Professional Documents
Culture Documents
CHAPTER 2
Material
Material Engineering : Material Science Material Technology Science : Material Structure Material Propeties Relationship between Internal Structure & Propeties Technology : Processing from Raw Material into Material Application Design and new development.
Processing techniques are economical (extraction, refining, alloying, fabrication) High strength Very versatile metallurgy - a wide range of mechanical and physical properties can be achieved, and these can be tailored to the application
Disadvantages:
High density: 7.9 g cm-3 (use e.g. aluminium, magnesium instead) High temperature strength could be better (use nickel instead) Basic distinction between ferrous and non-ferrous alloys: Ferrous metals are all-purpose alloys
Non-ferrous metals used for niche applications, where properties of ferrous metals are inadequate
Steel structure
Ferrite : (Ferrum), soft, easy to be processed at low temperature Austenite ( Roberts Austen), easy to be processed, non magnetic Zementite Fe3C : hard Ledeburite ( A. Ledebur): Structure at Eutectic point, hard to be processed Pearlite : Layer structure like pearl layers
9
Steel 2
Cast Iron 4
C%
Inhomogeneous
is the phenomenon that the crystal configuration changes with the temperature in the state of solid.
Classification
t < 910 Cubic Lattice in Bulk Center, called -Fe t > 910 Cubic Lattice in Face Center, called -Fe
micrograph
Steel metallurgy
Iron is allotropic / polymorphic i.e. exhibits different crystal structures at different temperatures Most importantly: bcc <-> fcc transformation at 912C (for pure iron)
Solubility of carbon in ferrite (-iron, bcc): 0.02 wt% austenite (-iron, fcc): 2.1 wt% What happens to carbon when crystal structure transforms from fcc to bcc? Fundamental issue in metallurgy of low alloy steels
Pearlite
NB Pearlite is a MIXTURE of phases (on a very fine scale) Alternating layers of ferrite and cementite formed simultaneously from the remaining austenite when temperature reaches 723qC
Fe 1.3 wt% C: Cementite precipitates at austenite grain boundaries, remaining austenite is transformed into pearlite
25
29
30
The transformation
-Fe
910
-Fe
er u are p m T t e
The lattice structure of steel varies from one form to another as the temperature changes. This is illustrated in the above diagram. Between room temperature and 722C, the steel consists of what is known as ferrite and pearlite. Ferrite is a solid solution of a small amount of carbon dissolved in iron. Pearlite, which is shown in the diagram, is a mixture of ferrite and iron carbide. The carbide is very hard and brittle. In the previous diagram between line A1 (lower critical temperature) and A3 (upper critical temperature) the carbide dissolves more readily into the lattice that is now called Ferrite and austenite. Austenite is a solid solution of carbon and iron that is denser than ferrite.
Above line A3 the lattice is uniform in property with the austenite the main structure. The actual temperature for this austenite range is a function of the carbon content of the steel as shown in the figure.
Dissolution
C dissolute in the lattice of Fe to form Solid Solution Fe-C Solid Solution. Solvent the element without changing in lattice Fe is the solvent Solute the element dissolving in solvent C is the solute
Properties
Low strength b = 200 ~ 280 MPa , s = 90 ~ 170 MPa Low hardness HB = 5.5 ~ 8.0 MPa Good plasticity
= 30 ~ 40%
Good toughness
ak = 1.8 ~ 2.5MJ / m
Austenite(A)
The solid solution formed by C dissolving in -Fe is called Austenite, it is denser than Ferrite. The lattice of C keeps in that of -Fe, i.e. Cubic Lattice in Face Center. Characteristics: Because the gap between atoms is large, the capacity to dissolve C is strong. Solubility of C 723 1147 0.8 % 2.06 %(maximum)
Properties
High strength High hardness Good plasticity Good toughness No ironic magnetism
The transformation between F and A: The irons that dissolve C will take the transformation between -Fe and -Fe in different temperature. Ferrite (F) 723 ~ 910 Austenite (A)
Both F and A have good plasticity and they are the structural basis of steels characteristic of excellent plasticity.
Cementite
Chemical Combination: C and Fe form the metallic compound Iron Carbide (Fe3C) whose crystal structure is called Cementite indicated by C.
C + 3Fe
Fe3C
Characteristics:
a)The carbon content of Cementite is high, the mass proportion is 6.67%. b)Hard and brittle (HB=78.4MPa) c)Almost no plasticity and toughness
Cementite
a) Low break-down strength (b35 MPa ) b) The Cementite is semi-stable compound, it will decompose into Fe and C at certain conditions, the extricated C exists in the form of graphite.
