Steel and Iron: Production and Properties: Introduction To Materials Engineering

INTRODUCTION TO MATERIALS ENGINEERING
Module 4
Steel and Iron:

Production and Properties
Dept. Metallurgy and Materials Engineering

Prof. Bondan T. Sofyan University of Indonesia
1
Steel: Production and Properties
1. Classification of Metals
2. Steel
3. Iron
4. Steelmaking
a. Indirect Reduction
b. Direct Reduction

2
Classification of Metal Alloys
Metal Alloys
Ferrous Non Ferrous
Steel Cast Iron
Low Alloy High Alloy
Grey Nodular Malleable White

Cast Iron Cast Iron Cast Iron Cast Iron
Low Medium High Stainless
Carbon Carbon Carbon Steel Tool Steel
Steel Steel Steel

Prof. Bondan T. Sofyan University of Indonesia 3
Steel and Iron
• Iron and steel alloy is the most widely
used metals in engineering application,
because:
– It is abundantly available in the earth crust.
– Economical: low processing and refining cost.
– Can be produced in a vast range of
properties, to meet design requirement.

4
Steel vs Iron
• C<2%
• High pitch sound when hit • C>2%
• Bounded C  a or Fe3C • Low pitch sound when hit
lamella • Free C as graphite
• Tmelting > 1550OC • Tmelting 1300–1400 OC
• High strength and ductility • Low strength and ductility (150-
(200-500 MPa, 18-35 %) 300 MPa)
• Malleable • Not malleable
• Long machinary chips • Short machinary chips
• Low yellowish spark • High red spark

5
Steel
• Steel : material which consists of Fe as the
base metal with C addition up to 2 %.
• Carbon is the most important alloying
element in steel.
• Other alloying elements:
– Impurities: Si, P, S, Mn  can’t be removed
from steel.
– Alloying: Cr, Ni, Mo, etc  intentionally
added.

6
7
Classification of Ferrous Alloys
Ferrous
Steel Cast Iron
Low Alloy High Alloy
Grey Nodular Malleable White

Cast Iron Cast Iron Cast Iron Cast Iron
Low Medium High Stainless
Carbon Carbon Carbon Steel Tool Steel
Steel Steel Steel

8
Low Carbon Steel
• C ≤ 0,25 %.
• Microstructure consists of ferrite and pearlite 
soft, ductile and relatively tough.
• Not responsive to heat treatment.
• Application: automobile body, pipe, sheet, etc.

9
Low Carbon Steel
ε
Symbol ASTM Class C Si Mn P S UTS HRB
0.2%
ASTM 0.50 0.040 0.045 270 60

SPCC CR-CQ 0.12 max - 32 min
A366-72 max max max min max
ASTM 0.45 0.035 0.035 270

SPCD CR-DQ 0.10 max - 34 min 50
A619-82 max max max min
ASTM CR- 0.40 0.030 0.030 270

SPCE 0.08 max - 36 min 50
A620-82 DQSK max max max min
10
11
Low Carbon Steel
Posco Steel
Steel with the same

composition, may have different
microstructures and different
properties.
Nippon Steel
12
13
Medium Carbon Steel
• C: 0.25 – 0.6 %
• Lower ductility, higher strength and toughness compared
to low carbon steel.
• Responsive to heat treatment.
• Application: gears, railways, cranckshaft, etc.

High Carbon Steel
• C: 0.6 – 1.2 wt. %
• High strength, high hardness
and low ductility  is heat
treated (hardening + temper)
to increase toughness while
keeping the high strength.
• Microstructure: pearlite +
cementite (Fe3C).
• Application: tool steel, die,
cutting blade.

