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Ferrus Alloys
Ferrus Alloys
Group 5
Session Objectives
Classification of material
Ferrous alloys and its classification
Cast iron and types
Alloy
Alloy = When 2 or more metals are dissolved
together in a solid solution
Steel = alloy of Fe & C
Bronze = alloy of Cu & Sn
Brass = alloy of Cu & Zn
Metal Alloys
• Ferrous Alloys
and
• Non-ferrous Alloys
Ferrous Alloys:
Low High
alloy alloy
Widely used
Used as cutting tools,
Ferritic Martensitic Austenitic Precipitation
mould & dies
hardening
Machine parts
Stainless Steels
Stainless Steels:
Addition of Cr and Nickel to Fe-C will significantly increase corrosion resistance
Corrosion resistance enhanced by Ni & Mo
Cr forms a surface oxide that protects the underlying Fe-Cr alloy from corroding. To
produce the protective oxide, the SS must be exposed to oxidizing agents
Three basic classes, specified by microstructure:
Ferritic: Fe-Cr alloys (12~25%Cr), can be cheap
Martensitic: Fe-Cr alloys, low Cr, hard, cutting tools
Austenitic: Fe-Cr-Ni alloys (18Cr-8Ni), corrosion resistance
Ultra high strength stainless steel (17-7PH): Precipitation hardened, high strength and
hardness
Ferritic Stainless Steel
FSS are essentially Fe-Cr binary alloy containing about 12 ~ 30% Cr
Called ferritic bcause their structure remains mostly ferritic (BCC, α iron type) at normal
heat treatment conditions.
The present of the carbides in this steel reduces its corrosion resistance to some extent
Considered non-heat-treatable because they are all single phase, α iron type alloys whose
crystal structure does not change under normal heat-treatment conditions.
Eg;
430 SS (general-purpose, non-hardenable uses, range hood, restaurant equipment)
446 SS (High-temp. application, heater, combustion chambers)
Type 430 (ferritic) SS strip annealed at 788oC.
The structure consists of a ferrite matrix equiaxed grain & dispersed carbide
particles.
Martensitic Stainless Steel
MSS are essentially Fe-Cr alloys containing 12 ~ 17 % Cr with sufficient C (0.15 ~ 1.0 %).
Called martensitic because they are capable of developing a martensitic structure from austenitic
condition by quenching heat treatment.
Can be adjusted to optimize strength & hardness but corrosion resistance is relatively poor compared
to the ferritic & austenitic steel
High hardness due to hard martensitic matrix & the presence of a large concentration of primary
carbides.
Considered as heat-treatable because the carbon content is sufficient for the formation of a
martensitic structure by austenitizing and quenching processes.
E.g.;
410 SS ( General purpose, heat-treatable machine parts, pump shafts, valves)
440A SS (Cultery, bearing, surgical tools)
440C SS (Balls bearing, valve parts)
Type 440 (martensitic) SS hardened by autenitizing at 1010oC &
air cooled. Structure consists of primary carbides in martensite
matrix.
Austenitic Stainless Steel
Austenitic steel are essentially Fe-Cr-Ni ternary alloys containing about 16~25% Cr
& 7~20% Ni.
Called austenitic since their structure remains austenitic (FCC, γ iron type) at all
normal heat-treating temperatures.
Better corrosion resistance than ferritic & martensitic SS because the carbides can
be retained in solid solution by rapid cooling.
E.g.;
301 SS (High work hardening rate alloy, structural applications)
304 SS (Chemical & food processing equipment)
304L SS (Low carbon for welding, chemical tank)
321 SS (Stabilized for welding, process equipment, pressure vessels)
347 SS (Stabilized for welding, tank cars for chemicals)
Type 340 (austenitic) SS hardened strip annealed 5 min at 1065oC
and air cooled. Structure consists of equiaxed austenite grains.
CAST IRON
Iron-Carbon alloys of 2.0 ~ 6.0%C
Typical composition: 2.0-4.0%C,0.5-3.0% Si, less than
1.0% Mn and less than 0.2% S.
Very hard and brittle
Strong under compression
Suitable for casting [can be pour at a relatively low
temperature]
Si-substitutes partially for C and promotes formation of
graphite as the carbon rich component instead Fe3C.
Engine block, engineer vices, machine parts
Gray Cast Iron
Fe-C-Si alloys
Malleable cast irons are 1st cast as white cast iron & then are heat-
treated at about 940 C & held about 3~20 hrs.
o
Advantageous properties of
malleable cast irons are toughness,
moderate strength, uniformity of
structure and ease of machining
and casting.
Ductile Cast Iron
Fe-C-Si alloy
3.0 ~ 4.0% C, 1.8 ~ 2.8% Si.
Ductile cast iron contain large amount of
C in the form of graphite nodules
(spheres).
Without a heat treatment by addition of
ferrosilicon (MgFeSi) formation of
smooth spheres (nodules) of graphite is
promoted.
Properties: 2-18% EL, 40-90 ksi yield
strength, 60-120 ksi tensile strength.
Attractive engineering material due to: good ductility, high
strength, toughness, wear resistance, machinability and low
melting point castability.
Compacted graphite iron has characteristics midway between ductile and gray iron and combines many of
the properties of both. Compacted graphite iron is challenging to make with uniformity, Waupaca
Foundry closely monitors the production process. This type of iron provides many advantages :
The internal porosity solidifies in a manner similar to gray iron with the strength of ductile iron and allows
complicated castings.
It has the ability to dissipate heat
Increased dampening properties
The first commercial application for compacted graphite iron was for the brake discs for high-speed rail
trains
More recently compacted graphite iron has been used for diesel engine blocks. It has proven to be useful in
the manufacture of V topology diesel engines where the loading on the block is very high between the
cylinder banks, and for heavy goods vehicles which use diesel engines with high combustion pressures.
It is also used for turbo housings and exhaust manifolds, in the latter case to reduce corrosion.
Why Ferrous Alloys are important as
engineering construction materials?
Iron-containing compounds exist in abundant quantities within the earths
crust
Metallic iron and steel alloys may be produced using relatively economical
manufacturing techniques
Extremely versatile
Thank you…