Fe3C
C + 3Fe
Damascus sword: which Westerners first encountered during the Crusades against the Muslim nations
46
Assemble the ingredients to load into the crucible, including high-purity iron, Sorel iron, charcoal, glass chips and green leaves. The quantity of carbon and impurity elements that end up in the ingot is controlled by the proportions of iron, Sorel iron and charcoal added to the mix.
Heat the crucible. During this process, the glass melts, forming a slag that protects the ingot from oxidizing. The leaves generate hydrogen, which is known to accelerate carburization of iron. The carbon content of the iron is raised to 1.5 percent, a good proportion for forming the hard iron carbide particles whose accretion into bands gives Damascus blades their characteristic wavy surface pattern. The leaves and glass can be left out, but ingots made without them are more prone to cracking during hammering.
When the crucible has cooled, remove the ingot, which bears a resemblance to the wootz cakes used by the ancients.
Heat the ingot to a precise temperature. Pendray is using a gas-fired furnace with the propane-to-air ratio adjusted to minimize the formation of oxide scale during forging. Typically, a surface oxide layer of about half a millimeter in thickness forms, and the final grinding operation must be sufficient to remove it.
Forge the ingot (deform it slightly with hammer blows while it is still hot). When the ingot gets too cold to deform without cracking, heat it up and forge again. Four separate stages of the ingot are shown here; each stage is the result of several cycles of heating and forging. A total of about 50 cycles may be needed to bang out the blade shape from the ingota highly labor-intensive process. Pendray uses a modern air hammer. A handheld hammer works, too, but it takes longer.
Cut the blade to final shape and hand-forge to add finer details.
Remove the excess steel and the decarburized surface metal. Pendray is using an electric belt grinder for this step.
Cut grooves and drill holes into the surface of the blade to create Mohammed's ladder and rose patterns, if desired. Forge the blade flat again and polish the surface to give the blade its near final form.
Etch blade surface with an acid to bring out the pattern; the softer steel darkens, and the harder steel appears as brighter lines.
Manganese (Mn):
Coming from the deoxidizing and desulfurizing agent in the process of smelting. Function: eliminating S and O2.
They wont effect the properties of steels if the content of both are little. Mn > 0.8% ( the alloy element intentionally)
Function: Mn can disolve in the ferrite to form the solid solution strengthening the effect of ferrite.
Silicon (Si):
Si < 0.5% (common existing impure element)
Coming from the deoxidizing agent and ore. Function: 2FeO + Si 2 Fe + SiO2
Ability of deoxidation is stronger than Mn. Si can dissolve in the Ferrite and improve the strength and hardness of steels.
Sulphur (S):
Originating in the fuels in ore or which are used in the process of smelting (Coke). The existing form: FeS (S doesnt dissolve in Fe) Function: The low-melting-pointed compound (985C) formed by FeS and Fe makes the steel unit crack in the process of hot-working, this phenomenon is called Hot Brittle.
Controlling of the content of S: Common Steel : High Grade Steel : S 0.055 0.07% S 0.03 0.045% S 0.02 0.03%
Phosphorus (P):
Originating in the ore. Function: P in steels can dissolves in -Fe and improves the strength of steels in normal atmospheric temperature & brittleness, but dramatically reduces their plasticity and toughness, this phenomenon is called Cold Brittle. When the content of P in the steel is P=0.3%, the impact toughness ak = 0. Controlling of the content of P: P 0.06%
Oxygen (O2)
Originating in the air. Existing form: O2 always exists in the steels in the form of non-metallic inclusion, such as FeO, SiO2 , MnO, MgO, Al2O3, etc. Function: These oxidations is in the steels as solid grains which are hard but brittle and damage the continuity of basic structure of steels sharply reducing the mechanical property of steels. Eliminating the O2 in the process of smelting.
Nitrogen (N)
Originating in the air. Function: Low Carbon Steels with high-content of N2 are particularly lack of resistance to corrosion. Easy to form the air bubble to be loose. Cause the phenomenon of Age-hardening. Methods: Adding Al and Ti to form AlN and TiN as if making the N fix in the steels (called N-fixed Treatment), this will eliminate the age-hardening.
Hydrogen (H2)
Originating in moist feed in steel-melting stove, pouring system and the moist air, etc. Function: Making the steels to be brittle (H-Brittle) Making the steels to be seriously defective (Fish-eye) Methods: Improve the environment of smelting. Clear up the moisture content in the feed. Purify the steel liquid.
