Lecture 9

Appls and Proc. of Metal Alloys

IME-218 Material Teknik
Dr. Ir. Bagus M. Arthaya, M.Eng
Teknik Mekatronika
Fakultas Teknologi Industri
Universitas Katolik Parahyangan

Edited by: Bagus Arthaya Introduction to Eng. Materials

TYPE OF METAL ALLOYS

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Introduction
Metal alloys are often grouped into 2 classes:
1. Ferrous alloys
the alloys of which iron is the prime constituent
2. Nonferrous alloys
Ferrous alloys are produced in larger quantities
than others, because:
1. Iron-containing compounds exist in abundant
quantities
2. May be produced using relatively economical
3. May be tailored to have a wide range of mechanical
properties

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Classification Scheme for the Various Ferrous Alloys

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Steels (usually less than 1.0%wt C)

Steels Characteristics Applications

Relatively soft and weak, automobile body components,

Low-Carbon Steels
but have outstanding sheets used in pipelines,
(less than 0.25%wt C)
ductility & toughness buildings, bridges, tin cans

Those need a combination of high

Medium-Carbon Steels Stronger than low-carbon strength, wear resistance, and
(about 0.25-0.60%wt C) steels, but less ductile toughness, ex. railway wheels,
crankshafts, machine parts

Hardest, strongest, yet They are wear resistant,

High-Carbon Steels
least ductile of all carbon ex. cutting tools and dies for
(about 0.60-1.4%wt C)
steels forming materials.

Stainless Steel Automotive exhaust components,

Highly resistant to
(predominant alloying chemical & food processing
corrosion
element is 11%wt Cr) equipment
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Cast Irons (usually more than 2.1%wt C)

Cast Irons Characteristics

Gray Iron Characteristic: very effective in damping vibrational energy

The result of adding small amount of Magnesium or Cerium to gray

Ductile (Nodular)
iron
Iron
Characteristics: stronger & more ductile than gray iron
The result of rapidly cooling cast iron
Characteristics: extremely hard, but very brittle (virtually
White Iron unmachinable)
Application: rollers in rolling mills (which need to have a very hard
and wear-resistant surface)
The result of re-heating white iron and cooling it down.
Malleable Iron Characteristics: relatively high strength and appreciable ductility
(malleability)

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 Commercial Cast
Irons

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 Nonferrous Alloys: Copper
Very soft and ductile, difficult to machine
Has almost unlimited capacity to be cold worked
Highly resistant to corrosion

Copper + Zinc = Brass

The higher zinc content results in a harder and
stronger phase.

Copper + (tin, aluminum, silicon, nickel) = Bronze

Stronger than brasses.
Sill have a high degree of corrosion resistance.

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 Nonferrous Alloys: Aluminum

Relatively low density (compared to steel)

High electrical & thermal conductivities
Resistance to corrosion

These alloys are easily formed, because of

high ductility.

Chief limitation: low melting temperature.

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 Nonferrous Alloys: Magnesium & Titanium
Magnesium
Very low density, thus it is used where light
weight is an important consideration.
At room temperature: difficult to deform, thus
most fabrication is done by casting.
Especially susceptible to corrosion (rentan
terhadap korosi) in marine environment.

Titanium
Low density.
High melting point.
Extremely strong, but highly ductile.
Major limitation: chemical reactivity with
other materials at elevated temperature.

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THERMAL PROCESSING OF METALS

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 Introduction

The phenomena occurring in metals and alloys at

elevated temperatures have been discussed
previously, such as recrystallization, the forming of
spheroidite, tempered martensite, etc.

Some of these processes will be discussed in more

detailed:
1. Annealing
2. Heat treating of steels
3. Precipitation hardening

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 Annealing Processes
Annealing: heat treatment in
which a material is exposed to
an elevated temperature for an
extended time period and then
slowly cooled.
Heating Cooling

Holding at
that
temperature
The purpose:
1. Relieving stresses.
2. Increasing softness, ductility and
toughness of a previously strain-hardened
metal.
3. Producing a specific microstructure.
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Annealing of Ferrous Alloys

A1 lower critical temperature

A3 and Acm upper critical temperature

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 Normalizing
Steels that have been plastically deformed consist
of irregular and large grains.

