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m.s ch7 (1) (1) (1)
m.s ch7 (1) (1) (1)
Metal Alloys
ISSUES TO ADDRESS...
• How are metal alloys classified and what are their
common applications?
• What are some of the common fabrication techniques
for metals?
• What heat treatment procedures are used to improve the
mechanical properties of both ferrous and nonferrous alloys?
1
Classification of Metal Alloys Metal Alloys
Steels
Steels Cast Irons
Cast Irons
<1.4 wt% C
<1.4wt%C 3-4.5 wt%C
3-4.5 wt% C
heat
Name plain HSLA plain
plain tool stainless
treatable
Cr,V Cr, Ni Cr, V,
Additions none none none Cr, Ni, Mo
Ni, Mo Mo Mo, W
Example 1010 4310 1040 4340 1095 4190 304, 409
Hardenability 0 + + ++ ++ +++ varies
TS - 0 + ++ + ++ varies
EL + + 0 - - -- ++
Uses auto bridges crank pistons wear drills high T
struc. towers shafts gears applic. saws applic.
sheet press. bolts wear dies turbines
vessels hammers applic. furnaces
blades Very corros.
resistant
increasing strength, cost, decreasing ductility
Based on data provided in Tables 11.1(b), 11.2(b), 11.3, and 11.4, Callister & Rethwisch 8e.
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Refinement of Steel from Ore
Coke
Iron Ore Limestone
BLAST FURNACE
heat generation
gas C+O2 CO2
refractory
vessel reduction of iron ore to metal
layers of coke CO2 + C 2CO
and iron ore 3CO + Fe2O3 2Fe+3CO2
air purification
slag
Molten iron CaCO3 CaO+CO2
CaO + SiO2 + Al2O3 slag
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Ferrous Alloys
Iron-based alloys
• Steels
• Cast Irons
11
Fe-C True Equilibrium Diagram
T(ºC)
1600
Graphite formation
1400 L Liquid +
promoted by
g +L Graphite
• Si > 1 wt% 1200 g 1153ºC
Austenite 4.2 wt% C
• slow cooling
1000
a+g g + Graphite
800
740ºC
0.65
600
Adapted from Fig. 11.2,
a + Graphite
Callister & Rethwisch 8e. 400
[Fig. 11.2 adapted from 0 1 2 3 4 90 100
Binary Alloy Phase (Fe) C, wt% C
Diagrams, 2nd ed.,
Vol. 1, T.B. Massalski (Ed.-
in-Chief), ASM International,
Materials Park, OH, 1990.]
12
Types of Cast Iron Adapted from Fig.
Gray iron 11.3(a) & (b),
Callister &
Ductile iron
• add Mg and/or Ce
• graphite as nodules not flakes
• matrix often pearlite – stronger but
less ductile
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Types of Cast Iron (cont.) Adapted from Fig.
White iron 11.3(c) & (d),
Callister &
Rethwisch 8e.
• < 1 wt% Si
• pearlite + cementite
• very hard and brittle
Malleable iron
• heat treat white iron at 800-900ºC
• graphite in rosettes
• reasonably strong and ductile
14
Types of Cast Iron (cont.)
Compacted graphite iron
• relatively high thermal conductivity
• good resistance to thermal shock
• lower oxidation at elevated
temperatures
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Production of Cast Irons
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Limitations of Ferrous Alloys
1) Relatively high densities
2) Relatively low electrical conductivities
3) Generally poor corrosion resistance
17
Nonferrous
• Cu Alloys Alloys • Al Alloys
Brass: Zn is subst. impurity -low r: 2.7 g/cm3
(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 r: 1.7g/cm3
precip. hardened Alloys -ignites easily
for strength -aircraft, missiles
• Ti Alloys
• Refractory metals
-relatively low r: 4.5 g/cm3
-high melting T’s
vs 7.9 for steel • Noble metals -Nb, Mo, W, Ta
-reactive at high T’s -Ag, Au, Pt
-space applic. -oxid./corr. resistant
Based on discussion and data provided in Section 11.3, Callister & Rethwisch 3e.
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Metal Fabrication
• How do we fabricate metals?
• Blacksmith - hammer (forged)
• Cast molten metal into mold
• Forming Operations
• Rough stock formed to final shape
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Metal Fabrication Methods (iii)
FORMING CASTING MISCELLANEOUS
• Sand Casting
(large parts, e.g.,
• What material will withstand T >1600ºC
auto engine blocks)
and is inexpensive and easy to mold?
• Answer: sand!!!
Sand Sand
• To create mold, pack sand around form
molten metal (pattern) of desired shape
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Metal Fabrication Methods (iv)
FORMING CASTING MISCELLANEOUS
• Investment Casting
(low volume, complex shapes
e.g., jewelry, turbine blades)
• Stage I — Mold formed by pouring wax I
plaster of paris around wax pattern.
Plaster allowed to harden.
• Stage II — Wax is melted and then II
poured from mold—hollow mold
cavity remains.
• Stage III — Molten metal is poured
III
into mold and allowed to solidify.
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Metal Fabrication Methods (v)
FORMING CASTING MISCELLANEOUS
molten
solidified
24
Metal Fabrication Methods (vi)
FORMING CASTING MISCELLANEOUS
changed).
25
Thermal Processing
Annealing: Heat to T
of Metals
, then cool slowly. anneal
A
a) Full Annealing P
b) Quenching
c) Tempering
(Tempered
Martensite) A
B
Fig. 10.25,
Callister &
Rethwisch 8e.
b) a)
c)
27
Hardenability -- Steels
• Hardenability – measure of the ability to form martensite
• Jominy end quench test used to measure hardenability.
Hardness, HRC
60
40
0 M(finish)
Hardness, HRC
100
C = 0.4 wt% C
4340 80 %M
50
40 4140
31
Precipitation Hardening
• Particles impede dislocation motion.
700
• Ex: Al-Cu system
T(ºC) L CuAl2
• Procedure: 600 a a+L
-- Pt A: solution heat treat q+L
A
(get a solid solution) 500 q
a+q
-- Pt B: quench to room temp. C
400
(retain a solid solution)
-- Pt C: reheat to nucleate 300
small q particles within 0 B 10 20 30 40 50
(Al) wt% Cu
a phase. composition range
available for precipitation hardening
• Other alloys that precipitation
Adapted from Fig. 11.24, Callister & Rethwisch 8e.
harden: Temp. (Fig. 11.24 adapted from J.L. Murray, International
• Cu-Be Pt A (sol’n heat treat) Metals Review 30, p.5, 1985.)
• Cu-Sn
• Mg-Al Pt C (precipitate q)
30
%EL (2 in sample)
400
20
300
149ºC 10
200 204ºC 149ºC
204ºC
100 0
1min 1h 1day 1mo 1yr 1min 1h 1day 1mo 1yr
precipitation heat treat time precipitation heat treat time
Adapted from Fig. 11.27, Callister & Rethwisch 8e. (Fig. 11.27 adapted from Metals Handbook:
Properties and Selection: Nonferrous Alloys and Pure Metals, Vol. 2, 9th ed., H. Baker (Managing 33
Ed.), American Society for Metals, 1979. p. 41.)
Summary
• Ferrous alloys: steels and cast irons
• Non-ferrous alloys:
-- Cu, Al, Ti, and Mg alloys; refractory alloys; and noble metals.
• Metal fabrication techniques:
-- forming, casting, miscellaneous.
• Hardenability of metals
-- measure of ability of a steel to be heat treated.
-- increases with alloy content.
• Precipitation hardening
--hardening, strengthening due to formation of
precipitate particles.
--Al, Mg alloys precipitation hardenable.
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