2.1 Concept of phase, pure metal, alloy and solid solutions.
2.2 i Iron Carbon Equilibrium diagram various phases Critical temperatures and significance ii. Reactions on Iron carbon equilibrium diagram
2.3 Broad Classification of steels
i. Plain carbon steels: Definition, Types and Properties, Compositions and applications of low, medium and high carbon steels
ii. Alloy Steels: Definition and Effects of alloying elements on properties of alloy steels.iii. Tool steels: Cold work tool steels, Hot work tool steels, High speed steels(HSS) iv. Stainless Steels: Types and Applications v. Spring Steels: Composition and Applications vi. Specifications of steels and their equivalents
2.4 Steels for following: Shafts, axles, Nuts, bolts, Levers, crank shafts, camshafts, Shear blades, agricultural equipments, house hold utensils, machine tool beds, car bodies, Antifriction bearings and gears
4.1 Copper and its alloys - brasses, bronzes Chemical compositions, properties and Applications.
4.2 Aluminium alloys –Y-alloy, Hindalium, duralium with their composition and
Applications.
4.3 Bearing materials like white metals (Sn based), aluminium bronzes. Porous, Self lubricating bearings
3.1 Types of cast irons as white, gray, nodular, malleable
3.2 Specifications of cast Iron.
3.3 Selection of appropriate cast iron for engineering applications.
3.4 Designation and coding (as per BIS, ASME, EN, DIN, JIS) of cast iron, plain and alloy steel.
5.1 Polymeric Materials i. Polymers- types, characteristics, ii. Properties and uses of Thermoplastics, Thermosetting Plastics and Rubbers.
5.2 Thermoplastic and Thermosetting Plastic materials
5.3 Characteristics and uses of ABS, Acrylics. Nylons and Vinyls,Epoxides, Melamines and Bakelites
5.4 Rubbers: Neoprene, Butadiene, Buna and Silicons – Properties and applications.
5.5 Ceramics –types of ceramics, properties and applications of glasses and
refractories
5.6 Composite Materials - properties and applications of Laminated and Fibre
reinforced materials
5.7 Advanced Engineering Materials Properties and applications of Nano
materials and smart materials
1.1 Classification of engineering materials.
1.2 Crystal structure, Unit cell and space lattice
1.3 Microstructure, types of microscopes
1.4 Sample preparation, etching process, types of etchant.
1.5 Properties of metals Physical Properties, Mechanical Properties.
1.6 Hardness testing procedure on Brinell and Rockwell tester
Alloy steel is steel that contains other alloying elements in addition to carbon. Common alloying elements include manganese, nickel, chromium, molybdenum, vanadium, silicon, and boron. Alloy steel has improved properties over carbon steel such as higher tensile strength, hardness, toughness, wear resistance, creep resistance, and high temperature resistance. These properties make alloy steel suitable for applications in automotive, engineering, construction, agriculture, home goods, and military uses. Production of alloy steel has been increasing to meet the demands of growing industries such as automotive and engineering.
6.1 Annealing: Purposes of annealing, Annealing temperature range, Types and applications
6.2 Normalizing: Purposes of Normalizing, Temperature range, Broad applications of Normalizing
6.3 Hardening: Purposes of hardening, Hardening temperature range ,application
6.4 Tempering: Purpose of tempering, Types of tempering and its applications
6.5 Case hardening methods like Carburizing, Nitriding, and Cyaniding.
6.6 Heat treatment Furnaces – Muffle , Box type
1. Carbon steels are classified as mild, medium, and high carbon based on their carbon content ranging from 0.05% to 1.5%. Mild steels contain up to 0.3% carbon, medium steels contain 0.3-0.7% carbon, and high carbon steels contain 0.7-1.5% carbon.
2. Alloy steels contain additional alloying elements added in amounts exceeding 1% to improve properties such as strength, corrosion resistance, and hardenability. Common alloying elements include chromium, nickel, molybdenum, and vanadium.
3. Stainless steels contain a minimum of 11.5% chromium which
The document describes the process of forming iron and steel using a blast furnace. It involves the following key steps:
1. Sinter is added to the top of the blast furnace. Air is blasted into the bottom to fuel reactions that melt the iron out of the sinter.
2. Molten iron collects at the bottom of the furnace and is tapped out periodically. Slag floats on top and is also tapped out. Wasted gases exit from the top.
