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MATERIALS SCIENCE
CHAPTER 4
Ferrous alloys
include steels and
cast irons.
Low Alloy
steels are
usually
considered
to be those
containing a
total of less
than 5% of
such added
constituents.
5.2 CLASSIFICATION OF FERROUS ALLOYS
Generally, carbon is the most important commercial
steel alloy. Increasing carbon content increases
hardness and strength and improves hardenability.
But carbon also increases brittleness and reduces
weldability because of its tendency to form
martensite. This means carbon content can be both a
blessing and a curse when it comes to commercial
steel.
Advantages:
• Posses good formability
• Posses good weldability: best of all metals :
Note: As a percentage of carbon increases there is a
tendency for the metal to harden and crack.
• Lowest cost and should be considered first
• Rated at 55-60% machinability (soft and drags which
builds
up heat on the tool.
Typical Uses:
• 0.1- 0.2%: Automobile panels, rivets, nails, wire, and
pipelines
• 0.2 - 0.3%: concrete reinforcing bars, structural shapes
Low Carbon Steel combine with 10% of other alloying
elements such as Copper, Vanadium, Nickel, and
Molybdenum produced High Strength Low Alloy (HSLA)
steels and possess higher strength than plain low
carbon steels. They are ductile, formable, and
machinable.
Typical Uses:
• 0.3-0.4 : lead screws, gears, spindles, shafts, and machine
parts.
• 0.4-0.5: crankshafts, gears, axles, and heat-treated
machine parts.
• 0.6-0.7: called “low carbon tool steel” and is used where a
5.3.4 High Carbon Steels
Over 0.8% Carbon and less than 1.4% Carbon are the
hardest, strongest, and yet least ductile of the carbon
steels.
Disadvantages:
Advantages:
• Hardness is high
• Wear resistance is high
Typical Uses:
TEE pipe
5.4.4 Malleable Cast Irons
• Malleable cast iron is produced by the heat treatment of
white cast irons.
• Heating white iron at temperatures 800 c to 900 c for 50
hours in a neutral atmosphere (to prevent oxidation)
causes a decomposition of the cementite, forming
graphite in the form of clusters/ rossettes surrounded by
a ferrite or pearlite matrix depending on cooling rate.
• The mechanical characteristic of malleable cast iron is
similar to nodular cast iron and give higher strength and
more ductility and malleability. The silicon content is low.
MALLEABLE THE MICRISTRUCTURE
CAST OF MALLEABLE
IRON CAST IRON
PRODUCTS
CLAMPS
NONFERROUS ALLOYS
The term non-ferrous alloys are used for those alloys
which
do not have iron as the base element. Generally, the
non-
ferrous alloys commonly used in engineering
application are
The advantages
Aluminium ofCopper
alloys, Ferrous alloysMagnesium
alloys, over non-ferrous
alloys,
alloys arealloys
Titanium as follows:
etc.
a) Generally greater strengths.
b) Generally greater stiffness, i.e. larger values
of
Young’s Modules.
c) Better for welding.
The advantages of Non-ferrous alloys over ferrous
alloys are
as follows:
(3) Controlled
decomposition of the SSSS to
form a finely dispersed
precipitate, usually by ageing
for convenient times and
temp. (T2) where diffusion is
appreciable – β phase starts
to form.
Effects of Ageing on
Ageing curve: Strength
• Plot of strength or hardness vs. aging time.
• As aging time increases alloy becomes stronger harder
and less ductile.
• Over-ageing
decreases
strength & hardness.
5.5.2 Copper And Its Alloys
(Chemical symbol Cu) - Element No. 29 of the
periodic system, atomic weight 63.57. A
characteristically reddish metal of bright luster,
highly malleable and ductile and having high
electrical and heat conductivity; melting point
1083°C; boiling point 2336°C; specific gravity 8.94.
Universally used in the pure state as sheet, tube,
rod and wire and also as alloyed by other elements
as an alloy with other metals.
i. Brasses
Copper base alloys in which zinc is the principal
added element. Brass is harder and stronger than
either of its alloying elements copper or zinc; it is
malleable and ductile; develops high tensile with
cold-working and not heat treatable for purposes of
hardness development.
Types of brasses are as follows:
• Gilding Brass: 85% copper and 15% Zn is used for jewellery
because it has a colour resembling that of gold.
• Cartridge brass: 70% copper and 30% Zn is used in the
production of cartridge and shell cases.
• Muntz metal: 60% copper and 40% zinc is used for castings and
hot-worked products. High strength brasses are developed
from this by adding other elements such as 0.8% Pb .
For example;
Tungsten (W), melts at 3,410°C, which is more
than double that of iron and ten times that of
lead.
Typical applications:
extrusion dies, structural parts in space vehicles,
incandescent light filaments, x-ray tubes, and welding
electrodes.
REFRACTORY METAL (Cont…)
- Excellent strength at high temperatures.
Even when heated to 10000C tungsten rocket nose
cones still have twice the tensile strength iron has at
room temperature.
Properties
- Highly resistant to corrosion or oxidation,
especially
at elevated temperatures
-Soft and ductile.
-They tend to be very valuable.
Typical applications
-Jewellery , dental restoration materials, coins,
catalysts, and thermocouples.
TQ