61
Mechanical Properties:
Definition: The capability of materials to resist external forces, but does not deformation beyond allowance or wreck. Main Performance Index: Five Index: Elasticity, Plasticity, Strength, Hardness, Toughness
62
Mechanical properties
Ferrite: soft and ductile Cementite: hard and brittle
Mechanical Properties:
Elastic State(curve o-b) 1.proportional limit:
Elasticity
2.elastic limit:
b a
64
Mechanical Properties:
Elasticity
Strength
ultimate tensile stress b yielding point s, creep limit n creep rupture strength D fatigue limit (strength) -1 shrinkage do Ao= do 4
2
Stress=
P Ao
(MPa)
lo
Strain= ll o
66
Mechanical Properties:
When it is stretched to a certain degree, there will be shrinkage ,and then break.
1. Yielding State (near point c) Conditional Yielding
Ps = Fo
0. 2
P0.2 = Fo
P = b Fo
Mechanical Properties:
Yielding Point (MPa)
s
Yielding point
0.2
b s Yielding point Generally speaking, s <b s/ b , Plasticity , Deformation s/ b , Plasticity, Deformation Strength Usage
Elastic Plastic
Temperature( C) 1Cr18Ni9Ti Creep Rate mm/mm*h(P con.) 425 176 475 91 520 33 550 6
10-6
Mechanical Properties:
Creep Limit
n
Creep phenomena: When the materials is in high temperature and in certain stress, the stress increases as the time is going. The temperature in which metals creep Carbon steel Alloy steel Light metal and alloy Pt, Sn > 420 0C > 450 0C 0 > 50-150 C Normal Temperature
Mechanical Properties:
Creep Curve
Mechanical Properties:
Creep limit (MPa)
n
Definition: The ability of materials to resist the slowly plastic deformation under high temperature.
Under certain temperature, the creep speed does not excess the stress stipulated.
10-7 mm / mm . H 10-6 mm / mm . H
Mechanical Properties:
Creep Rupture Strength D (MPa)
Definition: Rupture strength under certain temperature, the material cracks in a stress after a period of stipulated time. This stress is called creep rupture strength.
Stipulated time: 105 hours Because the designed life time of chemical equipments is commonly 10 5 hours, the stress under which material cracks is said to be rupture strength. Creep rupture strength is the ability to resist cracking under certain temperature and load. The stronger the ability is, the longer it will endure under the same conditions.
Mechanical Properties:
Fatigue limit (Strength) -1(MPa)
Fatigue
phenomenon: the constructional elements destruct under the alternate load action.
Fatigue
strength: the maximum stress, under which the materials do not happen fatigue destruction or failure after infinite times of alternate load action.
Times
Elongation
After the unit of structure is cracked by tensile force, the ratio of the total stretched length and the origin length is called Percentage Elongation, described by %
Mechanical Properties:
l k l0 lk = 100% = 100% l0 l0
lk the gauge length after cracking, mm l0 the origin gauge length, mm lkthe absolute length after cracking, mm
Mechanical Properties:
The meaning of Percentage Elongation: i) The value of reflects the degree of the plastic deformation before the material cracks. ii) The larger , the better the plasticity of material. iii) Plastic material > 5%; Low carbon steel = 20~30% iv) Hard brittle material < 5%; Cast iron = 1%
Mechanical Properties:
SHRINKAGE SECTION After the unit of structure is cracked, the ratio of the reduced area of the cross-section and the original (cross) sectional area is called Shrinkage of Sectional Area which is described by %.
F Fk = 100% F
Fkthe minimum As after cracking mm2 F0original sectional area As mm2
Mechanical Properties:
The larger the , the better the plasticity
Cold Bending Property
Welding joint
The real meaning of the Plastic Index: i) Forming handling(process) and welding ease, such as bending and rolling forging press cold impacting welding and etc. ii) Make the unit of structure to avoid cracking for deformation after bearing load. iii) The Pressure Vessels and their spare parts should have the characteristic.
Mechanical Properties:
Mechanical Properties:
The test of HB:
P p Pressure, N DThe diameter of the rigid ball, mm d The diameter of the indent, mm F The area of the Indent, mm2
p 2p HB = = F D( D D 2 d 2 )
( MPa )
Mechanical Properties:
The relationship of Hardness and Strength:
Generally, good Hardness leads to good Strength and good resistance to wear and tear. Experimental Value (MPa): Low Carbon Steel b 36 HB High Carbon Steel b 34 HB Gray Cast Iron b 10 HB
88
Mechanical Properties:
Impact Toughness
Mechanical Properties:
The larger is a k , the better is the ability of materials to resist the impact load.
The relationship between Toughness and Plasticity: Generally, stronger toughness makes stronger plasticity; but strong plasticity may not make strong toughness . For Mediate and Low Pressure Vessels, a k30 35J/cm2 , commonly a k 60 J/cm2.
