ME 140 - WORKSHOP TECHNOLOGY

Introduction
ME – 140 WORKSHOP TECHNOLOGY
FALL 2009

Classification Instructor

Asst. Prof. Ejaz Yaqub

Ferrous
Asst. Prof. Rizwan Arshad
Metals
Lecture 1 – Part II – Engineering Materials
Non Ferrous
Department of Mechanical & Aerospace Engineering
Metals
Institute of Avionics & Aeronautics (IAA)
AIR University, E-9 Islamabad

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Introduction

• Engineering materials are used to manufacture products

Introduction • Type of material decides the kind of manufacturing

process that will be used to get the desired shape
Classification • It is important to know what kind of materials are available

Ferrous • Material Properties - physical, chemical, mechanical,

Metals thermal, optical, electrical etc
Non Ferrous
Metals • A design engineer must have knowledge of engineering
materials, their properties and applications to meet the
functional requirements of the design product

• Additionally, one must understand the effects of manufacturing

processes and heat treatment on the properties of the
engineering materials

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Examples of products in different Engg. Materials

Introduction

Classification

Ferrous [Stainless steel rods, [Malleable cast iron pipe fittings

Salem Steel Trading Co, India] , SDH China]
Metals

Non Ferrous
Metals

[Pure Aluminum Pellets, [Pure Copper wire]

EPSI Metals, Oregon, USA]
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Examples of products in different Engg. Materials

Introduction

Classification

Ferrous [Plastic bottles] [A section of yew branch of wood]

Metals

Non Ferrous
Metals

[Glass] [Ceramic tiles]

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Materials Classification

Introduction

Classification

Ferrous
Metals

Non Ferrous
Metals

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Iron (Fe)
• Ferrous materials have iron as their main constituent

• Pure Iron is a soft metal having crystalline structure

Introduction
• Microstructure of pure iron looks like a map having fields
separated by hedges
Classification
Shape looking like fields - Crystals
Ferrous Line like hedges - Where crystals join
Metals
• Average size of crystal – depends upon the metal treatment
Non Ferrous
Metals
Crystal

Crystal boundary

[Schematic diagram. Microstructure of pure iron]

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Occurrence
• Iron is found naturally in the form of ores

• Iron ores chiefly exist in the form of oxides and carbonates

Introduction
• Iron ores are cleaned from earthly impurities before
processed for getting iron
Classification

Ferrous
Metals

Non Ferrous
Metals

[Main types of Iron Ore]

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Iron Ores

Introduction

Classification

Ferrous [Hematite (blood ore) from the [Limonite]

Metals US state of Michigan]

Non Ferrous
Metals

[Magnetite from the Kola Peninsula, Russia] [Siderite from Poland]

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Production of Ferrous Materials

Ore

Blast Furnace

Introduction Smelting, Reduction

Cupola Pig Iron Reverberatory Furnace

Classification Puddling
Remelt

Bessemer Open Hearth Electric Wrought Iron

Ferrous Converter
Metals
Arc High Frequency
Cast Iron Furnace Furnace
Non Ferrous Blister Steel
Metals
Remelt Forge

Crucible Shear
Steel Steel
Steel for general use

Tool Steel

[Diagram showing production of the materials in the iron and steel group]
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Main Types of Iron

Pig Iron

Introduction

Wrought Plain Carbon

Classification Cast Iron Alloy Steels
Iron Steels

Ferrous Dead Carbon steels

Metals High speed
Low Carbon steels
Grey cast iron
Non Ferrous Medium Carbon steels Stainless
Metals White cast iron
High Carbon steels
Ductile cast iron

Malleable cast iron

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Pig Iron (Carbon Content 3.5% – 4.5%)

• Smelting and reduction of iron ore is
carried out to produce pig iron in a tall
structure call Blast furnace
Introduction
• Blast furnace is charged with ore, small
quantities of coke and lime stone
Classification
• Coke provide fuel – provides heat
Ferrous necessary to reduce iron oxide to iron
Metals
• Limestone serves as flux – combines with
Non Ferrous
Metals nonmetallic part to produce slag

• Hot air is blown into lower portion via the

tuyeres

• Slag over molten iron is tapped of from [Blast Furnace]

the hole and molten iron from hearth

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Pig Iron (Carbon Content 3.5% – 4.5%)

