Chapter 13: Properties and

Applications of Metals
ISSUES TO ADDRESS...
How are metal alloys classified and what are their
common applications?
What are the microstructure and general characteristics of
cast irons?
What are the distinctive physical and mechanical properties of
nonferrous alloys?

Chapter 13 - 1

Classification of Metal Alloys

Metal Alloys

Ferrous
Steels
Steels
<1.4wt%C
<1.4
wt% C

Cast Irons
Cast
Irons
3-4.5 wt%C
3-4.5
wt% C

microstructure: ferrite,
graphite/cementite

T(C)
1600

1400

austenite

1200

+L

L+ Fe3C

1148C
4.30

1000

600
400

727C

800
ferrite

0
(Fe)

Adapted from Fig.

13.1, Callister &
Rethwisch 9e.

Nonferrous

Eutectoid:

0.76

Eutectic:

+ Fe3C

[Adapted from Binary Alloy Phase

Diagrams, 2nd edition, Vol. 1, T. B.
Massalski (Editor-in-Chief), 1990. Reprinted
by permission of ASM International,
Materials Park, OH.]

Fe3C
cementite

+ Fe3C
3

Fig. 11.23, Callister & Rethwisch

9e.

Co , wt% C

6.7

Chapter 13 - 2

Steels
High Alloy

Low Alloy
low carbon Med carbon
<0.25 wt% C 0.25-0.6 wt% C

high carbon
0.6-1.4 wt% C

heat
plain
treatable
Cr,V
Cr, Ni
Additions none
none
none
Ni, Mo
Mo
Example 1010 4310
1040
4340 1095
Hardenability 0
+
+
++
++
TS
0
+
++
+
EL
+
+
0
Name

plain

Uses

auto
struc.
sheet

HSLA

bridges
towers
press.
vessels

plain

crank
shafts
bolts
hammers
blades

pistons
gears
wear
applic.

wear
applic.

tool
Cr, V,
Mo, W
4190
+++
++
-drills
saws
dies

increasing strength, cost, decreasing ductility

stainless
Cr, Ni, Mo
304, 409
varies
varies
++
high T
applic.
turbines
furnaces
Very corros.
resistant

Based on data provided in Tables 13.1(b), 14.4(b), 13.3, and 13.4, Callister & Rethwisch 9e.
Chapter 13 - 3

Refinement of Steel from Ore

Coke
Iron Ore

gas
refractory
vessel
layers of coke
and iron ore
air
slag
Molten iron

Limestone
BLAST FURNACE
heat generation
C+O2 CO2
reduction of iron ore to metal
CO2 + C 2CO
3CO + Fe2O3 2Fe+3CO2
purification
CaCO3 CaO+CO2
CaO + SiO2 + Al2O3 slag

Chapter 13 - 4

Ferrous Alloys
Iron-based alloys
Steels
Cast Irons
Nomenclature for steels (AISI/SAE)
10xx Plain Carbon Steels
11xx Plain Carbon Steels (resulfurized for machinability)
15xx Mn (1.00 - 1.65%)
40xx Mo (0.20 ~ 0.30%)
43xx Ni (1.65 - 2.00%), Cr (0.40 - 0.90%), Mo (0.20 - 0.30%)
44xx Mo (0.5%)
where xx is wt% C x 100
example: 1060 steel plain carbon steel with 0.60 wt% C
Stainless Steel >11% Cr
Chapter 13 - 5

Cast Irons
Ferrous alloys with > 2.1 wt% C
more commonly 3 - 4.5 wt% C
Low melting relatively easy to cast
Generally brittle
Cementite decomposes to ferrite + graphite
Fe3C 3 Fe () + C (graphite)
generally a slow process
Chapter 13 - 6

Fe-C True Equilibrium Diagram

T(C)
1600

Graphite formation
promoted by

1400

Si > 1 wt%

1200

slow cooling

Austenite

+L
1153C
4.2 wt% C

1000

+ Graphite
800

740C
0.65

600

+ Graphite

Fig. 13.2, Callister & Rethwisch 9e.

[Adapted from Binary Alloy Phase
Diagrams, T. B. Massalski (Editor-inChief), 1990. Reprinted by permission of
ASM International, Materials Park, OH.]

Liquid +
Graphite

400
(Fe)

90

C, wt% C

100

Chapter 13 - 7

Types of Cast Iron

Figs. 13.3(a) & (b),
Callister &
Rethwisch 9e.

Gray iron
[CourtesyofC.H.
BradyandL.C.Smith,
graphite flakes
NationalBureauof
Standards,Washington,
weak & brittle in tension DC(nowtheNational
InstituteofStandards
andTechnology,
stronger in compression Gaithersburg,MD]
excellent vibrational dampening
wear resistant
Ductile iron
add Mg and/or Ce
graphite as nodules not flakes
matrix often pearlite stronger
but less ductile

Chapter 13 - 8

Types of Cast Iron (cont.)

< 1 wt% Si
pearlite + cementite
very hard and brittle

heat treat white iron at 800-900C

graphite in rosettes
reasonably strong and ductile

Reprintedwithpermissionofthe
IronCastingsSociety,DesPlaines,IL

Malleable iron

CourtesyofAmcastIndustrialCorporation

White iron

Figs. 13.3(c) & (d),

Callister &
Rethwisch 9e.

Chapter 13 - 9

Types of Cast Iron (cont.)

relatively high thermal conductivity
good resistance to thermal shock
lower oxidation at elevated
temperatures

CourtesyofSinterCast,Ltd.

Compacted graphite iron

Fig. 13.3(e), Callister & Rethwisch 9e.

Chapter 13 - 10

Production of Cast Irons

Fig.13.5, Callister & Rethwisch
9e. (AdaptedfromW.G.Moffatt,G.W.
Pearsall,andJ.Wulff,TheStructureand
PropertiesofMaterials,Vol.I,Structure,p.
195.Copyright1964byJohnWiley&
Sons,NewYork.Reprintedbypermissionof
JohnWiley&Sons,Inc.)

Chapter 13 - 11

Limitations of Ferrous Alloys

1) Relatively high densities
2) Relatively low electrical conductivities
3) Generally poor corrosion resistance

Chapter 13 - 12

Nonferrous Alloys
Cu Alloys

Al Alloys

-low : 2.7 g/cm3

Brass: Zn is subst. impurity
(costume jewelry, coins,
-Cu, Mg, Si, Mn, Zn additions
corrosion resistant)
-solid sol. or precip.
Bronze : Sn, Al, Si, Ni are
strengthened (struct.
subst. impurities
aircraft parts
(bushings, landing
& packaging)
gear)
Mg Alloys
NonFerrous
Cu-Be:
-very low : 1.7 g/cm3
Alloys
precip. hardened
-ignites easily
for strength
-aircraft, missiles

Ti Alloys

Refractory metals
-relatively low : 4.5 g/cm3
-high melting Ts
vs 7.9 for steel
Noble metals -Nb, Mo, W, Ta
-reactive at high Ts -Ag, Au, Pt
-oxid./corr. resistant
-space applic.
Based on discussion and data provided in Chapter 13, Callister & Rethwisch 9e.
Chapter 13 - 13

Summary
Ferrous alloys:
-- steels
-- cast irons
Non-ferrous alloys:
-- Cu, Al, Ti, and Mg alloys; refractory alloys; and noble metals

Chapter 13 - 14

ANNOUNCEMENTS
Reading:
Core Problems:
Self-help Problems:

Chapter 13 - 15