3. The iron produced contains carbon and impurities, making it cast iron. Steel is made by removing carbon from cast iron through oxidation, then adding other metals to produce alloys with specific properties.
4.1 Copper and its alloys - brasses, bronzes Chemical compositions, properties and Applications.
4.2 Aluminium alloys –Y-alloy, Hindalium, duralium with their composition and
Applications.
4.3 Bearing materials like white metals (Sn based), aluminium bronzes. Porous, Self lubricating bearings
3.1 Types of cast irons as white, gray, nodular, malleable
3.2 Specifications of cast Iron.
3.3 Selection of appropriate cast iron for engineering applications.
3.4 Designation and coding (as per BIS, ASME, EN, DIN, JIS) of cast iron, plain and alloy steel.
5.1 Polymeric Materials i. Polymers- types, characteristics, ii. Properties and uses of Thermoplastics, Thermosetting Plastics and Rubbers.
5.2 Thermoplastic and Thermosetting Plastic materials
5.3 Characteristics and uses of ABS, Acrylics. Nylons and Vinyls,Epoxides, Melamines and Bakelites
5.4 Rubbers: Neoprene, Butadiene, Buna and Silicons – Properties and applications.
5.5 Ceramics –types of ceramics, properties and applications of glasses and
refractories
5.6 Composite Materials - properties and applications of Laminated and Fibre
reinforced materials
5.7 Advanced Engineering Materials Properties and applications of Nano
materials and smart materials
1.1 Classification of engineering materials.
1.2 Crystal structure, Unit cell and space lattice
1.3 Microstructure, types of microscopes
1.4 Sample preparation, etching process, types of etchant.
1.5 Properties of metals Physical Properties, Mechanical Properties.
1.6 Hardness testing procedure on Brinell and Rockwell tester
Alloy steel is steel that contains other alloying elements in addition to carbon. Common alloying elements include manganese, nickel, chromium, molybdenum, vanadium, silicon, and boron. Alloy steel has improved properties over carbon steel such as higher tensile strength, hardness, toughness, wear resistance, creep resistance, and high temperature resistance. These properties make alloy steel suitable for applications in automotive, engineering, construction, agriculture, home goods, and military uses. Production of alloy steel has been increasing to meet the demands of growing industries such as automotive and engineering.
6.1 Annealing: Purposes of annealing, Annealing temperature range, Types and applications
6.2 Normalizing: Purposes of Normalizing, Temperature range, Broad applications of Normalizing
6.3 Hardening: Purposes of hardening, Hardening temperature range ,application
6.4 Tempering: Purpose of tempering, Types of tempering and its applications
6.5 Case hardening methods like Carburizing, Nitriding, and Cyaniding.
6.6 Heat treatment Furnaces – Muffle , Box type
1. Carbon steels are classified as mild, medium, and high carbon based on their carbon content ranging from 0.05% to 1.5%. Mild steels contain up to 0.3% carbon, medium steels contain 0.3-0.7% carbon, and high carbon steels contain 0.7-1.5% carbon.
2. Alloy steels contain additional alloying elements added in amounts exceeding 1% to improve properties such as strength, corrosion resistance, and hardenability. Common alloying elements include chromium, nickel, molybdenum, and vanadium.
3. Stainless steels contain a minimum of 11.5% chromium which
The document describes the process of forming iron and steel using a blast furnace. It involves the following key steps:
1. Sinter is added to the top of the blast furnace. Air is blasted into the bottom to fuel reactions that melt the iron out of the sinter.
2. Molten iron collects at the bottom of the furnace and is tapped out periodically. Slag floats on top and is also tapped out. Wasted gases exit from the top.
3. The iron produced contains carbon and impurities, making it cast iron. Steel is made by removing carbon from cast iron through oxidation, then adding other metals to produce alloys with specific properties.
This document provides an overview of basic metallurgy. It discusses the classification of materials, including metals and alloys, ceramics, polymers, and composites. The key metallurgy processes of casting, forming, welding, and powder metallurgy are described. Advanced materials like electronic materials, biomaterials, and nanomaterials are also introduced. The document is authored by K. Sevugarajan of Metz Lab Pvt. Ltd and provides their contact information.
The document discusses various topics related to iron making and steel production, including:
1. It defines metallurgy and divides it into extractive metallurgy, physical metallurgy, and other subfields. Extractive metallurgy involves separating and concentrating raw materials.