91
Physical Properties:
a. Modulus of elasticity (E)
E
(M Pa)
Nature of E: 1) Its the index of materials ability to resist elastic deformation. E , ability to resist deformation. E of steel is about 2.105 M Pa . 2) For the same material, T , E .
Physical Properties:
b. Poissons Ratio
' =
(For steel: 0.3) transverse stress longitudinal stress
Physical Properties:
c. Thermal Expansion Coefficient () l = l
lt
lt
(1 / C
Physical Meaning of :
When T increases by 1, the increasing length per unit length is called Thermal Expansion Coefficient. Application of in Engineering.
Chemical Properties:
Definition: Its the chemical stability of materials in medium, i.e. , its the nature that whether the materials react with medium chemically or electro-chemically leading to corrosion. Two index: Corrosion Resistance Resistance to Oxidation
Chemical Properties:
a. Corrosion resistance the ability of metal materials to resist the corrosion caused by the medium (such as atmosphere, water vapor, electrolyte). b. Oxidation resistance 1 Resist to high temperature oxidation; 2 Resist to oxide etch by other gaseous medium, such as water vapor, CO2 , SO2 , etc.
Manufacturing Properties
A. Definition: Proterties ( mechanical, physical & chemical) are technical / processing properties of material. B.Classification: Casting Forging Welding Machining Heat treatment Cold Warm forming
Manufacturing Properties
Casting Property : Fluidity, Congealing Shrinkage Rate Forging Property : Resistance to Thermal Fragment, Resistance to Oxidation, Thermo-plasticity. Welding Property : Fluidity of parent material and welding flux in the melting state, Congealing, Shrinkage Rate, Thermo-plasticity. Machining Property : Hardness, Brittleness. Heat Treatment Property : Heat Treatment Feasibility. Cold & Warm forming Property: Plasticity, Toughness.
1. According to the content of carbon (C%): Low Carbon Steel Medium Carbon Steel High Carbon Steel 2.According to the smelting methods: Full Killed Steel Rimmed Steel Semi-killed Steel 3.According to the quality: Common Steel High Grade Steel Super High Grade Steel
1. Low-carbon steel (C<0.25%) : Low strength and good plasticity, used in chemical vessels in welding and mechanical units with low loads. 2. Medium Carbon Steel (C=0.25%~0.6%) : Medium strength and plasticity, used as the important units of shaft, gear, top cap of high pressure equipments and so on . 3. High Carbon Steel (C>0.6%) : High strength and hardness, poor plasticity, used as string, wire line and so on.
Martensite ()
Distorted bcc lattice Non-equilibrium carbon content Forms plate-like or needle-shaped
grains
Martensite
Hard and brittle Applications: crankshafts, spanners, high-tension bolts
In general too brittle to be useful, BUT if tempered can be used to produce optimum steel microstructure
Tempering
Heat treatment of martensite carried out at 200-600 C -> allows C atoms to diffuse out of martensite +Fe3C Result: Fe3C present as uniform distribution of fine, round precipitates high strength and toughness Qquenched & tempered steels
Medium carbon steels generally used in quenched and tempered condition, high-carbon steels almost always. Applications: chisels, hammers, drills, cutting tools, springs... Quenching and tempering not possible for low carbon steels -> microstructure = ferrite + pearlite Applications: car panels, bridges, pipes.
Corrosion
m2
h
Metallic density
mm/year
V = F h _ and _ V =
h = p F
P
F
Harm of corrosion 3.Three Grades Standard of Metallic Resistance to Corrosion: Grade I: Ka < 0.1 mm/year (corrosion resistant) Grade II: Ka = 0.1 ~ 1.0 mm/year (available) Grade III: Ka > 1.0 mm/year (unavailable)
2.Local Corrosion:
i. Corrosion is at the local region in metals ii. Very dangerous iii. Remaining the corrosion allowance in designation has no effect.
2.Local Corrosion:
iv. Categories of Local Corrosion (1)Seam Corrosion (2)Pitting Corrosion For example: the pitting corrosion of Cr-Ni stainless steel in the media containing [Cl- ]
2.Local Corrosion:
(3)Stress Corrosion (4)Inter-crystalline Corrosion For example: the inter-crystalline corrosion of Cr-Ni stainless steel under certain conditions
Chemical Corrosion
1.Definition:
The corrosion caused by chemical reactions between metals and drying gas or non-electrolyte solution is called Chemical Corrosion.
