Topic 5:

engineering
material
Introduction
EXAMPLE : MATERIAL USE IN AUTOMOBILES
Introduction
Many engineers whether mechanical, civil or electrical will at one time be exposed
to a design problem involving materials.

Materials problem is when selecting the right material from the many thousands
that are available.

There are several criteria on which the final decision is normally based such as :

- The properties required of the material.

- Deterioration of material properties that may occur during service operation.
- Probably the overriding consideration is that of economics
 TOPIC 5: ENGINEERING MATERIAL

5.1
5.1
Metallic
Metallic
 Learning Outcomes
a)Define ferrous metal. b) Define non-ferrous
metal:
1. Describe the characteristics of
ferrous metal. 1. Describe the characteristics of
2. .Explain the following ferrous non-ferrous metal
metal: 2. Explain the following non-ferrous
iron; and metal:
Steel. copper;
*definition and common aluminium;
characteristic. zinc; and
tin.
*definition and common
characteristic.
 Define Ferrous
Metal
DEFINITION:
Ferrous metals are material with iron element
as the base metal.
The properties of ferrous metals may be
changed by adding various alloying elements.
Products of ferrous metals can be found as
plates, bars, wire rod and sheets.
FERROUS METAL

Examples of ferrous metals are steel and iron.

 CHARACTERISTIC OF
FERROUS METAL
Durable
Great tensile strength

Wallace Design Inc.

Usually magnetic
Low resistance to corrosion
Recyclable
Good conductors of electricity.
These qualities make them usable in
FERROUS METAL

building constructions as well as in

making tools, vehicle engines, pipelines,
containers, automobiles, cutlery etc
 IRON STEEL
CAST IRON CARBON STEEL
- GREY CAST - LOW CARBON
- MEDIUM CARBON
- WHITE CAST - HIGH CARBON
WROUGHT IRON ALLOY STEEL
FERROUS METAL
FERROUS METAL

IRON
 IRON
Basic constituent of steel.
Most rich metallic in the earth’s crust after aluminum.
Found in the form of ores as oxides, carbonates, silicates and
sulfides.
Carbon exerts the most significant effects on the
microstructure and properties of iron products.
FERROUS METAL

Increase in the amount of carbon decreases the melting point

of the metal.
Examples of iron metals are wrought iron and cast iron.
 CAST IRON 01

Cast iron is a group of iron-carbon alloys

with a carbon content greater than 2%.

Wallace Design Inc.

Its usefulness derives from its relatively
low melting temperature.
Cast iron is actually liquid metal casts
into a prepared mold.
Manufactured by reheating pig iron and
blending it with other material such as
FERROUS METAL

carbon and other alloys.

Two types of cast iron : Gray cast iron and
White cast iron.
 MECHANICAL PROPERTIES & ITS
APPLICATIONS - CAST IRON
Tends to be brittle, except for malleable
cast irons.

Wallace Design Inc.

Good castability
Excellent machinability
Resistance to deformation
Good wear resistance
Have high compressive strength
FERROUS METAL

Low tensile strength

Some of the applications are used in pipes, machines
and automotive industry parts, such as cylinder heads,
cylinder blocks and gearbox cases.
 Cast Iron Products
1. Gray Cast Iron 1. White Cast Iron
- Contains graphite - Does not contains graphite.
2. Application 2. Application
- Pipes - Cement Mixer
-industrial components -Nozzle
- Ball mills
 ADVANTAGE OF CAST IRON
Cheap
Low melting point
Fluid – easy to cast, especially advantageous into large
complex shapes
Excellent bearing properties
Excellent damping properties(ability to absorb noise and
FERROUS METAL

vibration)
Can be heat threatened
 WROUGHT IRON 02

Wrought iron is an iron alloy with a very

low carbon content (less than 0.08%).

Wallace Design Inc.

Wrought iron is made by repeatedly heating
and reworking cast iron
Has a far higher tensile strength and is
more ductile than cast iron.
Can be processed such as forging, knocking,
squeezing and rolling to get the desired
FERROUS METAL

shapes.
 MECHANICAL PROPERTIES & ITS
APPLICATIONS - WROUGHT IRON
Ductile
Highly malleable
Tough and has great shock resistance
Highly resistant to fatigue (if large amounts
of pressure are applied, it will undergo a
large amount of deformation before failing)
Strong in tension and weak in compression
when compared with cast iron
FERROUS METAL

Applications : used to make pipes, corrugated

sheets, grills, bars, chains, gates.
WROUGHT IRON ADVANTAGES AND APPLICATION

More resistant to corrosion

than steel

Tough, malleable, ductile

and easily welded.