2. It describes the production of pig iron using a blast furnace, which involves heating iron ore with coke to produce a molten iron alloy containing 3-4% carbon.
3. It then discusses the various processes for producing steel from pig iron, including the Bessemer process, open hearth furnace, and basic oxygen furnace, which reduce the carbon and impurity levels in pig iron
Ladle Metallurgy: Basics, Objectives and ProcessesElakkiya Mani
Worldwide steel production in 2019 reached 1869 million tons, with China as the largest producer at 996 million tons. India was the second largest steel producer at 111 million tons. Ladle metallurgy involves further refining of molten steel in a ladle after tapping from a converter or electric furnace. It allows for homogenization, deoxidation, desulfurization, and other processes. Key ladle metallurgy techniques include ladle furnace treatment, argon stirring, vacuum degassing, and alloy additions to adjust steel chemistry and properties.
This document discusses the effects of various alloying elements in steel, including manganese, silicon, chromium, molybdenum, vanadium, and copper. Manganese increases strength and hardness while promoting an austenitic structure. Silicon improves electrical and magnetic properties as well as oxidation resistance. Chromium increases corrosion and oxidation resistance along with hardenability. Molybdenum improves creep resistance and reduces temper brittleness. Vanadium stabilizes carbides and increases strength while maintaining ductility. Copper increases strength and corrosion resistance. Each of these elements is added in specific amounts to steel to achieve desired properties for applications like gears, shafts, springs, and architectural materials.
This document provides an overview of aluminum alloys, including their chemistry, classification system, applications, manufacturing processes, heat treatments, and common defects. It discusses the major alloying elements used in aluminum like copper, manganese, silicon, magnesium, and zinc. It also summarizes the various production methods for wrought aluminum alloys like extrusion and heat treating processes like annealing, solution heat treatment, and precipitation hardening. Finally, it outlines typical casting, extrusion, forging, and heat treatment defects seen in aluminum alloys.
This document provides an overview of various non-ferrous alloys including copper alloys like brass and bronze, aluminium alloys like duralumin and silumin, titanium alloys like Ti-6Al-4V, magnesium alloys and their properties and applications. It discusses the alloying elements, strengthening mechanisms, microstructure and common types of each alloy. Key alloys and their uses in various industries are also summarized.
This document discusses the basics of tool steels, including their types and applications. It outlines the four key factors for successful tool steel application: tool design, fabrication accuracy, steel selection, and heat treatment. It then describes various types of tool steel grouped by their intended application, such as high speed steels, hot work steels, cold work steels, shock resisting steels, and mold steels. For each group, it provides details on composition, hardness, uses, and heat treatment considerations.
The document classifies and describes different types of plain carbon and alloy steels. It discusses three types of plain carbon steels based on carbon content: low carbon steels containing less than 0.25% carbon, medium carbon steels containing 0.25-0.60% carbon, and high carbon steels containing more than 0.60% carbon. It then provides details on properties, applications and heat treatment of each type. The document also classifies alloy steels into low alloy steels containing 3-4% alloying elements and high alloy steels containing over 5% alloying elements. It discusses AISI, HSLA, tool/die and stainless varieties of alloy steels.
The document discusses materials science and engineering, specifically focusing on the production of iron and steel. It begins with an introduction to materials science and engineering. It then describes the production process of pig iron, including raw material procurement, blast furnace production, and products. It further discusses various steel production methods like basic oxygen furnace and electric arc furnace production. Continuous casting and different steel products are also outlined. In summary, the document provides an overview of the key industrial processes for producing iron and steel, from raw materials to final products.
Ch 27.7 alloying element of steel and alloy steelNandan Choudhary
Alloy steel is steel to which other elements have been added to achieve particular properties. Nickel increases strength and toughness. Invar, containing 36% nickel, has nearly zero coefficient of expansion. Austenitic stainless steel contains 18% chromium and 8% nickel which stabilizes the austenitic structure. It is non-magnetic, corrosion resistant and cannot be hardened by heat treatment. Chromium provides corrosion resistance in stainless steel by forming a protective oxide layer.
This document discusses aluminum alloys, including their types, heat treatment, and common alloying elements. It covers casting and wrought alloys, with casting alloys further divided based on their alloying elements like copper, silicon, magnesium, zinc, and tin. Heat treatable alloys can be strengthened through heat treatment to form precipitates, while non-heat treatable alloys rely on solid solution strengthening. Common alloying elements are discussed along with their effects on properties and example commercial alloys.
