JASHORE UNIVERSITY OF SCIENCE AND TECHNOLOGY (JUST)

IPE- 2203: Engineering Materials II (3 credit hours)

Dr. Md Mahfuzur Rahman

Assistant Professor, Dept. of IPE
October, 2022
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Intended Learning Outcomes (ILOs)
❖ Review of previous class
• Classification and Properties of Iron and Steels

– ILO 1: Products and forms of steel

– ILO 2: Classifications, applications, and properties of steels

– ILO 3: Classification, properties and uses of cast irons

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Steel Product Forms

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Steel Product Forms
Wrought Products
Cold formed products Tubular products
✓ Cold drawn shapes (welded or seamless)
✓ Cold finished bars ✓ Tube (pressure, structural, mechanical)
✓ Pipe (standard, line, oil, water, pressure)
Hot rolled products
Tin mill products
✓ Flats
✓ Bars and shapes
✓ Small angles, channels, and tees ✓ Sn or Zn plated
✓ Concrete reinforcing bar ✓ Galvanized
✓ Structural shapes (>3 in) ✓ Al, Cr coated

Steel castings

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Classification of Steels

Steelmaking process Application

basic oxygen process, electric tool steels, bearing steels, spring
process, etc. steels, etc.

De-oxidation practice Metallography

rimmed, capped, semi-killed, hypoeutectoid, eutectoid,
killed hypereutectoid

Product form Composition

wire, bar, plate, sheet, strip, plain carbon, low alloy, high alloy,
tubing, or structural shapes high strength-low-alloy (HSLA)

Finishing method
cold drawn, cold rolled, hot
rolled, extruded, etc.

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Classification by Carbon Content

✓ Dead soft (0.05 – 0.15)

Wires, rivets, chain, sheet, strip, welded pipe

✓ Mild (0.10 – 0.30)

Rolled plate, structural shapes, gears, forgings

✓ Medium Carbon (0.30 – 0.60)

Connecting rods, crane hooks, shafts, axles, gears, rotors, rails

✓ High Carbon (0.6 – 1.0)

Screw drivers, saws, drills, dies, hammers, wrenches, punches, chisels

✓ Ultrahigh Carbon (1.0 – 1.4)

Special applications

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Classification by Alloy Content

Plain carbon steels

Manganese steels
Silicon-manganese steels
Chromium steels
Chromium-nickel (stainless) steels
Tungsten-chromium-vanadium (tool) steels

etc.

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Steel Designation
Based on steel composition

Proposed by organisations such as American Iron and Steel Institute (AISI)

and the Society of Automotive Engineers (SAE)

4-numeral designation system:

1st digit Type of steel (1 for plain C steels, 2 for nickel steels, etc.)
2nd digit Approx. % of predominant alloying element
3rd & 4th digit Mean carbon content divided by 100

Example:
SAE 1035 Plain carbon steels with approx. 0.35 % C
SAE 2520 Nickel steels of approx. 5 % Ni and 0.20 % C.

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Steel Chemistry
An iron base alloy containing a small percentage of carbon (less that 2.0 wt.%) are
classified as steels.

✓ Other elements inevitably enter into steel during manufacture:

✓ Silicon (Si)
✓ Manganese (Mn) C and Mn – Principal hardener
✓ Sulphur (S) Si and Mn – Deoxidiser
✓ Phosphorous (P) S and P – Harmful elements

Carbon, Silicon and Manganese:

varied within certain ranges to exploit their beneficial effects
Sulphur and Phosphorous:
almost always considered detrimental to steel and are kept below certain limits

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Steel Microstructures
As influenced by carbon content

Ferrite Pearlite Cementite

(almost pure iron; very soft) (a mixture of Ferrite and Cementite) (an intermetallic compound, Fe3C, very brittle)