If honed to an edge, it

loses it quickly

Replace by mild steel

 DIFFERENCES BETWEEN CAST IRON & WROUGHT IRON
FERROUS METAL
FERROUS METAL

STEEL
 STEEL
Steel is defined as the element of iron and carbon.
Steel are supplied in various forms such as plates and wires to suit
its applications. Its usage depends on the percentage of carbon in
its composition.
Steel can be classified into two types :
-Carbon Steel
-Alloy Steel
FERROUS METAL

Carbon steel can be classified into three types :

-Low Carbon Steel
-Medium Carbon Steel
-High Carbon Steel
 CARBON STEEL 01
Carbon steel is a steel with carbon content up to 2.1% by weight.
FERROUS METAL
 ALLOY STEEL 02
Alloy steel is steel that is alloyed with a variety of elements in
total amounts between 0.1% and 50% by weight to improve its
mechanical properties

In general, with the additional of alloying elements, it will

altered the mechanical properties of steel like hardenability,
brittleness, toughness, stiffness, machinability and ductility.
FERROUS METAL

Some applications for alloys steel include pipelines, auto parts,

transformers, power generators and electric motors.
 ALLOY STEEL 02
Carbon steel is a steel with carbon content up to 2.1% by weight.
FERROUS METAL
 ADVANTAGES DISADVANTAGES
Iron ore is cheap and abundant Low corrosion resistance
Processing techniques are High Density
economical (extraction, Cannot withstand high
refining, alloying, fabrication) temperature
High strength to weight ratio Expensive
Very versatile metallurgy - a High cost of final finishing
wide range of mechanical and and polishing
physical properties can be High strength to weight ratio
achieved, and these can be compared to non-metals
tailored to the application
High quality material - readily
available worldwide in various
certificate grades
Speed of construction - easy to
assemble
FERROUS METAL

Aesthetics - steel has a broad

architectural possibilities
Environmental friendly
High quality and durable
material
Recyclable
 Define Non-
Ferrous Metal
DEFINITION:
Non-ferrous metals are metals that do not
contain iron element.
NON- FERROUS METAL
 CHARACTERISTIC OF NON-FERROUS
METAL
High Corrosion resistance.
Ease to fabrication (machinability, casting,
welding)
Great thermal conductivity.
Great electrical conductivity.
NON-FERROUS METAL

Colorful.
Mostly non-magnetic (exclude Nickel and
Colbalt)
 ALUMINIUM
CHARACTERISTICS

Silver in color.
Low melting point
Non-poisonous
Low density
High heat capacity
It is a good heat and electrical conductor
NON-FERROUS METAL

APPLICATIONS

Widely used in transportation vehicles,

construction industry, aeronautics, cooking
utensils and food containers industry.
 ZINC
CHARACTERISTICS

Blue-white in color
Hard, smooth material
Reasonable conductor of electricity
Does not corrode as easily as other metals,
hence it is an excellent material for
electroplating onto surfaces to protect them.

APPLICATIONS
NON-FERROUS METAL

It is mainly used for die-casting alloys and as

a coating for sheet steel, chain, wire, screws
and piping.
Widely used in die-casting industries to
produce automotive parts, building hardware,
padlock and toys.
 COPPER
CHARACTERISTICS

Reddish-colored metal
It is a good heat and electrical conductor.
Can be easily soldered, brazed and welded
without corrosion problems.
Alloys easily, the alloys are harder, stronger
and tougher than pure copper. Examples :
Brass: Copper + Zinc
Bronze: Copper + Tin
Cupro Nickel: Copper + Nickel
NON-FERROUS METAL

APPLICATIONS

Widely used in electrical and air-conditioning

industries.
 TIN
CHARACTERISTICS

Tin is silvery-white in color.

Low melting point
Good transmission of heat or electricity
Being so soft, tin is rarely used as a pure metal;
instead, it is combined with other metals in
order to make alloys that possess tin's
numerous beneficial properties.
Can be forged and hammered to a very thin
and fine sheet and wires.
NON-FERROUS METAL

APPLICATIONS

Use for electronic connections; soldering

Used to coat other metals to prevent corrosion
Used in food containers industry and pewter
industry.