This document discusses various ferrous materials including steels and cast irons. It describes the classification, properties and applications of different types of steels such as plain-carbon steels, mild steel, high-carbon steel, alloy steels, tool steels and stainless steels. It also discusses the effects of common alloying elements added to steel like manganese, chromium, nickel, molybdenum, and titanium.
This document summarizes super alloys, including their properties, applications, classifications, microstructure, and heat treatment. Super alloys exhibit high strength and corrosion/oxidation resistance at high temperatures due to strengthening from solid solution strengthening and precipitation hardening. They are classified based on their primary metal (nickel, iron, cobalt) and are used in applications such as jet engines and gas turbines due to their high temperature capabilities. Their microstructure includes a gamma matrix and gamma prime precipitates that increase strength. Heat treatments are used to control the precipitates and carbides for optimal properties.
This training report summarizes Santosh Kumar's summer training at the Rourkela Steel Plant from May to July 2014. It thanks the employees who supported and guided his training, particularly Mr. Panda and Mr. Patra. The report focused on gaining knowledge about the various processes used at the steel plant, especially in Steel Melting Shop-II.
The document is an industrial training report submitted by Abhishek Prajapati to OP Jindal University about his 4-week training at the DRI-1 (Direct Reduced Iron) section of Jindal Steel & Power Limited (JSPL) in Raigarh, Chhattisgarh, India. It provides an overview of the DRI production process, including information on raw materials, the rotary kiln, rotary cooler, and power distribution systems. The student thanks his guides Mr. Vivek Garg and Mr. Shalendra Pratap Singh for enabling his learning experience at the facility.
Production of Direct Reduced Iron in Rotary Hearth FurnaceSateesh Kumar
The document discusses the production of direct reduced iron (DRI) using a rotary hearth furnace (RHF). DRI is produced by reducing iron ore to a purity of 90-97% iron through a process using reducing gases like hydrogen and carbon monoxide at high temperatures below iron's melting point. In an RHF, iron ore and carbon pellets are heated on a rotating hearth through burners as the iron oxides are reduced over 6-12 minutes to produce DRI pellets. The furnace uses heat transfer primarily through radiation to facilitate the exothermic reduction reactions between iron oxides and reducing gases like carbon monoxide to produce solid sponge iron. RHF allows for efficient and lower cost
High strength interstitial free (IF) steels are produced with low carbon and nitrogen contents stabilized by titanium and niobium precipitates. These steels are soft and ductile without interstitial atoms. Three types of strengthening are used: precipitation strengthening from Ti and Nb carbides, and solid solution strengthening from alloying with phosphorus, silicon, and manganese. High strength IF steels can have tensile strengths ranging from 210 to 400 MPa while maintaining excellent formability for automotive applications like deep drawing. Heat treatments and alloying compositions are optimized to produce the desired mechanical properties.
Maraging steels are carbon-free iron alloys that are strengthened through precipitation hardening rather than carbon content. They contain additions of nickel, cobalt, molybdenum, titanium, and aluminum. Maraging steels are heat treated through solution treatment to form a martensitic structure, followed by aging to precipitate hardening intermetallic compounds within the martensite. This provides maraging steels with ultra-high strength even at elevated temperatures, along with excellent toughness. Common applications include aerospace components, ordnance, and tooling due to their combination of high strength, corrosion resistance, and fatigue endurance.
The document discusses different types of metals and alloys used in engineering. It describes ferrous metals like steel and cast iron, which are alloys of iron and carbon. It also discusses nonferrous metals like aluminum and copper, as well as superalloys. Key production processes for metals are described, including ironmaking in a blast furnace and steelmaking using basic oxygen or electric arc furnaces. Phase diagrams are introduced to show the different phases that can exist in metal alloys at various temperatures and compositions.
The document discusses the iron-carbon equilibrium diagram, which shows the different crystal structures of iron alloys at various temperatures and carbon concentrations. It defines the ferrite, austenite, and cementite phases and explains how their proportions change with cooling in hypoeutectoid, eutectoid, and hypereutectoid steel compositions. The key phase changes of peritectic, eutectic, and eutectoid reactions are also summarized along with how the diagram is used to understand the microstructures and properties of steels and cast irons.
