Professional Documents
Culture Documents
o Introduction 30
o Cast Iron 40
o Alloy steels 40
o Tool steels 30
o Magnetic Materials 30
Introduction: 30 mins
The word is derived from The Latin word ferrum ("iron"). Ferrous metals
include steel and pig iron (with a carbon content of a few percent) and
alloys of iron with other metals (such as stainless steel). Manipulation of
atom-to-atom relationships between iron, carbon, and various alloying
elements establishes the specific properties of ferrous metals.
Alloy steels are steels (iron and carbon) alloyed with other metals to
Ferrous Metals and Alloys _ Level 5 _ Semester 1 60
Facilitators Guide Engineering Materials and Metallurgy
improve properties. The most common metals in low alloyed steels are
molybdenum, chromium, and nickel to improve weldability, formability,
wear resistance, and corrosion resistance.
Tool steels are particular steels designed for being made into tools. They
are known for toughness, resistance to abrasion, ability to hold a cutting
edge, and/or their resistance to deformation at high temperatures. The
three types of tool steel available are cold work steels used in lower
operating temperature environments, hot work steels used at elevated
temperatures, and high speed steels able to withstand even higher
temperatures giving them the ability to cut at higher speeds.
Cast iron is an iron alloy derived from pig iron, alloyed with carbon and
silicon. Carbon is added to the base melt in amounts that exceed the
solubility limits in iron and precipitates out as graphite particles. Silicon is
added to the melt to nucleate the graphite which optimizes the
properties of cast iron. Often dismissed as a cheap, dirty, brittle metal;
cast iron is getting much more attention and use today because of its
machinability, light weight, strength, wear resistance, and damping
properties.
Application
Mild Steel Carbon content of 0.1 to 0.3% and Iron content of 99.7
99.9%. Used for engineering purposes and in general, none specialised
metal products.
Carbon steel Carbon content of 0.6 to 1.4% and Iron content of 98.6
to 99.4 %. Used to make cutting tools such as drill bits.
Stainless Steel Made up of Iron, nickel and chromium. Resists staining
and corrosion and is therefore used for the likes of cutlery and surgical
instrumentation. See our infographic celebrating 100 years of stainless
steel usage in buildings or the different types of stainless steel.
Cast Iron carbon 2 6% and Iron at 94 to 98%. Very strong but brittle.
Used to manufacture items such as engine blocks and manhole covers.
Wrought Iron Composed of almost 100% iron. Used to make items
such as ornamental gates and fencing. Has fallen out of use somewhat.
Fig: 2
The above figure shows the equilibrium diagram for combinations of
carbon in a solid solution of iron. The diagram shows iron and carbons
combined to form Fe-Fe3C at the 6.67%C end of the diagram. The left
side of the diagram is pure iron combined with carbon, resulting in steel
alloys. Three significant regions can be made relative to the steel portion
of the diagram. They are the eutectoid E, the hypo eutectoid A, and the
hypereutectoid B. The right side of the pure iron line is carbon in
combination with various forms of iron called alpha iron (ferrite), gamma
iron (austenite), and delta iron. Allotropic changes take place when there
is a change in crystal lattice structure.
From 2802 F - 2552 F the delta iron has a body-centred cubic lattice
structure. At 2552 F, the lattice changes from a body-centred cubic to a
face-centred cubic lattice type. At 1400 F, the curve shows a plateau but
Two very important phase changes take place at 0.83%C and at 4.3% C.
30 mins
Flow diagram for production of steel
Composition
Cast iron is iron or a ferrous alloy which has been heated until it liquefies,
and is then poured into a mould to solidify. It is usually made from pig
iron. The alloy constituents affect its colour when fractured: white cast
iron has carbide impurities which allow cracks to pass straight through.
Grey cast iron has graphite flakes which deflect a passing crack and
initiate countless new cracks as the material breaks.
Carbon (C) and silicon (Si) are the main alloying elements, with the
amount ranging from 2.14 wt% and 13 wt%, respectively. Iron alloys
with less carbon content are known as steel. While this technically makes
these base alloys ternary FeCSi alloys, the principle of cast iron
solidification is understood from the binary ironcarbon phase diagram.
