MAE 3344-001

Introduction to Manufacturing Engineering

Metal Alloys: Chapter 4

Ferrous Metals: Chapter 5
Nonferrous Metals: Chapter 6

Sunand Santhanagopalan
Multi-Scale Energy Systems (MuSES) Laboratory
Mechanical & Aerospace Engineering
University of Texas at Arlington
 Outline 2

Metal Alloys
 Alloy Structure 3

• Pure metals have limited properties

• Enhance by alloying—two or more chemical elements, at least one metal
• Solid solution
• Substitutional – brass (copper-zinc) alloy
• Interstitial – steel (iron-carbon) alloy
• Intermetallic compounds – Ti3Al, Ni3Al
• Two phase systems
• Second phase particles obstacles to dislocation movement
• Generally stronger, less ductile than solid solution
• E.g. lead added to copper in molten state (a)
• Most metals in engineering applications are alloys
Phase Diagrams – Pure Metal 4
Phase Diagrams – Alloy 5
Phase Diagrams – Eutectic Alloy 6
Phase Diagrams – Eutectic Alloy 7
Phase Diagrams – Eutectic Alloy 8
Phase Diagrams – Iron Carbon 9
Phase Diagrams – Iron Carbon 10
Phase Diagrams – Iron Carbon 11
 Effects of Alloying Elements in Iron 12

Main effect
• Shift eutectoid temperature
• Raised or lowered depending on alloying element
• Lower—increase austenite (γ iron) range
• Nickel—fcc—austenite former
• Chromium, molybdenum—bcc—ferrite stabilizers
• Shift eutectoid composition
• Always lower than 0.77%
• Also shift phase boundaries
 Heat Treatment – Ferrous Alloys 13

Structures
• Pearlite—cooling rate—fine or coarse lamellae
• Spheroidite—pearlite held at eutectoid temp—cementite lamellae transform
to spheroids
• Bainite—high cooling—fine microstructure, stronger, more ductile than
pearlite, same hardness
• Martensite—austenite quenched—fccbcc—hard and brittle, low
toughness, volume change
• Retained austenite—quench temp insufficiently low—dimensional
instability, cracking, lower hardness, strength
• Tempered martensite—heating process to reduce hardness, improve
toughness
Processes
• Annealing
• Quenching
• Tempering
Phase Transformations 14

Cooling curve
 MAE 3344-001

Introduction to Manufacturing Engineering

Metal Alloys: Chapter 4

Ferrous Metals: Chapter 5
Nonferrous Metals: Chapter 6

Sunand Santhanagopalan
Multi-Scale Energy Systems (MuSES) Laboratory
Mechanical & Aerospace Engineering
University of Texas at Arlington
 Production of Iron and Steel 16

Raw Materials
• Iron-ore
• Coke
• Limestone (calcium carbonate) or dolomite (calcium magnesium carbonate
ore)
 Iron Making 17

• Charge furnace—3 raw materials dumped into

blast furnace—lined with heat-resistant
refractory bricks
• Melted in reaction at 3000°F
• 2000°F air blasted into furnace through
nozzles (tuyeres)—increase temperature—
coke alone not sufficient
• Oxygen reacts with carbon results in carbon
monoxide
• Carbon monoxide reacts with iron oxide gives
iron
• Molten metal accumulates at bottom of
furnace
• Impurities float to top
• Molten metal (pig iron/hot metal) drawn off
(tapped) every 4-5 hours into ladle cars
 Steel Making 18

Electric Furnace
• Heat source—continuous electric arc between electrodes and charged metal
• Temperatures up to 3500°F
• Scrap carbon, limestone dropped into furnace
• Electrodes heat metal in about 2 hours
• Power turned off
• Molten metal poured into ladle
• Capacity 60-90 tons of steel per day
• Induction type for smaller quantities or to remelt metal for casting
 Steel Making 19

Basic-oxygen furnace—fastest and most common

• 200 tons molten pig iron and 90 tons scrap charged into vessel (some up to 350 tons)
• Oxygen agitation refines molten metal—oxidation processiron oxide
• Oxide reacts with carbon to produce CO and CO2
 Casting Ingots 20

Continuous-casting Continuous strip casting

 Steel Classifications 21

• Carbon and Alloy Steel

• Stainless Steel
• Tool and Die Steel
 Steel Designations 22

American Iron and Steel Institute (AISI) and Society of Automotive Engineers
(SAE)
• 4 digit designation
• First two digits—alloying elements
• Last two digits—carbon content
American Society for Testing and Materials (ASTM)
• Incorporates AISI and SAE designation, includes standard specification
• Ferrous metals—”A” followed by usually 3 numbers
Unified Numbering System (UNS)
• Letter indicating alloy class followed by 5 digits indicating chemical
composition
• G—AISI and SAE carbon and alloy steels
• J—cast steels
• K—miscellaneous steels and ferrous alloys
• S—stainless steels and superalloys
• T—tool steels
• E.g.—G41300 for AISI 4130 alloy steel; T30108 for AISI A-8 tool steel
 Carbon Steels 23

Generally classified by carbon content

• Low-carbon (mild) steel (< 0.30% C)
• Components that don’t require high strength
• Common industrial products—bolts, nuts, sheets, plates, tubes
• Medium-carbon steel ( 0.30 to 0.60% C)
• Higher strength
• Machinery, automotive & agricultural equipment parts (gears, axles, connecting rods,
crankshafts), railroad equipment, parts for metalworking machinery
• High-carbon steel (> 0.60% C)
• High strength, hardness, wear resistance
• Cutting tools, cable, music wire, springs, cutlery
• Usually heat treated and tempered after part manufacture
• Resulfurized carbon steel (11xx), rephosphorized and resulfurized carbon
steel (12xx)
• Sulfur and phosphorous added to improve machinability
Nonferrous Alloys 24
Nonferrous Alloys 25