High Profile Call Girls Nagpur Isha Call 7001035870 Meet With Nagpur Escorts
material selection.pptx
1. Material Selection
Contents
•Introduction
•Importance of Material Selection
•IndustrialApplications
•Material Properties Required
•Available Materials
•Fabrication Techniques
•Selection Criteria
•Selection Methodology
klcenter@gmail.com
2.
3. Sharing Experiences
Material Selection
Man & Materials
Stone Age to Space Age
•Meeting Needs
•Incomplete Knowledge
•Curiosity to Know More
Koncept Learning Center klcenter@gmail.com
9. Sharing Experiences
Material Selection
Industrial Applications
• Fluid Storage
• Fluid Transportation
• Fluid Heating/Cooling
• Fluid Conversion
• Fluid Separation
In Chemical Plant • Equipment
• Piping
• Instrument
• Electrical
• Civil/ Structure
Koncept Learning Center klcenter@gmail.com
10. Sharing Experiences
Material Selection
Industrial Applications
Equipment for Fluid Storage
Koncept Learning Center klcenter@gmail.com
Fluid
Water
Grains
Ethanol
Sulfuric Acid
Chlorine
Milk
Condition
Atmosphere
High Pressure
Vacuum
High Temperature
Low Temperature
Equipment
Concrete Pits
Riveted Silos
CS Welded Tanks
Epoxy Lined Tanks
SS Welded Tanks
Smooth Surface Finish Tanks
11. Sharing Experiences
Material Selection
Material Properties Required
•Mechanical – Strength, Elastic Modulus
•Electrical – Conductivity, Dielectric Constant
•Thermal – Heat Capacity, Thermal Conductivity
•Magnetic – Response of Material in Magnetic Field
•Optical – High Radiation, Index of Reflection/ Refraction
•Deteriorative – Chemical Reactivity of Materials
Koncept Learning Center klcenter@gmail.com
12. Sharing Experiences
Material Selection
Available Materials
Koncept Learning Center klcenter@gmail.com
•Metals – Strong, Heat Transfer, Deformable
•Ceramics – Hard but Brittle, Insulation
•Polymers – Light, Flexible, Compressible
•Composites – Strength of Fiber & Flexibility of Polymer
14. Sharing Experiences
Material Selection
Available Materials
Metal
Alloys
Koncept Learning Center klcenter@gmail.com
Ferrous
Steel
Low Alloys
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
High
Alloys
Tool Stainless
Cast Iron
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Non-
Ferrous
15. Sharing Experiences
Material Selection
Available Materials
Metal
Alloys
Koncept Learning Center klcenter@gmail.com
Ferrous
Steel
Low Alloys
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
High
Alloys
Tool Stainless
Cast Iron
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Non-
Ferrous
Steels : C < 1.0 %wt
Cast Iron : C > 2.14 %wt
16. Sharing Experiences
Material Selection
Available Materials
Low Alloys
Koncept Learning Center klcenter@gmail.com
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
High
Alloys
Tool Stainless
Steel Cast Iron
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Metal
Alloys
Ferrous Non-
Ferrous
Low Carbon Steels (C < 0.25 %wt)
•These alloys relatively soft and weak but have outstanding Ductility & Toughness.