Since the compositions of most cast irons are around the eutectic point
of the ironcarbon system, the melting temperatures closely correlate,
usually ranging from 1,150 to 1,200 C (2,100 to 2,190 F), which is about
300 C (572 F) lower than the melting point of pure iron.
Cast iron tends to be brittle, except for malleable cast irons. With its
relatively low melting point, good fluidity, castability, excellent
machinability, resistance to deformation and wear resistance, cast irons
have become an engineering material with a wide range of applications
and are used in pipes, machines and automotive industry parts, such as
cylinder heads(declining usage), cylinder blocks and gearbox cases
(declining usage). It is resistant to destruction and weakening by
oxidation (rust).
The earliest cast iron artefacts date to the 5th century BC, and were
discovered by archaeologists in what is now modern Luhe County,
Jiangsu in China. Cast iron was used in ancient China for warfare,
Ferrous Metals and Alloys _ Level 5 _ Semester 1 66
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agriculture, and architecture. During the 15th century, cast iron became
utilized for artillery in Burgundy, France, and in England during the
Reformation.[2] The first cast iron bridge was built during the 1770s by
Abraham Darby III, and is known as The Iron Bridge. Cast iron is also used
in the construction of buildings.
Classification:
1. White cast iron
The carbon is on the surface of ferrites with small fraction and is in the
form of Fe3c, the section of white cast iron is in sliver white color, its
features is hard and fragile, it is difficult to be processed with machine
and little used to produce parts. The main usage: it is used as the raw
materials to make steel, also can be deal to malleable irons.
4. Ductile Iron
Ductile iron is also called as spheroidal graphite cast iron or sg iron.
Because of the nodular agent, the graphite form is shown as the
spheroidal, so this iron will have larger elongation and higher tensile and
yield strength.
Typical uses
Cast iron is used in a wide variety of structural and decorative
applications, because it is relatively inexpensive, durable and easily cast
into a variety of shapes. Most of the typical uses include:
- historic markers and plaques
- hardware: hinges, latches
- columns, balusters
- stairs
- structural connectors in buildings and monuments
- decorative features
- fences
- tools and utensils
- ordnance
- stoves and firebacks
- piping.
The basic cast iron material in all of these applications may appear to be
the same, or very similar, however, the component size, composition,
use, condition, relationship to adjacent materials, exposure and other
factors may dictate that different treatments be used to correct similar
problems. Any material in question should be evaluated as a part of a
larger system and treatment plans should be based upon consideration
of all relevant factors.
Phosphoru 0.02 - Increases < 0.05 Above 0.05 % can < 0.05 Increases ductile-
s 1.2 hardness produce internal brittle transition
(P) and unsoundness temperature. Promotes
brittleness. defects. galvanizing and
Increases Embrittles the iron temper embrittlement.
tendency for - raises ductile-
internal brittle transition
unsoundness temperature.
defects. At Promotes
low levels galvanizing and
(0.04 %), temper-
increases embrittlement.
metal- Segregates to
penetration grain boundaries
and finning. and produces
carbide/phosphide
complexes.
Carbon Steel
40 mins
Carbon steel is steel in which the main interstitial alloying constituent is
carbon in the range of 0.122.0%. The American Iron and Steel Institute
(AISI) defines carbon steel as the following: "Steel is considered to be
carbon steel when no minimum content is specified or required for
chromium, cobalt, molybdenum, nickel, niobium, titanium, tungsten,
vanadium or zirconium, or any other element to be added to obtain a
desired alloying effect; when the specified minimum for copper does not
exceed 0.40 percent; or when the maximum content specified for any of
the following elements does not exceed the percentages noted:
manganese 1.65,silicon 0.60, copper 0.60."
The term "carbon steel" may also be used in reference to steel which is not
stainless steel; in this use carbon steel may include alloy steels. As the
carbon percentage content rises, steel has the ability to become harder
and stronger through heat treating; however it becomes less ductile.