Chemical Corrosion
2.Characteristics:
i. Corrosion products are on the metallic surface ii. No electric current in the cause of corrosion iii. The two natures of the products from chemical reactions: (1)Stability Passivation (2)Unstability Activation
Chemical Corrosion
i. Metallic high temperature oxidation (1)Oxidation resistance: oxidized rapidly at high T
Chemical Corrosion
(2)High temperature oxidation of carbon steel and cast iron:
T > 300 oxidation surface appears T < 570 oxidation layer forms inner layer Fe3O4 outer layer Fe2O3
Stable
Stable Unstable
T < 570
T > 570
Chemical Corrosion
(3)Solutions: Adding some Cr Si Al to form stable oxidation film of Cr2O3 SiO2 Al2O3 which can prohibit the oxidation reaction from proceeding.
Chemical Corrosion
ii. High temperature decarburization (1) T > 700 oxidation and decarburization both exist Fe3C + O2 3Fe + CO2 Fe3C + CO2 3Fe + 2CO Fe3C + H2O 3Fe + CO + H2
Chemical Corrosion
(2)Result *Cementite Ferrite with Strength, hardness and Fatigue Strength all decreasing. *Forming the air bubble which is the crack initiation point. (3)Prevention Adding Al or W
Chemical Corrosion
iii. Hydrogen corrosion (hydrogen brittleness) At relevant low temperature and pressure (T200 , P 5MPa), H2 wont corrode the carbon and alloy steels apparently. At high T and P, the corrosion actions of H2 to steels are obvious.
Chemical Corrosion
Mechanism of hydrogen corrosion:
Stage I Hydrogen brittleness stage H disperses inward and dissolves. Stage II Hydrogen attack stage Chemical reaction vary the structure of steels: Fe3C + 2H2 3Fe + CH4
Electrochemical Corrosion
1.Definition:
The corrosion caused by electrochemical reactions between metals and electrolytes is called Chemical Corrosion.
Electrochemical Corrosion
2.Mechanism:
Anode reaction Me Me+ + e Electron movement eanode
Electrochemical Corrosion
3.Conditions of electrochemical corrosion: There is potential difference on the parts of metallic surface or between different metals. The parts which have potential difference are connected with each other or the anode is connected with cathode. The metal with potential difference is in the electrolyte or the electrolyte where the anode and cathode are connected with each other.
Inter-crystalline corrosion
Definition It is the phenomenon that the corrosion occurs between two crystalline surfaces and causes the grain boundary continuously damaged. Nature Its a kind of local and selective corrosive damage.
Inter-crystalline corrosion
Occurring in Austenitic stainless steels Reason Lack of Cr element in the grain boundary Austenitic stainless steels (C<0.14%) *At high temperature (1050C) C distributes completely in whole alloy.
*Between 400~850 C + Cr + Fe
Cr 12.5% Cr lacking
Cr lacking region
Corroding minicell
Grain Cathode
Stress corrosion
i. Definition The destruction is caused by both corrosive media and the tensile stress action, this kind of damage is called Stress Corrosion.
Stress corrosion
ii. Initiation Circumstances Carbon steel and various kinds of Alloy steel (such as austenitic stainless steel) are in the media listed as following: (1)High concentrated chloride solution above 80 (2)High temperature and pressure water at 150~300 (3)High temperature and concentrated caustic solution
Stress corrosion
iii. Mechanism
Stress corrosion
iv. Prevention measure
(1)Decrease or clear up the stress concentration (2)Select the stress corrosion resistant materials: Two-phase stainless steel austenite + small amount (about 5%) of Ferrite such as: 1Cr18Mn10Ni5Mo3N 0Cr17Mn13Mo2N 0Cr21Ni5Ti
- + iii. Coating iv. Adding corrosion buffering agents v. Electrochemical protection such as: cathodic protection Cathodic Protection Apparatuses
Heat Treatment
Heat treatment is the technical process or treatments to steels in solid state according to the scheduled requirements like heating, keeping warm and cooling, their aims are to vary the internal structure and gain the desired properties. 2.Basic Theories of heat treatment: When the basic components of steels (Fe) is heated to a certain degree, its lattice structure of steel will vary from one form to another as the temperature. Ferrite (F) and Austenite (A) are both the solid solution of Fe, so they have the lattice structure of iron.
Heat Treatment
3.Bring forward the problem: Find out the method and path of altering the properties of steels 4.Purpose of heat treatment Eliminating some shortages of steels Improving some properties of steels 5.Advantages of heat treatment Intensifying the metallic materials, fully developing the potential of materials, lightening the mass of equipments and guaranteeing the security and expected life of equipments.
Keeping warm
Cooling
Cooling in furnace Cooling in still air Cooling in oil Cooling in water Cooling in brine
Quench
(1)Process :
Heating the steel pieces to the quenching temperature, cool them quickly in the quenching agents after the warm-keeping treatment, then the Austenite changes into the Matensite.