•They are Machinable, Weldable, Least Expensive
•Applications: Automobile Body Parts, Structural Shapes (I-Beam, Channels)
17. Sharing Experiences
Material Selection
Available Materials
Low Alloys
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
High
Alloys
Tool Stainless
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Koncept Learning Center klcenter@gmail.com
Metal
Alloys
Ferrous Non-
Ferrous
Steel Cast Iron
High Strength, Low Alloy
•Contain alloying elements such as copper, vanadium, nickel and molybdenum
•Higher strength than Plain Carbon Steel
•Strengthen by heat treatment
•Ductile, Formable and Machinable
•More resistant to corrosion than plain Carbon Steel
18. Sharing Experiences
Material Selection
Available Materials
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
Tool Stainless
ble
Iron
Metal
Alloys
Ferrous Non-
Ferrous
Steel Cast Iron
Low Alloys High Grey Iron Ductile White Mallea
Medium Carbon Steel (C: 0.25 – 0.60 %wt)
•May be heat treated by austenitizing, quenching and then tempering to improve
mechanical properties
•Plain medium carbon steels – Low harden abilities, can be heat treated only in thin
sections and with very rapid quenching rates
•Heat treated alloys are stronger than low carbon steels but at sacrifice of ductility
and toughness
Alloys Iron Iron
Koncept Learning Center klcenter@gmail.com
19. Sharing Experiences
Material Selection
Available Materials
Low Alloys
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
High
Alloys
Tool Stainless
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Koncept Learning Center klcenter@gmail.com
Metal
Alloys
Ferrous Non-
Ferrous
Steel Cast Iron
High Carbon Steel (C: 0.60 – 1.40 %wt)
•Hardest, Strongest, yet least ductile of carbon steel
•Used in a hardened and tempered conditions especially wear resistant and capable
of holding sharp cutting edge
•Tools & Die steels
•Knives, Razors, Hacksaw Blades
20. Sharing Experiences
Material Selection
Available Materials
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
Tool Stainless
eable
on
Metal
Alloys
Ferrous Non-
Ferrous
Steel Cast Iron
Low Alloys High Grey Iron Ductile White Mall
Alloys Iron Iron Ir
Stainless Steel
•Highly resistant to Corrosion
•3-Classes
•Martensitic (AISI-410) – Used for Cutlery, Riffle Barrel, Jet Engine Parts
•Ferritic (AISI-409) – Used for Automatic Exhaust Components
•Austenitic
•AISI-304 – Used for Chemical & Food Processing Equipment
•AISI-316L – Used for Welding Construction
Koncept Learning Center klcenter@gmail.com
21. Sharing Experiences
Material Selection
Available Materials
•Typical Composition of SS
Koncept Learning Center klcenter@gmail.com
SS304 SS304L SS316 SS316L
C (Max) 0.08% 0.03% 0.08% 0.03%
N 0.10% 0.10% 0.10% 0.10%
Cr 18-20% 18-20% 16-18% 16-18%
Ni 8-10.5% 8-12% 10-14% 10-14%
Mo - - 2-3% 2-3%
Si (Max) 0.75% 0.75% 0.75% 0.75%
P 0.045% 0.045% 0.045% 0.045%
S 0.03% 0.03% 0.03% 0.03%
22. Sharing Experiences
Material Selection
SS304 SS304L SS316 SS316L
C (Max) 0.08% 0.03% 0.08% 0.03%
N 0.10% 0.10% 0.10% 0.10%
Cr 18-20% 18-20% 16-18% 16-18%
Ni 8-10.5% 8-12% 10-14% 10-14%
Mo - - 2-3% 2-3%
Si (Max) 0.75% 0.75% 0.75% 0.75%
P 0.045% 0.045% 0.045% 0.045%
S 0.03% 0.03% 0.03% 0.03%
Available Materials
•Typical Composition of SS
Influence of Components on Material Properties
Cr – for Oxide Film Formation
Ni – for Toughness, Ductability and ease of Weldability improves, Improves Oxide Film Formation
Mo – for improving Pitting & Crevice Corrosion Resistance, Elevated Temperature Mechanical Properties Improves
C, N – to Increase Strength & Hardness
S, Se, Pb – to Improve Machinability, Prolong Tool Life and Reduces Machining Power Requirement.
Ti, Co, Ta – to prevent Sensitization and thereby eliminate susceptibility to inter-granular corrosion.
Columbium – improves high temperature creep strength.
