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Material Science
Material Science
Metal properties
• Hardness :
Hardness is the resistance of a material to localised plastic
deformation.
Hardness is a measure of how much a material resists changes
in shape. Hard things resist pressure.
Some examples of hard materials are diamond, boron carbide,
quartz, tempered steel, ice, granite, concrete. Ability of
material to resist wear, tear, scratching, abrasion cutting is
called hardness.
It is important when looking for a suitable material for an
environment that includes little particles that can induce
material wear. Soft materials suffer indentations while hard
ones resist to any change in shape
Hardness
Blast furnaces are used to produce pig iron from iron ore for
subsequent processing into steel
Steel Slag
• Constituent Mean % Range %
• Calcium Oxide (CaO) 39 34-43
• Silicon Dioxide (SiO2) 36 27-38
• Aluminum Oxide (Al2O3) 10 7-12
• Magnesium Oxide (MgO) 12 7-15
• Iron (FeO or Fe2O3) 0.5 0.2-1.6
• Manganese Oxide (MnO) 0.44 0.15-0.76
• Sulphur (S) 1.4 1.0-1.9
• The slag formed consists of the limestone flux, ash from the coke,
and substances formed by the reaction of impurities in the ore
with the flux; it floats in a molten state on the top of the molten
iron.
Steel Production
• Steel is iron that has most of the impurities removed. Steel also has a
consistent concentration of carbon throughout (0.5 to 1.5 percent). Impurities
like silica, phosphorous and sulphur weaken steel tremendously, so they must
be eliminated. The advantage of steel over iron is greatly improved strength.
• The open-hearth furnace is one way to create steel from pig iron. The pig iron,
limestone and iron ore go into an open-hearth furnace. It is heated to about
871 degrees C. The limestone and ore form a slag that floats on the surface.
Impurities, including carbon, are oxidized and float out of the iron into the
slag. When the carbon content is right, you have carbon steel.
• Another way to create steel from pig iron is the Bessemer process, which
involves the oxidation of the impurities in the pig iron by blowing air through
the molten iron in a Bessemer converter. The heat of oxidation raises the
temperature and keeps the iron molten. As the air passes through the molten
pig iron, impurities unite with the oxygen to form oxides. Carbon monoxide
burns off and the other impurities form slag.
Steel Production
• However, most modern steel plants use what's called a basic
oxygen furnace to create steel. The advantage is speed, as the
process is roughly 10 times faster than the open-hearth furnace.
In these furnaces, high-purity oxygen blows through the molten
pig iron, lowering carbon, silicon, manganese and phosphorous
levels. The addition of chemical cleaning agents called fluxes help
to reduce the sulphur and phosphorous levels.
• A variety of metals might be alloyed with the steel at this point to
create different properties. For example, the addition of 10 to 30
percent chromium creates stainless steel, which is very resistant
to rust. The addition of chromium and molybdenum creates
chrome-moly steel, which is strong and light
Steel Production : Smelting, Melting & Refining
• Smelting : In the smelting process a metal that is combined with oxygen—
for example, iron oxide—is heated to a high temperature, and the oxide is
caused to combine with the carbon in the fuel, escaping as carbon
monoxide or carbon dioxide.
• Melting : Melting is the process of liquefying a solid substance by heating.
It is the process by which a substance changes from the solid phase to the
liquid phase.
• melting converts a solid substance into a liquid whereas smelting converts
an ore to its purest form.
• Tool Steel : Tool steel is a type of carbon alloy steel that is well-
matched for tool manufacturing, such as hand tools or machine dies.
Its hardness, resistance to abrasion and ability to retain shape at
increased temperatures are the key properties of this material.
• Tool steel alloys are high carbon chrome steels containing differing
amounts of molybdenum, cobalt and/or vanadium or other elements.
Certain tool steels are engineered to withstand repeated high specific
loads and impacts at ambient temperature with exceptional wear
resistance
Mild Steel
• Common Applications of Mild Steel
• Structural steel.
• Signs.
• Automobiles.
• Furniture.
• Decorations.
• Wire.
• Fencing.
• Nails.
Carbon Steel
• Carbon steel with the lowest possible amount of carbon is
called ‘wrought iron’, used for fencing, gates and railings, hard
but not brittle.
• Carbon steel gears are able to withstand more force than
stainless steel gears. Other common types of products made
of carbon steel include :
springs, bolts, kitchen knives, wires, cables, bridges, ball
bearings and airplane components
Alloy Steel
• Alloy Steel : manufacture pipes, especially pipes for energy-
related applications. It's also used in the manufacturing of
heating elements in appliances like toasters, silverware, pots
and pans, and corrosion-resistant containers.
• Advantages of alloy steel :
• Corrosion resistance.
• Better solderability.
• Durable parts.
• Lighter weight for the strength.
• Thermal conductivity.
• Electrical conductivity
Stainless Steel
• Culinary uses. Kitchen sinks. Cutlery. Cookware.