This document provides an overview of basic metallurgy. It discusses the classification of materials, including metals and alloys, ceramics, polymers, and composites. The key metallurgy processes of casting, forming, welding, and powder metallurgy are described. Advanced materials like electronic materials, biomaterials, and nanomaterials are also introduced. The document is authored by K. Sevugarajan of Metz Lab Pvt. Ltd and provides their contact information.
The document discusses various topics related to iron making and steel production, including:
1. It defines metallurgy and divides it into extractive metallurgy, physical metallurgy, and other subfields. Extractive metallurgy involves separating and concentrating raw materials.
2. It describes the production of pig iron using a blast furnace, which involves heating iron ore with coke to produce a molten iron alloy containing 3-4% carbon.
3. It then discusses the various processes for producing steel from pig iron, including the Bessemer process, open hearth furnace, and basic oxygen furnace, which reduce the carbon and impurity levels in pig iron
Ladle Metallurgy: Basics, Objectives and ProcessesElakkiya Mani
Worldwide steel production in 2019 reached 1869 million tons, with China as the largest producer at 996 million tons. India was the second largest steel producer at 111 million tons. Ladle metallurgy involves further refining of molten steel in a ladle after tapping from a converter or electric furnace. It allows for homogenization, deoxidation, desulfurization, and other processes. Key ladle metallurgy techniques include ladle furnace treatment, argon stirring, vacuum degassing, and alloy additions to adjust steel chemistry and properties.
This document discusses the effects of various alloying elements in steel, including manganese, silicon, chromium, molybdenum, vanadium, and copper. Manganese increases strength and hardness while promoting an austenitic structure. Silicon improves electrical and magnetic properties as well as oxidation resistance. Chromium increases corrosion and oxidation resistance along with hardenability. Molybdenum improves creep resistance and reduces temper brittleness. Vanadium stabilizes carbides and increases strength while maintaining ductility. Copper increases strength and corrosion resistance. Each of these elements is added in specific amounts to steel to achieve desired properties for applications like gears, shafts, springs, and architectural materials.
This document provides an overview of aluminum alloys, including their chemistry, classification system, applications, manufacturing processes, heat treatments, and common defects. It discusses the major alloying elements used in aluminum like copper, manganese, silicon, magnesium, and zinc. It also summarizes the various production methods for wrought aluminum alloys like extrusion and heat treating processes like annealing, solution heat treatment, and precipitation hardening. Finally, it outlines typical casting, extrusion, forging, and heat treatment defects seen in aluminum alloys.
This document provides an overview of various non-ferrous alloys including copper alloys like brass and bronze, aluminium alloys like duralumin and silumin, titanium alloys like Ti-6Al-4V, magnesium alloys and their properties and applications. It discusses the alloying elements, strengthening mechanisms, microstructure and common types of each alloy. Key alloys and their uses in various industries are also summarized.
This document discusses the basics of tool steels, including their types and applications. It outlines the four key factors for successful tool steel application: tool design, fabrication accuracy, steel selection, and heat treatment. It then describes various types of tool steel grouped by their intended application, such as high speed steels, hot work steels, cold work steels, shock resisting steels, and mold steels. For each group, it provides details on composition, hardness, uses, and heat treatment considerations.
The document classifies and describes different types of plain carbon and alloy steels. It discusses three types of plain carbon steels based on carbon content: low carbon steels containing less than 0.25% carbon, medium carbon steels containing 0.25-0.60% carbon, and high carbon steels containing more than 0.60% carbon. It then provides details on properties, applications and heat treatment of each type. The document also classifies alloy steels into low alloy steels containing 3-4% alloying elements and high alloy steels containing over 5% alloying elements. It discusses AISI, HSLA, tool/die and stainless varieties of alloy steels.
The document discusses materials science and engineering, specifically focusing on the production of iron and steel. It begins with an introduction to materials science and engineering. It then describes the production process of pig iron, including raw material procurement, blast furnace production, and products. It further discusses various steel production methods like basic oxygen furnace and electric arc furnace production. Continuous casting and different steel products are also outlined. In summary, the document provides an overview of the key industrial processes for producing iron and steel, from raw materials to final products.
Ch 27.7 alloying element of steel and alloy steelNandan Choudhary
Alloy steel is steel to which other elements have been added to achieve particular properties. Nickel increases strength and toughness. Invar, containing 36% nickel, has nearly zero coefficient of expansion. Austenitic stainless steel contains 18% chromium and 8% nickel which stabilizes the austenitic structure. It is non-magnetic, corrosion resistant and cannot be hardened by heat treatment. Chromium provides corrosion resistance in stainless steel by forming a protective oxide layer.