(2)Quenching Temperature
*Hypo-eutectoid Steel (C<0.8%) heating above the A3 line 30~50C *Hyper-eutectoid Steel (C>0.8%) heating above the A1 line 30~50C
(3)Quenching Agent
*Mineral Oil, Water, and Brine. *Generally speaking: Carbon Steel, cooling in water and brine. Alloy Steel, cooling in oil.
Quench
(4)Quenching Function
developing the hardness, strength and wear (abrasion) resistance. *The emergency cooling in quenching is apt to make flaw in the steel pieces, so the tempering is commonly needed to clear up the stress after quenching. *Quenching and Tempering are always combined to the technical process.
iii. Tempering
(1)Process
Heat the steel pieces which are already quenched to the certain temperature (T<Tcritical), cool them quickly in still air after the warm-keeping treatment.
(2)Purpose
Reduce or clear up the internal stress of workpieces after quenching, stabilize the internal structure and gain the different mechanical properties.
Items
Roofing steel sheet. Galvanized, acid-pickled. Roofing steel sheet Thin acid-pickled sheet steels Tinplate. Size, dimensions Zincplate steel sheet. Technical requirements Hot-dip zinc-coated carbon steel sheet Coated metal products, used in internal and external construction works. Technical properties Aluminium coated and hot dip galvanised steel strip and sheets Carbon steel
(N /mm 2 )
<310 310- 400 320- 420 330-420 340- 440 370-470
CT38
CT51
CT61
Element
c
Mn p
s
Stainless steels
Definition: > 11 wt% Cr. Ni, Mn may also be present Cr -> adherent Cr2O3 film -> protection against corrosion and oxidation Most stainless steels are austenitic (alloying elements stabilise phase down to room T) Austenitic stainless steel is non-magnetic -> useful as quick test Ferritic and martensitic stainless steels also available -> increases range of mechanical properties available for specific applications (Corrosion resistance not as good as for austenitic stainless steel)
Cast Iron
1.The chemical components of commonly used cast iron:
95% Fe + (2.5% ~ 4%) C + ( ~1%) Purities
2.Structure:
Pealite + Cementite + Ladeburite + Graphite
Cast Iron
High carbon content low melting point
Cast Iron
Cheap can produce complex parts quickly and easily through sand casting BUT brittle Two types: Grey iron: Fe + C (graphite)
Formation of graphite rather than cementite promoted through high C and Si content, slow solidification rate White iron: Fe + Fe3C
Excellent casting property Good machinability Good wear resistance Excellent property to reduce vibration Low plasticity and brittleness Low tensile strength and high (ultimate) compression strength
Graphite flakes -> high damping capacity and good machineability -> used e.g. as base structure for machines and heavy equipment BUT brittle due to shape of graphite flakes -> nodular iron better
Spherical graphite cast iron (1)Properties and characteristics *C exists in the form of spherical graphite *Have better strength and a certain plasticity and toughness, its overall mechanical properties are close to that of steels. *Better corrosion resistance than that of Gray Cast Iron except when it is in the acid solution.
High-silicon cast iron (G) Highly corrosion resistant media: nitric acid, sulfuric acid, phosphorus acid, acetic acid Medium corrosion resistant media: hydrochloric acid, Oxalic acid , formic acid Corrosive media: caustic soda, hydrofluoric acid
Objectives Select suitable material of construction Specify design temperature and pressure Calculate wall thickness
01/09/12
Material of Construction
Mechanical and physical properties Corrosion resistance Ease of fabrication Availability in standard sizes Cost
01/09/12
Material of Construction
Preliminary Selection
Selection Charts
Literature Previous experience Advise from materials supplier Advise from equipment manufacturer Advise from consultants
01/09/12
Material of Construction
Final Selection Based on economic analysis which would include Material cost Maintenance cost
01/09/12
01/09/12
Metals
01/09/12
Carbon Steels
Most common engineering material Advantages Inexpensive Good tensile strength and ductility Available in a wide range of standard forms and sizes Easily worked and welded
01/09/12
01/09/12
Stainless Steels
Most frequently used corrosion resistant materials in the chemical industry High chromium or high nickel-chromium alloys of iron chromium content must be > 12% Nickel added to improve weldability and corrosion resistance in non-oxidizing env.
01/09/12
Stainless Steels
Main Types of Stainless Steel Type 304 18% Cr & 8% Ni Type 304L low carbon version to improve welding of thick plates Type 316 Mo added to improve corrosion resistance in reducing conditions and at high temperature.