• Molten pig iron can be further used in following ways
ƒ Cast in pig beds
ƒ Cast in pig casting machine
Introduction ƒ Transferred in hot metal ladles direct to an
adjacent steelmaking process
Classification • Pig iron acts as the raw material for production of all
kinds of cast iron and steel products
Ferrous
Metals

Non Ferrous
Metals

[Foundry pig iron. Courtesy: Hui [Double Strand Pig Casting Machine at
Cheng, China] Maryland Pig Co..]
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Types of Pig Iron (on the basis of combined and
free form of carbon)
• Grey pig iron (Grades 1, 2 & 3)
- soft type of pig iron
Introduction ƒ Approx. 3% carbon in free form (i.e., graphite form)
ƒ Approx. 1% carbon in combined form
Classification
• White pig iron (Grades 4)
- hard and strong
Ferrous
Metals
ƒ Contains almost all of the carbon in the combined form
Non Ferrous
Metals • Mottled pig iron (Grade 5)
- average hardness and mottled appearance

ƒ Between the grey and white pig iron

ƒ The free and combined forms of carbon are in almost
equal proportion in mottled pig iron

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Cast Iron

• Cast iron is basically an alloy of iron and carbon

• Obtained by re-melting pig iron with coke, limestone and

Introduction steel scrap in a furnace known as Cupola

Classification • Carbon content in cast iron varies from 2% – 4.5%

• Impurities of silicon, manganese, phosphorus

Ferrous
Metals and sulphur elements are present

Non Ferrous • Properties

Metals ƒ Very brittle and weak in tension
ƒ Low cost, good casting characteristics,
ƒ High compressive strength, high wear resistance
ƒ Excellent machinability

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Producing Cast Iron

• Obtained by re-melting pig iron with coke, limestone and

steel scrap in a furnace known as cupola
Introduction
• Coke fire is lit first at the bottom.
Classification
• Cupola is charged by adding alternate layers of coke and pig
iron along with limestone
Ferrous
Metals
• Pig iron is mixed with a set proportion of iron and steel scrap
Non Ferrous
Metals • Proportion depends upon the desired quality of melt

• When charge has burnt up, the blast is gradually increased

and the cupola is closed

• Iron melts and sinks to the bottom of the furnace

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Introduction

Classification

Ferrous
Metals

Non Ferrous
Metals

[A cupola furnace in operation at Wayne

State University, in Detroit, Michigan]

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Grey Cast Iron

• Grey cast iron is grey in colour due to the carbon being

in the form of graphite (C in free form in iron)
• Produced in cupola furnace by refining pig iron
Introduction
• Composition
Classification C = 2.5 to 3.8%.
Si = 1.1 to 2.8 %
Mn = 0.4 to 1.0%
Ferrous
Metals P = less than 0.15%
S = less than 0.1%
Non Ferrous Fe = Remaining
Metals

[Typical structure of grey cast iron]

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Grey Cast Iron

• Properties

1. When fractured it gives grey color.

Introduction 2. Easily casted
3. Easily machined
4. Lowest melting of ferrous alloys.
Classification 5. High vibration damping capacity.
6. High resistance to wear.
Ferrous 7. High fluidity and hence can be casted into complex
Metals shapes and thin sections.
8. High compressive strength.
Non Ferrous
Metals 9. Low tensile strength.
10. Low ductility and low impact strength as compared
with steel

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Grey Cast Iron

• Applications
1. Machine tool structures such as bed, frames, column
2. Household appliances etc
Introduction 3. Gas or water pipes for under ground purposes.
4. Man holes covers
Classification 5. Piston rings
6. Rolling mill and general machinery parts
7. Cylinder blocks and heads for I.C. engines
Ferrous
Metals 8. Frames of electric motor
9. Ingot mold
Non Ferrous 10. General machinery parts
Metals 11. Sanitary wares
12. Tunnel segment