Normalizing is used to refine the grains (decrease

the average grain size).

After sufficient time to allow the alloy transforming

to austenite (austenitizing), the treatment is
terminated by cooling in air.
Result: fine pearlite
Purpose: enhance toughness

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 Full Anneal

Full annealing is utilized in low and medium

carbon steels that will be machined or will
experience extensive plastic deformation.

After heating to the required temperature, the

alloy is furnace cooled.

Result: coarse pearlite

Purpose: create a soft and ductile alloy

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 Normalizing & Full Anneal
in CCT Diagram

Fine pearlite is
tougher than
coarse pearlite.

Coarse pearlite is
relatively soft
and ductile.

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 Heat Treatment of Steels
Conventional heat treatment to produce martensitic
steels involve rapid cooling of an austenitized
specimen.

The optimum properties of a steel that has been

quenched and then tempered can only be obtained if
high content of martensite is formed during quenching.

The successful quenching to produce a martensitic

steel:
1. The composition of the alloy determines its hardenability
2. Type and character of quenching medium (media
pendingin)
3. Size and shape of the specimen

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 Hardenability
Hardenability ability of an alloy to be hardened
by the formation of martensite as a result of a given
heat treatment.
(it is different with hardness, which is the ability to resist indentation)

High hardenability means that the steel alloy

hardens (form martensite) not only at the surface
but to a large degree throughout the entire
interior.

Measure hardenability Jominy End-Quench Test

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 Jominy End-Quench Test

The hardness measured form steb (b) is plotted to the Hardenability Curves.

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 Rockwell Hardness Test

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Hardenability Curves

A highly hardenable steel retains large hardness values

for relatively long distances.
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Hardenability
Curves

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 Influence of Quenching Medium
The most common quenching media:
Water, oil and air
Water produces the most severe (rapid)
quench while air is the least severe.
Water is too severe as it may produce
cracking and warping.
Oil quenches are suitable for many alloy
steels.

Increasing the velocity of the

quenching medium across the
specimen surface enhances the
quenching effectiveness.

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Influence of Specimen Size

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 Influence of Geometry

The rate of cooling for a particular quenching

treatment depends on the ratio of surface area
to the mass of the specimen.

The larger the ratio, the more rapid will be the

cooling rate and, consequently, the deeper the
hardening effect.

Irregular shapes have larger ratio than regular

and rounded shapes.

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 Precipitation Hardening

Precipitation hardening: the appropriate heat treatments

to form extremely small uniformly dispersed particles of a second
phase within the original phase matrix.
pemanasan dengan suhu yang sesuai untuk membentuk partikel-
partikel yang sangat kecil dan tersebar dengan seragam.

Purpose: meningkatkan kekuatan dan

kekerasan beberapa campuran logam

Precipitation hardening is accomplished by

two steps:
1. Solution heat treating
2. Precipitation heat treating

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 Hypothetical Phase Diagram
(as an example for Precipitation Hardening)

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 Precipitation Hardening
Solution Heat Treating
Heating the alloy to a temperature within the field (T0).
Waiting until all phase is dissolved.
Rapid cooling (quenching) to temperature T1, results in
supersaturated .

Precipitation Heat Treating

The supersaturated solid solution is heated to an
intermediate temperature (T2).
phase begins to form as finely dispersed particles.
After an appropriate time at T2, the alloy is cooled to the
room temperature.

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 Schematic Plot Showing Heat Treatments for
Precipitation Hardening

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 TUGAS

Pelajari Bab 13, 14-15, 16

Bab 13 Applications and Processing of Ceramics
Bab 14 Polymer Structures
Bab 15 Charteristics, Applications and Processing
of Polymers
Bab 16 Composites

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 End of presentation

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