Material Science - UNIT 5.

Unit – V
Alloying of steel, properties of stainless steel and

tool steels, maraging steels- cast irons; grey, white,
malleable and spheroidal cast irons- copper and
copper alloys (Brass, bronze and cupro-nickel)-
Aluminium and Al-Cu – Mg alloys- Titanium alloys.
Classification of Metal
Classification of Ferrous Materials
Classification of Steel
 Steels - Alloys of iron and carbon.
Several grades are available.
 Low Alloy (<10 wt%)
 Low Carbon (<0.25 wt% C)
(Automobile Body parts, Buildings, Pipes,
Chains, Rivets, Screws, Nails)
 Medium Carbon (0.25 to 0.60wt%)
(Connecting rods, Crank Pins, Axles,
Drop Forgings)
 High Carbon (0.6 to 1.4 wt%)
(Punches, cold chisels, hammers)
 High Alloy
1. Stainless Steel (> 11 wt% Cr)
2.Tool Steel
Stainless steel
 Stainless steel is a metal alloy, made up of steel mixed with elements such
as chromium, nickel, molybdenum, silicon, aluminum, and carbon.
 Iron mixed with carbon to produce steel is the main component of stainless
steel
Properties of Stainless steel
 Corrosion resistant.(metal can withstand damage caused by oxidation)
 High tensile strength.(resistant of a material breaking under tension)
 Very durable.(able to withstand wear)
 Temperature resistant.
 Easy formability and fabrication.
 Low-maintenance (long lasting)
 Attractive appearance.
 Environmentally friendly (recyclable)
Application of stainless steel
 Pressure vessels, heat exchangers.
 Marine and high chloride conditions.
 Food processing equipment.
 Biofuel plants.
Tool Steel
 Tool steel refers to a variety of carbon steel and alloy steel that are particu-
larly well-suited to be made into tools.
 The four major alloying elements that form carbides in tool steel are tung-
sten, chromium, vanadium and molybdenum.
 Tool steel are resistance to abrasion and their ability to hold a cutting edge
at elevated temperatures. As a result, tool steels are suited for use in the
shaping of other materials.
Properties of Tool steel at elevated temperature
 Toughness (ability of material absorb energy and plastically deform with-
out fracturing)
 Wear resistance(loss of material from a surface by mechanical action)
 Hardness.(resistant to scrathes,resistant to wear, resistant to indentation)
 Heat resistance
Application of tool steel
• Forming, cutting and shearing of plastics and metals
• Extrusion of plastic sections e.g. vinyl window frames and pipes
• Stamping (pressing)of computer parts from metal sheets
• Dies for compacting of powder metal into forms such as gears.
Maraging steel
 Maraging steels are known for possessing superior strength and tough-
ness without losing its ductility.
 The alloying element is 15-25 wt% nickel and Secondary alloying elements
such as cobalt, molybdenum and titanium, are added to produce Maraging
steel.
Properties of Maraging steel
 Ultra-high strength at room temperature
 Simple heat treatment, which results in minimum distortion
 Superior fracture toughness compared to quenched and tempered steel of
similar strength level
 Good weldability.
 Maraging steel offers an unusual combination of high tensile strength and
high fracture toughness.
Application of Maraging steel
 Maraging steel is used in aircraft, with applications including landing
gear, helicopter undercarriages, and rocket motor cases
– applications which require high strength-to-weight material.
Cast Iron
 Carbon 2.1- 4.5 wt% and Si (normally 1-3 wt%).
 Lower melting point due to presence of eutectic point at 1153 °C and 4.2
wt% C.
 Cast iron tends to be brittle, except for malleable cast irons.
Properties of cast iron
The useful properties of cast iron are
i) Good fluidity (ability to fill narrow cavities in castings )
ii) Low melting point
iii) Good machinability (removal of material at satisfactorily finish at low
cost)
iv) Cast irons are brittle (It is the property of breaking of a material with little
permanent distortion) and have low tensile strength than most of the
steels.
v) Good castability (ease of forming a good quality casting)
vi)resistance to deformation and wear resistance
Types of cast iron
 White cast iron
 Grey cast iron
 Malleable cast iron
 Spheroidal cast iron
Application of cast iron
 Foundation for big machines

 Bridges, buildings
 Pipes, lids (manhole) and automotive industry parts, such
as cylinder heads, cylinder blocks and gearbox cases. It is re-
sistant to damage by oxidation.
Cast Iron
White Cast Iron
• White cast iron – C: 2.5 – 3 wt.%, Si: 0.5 – 1.5%.
• Most of the carbon is in the form of cementite.
• Cast iron obtained from rapid cooling Contains pearlite + cementite ,not
graphite.
• Very hard ,brittle, wear resistant
• Used as intermediate to produce malleable cast iron.
• microstructure consisting of Cementite, Pearlite and transformed ledebu-
rite.
Application of white cast iron
Grey Cast Iron
 Grey cast iron contains graphite in the form of flakes.
 Composition - C:3.0 – 4.0 wt%, Si: 1.0 – 3.0 %
 Microstructure: graphite flakes in a ferrite or pearlite matrix
 Weak & brittle in tension and Stronger in compression
 Excellent damping capacity, wear resistance.
 Casting shrinkage is low
 Graphite flakes and white portion which is ferrite can also be seen. Alterna-
tive black and white potion is pearlite.
Graphite flakes
ferrite or pearlite matrix