Regardless of the heat treatment, a higher carbon content reduces
weldability. In carbon steels, the higher carbon content lowers the melting
point.
Element Content
Phosphorous, P 0.040 %
Sulphur, S 0.050 %
Classification / Properties
Electrical
Metric English Comments
Properties
0.0000219 - annealed
@100 C/ 212 F 0.0000219 -cm
cm condition
0.0000293 - annealed
@ 200 C/392 F 0.0000293 -cm
cm condition
Element Content
Phosphorous, P 0.040 %
Sulphur, S 0.050 %
Classification /Properties
Mechanical Properties
Applications
Application
High carbon steel is used for applications in which high strength, hardness
and wear resistance are necessary, such as wear parts, knives, saw blades,
springs, gear wheels, chains, brackets etc. cold chisels, wrenches, Jaws for
vices, pneumatic drill bits, wheels for railways service, wire for structural
work, shear blades, hacksaws.
Every steel is truly an alloy, but not all steels are called "alloy steels". Even
the simplest steels are iron (Fe) (about 99%) alloyed withcarbon (C) (about
0.1% to 1%, depending on type). However, the term "alloy steel" is the
standard term referring to steels with other alloying elements in addition
to the carbon. Common alloy ants include manganese (the most common
one), nickel, chromium,molybdenum, vanadium, silicon, and boron. Less
common alloyants include aluminium, cobalt, copper, cerium, niobium,
titanium,tungsten, tin, zinc, lead, and zirconium.
1. Low Alloy Steel Definition Among alloy steels, when Ni, Cr, Mo, and
other alloy elements content consist of less than 10.5% are defined as low
alloy steels.
Chromium-Molybdenum Steel :
This low alloy steel series contains 0.5% ~ 9% Cr and 0.5% ~ 1% Mo. Its
carbon content on average is lower than 0.20%, with decent weldability
and higher hardening ability due to its alloy trait. The Cr content improves
its anti-oxidization and anti-corrosion ability, and Mo enhances its strength
in high temperature condition; The steel supplying conditions are generally
gone through annealing or normalizing and tempering
processes.Chromium-Molybdenum Steel has been widely used in the areas
such as petrol chemical industry, steam power equipment, and high
temperature services.
Nickel Steel :
The average steel in low temperature environment will have higher
strength but lower elongation and toughness, thus increases the chance
for brittle fracture. If the steel is needed in a low temperature
Weathering Steel :
Generally there are two categories of rust prevention methods: one type
for instance, is paint coating, electroplate, ceramic coating, or adding
layers of anti-corrosion material, anything to shield the steel surface from
corrosive environment. Another type is to use stainless steel or weather
steel, meaning adding anti-corrosion alloy elements into the steel.
Weathering steel is formed by adding small amounts of Cu, Cr, P, Ni, and
other alloy elements into low alloy steel. During the initial application, it
will also rust like the average carbon steel; however, after certain period
(usually one year) the rustic surface will serve as an impermeable
protective cover, preventing the further expansion of rust into inner part
of steel.
Stainless steels are high alloy steels that have the ability to resist corrosion.
This characteristic is mainly due to the high chromium content, i.e., 10% or
greater. Nickel is also used in substantial quantities in some stainless
steels.
Tool steels are used for cutting and forming operations. They are high
qualitysteels used in making tools, punches, forming dies, extruding dies,
forgings and so forth.Depending upon their properties and usage, they are
sometimes referred to as water hardening, shock resisting, oil hardening,
air hardening, and hot work tool steel.
Because of the high levels of alloying elements, special care and practices
are required when welding high alloy steels. Ferritic stainless steels have
12 to 27 percent chromium with small amounts of austenite-forming
alloys.
Martensitic stainless steels make up the cutlery grades. They have the least
amount of chromium, offer high hardenability, and require both pre- and
post-heating when welding to prevent cracking in the heat-affected zone
(HAZ).