01/09/12
Special Alloys
Better corrosion resistance than SS No stress-corrosion cracking in chloride solutions Temp. up to 500oC
01/09/12
Plastics
Provide corrosion resistance at low cost. Main advantages: Excellent resistance to weak mineral acids Tolerate small changes in pH, minor impurities or oxygen content Light weight, easy to fabricate and install
01/09/12
Plastics
Major Limitations: Moderate tempeature and pressure applications (T < 100oC; P < 5 atm.) Low mechanical strength Only fair resistance to solvents
01/09/12
Plastics
Main Classes: 1. Thermoplastic can be reshaped 2. Thermosetting cannot be remoulded Thermoplastic Polyethylenes (low cost; T < 50oC) Polypropylene ( T up to 120oC) Polyvinyl chloride ( T 60oC)
01/09/12
Plastics
Thermosetting - good mechanical properties (T 95oC) - good chemical resistance (except strong alkalies) Examples: Phenolic resins filled with carbon, graphite, silica Polyester resins reinforced with glass or carbon fibre to improve strength
01/09/12
Plastics
Polytetrafloroethylene (PTFE) Known under the trade names of Teflon and Fluon Can be used up to 250oC highest for all plastics Resistant to all chemicals except fluorine and molten alkalies
01/09/12
Rubber Lining
Metal surface lined with rubber to provide;
Cost effective solution for corrosion control and abrasion resistance e.g. acid storage, steel pickling Why rubber?
Able to bond strongly to various surfaces Good combination of elasticity and tensile strength
01/09/12
Ceramic Materials Provide high temperature corrosion resistance and/or thermal protection (up to 2000oC) Ceramic or refractory materials metal oxides, carbides and nitrides Used as either solid bodies or coatings Glass mostly used in glass lining
01/09/12
1.Alloy elements:
i. Definition The elements that are added on purpose to develop the structure and characteristics of steels. ii. Main alloy elements Cr Ni Mn Si Al Mo V Ti Cu B Nb W Re
2.Alloy Steel
Definition Alloy steels are those steels that contain the alloy elements which develop the properties of steels.
ii. Ni (1)Enlarge the range of corrosion resistance of stainless steel, especially improve the resistance to base. (2)Broad the -phase region as to be the element that form the austenite. (3)Develop the strength as well as keep excellent properties of plasticity and toughness. (4)Improves strength at high T
iii. Mn
(1)Develop the strength and impact toughness at low temperature. (2)Broad the -phase region. (3) Counteracts sulfur brittleness. (4)Increases hardenability.
iv. Si (1)Develops strength and fatigue durability at high temperature. (2)Improve heat resistance (3)Resistant to the corrosion of such media as H2S and so on. (4)If amount of Si is too much, plasticity and impact toughness both (5)Strengthens steel (6)Increases hardenability
v. Mo (1)Develop the resistance of stainless steels to the chloride anion Cl-. (2)Enhances H corrosion resistance. (3)Improve the heat resistance. (4)Raises grain-coarsening temperature. (5)Mo<0.6%, plasticity . (6)Counteracts tendency toward temper brittleness.
vi. Al (1)Restricts grain growth. (2)Develops the impact toughness. (3)Resistant to the corrosion caused by H2S. (4)Improves the oxidation and heat resistance. (5)Cheap, common substitute for Cr among heat-resistant steels.
vii. Ti (1)Restricts grain growth. (2)Develops strength and toughness. (3)Improves the oxidation and heat resistance. (4)Stablizes C to prevent the inter-crystalline corrosion. (5)Prevents formation of austenite in high chromium steels; prevents localized depletion of chromium in stainless steel during long heating.
viii. V (1)Developes high-temperature strength. (2)Increases hardenability. (3)Restricts grain growth. (4)Keeps the strength and improve the plasticity. (5)Resists tempering
AE Cr Ni Mn Si Mo Al Ti V Re
H/WR IT
CR
OR
HR
FD
GR
Interpretation: AEalloy element S strength P plasticity H/WR hardness and wear resistance IT impact toughness CR corrosion resistance OR oxidation resistance HR heat resistance FD fatigue durability GR grain refining H hardability in-c inter-crystalline
2.Composition:
(1)C<0.2% (2)Alloy elements *Mn 1~1.5% *Si Cr Ti V Nb Ni Al 0.015 ~ 0.6%
3.Structure:
Ferrite + Pearlite
Indicate the main alloy elements, the number thereafter is the percentage of that element. If it is less than 1.5%, it can be omitted. Content of alloy elements: 1.5 ~ 2.49% Sign as 2 Sign as 3 3.5 ~ 4.49% 2.5 ~ 3.49% Sign as 4
Commonly-used Designation:
i. Boiler Steel 20g 22g 12Mng 16Mng 15MnVg 14MnMoVg 18MnMoNbg ii. Vessel Steel Q235-AR 20R 16MnR 15MnVR 09MnVR 18MnMoNbR
iii. Theories of corrosion resistance (1)In the oxidizing medium, a oxide skin Cr2O3 which is stable and tight will be formed, it has an effect on passivation, i.e. there is a passivation layer on the surface of the steels. (2)The degree of corrosion resistance depends on the content of C and Cr. The more Cr, the better the resistance The less C, the better the resistance
iv. Commonly-used Chromium Stainless Steel 1Cr13 2Cr13 0Cr13 0Cr17 0Cr17Ti v. Designation (1)The first number: Average C content Average with C amount of 1000 points 0 C < 0.1% 1: C0.15% 2: C0.2% (2)The second number: percentage of the average content of Cr
iii. Characteristics (1)High strength and good plasticity & toughness (2)Large range of suitable temperature -196 ~ 800 (3)Excellent technical properties (4)Good corrosion resistance
Non-corrosive media: cold phosphorus acid, nitric acid, acetic acid, hydrogen sulfide, sulfate, nitride, base liquid, petroleum chemicals, etc. Corrosive media: hydrochloric acid, dilute sulfuric acid (<10%), hot phosphorus acid, oxalic acid , melting caustic potassium, melting caustic alkali, Cl-, bromine (Br), iodine (I), etc.