Hypoeutectoid steel Hypereutectoid steel

Eutectoid steel
C <0.80% C >0.80%
C = 0.80%
contains mostly ferrite grains contains mostly pearlite with
contains 100% pearlite grains
with small pearlite small cementite network

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Non-equilibrium Structure
as formed during fast cooling

Martensite
extremely hard (HRC ~ 64) and brittle

Tempered Martensite

Martensite needles (black) Tough (reduced hardness and brittleness and

increased ductility
Comparison with the Equillibrium Structures
Ferrite
Soft (HRC <0) and ductile
TS = 40,000 psi, E = 40%
Pearlite
Hard (HRC = 20) and strong
TS = 120,000 psi, E = 20%

Tempered Martensite

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 Ferrous Materials

Ferrous

Steels Cast iron

Low Alloy High Alloy

Tool steel Stainless steel

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CLASSIFICATION OF STEELS
 Ferrous Material - Steels
• Steels - alloys of iron-carbon.
- May contain other alloying elements.
• Several grades are available
• Low Alloy (<10 wt%)
.
–Low Carbon (<0.25 wt% C)
–Medium Carbon (0.25 to 0.60 wt% C)
–High Carbon (0.6 to 1.4 wt% C)
•High Alloy
– Stainless Steel (>11 wt% Cr)
- Tool Steel

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 Low Carbon Steel
- Also known as Mild Steel

- Tensile strength of 555 N/mm

- Hardness of 140 BHN

- Bright fibrous structure

- Tough , malleable , ductile and more elastic than wrought

iron

- Melting point 1410

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 Low Carbon Steel
Plain carbon steels - very low content of alloying elements and small
amounts of Mn.

Most abundant grade of steel is low carbon steel – greatest quantity

produced; least expensive.

Not responsive to heat treatment; cold working needed to improve

the strength.

Good Weldability and machinability

High Strength, Low Alloy (HSLA) steels - alloying elements (like Cu,
V, Ni and Mo) up to 10 wt %; have higher strengths and may be heat
treated.
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 Medium Carbon Steel

❖ Carbon content in the range of 0.3 – 0.6%.

❖ Can be heat treated - austenitizing, quenching and then tempering.

❖ Most often used in tempered condition – tempered martensite

❖ Medium carbon steels have low hardenability

❖ Addition of Cr, Ni, Mo improves the heat treating capacity

❖ Heat treated alloys are stronger but have lower ductility

❖ Typical applications – Railway wheels and tracks, gears, crankshafts.

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 Medium Carbon Steel
✓ Bright fibrous structure when fractured

✓ Tough and more elastic in comparison to wrought iron

✓ Eaisly forged , welded , elongated due to ductility

✓ Good malleability

✓ Its tensile strength is better than cast iron and wrought iron

✓ - Compressive strength is better than wrought iron but lesser than cast iron

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 High Carbon Steel

High carbon steel loses their hardness at temperature from 200 to 250
degree Celsius.
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Applications -

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Structural Steels
- Possess high strength and toughness

- resistance to softening at elevated temperatures

- resistance to corrosion

- possess weldability , workability & high hardenability

- principle alloying elements chromium , nickel , manganese

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Stainless Steels

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Effects of Alloying Elements on Steel
✓ Manganese contributes to strength and hardness; dependent upon the carbon
content. Increasing the manganese content decreases ductility and weldability. Manganese has a
significant effect on the hardenability of steel.
✓ Phosphorus increases strength and hardness and decreases ductility and notch impact toughness
of steel. The adverse effects on ductility and toughness are greater in quenched and tempered
higher-carbon steels.
✓ Sulfur decreases ductility and notch impact toughness especially in the transverse
direction. Weldability decreases with increasing sulfur content. Sulfur is found primarily in the
form of sulfide inclusions.

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Effects of Alloying Elements on Steel

✓ Silicon is one of the principal deoxidizers used in steelmaking. Silicon is less effective than
manganese in increasing as-rolled strength and hardness. In low-carbon steels, silicon is generally
detrimental to surface quality.

