ENGINEERING MATERIALS 214

Ferrous Metals and Alloys

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Alloy
 Combination of two or more metals

Functions:
1. To increase hardenability
 Plain carbon steel has relatively low hardenability
when they are more than 1” in diameter even with the
fastest possible cooling rate

 Therefore , when quenching and tempering of heavy

sections are involved, one must select a steel that can
be quenched to form a homogeneous structure
throughout the section

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 Since plain carbon steel has no sufficient
hardenability to produce high strength
throughout the heavy section, the selection of
alloy steel is necessary

2. To increase resistance to softening on

tempering
 As tempering temperature is increased the
hardness is decreased

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 The residual stresses are completely removed at
higher tempering temperatures hence there are
more applications that the complete removal of
residual stress is necessary
 Alloy steel permit much higher tempering
temperature thus removing more residual stress

3. To increase resistance to corrosion

 The plain carbon steels are not resistant to
corrosion; this is a definite limitation to the use of
plain carbon steel to many applications

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 by the addition of certain alloying elements in
proper quantities it is possible to improve the
resistance of steel to corrosion

4. To improve high temperature properties

 Not only steels oxide at elevated
temperatures but their strength decreases
with increasing temperature
 The use of alloying elements greatly improves
resistance to oxidation at elevated
temperature as well as short time rupture
strength
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5. To improve resistance to abrasion
The fully hardened steel are usually resistant
to abrasion, however there are some alloying
elements that may be added to improve
abrasion resistance
Ex: tungsten, molybdenum, chromium

6. To strengthen ferrite
The strength of steel can be increased
somewhat by the addition of some elements
that will form solid solutions with the ferrite

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 Steel Alloy
 1.Nickel
 Increase strength and toughness of steel for
heat exchanger tubes
 Has great resistance to corrosion (12 -21%
nickel + 0.1% carbon)
 Stainless steel with 36% nickel used for
tapes
 2 – 5% nickel is used for machine parts
which are subjected to shock
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2.Chromium

 Imparts corrosion resistant properties

 0.5 to 2.0% chromium + 0.1 to 1.5% carbon
= common chromium steel
 11 – 17% chromium = special chrome steel of
stainless variety

 uses : bearings, tools, armor plates, gears,

dies safes and vaults
 produce extreme hardness

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3. Manganese
1.5-5% manganese is very brittle and useless,
but from 7-19% the strength is increased
11-14% with extreme hardness
Used for machinery parts subjects to severe
wear, crushing, grinding
Also extensively used in railroads equipment's,
switches, and curved rails
Increase fluidity and reduces shrinkage in
casting steel

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4. Tungsten

Those steels with high tungsten content retain

their hardness (self hardening) at elevated
temperatures
Steels containing 3-18% tungsten and form 0.2
-1.5% carbon are used for dies and cutting tools
Has high magnetic reluctance (4 – 5% with
0.5-0.7% carbon is used for permanent
magnets)
10 – 12% used for cutting tools; dies; valves,
taps, permanents magnets
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5. Molybdenum
For increased machinability with the same
hardness
Similar to tungsten but mostly used with chromium
to produce good strength properties especially
resistant to repeated stress

6. Vanadium
used in combination with chrome to produce:
casting, forgings, springs, shafting, gears, pins
increases tensile strength if less than 0.2%

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7. Silicon
Has high elastic limit
Used in electricity due to its high permeability
Also used to produce spring due to its high
elastic limit
An alloy containing 5-7% chromium, 2-4%
silicon, and 0.4-0.5% carbon retains its hardness
at red heat and is very resistant to oxidation
which makes it suitable for valves in internal
combustion engines

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8. Chrome Nickel
When heat treated they acquire greatly
increased tensile strength, elastic limit and
endurance limit, together with toughness and
ductility
The most important group
Principal Uses: gears, forged axles,
crankshafts, propeller shafts, connecting rods,
machine rods