Cu – improves resistance to sulfuric acid
Mn – partial substitution for Nickel
Si, Al – improves Oxidation Resistance
Koncept Learning Center klcenter@gmail.com
23. Sharing Experiences
Material Selection
Available Materials
Steel
Koncept Learning Center klcenter@gmail.com
Low Alloys
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
High
Alloys
Tool Stainless
Cast Iron
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Metal
Alloys
Ferrous Non-
Ferrous
Cast Iron (C > 2.14 %wt)
•Alloys within this composition remain liquid at temperature 1150-1300oC
•Easily melted and amenable to casting
24. Sharing Experiences
Material Selection
Available Materials
Low Alloys
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
High
Alloys
Tool Stainless
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Metal
Alloys
Ferrous Non-
Ferrous
Steel Cast Iron
Grey Iron (C : 2.5-4 %wt, Si : 1-3 %wt)
•Mechanically – comparatively weak & brittle in tension
•Strength & Ductility – much higher under compressive loads
•Effective in dampening vibrational energy (base structure of machines & heavy
equipment exposed to vibrations)
•Least Cost
Koncept Learning Center klcenter@gmail.com
25. Sharing Experiences
Material Selection
Available Materials
Low Alloys
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
High
Alloys
Tool Stainless
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Koncept Learning Center klcenter@gmail.com
Metal
Alloys
Ferrous Non-
Ferrous
Steel Cast Iron
Ductile Iron
•Adding small amount of Mg & Cerium to Gray Iron before casting produces a
distinctly different microstructure and set of mechanical properties
•Graphite forms as nodules or sphere like particles instead of flakes
•Casting are much more stronger and ductile than Gray Iron
•Mechanical characteristics approaching those of steel
•Application: Valves, Pump Bodies, Crank Shafts, Gears
26. Sharing Experiences
Material Selection
Available Materials
Low Alloys
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
High
Alloys
Tool Stainless
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Metal
Alloys
Ferrous Non-
Ferrous
Steel Cast Iron
White Iron & Malleable Iron
•White iron – extremely hard due to cementite phase, but also brittle
(unmachinable)
•Used for very hard and wear resistant surface and without a high degree of ductility
e.g. rollers in rolling mills
•Connecting rods, transmission gears, flanges, pipe fittings
Koncept Learning Center klcenter@gmail.com
27. Sharing Experiences
Material Selection
Fabrication Techniques
Metal Fabrication Techniques
Koncept Learning Center klcenter@gmail.com
Forming
Forging
Rolling
Extrusion
drawing
Casting
Sand
Die
Investment
Continuous
Misc.
Powder Metallurgy
Welding
28. Sharing Experiences
Material Selection
Fabrication Techniques
Metal Fabrication Techniques
Forming
Forging
Rolling
Extrusion
drawing
Casting Misc.
Sand Powder Metallurgy
Die Welding
Investment
Continuous
Forming : Shape of metal piece is
changed by plastic deformation
•Forging – Hot metal put in Die
•Rolling – Metal passed through rollers
•Extrusion – Hot metal passed through Die
•Drawing – Metal pulled like wire making
Koncept Learning Center klcenter@gmail.com
29. Sharing Experiences
Material Selection
Fabrication Techniques
Metal Fabrication Techniques
Forming
Forging
Rolling
Extrusion
drawing
Casting
Sand
Die
Investment
Continuous
Misc.
Powder Metallurgy
Welding
Casting: Molten metal is
poured into a mould cavity
having desired shape
•Sand – Liquid metal in
sand mold
•Die – Liquid metal under
pressure in mold
•Investment – Wax casting
•Continuous – Casting with
Koncept Learning Center klcenter@gmail.com
Forming
30. Sharing Experiences
Material Selection
Fabrication Techniques
Metal Fabrication Techniques
c.
Forming Casting
Mis
Forging Sand
Rolling Die
Extrusion Investment
drawing Continuous
Powder Metallurgy
Welding
Welding: High te
Koncept Learning Center klcenter@gmail.com
mperatur
e
fusion.