Application of grey cast iron
It is used in cylinder blocks and I.C. Engines, rolling mills, sanitary wares
Malleable Cast Iron
 Malleable cast iron. – Carbon: 2.3 – 2.7 wt%, Si: 1.0 – 1.75 %
 Obtained by heat treating white iron for a prolonged period that causes de-
composition of cementite into graphite.
 Heat treatment : Two stages – Isothermal holding at 9500C and then hold-
ing at 7200C.
 Graphite forms in the form of rosettes in a ferrite or pearlite matrix.
 Reasonable strength and improved ductility (malleable)
 High Machinability, strong and shock resistant.
 The microstructure consists of pearlite with graphite.
Graphite
pearlite
Application of Malleable cast iron
Applications - automobile parts, railroad equipment, manhole covers
etc.,.
Nodular or Ductile Cast Iron
 Addition of Mg to grey cast iron converts the graphite flakes to nodules.
 Castings are stronger and much more ductile than grey iron.
 Due to spherodization tensile strength, ductility and toughness are im-
proved.
 microstructure - The graphite in the forms of Spheroidal graphite (black)
Graphite spheroid
Application of nodular cast iron
Application - hydraulic cylinders; valves, cylinder heads for compressor and diesel
engine.
Copper
 Very high electrical conductivity
 Excellent thermal conductivity –Copper cookware used for fast and uni-
form heating.
 Good corrosion resistance
 Good machinability
 Non-magnetic
 Brasses and Bronzes are most commonly used alloys of Cu .
 Brass is an alloy with Zn. Bronzes contain tin &aluminum
Brass
 Brass is the most common alloy of Cu – It’s an alloy
with Zn
 Brass has higher ductility than copper or zinc.
 Easy to cast - Relatively low melting point and high
fluidity
 Properties are good strength, machinability, ductility,
wear-resistance, hardness, electrical and thermal
conductivity, and corrosion resistance.
 Some of the common brasses are yellow, naval and
cartridge.
 Brass is frequently used to make musical instruments.
Application of Brass
• Application - Automotive radiator wires, tanks, head
light reflectors, electrical flashlight shells, plumping
accessories.
Bronze
 Cu-Sn Bronze is one of the earliest alloy to be discovered as Cu
ores
 Stronger than brasses with good corrosion and tensile properties
 Highly ductile and Brittle
 Bronze exhibits low friction against other metals
 Upon exposure to air, bronze oxidizes, but only on its outer layer
 Applications - Bearing, pump parts, linings, springs, gears,
clutch discs, ball bearings, surgical and dental instruments
Cupronickel Alloys
 Cupronickel (Cu-Ni) is an alloy of copper that con-
tains nickel and strengthening elements, such
as iron and manganese.
 Excellent corrosion resistance
 good tensile strength
 excellent ductility when annealed
 Good thermal conductivity
Application of cupronickel alloys
Application- marine engineering such as shipbuilding
and repair, offshore oil and gas structures and power
generation. Condensers and heat exchangers are suit-
able for cryogenic applications
Aluminum
 Aluminum is a light metal and easily machinable
 Good electrical and thermal conductivities.
 Versatile metal - can be cast, rolled, drawn, hammered, extruded and
forged into many shapes.
 Aluminum can be riveted, welded and brazed.
 Corrosion resistant - no protective coating needed
 Al and its alloys - high strength-to-weight ratio (high specific strength)
owing to low density.
 Aluminum alloys are classified into two categories – Cast and Wrought al-
loys.
Application of Aluminum
• Application - aerospace and automotive applications where
weight savings are needed for better fuel efficiency and per-
formance, electrical equipments, cooking utensils various ar-
chitectural components.
Al – Cu Alloys
 The aluminum-copper alloys typically contain between 2 to 10% copper,
with smaller additions of other elements.
 The copper provides substantial increases in strength hardening.
 The introduction of copper to aluminum can also reduce ductility and cor-
rosion resistance
Application of Al –cu alloys
• Applications - aerospace, military vehicles .and rocket fins
Magnesium Alloys
 Magnesium alloys are mixtures of magnesium with other metals such as
aluminum, zinc, manganese, silicon, copper and zirconium.
 Magnesium - Lightest among commonly used metals (1.7g/cm3).
 Magnesium alloys have a hexagonal lattice structure having Melting point
is 6500C .
 Is very reactive and readily combustible in air Can be used as igniter or
fire starter.
 Excellent corrosion resistance.
 good damping capacity - effective for high-speed applications
Application of Magnesium Alloys
• Applications -Auto parts, power tools, aerospace equipment,
electronic gadgets, Automotive applications include gear-
boxes, valve covers, alloy wheels, clutch housings, and brake
pedal brackets
Titanium alloys
 Titanium alloys are alloys that contain a mixture of titanium and other
chemical elements.
 Such alloys have very high tensile strength and toughness.
 They are light in weight, have extraordinary corrosion resistance and the
ability to withstand extreme temperatures.
 Titanium has high affinity to oxygen – strong deoxidizer, Can catch fire
and cause severe damage.
 Can be used in elevated temperature components.
Titanium Alloys

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Unit – V

Alloying of steel, properties of stainless steel and

 Foundation for big machines

ferrite or pearlite matrix

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