15
• SKD 11 = D2
Tool Steel
• Composition:
– 1.4-1.6 C; 0.6 Mn max; 0.6 Si max; 11.00-13.00 Cr; 0.3 Ni max; 1.10
V max; 0.7 – 1.2 Mo
• High C, high Cr, V, Mo.
• Hardness 54-61 HRC.
• Coeff. Thermal expansion: 10.4 – 12.2 mm/mK
• Depth hardening: deep
• Air-hardening alloy tool steel, high wear resistance, high surface
hardness, good dimensional stability

Cast Iron
• Cast iron is Fe with C > 2,14 %, with the
microstructure that consists of free carbon as
graphite in pearlitic, ferritic, austenitic,
martensitic or bainitic matrix.
• Other elements: Si, Mn, P and S (trace
elements)
• Alloying elements: Cr, Mo, Cu, Sn, etc to
improve particular properties.

17
Types of Cast Iron
1. Grey Cast Iron (FC)

2. White Cast Iron
3. Malleable Cast Iron
4. Ductile Cast Iron (FCD)
5. Austempered Ductile Iron
(ADI)
Matrix: Ferritic, pearlitic, austenitic,

martensitic, bainitic (austempered).

18
Grey Cast Iron
Ductile Cast Iron Malleable Cast Iron White Cast Iron
Dept.Austempered Ductile
Metallurgy and Materials Iron
Engineering
19
Types of Cast Iron
1. Grey Cast Iron (FC)

2. White Cast Iron
3. Malleable Cast Iron
4. Ductile Cast Iron (FCD)
5. Austempered Ductile Iron
(ADI)
Matrix: Ferritic, pearlitic, austenitic,

martensitic, bainitic (austempered).

Graphite Morphology
a) Flakes
b) Spheroidal
c) Mallaeble

21
Besi Tuang Kelabu (Grey Cast Iron)
(FC/Grey Cast Iron)

• Grafit flakes/serpihan (dua
dimensi)
• Eutektik sell berbentuk kol
(tiga dimensi)
Struktur mikro FC
• max = 10 - 30 kg/mm2
•  < 1,0%
• Mikrostruktur :matriks ferrite
dan flake grafit
Eutektik Cell Besi FC
22
Bentuk Grafit Pada Grey Cast Iron
Type B
Type A
Type D
Type C
Type E

23
Sifat Grey Cast Iron
Mekanik: Fisik dan Kimia:
Elongasi (%) 0.3 – 1.2 Berat jenis:
Kekerasan 130 – 270 Temp. kamar 7.1 – 7.3
brinell
Cair 6.75 –
Kekuatan Getas dan 6.95
bentur lemah
Koef. muai 10 x 10-
Mampu mesin Sangat panas 6/ 0 C
baik

24
Besi Tuang Putih (White Cast Iron)
• Seluruh C hadir dalam bentuk
Cementite, sehingga patahannya
berwarna putih.
• Mengandung Cr untuk mencegah
pembentukan grafit selama
pembekuan dan meningkatkan
stabilitas karbida (Cementite)
• Ada 3 group:
– Nickel Chromium White Irons,
mengandung: 3-5 % Ni, 1-4%Cr
– Chromiun Molybdenum Irons: 11-23
% Cr, 3 % Mo, kadang-kadang Cementite (putih),
ditambahkan Ni atau Cu. Pearlite (gelap)
– 25-28 % Cr White Irons: juga
mengandung Mo dan/atau Ni s/d
1.5%
25
Besi Tuang Mallable (Mampu Tempa)
• Grafit berbentuk kapas / aggregat.
• Hasil temper besi cor putih (waktu
lama = 50 jam)
• Fe3C  3 Fe + C grafit pada 950
oC
• Temper grafit hasil cor (merubah

struktur Fe3C = temper grafit)
• Kadar Si rendah, cegah timbul
grafit
• UTS : 40 – 47 Kg/mm2
• Yield : 28 – 30 Kg/mm2
• Regangan : 15 – 20 %
• Kekerasan : 135 – 155 HB
26
Besi Tuang Nodular (FCD) 1948
Mg : 0,040 – 0,080 % menyebabkan
grafit berubah menjadi bulat
S < 0,010 %, diatas nilai ini akan
bereaksi dulu dengan Mg,
kemudian baru berfungsi sebagai
noduliser.
Penemu :
Henton Morrogh, BCIRA, Inggris
dan Team INCO – USA
 = 45 - 55 kg/mm2
 = 3 – 20 %
Tergantung :
1. Nodularity grafit
2. Jumlah nodul/mm2
3. Komposisi Matriks (ferrite/pearlite)
4. Adanya paduan (Cu, Ni, Mo, dll.)