• Surgical tools and medical equipment. Hemostats(also called
a hemostatic clamp, arterial forceps, is a surgical tool used in
many surgical procedures to control bleeding. Surgical
implants. Temporary crowns (dentistry)
• Architecture, Bridges. Monuments and sculptures. ...
• Automotive and aerospace applications. Auto bodies. Rail cars
Heat Treatment
• three stages of heat treatment
• Includes heating the metal to a set temperature (the heating
stage), keeping it at that temperature for a specific length of
time (the soaking stage), and cooling it down to room
temperature with a method that depends on the type of
metal and the desired properties (the cooling stage).
• four basic types of heat treatment steel undergoes today:
-annealing
-normalizing
-hardening
-tempering.
Annealing
• The purpose of annealing is to (Opposite of Hardening)relieve
stress, soften the metal, increase ductility, and improve their
grain structures. T
• o anneal steels and other ferrous metals to produce the highest
level of ductility, you must heat the metal slowly to the
appropriate temperature, soak it, and then allow it to cool slowly
by either burying it in some sort of insulating material or by
simply turning off the furnace and letting both the furnace and
the part cool slowly together.
• The amount of time you let the metal soak depends on both its
type and its mass. If it’s low-carbon steel, it’ll require the highest
possible annealing temperature and, as the carbon content
increases, its annealing temperature will decrease.
Normalising
• The purpose of normalizing is to remove any internal stresses from heat
treatment, machining, forging, forming, welding, or casting. Metal failure can
result from uncontrolled stress, so normalizing steel before any hardening can
help ensure the success of projects.
• Steel is heated to 720-9300 C, soaked at the temperature and then air cooled.
• Difference Between Annealing & Normalizing
• Normalizing only applies to ferrous metals like steel. But there’s another key
difference in the heat treatment process: when normalizing, after the metal is
heated to a higher temperature, it is air-cooled after removal from the furnace.
• Normalized steel is stronger than annealed steel. With both high strength and
high ductility, it is tougher than annealed steel. If the metal part needs to
withstand impact or have maximum toughness to resist external stresses, it is
usually recommended that it is normalized rather than annealed.
• Since normalized metals are air-cooled, the mass of the metal is a key
determinant of the cooling rate and resulting part’s level of hardness. During
normalizing, thinner pieces will cool faster in the air and become harder than
thicker pieces. But, with annealing and its furnace cooling, the hardness of both
thick and thin parts will be comparable
Hardening
• The intent of hardening is not onlyto harden the steel, but also to
make it stronger.
• While hardening does increase strength, it also decreases
ductility, making the metal more brittle. After hardening, steel
may need to temper the metal to remove some of the
brittleness.
• To harden most steels, steel undergoes two stages of heat
treatment (slow temperature heat followed by soaking by a
specified time to a uniform temperature), the third stage is
different. When you harden metals, you rapidly cool them by
plunging them into water, oil, or brine. Most steels require rapid
cooling, called quenching, to be hardened, but there are a few
that can be successfully air-cooled
Hardening
• Alloy Steel Hardening :
As alloys are added to steel, the cooling rate that’s required to harden it
decreases. The slower cooling rate lessens the risk of either cracking or
warping
• Carbon Steel Hardening :
The hardness of carbon steel depends on its carbon content: up to .80%
carbon, the ability to harden increases alongside the carbon content.
Beyond .80%, it increase wear resistance due to hard cementite (also
known as iron carbide, is a compound of iron and carbon, more precisely
an intermediate transition metal carbide with the formula Fe3C) forming,
but it does not increase the hardness.
• When carbon steel is hardened, the steel must be cooled to under 538 0 C in
less than one second
• Alloys steel increases the effectiveness of the carbon, allows to increase the
time limit beyond one second. That allows you to select a slower quenching
medium to get the specified hardness.
Case Hardening
• Case hardening is a process of hardening a ferrous alloy so that
the surface layer or case is made substantially harder than the
interior or core. The chemical composition of the surface layer is
altered during the treatment by the addition of carbon,
nitrogen, or both. The most frequently used case-hardening
processes are
-Carburising : uses carbon to harden the case
-Cyaniding : uses cyanide (Cyaniding is a case-hardening process
that is fast and efficient; it is mainly used on low-carbon steels.
The part is heated to 871–954 °C in a bath of sodium cyanide
and then is quenched and rinsed, in water or oil, to remove any
residual cyanide.
-Carbonitriding : uses carbon and nitrogen (Amonia) to harden
the case
-Nitriding : uses nitrogen to harden the case
Tempering
• Tempering (sometimes called drawing) is the process of reheating
hardened or normalized steels to some temperature below 7200 C
• Typically, carbon steels are quenched in brine or water, whereas
alloy steels are quenched in oil.
• Unfortunately, quenching is a process that produces high internal
stress and, to relieve the steel, one option is to temper it. Right
before the part becomes cold, you remove it from the quenching
0
bath at a temperature of 93-95 C and let it air cool.