Tool Steels:
Tool steel refers to a variety of carbon and alloy steels that are particularly
well-suited to be made into tools. Their suitability comes from their
distinctive hardness, resistance to abrasion, their ability to hold a cutting
edge, and/or their resistance to deformation at elevated temperatures
(red-hardness). Tool steel is generally used in a heat-treated state. Many
high carbon tool steels are also more resistant to corrosion due to their
higher ratios of elements such as vanadium and niobium.
With a carbon content between 0.7% and 1.5%, tool steels are
manufactured under carefully controlled conditions to produce the
required quality. The manganese content is often kept low to minimize the
possibility of cracking during water quenching. However, proper heat
treating of these steels is important for adequate performance, and there
are many suppliers who provide tooling blanks intended for oil quenching.
Tool steels are also used for special applications like injection molding
because the resistance to abrasion is an important criterion for a mold that
will be used to produce hundreds of thousands of parts.
F-type tool steel is water hardened and substantially more wear resistant
than W-type tool steel.
Stainless Steels
In metallurgy, stainless steel, also known as inox steel or inox from French
"inoxydable", is a steel alloy with a minimum of 10.5% chromium content
by mass.
Stainless steel does not readily corrode, rust or stain with water as
ordinary steel does, but despite the name it is not fully stain-proof, most
notably under low-oxygen, high-salinity, or poor-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 and resistance to corrosion are required.
Applications
Stainless steels resistance to corrosion and staining, low maintenance and
familiar lustre make it an ideal material for many applications. There are
over 150 grades of stainless steel, of which fifteen are most commonly
used.
The alloy is milled into coils, sheets, plates, bars, wire, and tubing to be
used in cookware, cutlery, household hardware, surgical instruments,
major appliances, industrial equipment (for example, in sugar refineries)
and as an automotive and aerospace structural alloy and construction
material in large buildings.
Storage tanks and tankers used to transport orange juice and other food
are often made of stainless steel, because of its corrosion resistance. This
also influences its use in commercial kitchens and food processing plants,
as it can be steam-cleaned and sterilized and does not need paint or other
surface finishes.
Stainless steel is used for jewellery and watches with 316L being the type
commonly used for such applications. It can be re-finished by any jeweller
and will not oxidize or turn black. Some firearms incorporate stainless steel
components as an alternative to blued or parkerized steel. Some handgun
models, such as the Smith & Wesson Model 60 and the Colt M1911 pistol,
can be made entirely from stainless steel. This gives a high-lustre finish
similar in appearance to nickel plating.
Unlike plating, the finish is not subject to flaking, peeling, wear-off from
rubbing (as when repeatedly removed from a holster), or rust when
scratched. Some automotive manufacturers use stainless steel as
decorative highlights in their vehicles.
Chromium:
As with manganese, chromium has a tendency to increase hardness
penetration. This element has many interesting effects on steel. When 5
percent chromium or more is used in conjunction with manganese, the
critical quenching speed is reduced to the point that the steel becomes air
hardening. Chromium can also increase the toughness of steel, as well as
the wear resistance. Probably one of the most well-known effects of
chromium on steel is the tendency to resist staining and corrosion. Steels
with 14 percent or more chromium are referred to as stainless steels. A
more accurate term would be stain resistance. Stainless tool steels will
infact darken and rust, just not as readily as the non-stainless varieties.
Steels with chromium also have higher critical temperatures in heat
treatment.
Nickel
Nickel is added in large amounts, over about 8%, to high chromium
stainless steel to form the most important class of corrosion and heat
resistant steels.Nickel increases the strength of ferrite, therefore
increasing the strength of the steel. It is used in low alloy steels to increase
toughness and hardenability. Nickel also tends to help reduce distortion
and cracking during the quenching phase of heat treatment.
Manganese
Manganese slightly increases the strength of ferrite, and also increases the
hardness penetration of steel in the quench by decreasing the critical
quenching speed. This also makes the steel more stable in the quench.
Steels with manganese can be quenched in oil rather than water, and
Molybdenum
Molybdenum increases the hardness penetration of steel, slows the critical
quenching speed, and increases high temperature tensile strength.