✓ Copper in significant amounts is detrimental to hot-working steels. Copper can be detrimental

to surface quality. Copper is beneficial to atmospheric corrosion resistance when present in
amounts exceeding 0.20%.
✓ Nickel is a ferrite strengthener. Nickel does not form carbides in steel. It remains in solution in
ferrite, strengthening and toughening the ferrite phase. Nickel increases the hardenability and
impact strength of steels.
✓ Molybdenum increases the hardenability of steel. It enhances the creep strength of low-alloy
steels at elevated temperatures.

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Cast irons
➢ Cast irons are complex alloys of iron, carbon (up to 4.0 wt.%) and silicon (up to
3.5 wt.%).
➢ Presence of high carbon makes these alloys hard and brittle, which limits their
formability.
➢ Casting is the only way of making any product using cast irons.

Some general properties:

✓ low melting point and excellent fluidity
✓ very good corrosion resistant
✓ excellent wear resistant
✓ excellent machinability

Wide variation in properties are achieved by

✓ varying the balance between C and Si
✓ alloying with various metallic and non-metallic elements
✓ melting, casting, and heat treatment practices
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Cast irons
❖ Cast irons are manufactured by melting pig iron in a cupola or other melting
furnaces
❖ Little or no change in composition takes place during melting

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Microstructural comparison with steel

as graphite
flake
Ferrite carbon Steel Matrix
Pearlite carbon as (FERRITE – PEARLITE)
in solution
Fe2C3 compound

Grey cast iron (un-etched)

Steel (etched)

❖ It is the form of carbon, not the steel matrix, that controls the properties of cast irons
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Classification of cast irons
Based on the form of carbon in the microstructure

1. Grey cast iron

✓ carbon presents as free “flaky” graphite in the ferrite-pearlite matrix
✓ because of this free graphite, the fractured surface takes on a grey appearance
✓ grey irons are weak and brittle due these graphite flakes, which act as cracks
✓ have good compressive strength,
Graphite Flakes
making them suitable for damping
Applications
✓ good wear and corrosion resistant

✓ have high fluidity in molten conditions

and cause low shrinkage during
solidification, making them suitable
raw materials for producing intricate
shapes by casting
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Grey Cast Iron
Classification of cast irons
Based on the form of carbon in the microstructure

2. White cast iron

✓ carbon presents as extremely hard and brittle iron carbide (Fe3C) compound in
pearlite
✓ because of this carbide phase, the fractured surface takes on a white appearance

Iron carbide (or, cementite)

(the white phase)

✓ virtually un-machinable, not workable;

have very little commercial uses

✓ use is limited to only where a hard

wear-resistant surface is required

White Cast Iron 30

Classification of cast irons
Based on the form of carbon in the microstructure

3. Malleable cast iron

✓ carbon presents as “nested” graphite in the ferrite-pearlite matrix
✓ produced by prolonged heat treatment of white cast iron (to break cementite (iron
carbide) into ferrite (almost pure iron) and graphite)

✓ the decomposed graphite grouped

irregular
“tempered into clusters, known as “tempered
carbon” carbon”
✓ because of this clustered form
(not flakey form), cast iron
becomes more malleable and
ductile than grey iron

Malleable cast iron

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Classification of cast irons
Based on the form of carbon in the microstructure
4. Ductile (or, nodular) cast iron
✓ carbon presents as graphite “nodules” in the ferrite-pearlite matrix
✓ produced directly by melting low-sulphur grade pig/grey iron and adding a small
amount of magnesium or cerium before casting
✓ the graphite formed as nodules or spheroids instead of flake in presence of
magnesium or cerium

✓ ductile/nodular/spheroidal
graphite irons are the most ductile
and malleable cast irons, having
mechanical properties
approaching to steels
graphite
spheroids or
nodules

Nodular Cast Iron

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