Solidification of Metals

Pure metals have clearly defined melting or freezing points, and

solidification takes place at a constant temperature.
When the temperature of the molten metal is reduced to the freezing
point, latent heat of fusion is given off while the temperature remains
constant.
Unlike pure metals, alloys solidify over a range of temperatures.

Chapter 5: Metal-Casting Processes and Equipment; Heat Treatment

Manufacturing Processes for Engineering Materials, S. Kalpakjian and S. R. Schmid, Prentice Hall

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Phase Diagrams

Unlike pure metals, alloys solidify over a range of temperatures. Solidifications

begins when the temperature of the molten metal drops below the liquidus and is
completed when the temperature reaches the solidus.
A phase diagram, also called equilibrium diagram or constitutional diagram,
graphically illustrates the relationships among temperature, composition, and the
phases present in a particular alloy system. Equilibrium means the state of a
system remains constant over an indefinite period of time. Constitutional indicates
the relationships among structure, composition, and physical makeup of the alloy.
< A binary phase diagram for the nickel-copper alloy >

Chapter 5: Metal-Casting Processes and Equipment; Heat Treatment

Manufacturing Processes for Engineering Materials, S. Kalpakjian and S. R. Schmid, Prentice Hall

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Lever Rule

Composition of phases can be found by lever rule.

Weight fraction of solid is proportional to the distance between C0 and CL:

C CL
S
= 0
S + L CS C L

Weight fraction of liquid is proportional to the distance between CS and C0:

C S C0
L
=
S + L CS C L

< A binary phase diagram for the nickel-copper alloy >

Chapter 5: Metal-Casting Processes and Equipment; Heat Treatment

Manufacturing Processes for Engineering Materials, S. Kalpakjian and S. R. Schmid, Prentice Hall

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The Iron-Carbon System

Iron-carbon binary system is represented by the iron-iron carbide phase diagram. Note
that pure iron melts at a temperature of 1811K; as it cools, it first forms -iron, then -iron,
and finally -iron. Commercially pure iron contains up to 0.008% C, steels up to 2.11% C,
and cast irons up to 6.67% C, although most cast irons contains less than 4.5% C.

(a) The iron-iron carbide phase diagram and (b) detailed view of the microstructures above
and below the eutectoid temperature of 1000K. Because of the importance of steel as an
engineering material, this diagram is one of the most important phase diagrams.
Chapter 5: Metal-Casting Processes and Equipment; Heat Treatment
Manufacturing Processes for Engineering Materials, S. Kalpakjian and S. R. Schmid, Prentice Hall

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Ferrite

Alpha ferrite, or simply ferrite, is a solid solution of body-centered cubic iron and has a
maximum solid solubility of 0.022% C at a temperature of 1000K. Delta ferrite is stable
only at very high temperatures and has no significant or practical engineering applications.
Ferrite is relatively soft and ductile. Although very little carbon can dissolve interstitially in
bcc iron, the amount of carbon significantly affects the mechanical properties of ferrite.

Chapter 5: Metal-Casting Processes and Equipment; Heat Treatment

Manufacturing Processes for Engineering Materials, S. Kalpakjian and S. R. Schmid, Prentice Hall

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Austenite

Between 1667.15 K and 1185.15 K iron undergoes an allotropic transformation from the
bcc to fcc structure, becoming what is known as gamma iron or, more commonly, austenite.
This structure has a solid solubility of up to 2.11% C at 1421.15 K, which is about two
orders of magnitude higher than that of ferrite, with the carbon occupying interstitial
positions. Note that the atomic radius of Fe is 0.124 nm and for C it is 0.071 nm. Austenite
is an important phase in the heat treatment of steels. It is denser than ferrite, and its
single-phase fcc structure is ductile at elevated temperatures, thus it possesses good
formability.

Chapter 5: Metal-Casting Processes and Equipment; Heat Treatment

Manufacturing Processes for Engineering Materials, S. Kalpakjian and S. R. Schmid, Prentice Hall

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Cementite

Also called carbide, which is 100% iron carbide (Fe3C), with a carbon content of 6.67%.
Cementite is a very hard and brittle intermetallic compound and significantly influences the
properties of steels.

Chapter 5: Metal-Casting Processes and Equipment; Heat Treatment

Manufacturing Processes for Engineering Materials, S. Kalpakjian and S. R. Schmid, Prentice Hall

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Sword

http://en.wikipedia.org/wiki/Differential_heat_treatment

Movie: Japanese Samurai Sword vs. Viking Sword

PDF: Japanese Sword: History Art Science
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