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Cobalt

is a hard, lustrous, silver-grey metal,

It is found in various ores, and is used in the
preparation of magnetic, wear-resistant, and high-
strength alloys.
Its compounds are used in the production of inks,
paints, and varnishes
Has high heat resistance
Maintain mechanical properties at high
temperature
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 Tool Steel
0.60—0.75% carbon: machine parts, chisels,
setscrews; properties include medium hardness with
good toughness and shock resistance.
0.76—0.90% carbon: forging dies, hammers, and
sledges.
0.91—1.10% carbon: general purpose tooling
applications that require a good balance of wear
resistance and toughness, such as drills, cutters, and
shear blades.
1.11—1.30% carbon: small drills, lathe tools, razor
blades, and other light-duty applications where
extreme hardness is required without great
toughness.
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 Non Ferrous Metals and Alloys
 Metals and alloys of the non ferrous group
have an important place in engineering
construction.
 They are adapted where ferrous are not
suitable
 As a general rule non ferrous alloys are
more expensive than iron or steel but they
hold their place in the industry because they
meet special requirements

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1. Copper
Find great application in electrical industry
(generators, motors, bus bars, wire)
Also used for articles which require good heat
transfer such as cooking vats and heat
exchangers (condensers and evaporators)

Produce: brass, bronze, monel metals

2. Zinc
Used largely for galvanizing die casting

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3. Tin
Very malleable and highly resistant to corrosion
used to manufacture tin cans for solder, bearing
metals and bronze

4. Aluminum
Very ductile and malleable
Widely used for cooking utensils, electrical cables

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5. Lead
Soft, weak, and malleable and has little ductility
storage batteries, electric cables, solder and
bearing alloys

6. Titanium
Resistant to corrosion at ATM temperature,
used in aircrafts and in engines where
temperature are not too high
Too expensive

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Copper – Zinc Alloy
Make brass

Copper – Tin Alloy

Bronze
Has properties suitable for bearing materials
Has high resistance to wear

Copper Nickel Alloy

“R” Monel; monel metals 63% to 67% nickel
30% Cu

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 used for sinks, kitchen equipment, laundry
machines, pump rods and marine
equipments

 “H” monel; used for impellers, valve bodies,

pumps, bushings and fittings because of its
resistance to corrosion

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Tin Bronze
known for being phosphorous

Manganese and Bronze

produced metals used for propellers

Copper Silicon
produced metals used for bolts which must
resist corrosion

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Copper – Beryllium
Used to manufacture non sparking tools such as
hammers, screw drivers and chisels
Has the combination of strength and hardness
good conductivity and corrosion resistance
Aluminum – Alloys
used to reduce weight extremely in the machine
parts for aeronautical and automotive industries
Has low density and corrosion resistance

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Bearing Metals (2 classes)

hard type
bronze (85% Cu + 10% tin) used for heavy
machinery where bearing pressure are severe

Soft bearing metal

include the famous babbit metal (80 to 90% tin
+ 3-10% Cu)
Used for cheaper machineries with light load

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 Solder and Brazing Alloys
Solder Alloys
Lead and tin; used principally for joining sheets,
tin smiting, electrical work
Low melting point

Brazing Alloys
Hard solders
Copper base or silver base

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Fusible Alloys
Lead, tin, bismuth, cadmium
Used in automatic sprinklers safety plug of boilers
Has very low melting point

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Dezincification
 Dezincification is an example of "dealloying" in
which one of the constituents of an alloy is
preferentially removed by corrosion.
 Dezincification was first recognized as a serious
problem in 70/30 brass tubes used for ships’
condensers before about 1920. It was stated as
"Condenseritis"
 Research on the problem established that
dezincification could be prevented by the
incorporation of about 0.03% arsenic in the 70/30
brass alloy and this addition is now standard in all
alpha-brass tube specifications including admiralty
brass and aluminium brass.
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Galvanizing
is a form of galvanization
It is the process of coating iron or steel with a thin
zinc layer, by passing the steel through a molten bath
of zinc at a temperature of around 860 °F (460 °C).
When exposed to the atmosphere, pure zinc reacts
with oxygen to form zinc oxide, which further reacts
with carbon dioxide to form zinc carbonate, a dull
grey, fairly strong material that stops further corrosion
in many circumstances, protecting the steel below
from the elements.
 Galvanized steel is widely used in applications where
rust resistance is needed

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THANKK YOU