baffles, deck
fittings(naval brass), fasteners, screws, nails (silicon bronze).
Wood
Carvel planking, hulls, frames, decking, flooring, cross-planks, topside planks, strip
planking, moulds, exterior woodwork, bulkheads, shelving, berth bottoms, cabin
MATERIALS
LGB 21203
tops, doors, interior woodwork, bench tops, cupboard doors, SHIP
tables,
chairs, /rails,

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EXERCISES;
1. Write a typical chemical reaction for the reduction of iron oxide
(Fe2O3) by carbon monoxide to produce iron.
2. Explain the numbering system used by the AISI and SAE for plain
carbon steels.
3. Explain how the aluminum oxide extracted from bauxite ores and
aluminum extracted from pure aluminum oxide.
4. Determine how are copper alloys classified by the Copper
Development Association system.
5. Explain why ferritic stainless steel considered non-heat-treatable.
6. Describe why ductile cast iron in general more ductile than gray
cast iron.

Ch. 2 - Metal Mat

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DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

- UNIVERSITI KUALA LUMPUR : MALAYSIAN INSTITUTE OF MARINE ENGINEERING TECHNOLOGY

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

Metallic materials suited to marine environment.

SHIP MATERIALS / LGB 21203

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

INTRODUCTION: METALLIC MATERIAL

SHIP MATERIALS / LGB 21203

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

INTRODUCTION: FERROUS & NONFERROUS ALLOY

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

SHIP MATERIALS / LGB 21203

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

PRODUCTION OF IRON AND STEEL

Iron extracted from iron ores in large blast

Coke (carbon) acts as a reducing agent to

Pig iron from the blast furnace usually

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

Plain carbon steel essentially alloys of iron and carbon with up to

SHIP MATERIALS / LGB 21203

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

SHIP MATERIALS / LGB 21203

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

Steel are iron-carbon alloys.

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

LOW ALLOY STEELS, STAINLESS STEEL & CAST IRON

SHIP MATERIALS / LGB 21203

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

LOW ALLOY STEELS, STAINLESS STEEL & CAST IRON

SHIP MATERIALS / LGB 21203

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

LOW ALLOY STEELS

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

MEDIUM ALLOY STEELS

SHIP MATERIALS / LGB 21203

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

HIGH ALLOY STEELS

concrete drill, blacksmith tools

SHIP MATERIALS / LGB 21203

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

SHIP MATERIALS / LGB 21203

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

FERRITIC STAINLESS STEELS

SHIP MATERIALS / LGB 21203

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

FERRITIC STAINLESS STEELS

Duplex Microstructure with ferrite and autenite grains. (ASM Metals

Microstructure in weld, HAZ and base

SHIP MATERIALS / LGB 21203

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

MARTENSITIC STAINLESS STEELS

SHIP MATERIALS / LGB 21203

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

MARTENSITIC STAINLESS STEELS

Microstructure of martensite formed

SHIP MATERIALS / LGB 21203

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

AUSTENITIC STAINLESS STEELS

Austenitic stainless steels normally have better corrosion

SHIP MATERIALS / LGB 21203

DEPARTMENT OF APPLIED SCIENCE & ADVANCED TECHNOLOGY (ASAT)

MARTENSITIC STAINLESS STEELS