•Alteration of properties/ microstructures
•If work piece material was previously cold worked, heat
affected zone may have experienced re-crystallization and
grain growth , thus diminishment of strength, hardness and
toughness
•Upon cooling, residual stresses may form in this region,
which weakens the joint
•For steels, material heated to form Austenite
•Some stainless steels may be “sensitized” during welding
which renders them susceptible to inter-granular corrosion.
32. Sharing Experiences
Material Selection
Selection Criteria
A.) Operating Conditions
•Pressure – Plastic/ rubber will not be suitable for high
pressure applications
•Temperature – For high temperature applications like
furnaces, even metals will not be suitable
•Fluid Concentration – Low alloy materials may not be
suitable for high concentration acids/ alkalies
Koncept Learning Center klcenter@gmail.com
33. Sharing Experiences
Material Selection
Selection Criteria
B.) Fabrication Requirement
• Cutting
• Welding
• Molding
• Forging
• Casting
• Grinding (Polishing)
• Hardening
Koncept Learning Center klcenter@gmail.com
34. Sharing Experiences
Material Selection
Selection Criteria
Koncept Learning Center klcenter@gmail.com
C.) Environmental Conditions
• Salty wind in coastal area
• High humidity air
• Hot or cold environment
36. Sharing Experiences
Material Selection
Selection Criteria
E.) Other Requirements
• Thermal Conductivity – Insulation, Heat Exchanger Tubes
• Electrical Conductivity – Earthing
• Compressibility – For sealing of fluids
• Flexibility – hoses
• Economics – Cheaper is better
• Ease of Operation – Light material like rubber hose
• Safe in Operation – Glass wool with Al cladding
Koncept Learning Center klcenter@gmail.com
38. Sharing Experiences
Material Selection
Selection Criteria
Commercial Gas Cylinder
Available Options
•Metal
•Ceramics
•Polymers
•Semi-conductors
•Composites
High Strength but poor ductility
Koncept Learning Center klcenter@gmail.com
High Strength & Ductility but High Cost
Requirements
Strength Ductility Cost
High Strength & Ductility with Low Cost (Selected)
39. Sharing Experiences
Material Selection
Selection Criteria
Commercial Gas Cylinder Metal
Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain T
Cast Iron
High Grey Iron Ductile
Alloys Iron
Tool Stainless
ool
White
Iron
Malleable
Iron
Non-
Ferrous
ASTM A414-Grade G
Iron
+ 0.31 wt% C (max)
+ 1.35 wt% Mn (max)
+ 0.035 wt% P (max)
+ 0.04 wt% S (max)
Koncept Learning Center klcenter@gmail.com
40. Sharing Experiences
Material Selection
Selection Criteria
Aero Space Pressure Vessel
Available Options
•Metal
•Ceramics
•Polymers
•Semi-conductors
•Composites
Requirements
Strength Ductility Cost
Despite High Cost, Need of Light Material
makes Composite as Suitable Material
Koncept Learning Center klcenter@gmail.com
41. Sharing Experiences
Material Selection
Selection Criteria
Liquid Bulk Storage Tank
• Non-Corrosive Liquid : Carbon Steel Plates (IS2061)
• Salt Solution (Brine) : Carbon Steel Rubber Lined (CSRL)
• Corrosive Liquid : SS-304 Plates
• Hygienic Liquids (Milk) : SS-316 Plates with high surface finish
Koncept Learning Center klcenter@gmail.com
42. Sharing Experiences
Material Selection
Selection Criteria
Reactor
• Shell Plates
• Undergoes Cutting, Rolling, Welding
• Selected MOC Code: ASTM-A240 TP304
• Equivalent Steel Grades : BS-1501 Gr 304S15, IS-1570
Koncept Learning Center klcenter@gmail.com
43. Sharing Experiences
Material Selection
Selection Criteria
Reactor
• Nozzles
• Pipe Material Specifications
• Selected MOC Code : ASTM- A312 TP304
• Equivalent Steel Grade : BS-3605 Gr.304S18
Koncept Learning Center klcenter@gmail.com