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White Cast Iron

• White color - carbon in combined form as iron carbide

• Hardest constituent of iron
• Produced by casting against metal chills or by regulating
Introduction analysis
• The chills are used when a hard and wear resistance surface
Classification is desired for products such as for wheels, rolls crushing jaw,
crusher plates
Ferrous
Metals • Composition
C = 3.2 to 3.6%
Non Ferrous Si = 0.4 to 1.1 %
Metals Mg = 0.1 to 0.4%
P = less than 0.3%
S = less than 0.2%
Fe = Remaining

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White Cast Iron

• Properties
1. Freshly broken surface shows a bright white fracture
2. Very hard due to carbon chemically bonded with iron
Introduction as iron carbide (Fe3C)
1. Brittle
2. Excellent abrasive wear resistance
Classification 3. Extremely hard, therefore it is very difficult to machine
4. Solidification range is 2650-2065°F
Ferrous 5. Shrinkage is 1/8 inch per foot
Metals 6. High tensile strength
7. Low compressive strength
Non Ferrous
Metals

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White Cast Iron

• Applications

1. For producing malleable iron castings

Introduction
2. For manufacturing those component or parts which
Classification require a hard, and abrasion resistant surface such as
rim of car
Ferrous
Metals 3. Railway brake blocks

Non Ferrous
Metals

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Ductile Cast Iron

• Small quantities of magnesium or cerium added to cast iron

• Graphite content is converted into spheroidal or nodular
Introduction form
• It is well dispersed throughout the material
Classification

Ferrous • Composition
Metals Carbon = 3.2 to 4.2%
Silicon = 1.0 to 4.0 %
Non Ferrous
Metals Magnesium = 0.1 to 0.8%
Nickel = 0.0 to 3.5%
Manganese = 0.5 to 0.1%
Iron = Remaining

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Ductile Cast Iron

• Properties
1. High fluidity
2. Excellent castability, strength,
Introduction 3. High toughness, excellent wear resistance
4. Pressure tightness,
5. Weldability and higher machinability in comparison to
Classification grey cast iron.

Ferrous
Metals

Non Ferrous
Metals

[Ductile cast iron (Ferritic matrix), Courtesy: Toa Koki Ko Ltd. Japan]
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Introduction

Classification

Ferrous
Metals

Non Ferrous
Metals

[(a) Schematic diagram of spheriodal cast iron (b)

Ductile iron microstructure at 100x. Note carbon islanding effect around nodules,
Courtesy: Apex Metal Co Ltd.]

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Introduction

Classification

Ferrous
Metals

Non Ferrous
Metals

[Comparison among Grey, White and Spherodidal Cast Iron]

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Malleable Cast Iron

• A malleable metal is one easily spread or flatten under
pressure or hammering

Introduction • Produced by White heart and Black heart process

• Name given due to colour of fracture given by castings

Classification produced by each method

Ferrous
Metals

Non Ferrous
Metals

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Malleable Cast Iron

• White heart
- Castings consisting of all carbon in combined form
are packed in iron or steel boxes
Introduction
- These boxes are surrounded with a mixture of new and
used haematite ore
Classification
- Boxes heated from 900 to 950 deg. C
Ferrous
Metals - Temperature maintained for several days
Non Ferrous
Metals - During this time part of carbon is oxidised and remainder is
dispersed in small specks through out the structure

- Heating period is followed by very slow cooling for several

days

- Resulting casting is tough and can withstand hard treatment

without fracture
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Wrought Iron
• Produced in a reverberatory furnace

• Wrought iron is produced by Puddling process

Introduction
• Puddling leads to the oxidation of nearly all carbon and other
elements from pig iron
Classification
• Furnace hearth is lined with iron oxide, grey pig iron, and
Ferrous and millscale (oxide) are fed into it
Metals
• Slag is formed when melting is complete
Non Ferrous
Metals
• Slag is stirred into the melt and more millscale is added

• This leads to the oxidation of carbon and other elements

• After oxidation the iron becomes stiffer and pasty in form

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Producing Wrought Iron

• Assumed approximately as purest iron - 99.5% iron.