Tungsten
Used in small amounts, tungsten combines with the free carbides in steel
during heat treatment, to produce high wear resistance with little or no
loss of toughness. High amounts combined with chromium gives steel a
property known as red hardness. This means that the steel will not lose its
working hardness at high temperatures. An example of this would be tools
designed to cut hard materials at high speeds, where the friction between
the tool and the material would generate high temperatures.
Vanadium
Vanadium helps control grain growth during heat treatment. By inhibiting
grain growth it helps increase the toughness and strength of the steel.
AISI Designations
W: Water-Hardening
S: Shock-Resisting
O: Cold-Work (Oil-Hardening)
A: Cold-Work (Medium-Alloy, Air-Hardening)
D: Cold-Work (High-Carbon, High-Chromium)
L: Low-Alloy
F:Carbon-Tungsten
P:P1-P19-Low-Carbon Mold Steels
P20-P39 -Other Mold Steels
H:H1-H19:Chromium-Base Hot Work
H20-H29:Tungsten-Base Hot Work
H40-H59:Molybdenum-Base Hot Work
Magnetic Materials
30 mins
There are a few materials which are naturally magnetic, and have the
potential to be turned into magnets. Some of these materials are
iron
hematite
magnetite
ionized gases (such as the material stars are made of)
A magnet can be made to stick to objects which contain magnetic material
such as iron, even if they are not magnets. But a magnet cannot be made
to stick to materials which are plastic, or cotton, or any other material,
such as silicate rock, which is not magnetic.
The origin of magnetism lies in the orbital and spin motions of electrons
and how the electrons interact with one another. The best way to
introduce the different types of magnetism is to describe how materials
respond to magnetic fields. This may be surprising to some, but all matter
is magnetic. It's just that some materials are much more magnetic than
others. The main distinction is that in some materials there is no collective
interaction of atomic magnetic moments, whereas in other materials there
is a very strong interaction between atomic moments.
The magnetic behaviour of materials can be classified into the following
five major groups:
1. Diamagnetism
2. Paramagnetism
3. Ferromagnetism
4. Ferrimagnetism
5. Antiferromagnetism
Ferromagnetism
When you think of magnetic materials, you probably think of iron, nickel or
magnetite. Unlike paramagnetic materials, the atomic moments in these
materials exhibit very strong interactions. These interactions are produced
by electronic exchange forces and result in a parallel or antiparallel
alignment of atomic moments. Exchange forces are very large, equivalent
to a field on the order of 1000 Tesla, or approximately a 100 million times
the strength of the earth's field.
The elements Fe, Ni, and Co and many of their alloys are typical
ferromagnetic materials.
Spontaneous Magnetization
The spontaneous magnetization is the net magnetization that exists inside
a uniformly magnetized microscopic volume in the absence of a field. The
magnitude of this magnetization, at 0 K, is dependent on the spin magnetic
moments of electrons.
Curie Temperature
When domain wall can easily migrate, the ferromagnetic material can be
easily magnetized at low magnetic field. These types of ferromagnetic
materials are called soft magnetic material, and are suitable for
applications of magnetic cores or recording heads. Since soft magnetic
materials can be demagnetized at low magnetic field, coercivity Hc is low.
As they can be easily magnetized, permeability is high. For ferromagnetic
materials to be soft, their magnetocrystalline anisotropy and
magnetostriction constant must be low. In addition, for easy migration of
magnetic domains, they must have small number of defects such as crystal
grains.
Field of
Products Requirements Materials
application
Soft Magnets
Power
Motors
conversion
Generators Large MR
electrical -
Electromagnets Small HC
mechanical
Low losses = small Fe based materials, e.g.
conductivity Fe + (0,7 - 5)% Si
Power (Power) low w Fe + (35 - 50)% Co
adaption Transformers
Transformer
Linear M - H curve
("bertrger")
LF ("low"
Small conductivity Fe + 36 %
Signal frequency; up
medium w Fe/Ni/Co 20/40/40
transfer to 100 kHz)
HF ("high"
Very small conductivity
frequency up Ni - Zn ferrites
high w
to 100 kHz)
Magnetic
Large dM/dH for H 0
field "Mu-metal" Ni/Fe/Cu/Cr 77/16/5/2
ideally mr = 0
screening
Hard Magnets
Hard disc,
Floppy disc
Data storage
digital
Magnetic garnets (AB2O4,
or A3B5O12), e.g.