This document discusses aluminum alloys, including their types, heat treatment, and common alloying elements. It covers casting and wrought alloys, with casting alloys further divided based on their alloying elements like copper, silicon, magnesium, zinc, and tin. Heat treatable alloys can be strengthened through heat treatment to form precipitates, while non-heat treatable alloys rely on solid solution strengthening. Common alloying elements are discussed along with their effects on properties and example commercial alloys.
This document discusses various ferrous materials including steels and cast irons. It describes the classification, properties and applications of different types of steels such as plain-carbon steels, mild steel, high-carbon steel, alloy steels, tool steels and stainless steels. It also discusses the effects of common alloying elements added to steel like manganese, chromium, nickel, molybdenum, and titanium.
This document summarizes super alloys, including their properties, applications, classifications, microstructure, and heat treatment. Super alloys exhibit high strength and corrosion/oxidation resistance at high temperatures due to strengthening from solid solution strengthening and precipitation hardening. They are classified based on their primary metal (nickel, iron, cobalt) and are used in applications such as jet engines and gas turbines due to their high temperature capabilities. Their microstructure includes a gamma matrix and gamma prime precipitates that increase strength. Heat treatments are used to control the precipitates and carbides for optimal properties.
This training report summarizes Santosh Kumar's summer training at the Rourkela Steel Plant from May to July 2014. It thanks the employees who supported and guided his training, particularly Mr. Panda and Mr. Patra. The report focused on gaining knowledge about the various processes used at the steel plant, especially in Steel Melting Shop-II.
The document is an industrial training report submitted by Abhishek Prajapati to OP Jindal University about his 4-week training at the DRI-1 (Direct Reduced Iron) section of Jindal Steel & Power Limited (JSPL) in Raigarh, Chhattisgarh, India. It provides an overview of the DRI production process, including information on raw materials, the rotary kiln, rotary cooler, and power distribution systems. The student thanks his guides Mr. Vivek Garg and Mr. Shalendra Pratap Singh for enabling his learning experience at the facility.
Production of Direct Reduced Iron in Rotary Hearth FurnaceSateesh Kumar
The document discusses the production of direct reduced iron (DRI) using a rotary hearth furnace (RHF). DRI is produced by reducing iron ore to a purity of 90-97% iron through a process using reducing gases like hydrogen and carbon monoxide at high temperatures below iron's melting point. In an RHF, iron ore and carbon pellets are heated on a rotating hearth through burners as the iron oxides are reduced over 6-12 minutes to produce DRI pellets. The furnace uses heat transfer primarily through radiation to facilitate the exothermic reduction reactions between iron oxides and reducing gases like carbon monoxide to produce solid sponge iron. RHF allows for efficient and lower cost
High strength interstitial free (IF) steels are produced with low carbon and nitrogen contents stabilized by titanium and niobium precipitates. These steels are soft and ductile without interstitial atoms. Three types of strengthening are used: precipitation strengthening from Ti and Nb carbides, and solid solution strengthening from alloying with phosphorus, silicon, and manganese. High strength IF steels can have tensile strengths ranging from 210 to 400 MPa while maintaining excellent formability for automotive applications like deep drawing. Heat treatments and alloying compositions are optimized to produce the desired mechanical properties.
Maraging steels are carbon-free iron alloys that are strengthened through precipitation hardening rather than carbon content. They contain additions of nickel, cobalt, molybdenum, titanium, and aluminum. Maraging steels are heat treated through solution treatment to form a martensitic structure, followed by aging to precipitate hardening intermetallic compounds within the martensite. This provides maraging steels with ultra-high strength even at elevated temperatures, along with excellent toughness. Common applications include aerospace components, ordnance, and tooling due to their combination of high strength, corrosion resistance, and fatigue endurance.
The document discusses different types of metals and alloys used in engineering. It describes ferrous metals like steel and cast iron, which are alloys of iron and carbon. It also discusses nonferrous metals like aluminum and copper, as well as superalloys. Key production processes for metals are described, including ironmaking in a blast furnace and steelmaking using basic oxygen or electric arc furnaces. Phase diagrams are introduced to show the different phases that can exist in metal alloys at various temperatures and compositions.