27
Austempered Ductile Iron (ADI)
• Besi Cor Austemper (FCA) 1970-
an
• Besi cor grafit bulat dengan
matriks ausferit (ferit + austenit).
– ferit berbentuk jarum 
kekuatan
– a u s t e n i t  keuletan
•  mencapai > 100kg/mm2 : ferit
jarum
•  = 4 – 7 % : austenit
• Aplikasi : pengganti komponen
baja cor/tempa

28
Sifat Mekanik Berbagai Besi Tuang
UTS (Kg/mm2) Elongasi (%)
Grey Cast Iron(FC) 10 – 35 <1
Mallable Cast Iron 40 – 47 15 – 20
Nodular Cast Iron 45 – 55 3 – 20

(FCD)
Austempered > 100 4–7
Ductile Iron (ADI)
Vermicular Cast 30 - 40 2-5
Iron
29
30
31
32
33
34
35
36
37
38
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
67
68
EAF & LADLE FURNACE

69
70
71
RH DEGASSING - CONCAST

72
Reheating Furnace & Sizing Press
5) Sizing
Press
7)

73
Hot Rolling Facilities

74
Cold Roll Facilities

75

76

77

Steel and Iron: Production and Properties: Introduction To Materials Engineering

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INTRODUCTION TO MATERIALS ENGINEERING

Steel and Iron:

Dept. Metallurgy and Materials Engineering

Dept. Metallurgy and Materials Engineering

Ferrous Non Ferrous

Steel Cast Iron

Low Alloy High Alloy

Grey Nodular Malleable White

Dept. Metallurgy and Materials Engineering

Dept. Metallurgy and Materials Engineering

Dept. Metallurgy and Materials Engineering

Dept. Metallurgy and Materials Engineering

Steel Cast Iron

Low Alloy High Alloy

Grey Nodular Malleable White

Dept. Metallurgy and Materials Engineering

Dept. Metallurgy and Materials Engineering

ASTM 0.50 0.040 0.045 270 60

ASTM 0.45 0.035 0.035 270

ASTM CR- 0.40 0.030 0.030 270

Steel with the same

Dept. Metallurgy and Materials Engineering

Dept. Metallurgy and Materials Engineering

Dept. Metallurgy and Materials Engineering

Dept. Metallurgy and Materials Engineering

1. Grey Cast Iron (FC)

Matrix: Ferritic, pearlitic, austenitic,

Dept. Metallurgy and Materials Engineering

Ductile Cast Iron Malleable Cast Iron White Cast Iron

1. Grey Cast Iron (FC)

Matrix: Ferritic, pearlitic, austenitic,

Dept. Metallurgy and Materials Engineering

Dept. Metallurgy and Materials Engineering

(FC/Grey Cast Iron)

Dept. Metallurgy and Materials Engineering

Dept. Metallurgy and Materials Engineering

• Temper grafit hasil cor (merubah

Dept. Metallurgy and Materials Engineering

Dept. Metallurgy and Materials Engineering

Grey Cast Iron(FC) 10 – 35 <1

Mallable Cast Iron 40 – 47 15 – 20

Nodular Cast Iron 45 – 55 3 – 20

Dept. Metallurgy and Materials Engineering

Dept. Metallurgy and Materials Engineering

Dept. Metallurgy and Materials Engineering

Dept. Metallurgy and Materials Engineering

Dept. Metallurgy and Materials Engineering

Dept. Metallurgy and Materials Engineering

Dept. Metallurgy and Materials Engineering

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