Special domain with A = Yttrium (or mixtures of
Bubble memory
structure rare earth), and B = mixtures
of Sc, Ga, Al
Most common: Gd3Ga5O12
Specialties
Many types of tool materials, ranging from high carbon steel to ceramics
and diamonds, are used as cutting tools in todays metalworking industry.
It is important to be aware that differences do exist among tool materials,
what these differences are, and the correct application for each type of
material.
The various tool manufacturers assign many names and numbers to their
products. While many of these names and numbers may appear to be
similar, the applications of these tool materials may be entirely different.
In most cases, the tool manufacturers will provide tools made of the
proper material for each given application. In some particular applications,
a premium or higher priced material will be justified.
This does not mean that the most expensive tool is always the best tool.
Cutting tool users cant afford to ignore the constant changes and
advancements that are being made in the field of tool material technology.
When a tool change is needed or anticipated, a performance comparison
should be made before selecting the tool for the job. The optimum tool is
not necessarily the least expensive or the most expensive, and it is not
always the same tool that was used for the job last time. The best tool is
the one that has been carefully chosen to get the job done quickly,
efficiently, and economically.
Cemented Carbides
Introduced in the 1930s, these are the most important tool materials today
because of their high hot hardness and wear resistance. The main
disadvantage of cemented carbides is their low toughness. These materials
are produced by powder metallurgy methods, sintering grains of tungsten
carbide (WC) in a cobalt (Co) matrix (it provides toughness). There may be
other carbides in the mixture, such as titanium carbide (TiC) and/or
tantalum carbide (TaC) in addition to WC.
the carbide insert is brazed to the tool holder, indexing is not available,
and after reaching the wear criterion, the carbide insert is reground on a
tool grinder.
ISO specifies three basic grades for cemented carbides according to use:
Stellite
Stellite alloys are a group or a range of cobalt-chromium alloys. They are
designed to be resistant to wear and corrosion. These alloys may also have
some portions of tungsten or molybdenum and some small but critical
amounts of carbon. Stellite is a trademarked name of Deloro Stellite
Company supplying Stellite alloys like Stellite3, Stellite 6, Stellite 12 and
Stellite 21.
The alloy Stellite 100 is mostly used nowadays for cutting tools as it is very
hard and is capable of maintaining a great cutting edge even when
exposed to high temperatures. The alloy is also resistant to processes such
as hardening and annealing that might result from excessive heat. Other
Stellite alloys are manufactured to combine the properties of corrosion
resistance, wear resistance and the ability to tolerate extreme
temperatures.
poppet valves as well as the valve seats for valves. These alloys
revolutionized the exhaust valves of internal combustion engines. The
interval between maintenance of the valves and re-grinding of the valve
seats was lengthened to a significant degree by reducing the erosion of the
valves from hot gases.
The first third of M60 machine gun barrels (starting from the chamber)
and the M2HB machine gun are lined with Stellite. Stellite alloys were also
used to make the shoulders and locking lugs of Voere Titan II rifles.
Stellite alloys are also frequently used to make the cast structure used
for dental prosthesis.
During early 1980s, experiments were conducted in United Kingdom to
see if precision-cast Stellite alloys could be used to create artificial hip
joints as well as other bone replacements.
Stellite alloys have been used to manufacture turning tools for lathes.
Stellite alloys have greater cutting abilities compared to carbon steel tools
as well as some high speed steel tools. They are especially capable of
cutting difficult materials like stainless steel. Improvements in tipped tools
over the years have greatly reduced the use of Stellite alloys in lathes.