(5)Inter-crystalline corrosion easily occurs between 400~800 Definition of inter-crystalline corrosion: It is the phenomenon that the corrosion occurs between two crystalline surfaces and causes the grain boundary continuously damaged. Nature: Its a kind of local and selective corrosive damage.
Occurring in: Austenitic stainless steels Reason: Lack of Cr element in the grain boundary Austenitic stainless steels (C<0.14%): *At high temperature (1050C) C distributes completely in whole alloy.
*Between 400~800 C + Cr + Fe
Cr 12.5% Cr lacking
Cr lacking region
Corroding minicell
Grain Cathode
Damage: To be brittle, even softly beating can makes it break into dust. Have very low strength. Preventive measures: *Solution heat treatment quenching again (1100~1150C) to dissolve C and Cr into the austenite. *Reduce the content of C preventing C to combine with Cr, then less Cr will be separated out. For example: 0Cr18Ni9 (C 0.08%) 00Cr18Ni9 (C 0.03%)
*C stabilization treatment adding Ti or Nb to form TiC or NbC to stabilize C. For example: 1Cr18Ni9Ti 1Cr19Ni11Nb *Add microelement adding B can vary the nature of grain boundary to prevent (Cr . Fe)23C6 to be separated out.
(6) Pitting corrosion occurs in the media containing [Cl-] Mechanism: [Cl-] intrudes into the flaw of passivation film (Cr2 O3) and reacts with metallic ion to form strong acidic salts ([M+] + [Cl-] MCl) which can dissolve the passivation film the locally corroded film becomes a passiveactive minicell with corrosion taking place.
Damage: Fast corrosion speed easily perforates the thin (only several mini-meter thick) stainless steel by corrosion. Preventive measures: *Adding some alloy elements The most effective elements to improve the pitting corrosion resistance: Cr, Mo Secondarily effective elements: Ni, Si, N, Re
*Cr25%, pitting corrosion wont occur. 2%Mo improve pitting corrosion resistance dramatically, Mo and [Cl-] form the protective film (MoOCl2) which can prevent the passivation film being perforated. *Materials resistant to the corrosion of [Cl -]: high Cr-Ni stainless steel containing Mo such as: 1Cr18Ni12Mo2Ti 00Cr20Ni30Mo2Nb 000Cr30Mo2
ii. Elements added Cr Mo V Ti W Si Ni Al iii. Commonly-used heat-resisting steel (a)Oxidation resistant steel *mainly resistant to oxidation, but has low strength. *used in the parts that are heated directly (800~1000) but small loaded. such as: heating tube support, nozzle, etc. *commonly used steels designation: Cr13SiAl Cr25Ti Cr17Ti Cr25Ni12
(b)Refractory steel *mainly resistant to creep but also resistant to oxidation. *used in the parts that are loaded at high T. such as: heating tube, reactor, etc. *commonly used steels designation: 12CrMo Cr5Mo 1Cr18Ni9Ti Cr25Ni20
2.Low-temperature Steel:
i. Working temperature < -20 Low temperature -20 ~-40 Non-cryogenic temperature < -40 Cryogenic temperature ii. Characteristics (1)Excellent low-temperature toughness (2)Excellent processing workability and weldability
iii. Requirements of structure (1)Low content of C (0.08~0.18%) form homogeneous ferritic structure. (2)Homogeneous austenitic structure is desirable at cryogenic temperature. iv. Elements added Mn Al Ti Nb Cu V N