• Contains a large number of minute threads of slag lying
parallel to each other giving the metal a fibrous appearance
Introduction when broken.
• Said as a mechanical mixture of very pure iron and a
Classification silicate slag.
• Also be said as a ferrous material, aggregated from a
solidifying mass of pasty particles of highly refined metallic
Ferrous
Metals iron with which a minutely and uniformly distributed quantity
of slag is incorporated without subsequent fusion.
Non Ferrous • Composition
Metals C = 0.02 – 0.03%
P = 0.05 – 0.25%
Si = 0.02 – 0.10%
S = 0.008 – 0.02%
Mn = 0.0 – 0.02%
Slag = 0.05 – 1.5%
Fe = remainder
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Producing Wrought Iron

Introduction

Classification

Ferrous
Metals

Non Ferrous
Metals

[Reverberatory Furnace for producing wrought iron]

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Wrought Iron

Introduction

Classification

Ferrous
Metals

Non Ferrous
Metals

The microstructure of wrought iron, showing dark slag inclusions in ferrite (iron)

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Wrought Iron
• Properties
1. Easily shaped by hammering, pressing, forging, etc.
2. It is never cast and it can be easily bent when cold.
Introduction 3. It is tough and it has high ductility and plasticity
4. Forged and welded easily. High resistance towards
corrosion.
Classification 1. It can accommodate sudden and excessive shocks loads
2. High resistance towards fatigue
Ferrous 3. Ultimate tensile strength - 2,500 kg/cm2 - 5,000 kg/cm2
Metals 4. Ultimate compressive strength - 3,000 kg/cm2.
5. Can be elongated considerably by cold working.
Non Ferrous
Metals 6. High electrical conductivity.
7. Melting point - 1530°C.
8. It has elongation 20% in 200 mm in longitudinal direction
and 2–5 % in transverse direction.
1. Its poison’s ratio is 0.30.
2. It can be easily formed when cold, without the outer side
cracking at the formed portion.

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Wrought Iron
• Applications

1. Making chains, crane hooks, railway couplings,

Introduction 2. Water and steam pipes.
3. Plates, sheets, bars, structural works etc.
Classification

Ferrous
Metals

Non Ferrous
Metals

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Steel
• Alloy of iron and carbon - carbon content max. upto 1.5%

• Upto 1.5 %Carbon occurs in the form of iron carbide having

Introduction the ability to increase hardness and strength of the steel

• Steels are classified as,

Classification • Plain Carbon Steel
• Alloy Steels
Ferrous
Metals

Non Ferrous
Metals

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Plain Steels

• Dead Mild steel

• Carbon content – 0.1 -0.125 %
• Applications: wire rod, thin sheets, solid drawn tubes etc.
Introduction
• Mild Steel
Classification • Carbon content – 0.15 – 0.3 %
• Applications: boiler plates bridge work, structural sections
Ferrous
Metals • Medium Carbon Steel
• Carbon content – 0.3 – 0.5 %
Non Ferrous • Applications: axles, drop forgings, high tensile tubes
Metals
• Carbon content – 0.5 – 0.7 %
• Applications: springs, locomotive tyres, , hammers etc

• Carbon content – 0.7 – 0.9 %

• Applications: shear blades, wood chisels etc.

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Plain Steels
• High Carbon Steel (Cast Steel, Carbon Tool Steels)

• Carbon content – 0.9 – 1.1 %

Introduction • Applications: cold chisels, press dies, punches,
screwing dies, wood working tools
Classification • Carbon content – 1.1 – 1.4 %
• Applications: razors, hand files, drills, gauges,
Ferrous metal cutting tools
Metals

Non Ferrous
Metals

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Alloy Steels
• High Speed Steel (HSS)

• 18% tungsten, 4% chromium and 1 % vanadium,

Introduction 0.8 carbon and remaining iron.

• Name given since these steels can be operated as cutting

Classification tools at high speeds

Ferrous • Cutting tool speed is 2 to 3 times higher than HCS cutting

Metals tool
Non Ferrous
Metals • Steels have the property of retaining their hardness even
when heated to red heat

• Generally used for making lathe cutting tools, planner

cutting tools, shaper cutting tools, slotting cutting tools,
drills, reamers, broaches, milling cutter and punches.

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Alloy Steels
• Stainless Steel

• Contains chromium together with nickel as alloy and

Introduction rest is iron

• Minimum chromium content of 12% for film formation

Classification
• 18% is sufficient to resist the most severe atmospheric
Ferrous corrosive conditions
Metals

Non Ferrous
Metals

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