The document discusses the iron-carbon equilibrium diagram, which shows the different crystal structures of iron alloys at various temperatures and carbon concentrations. It defines the ferrite, austenite, and cementite phases and explains how their proportions change with cooling in hypoeutectoid, eutectoid, and hypereutectoid steel compositions. The key phase changes of peritectic, eutectic, and eutectoid reactions are also summarized along with how the diagram is used to understand the microstructures and properties of steels and cast irons.
The document describes the iron-carbon phase diagram. It discusses the solid phases in the diagram including ferrite, austenite, cementite, pearlite, and ledeburite. It also discusses the critical temperatures for phase changes during heating and cooling. These include the A0, A1, A2, A3, Acm, and A4 temperatures. Finally, it discusses the three invariant reactions that occur on the iron-carbon phase diagram: the peritectic reaction, eutectic reaction, and eutectoid reaction.
The iron-carbon phase diagram shows the equilibrium phases that exist at different temperatures depending on the carbon content of the alloy. It includes the following phases:
1) Ferrite - a body-centered cubic phase stable at lower temperatures.
2) Austenite - a face-centered cubic phase stable at intermediate temperatures.
3) Cementite - an iron-carbon intermetallic compound.
4) Pearlite - a lamellar structure of ferrite and cementite that forms during slow cooling of eutectoid steel.
5) Martensite - a super-saturated solid solution of carbon in ferrite that forms during rapid quenching.
1. The document discusses the iron-carbon equilibrium diagram, which shows the different phases of iron as carbon content and temperature vary.
2. It describes the different phases of iron - ferrite, austenite, cementite - and how their crystal structures and carbon solubility change with temperature.
3. Pearlite, an important microstructure in steel, is a lamellar structure composed of alternating layers of ferrite and cementite that forms during a eutectoid reaction when austenite cools below 723°C.
The document provides an introduction to steels and alloys, including:
1) Definitions of key terms like system, phase, variables, pure metal, alloy, component, and solid solution.
2) Explanations of various phases in steel like ferrite, austenite, delta-ferrite, and cementite. Critical temperatures for phase changes are also defined.
3) Descriptions of three important reactions in the iron-carbon phase diagram: peritectic, eutectoid, and eutectic reactions.
This document discusses welding metallurgy and basic metallurgical concepts relevant to welding. It covers topics like crystalline structures of metals, phase transformations, alloying effects, microstructures like ferrite, pearlite, and martensite, and the influence of cooling rate on microstructure. It also discusses the heat affected zone and issues that can arise from changes in composition and cooling rate near the weld interface.
This document provides a root cause analysis and recommendations for corrosion issues in MPL's heat recovery steam generators (HRSGs). It discusses key factors influencing corrosion rates, including metallurgy, velocity, and circulation ratio. The document analyzes root causes of boiler tube failures and factors affecting repeat failures. It provides recommendations for corrective actions, future testing, and conclusions. Attachments include thickness measurement data and boiler chemistry guidelines.
Chapter 2 ferrous material structure and binary alloy systemsakura rena
The document provides information on ferrous materials and steel production processes. It discusses the types and content of iron ore, the blast furnace process for producing iron, and the basic oxygen furnace and electric arc furnace processes for producing steel. It also covers plain carbon steel, including the iron-carbon phase diagram and the various phases (ferrite, austenite, cementite, pearlite, ledeburite). Finally, it defines alloy steel and discusses how additional alloying elements can improve steel properties and the types of alloy steels.
Mumbai University.
Mechanical Engineering
SEM III
Material Technology
MOdule 2.2
Theory of Alloys& Alloys Diagrams :
Significance of alloying, Definition, Classification and properties of different types of alloys, Solidification of pure metal, Different types of phase diagrams (Isomorphous, Eutectic,
08
University of Mumbai, B. E. (Mechanical Engineering), Rev 2016 19
Peritectic, Eutectoid, Peritectoid) and their analysis, Importance of Iron as engineering material, Allotropic forms of Iron, Influence of carbon in Iron- Carbon alloying Iron-Iron carbide diagram and its analysis
This document provides an overview of coordination complexes and crystal field theory. It begins with a description of d-block elements and transition metals, and then discusses general trends among transition metals such as periodic trends in atomic radius and reactivity. It also covers topics like common oxidation states, ligand geometries including octahedral and tetrahedral, isomers, and nomenclature rules. Finally, it introduces crystal field theory and how the arrangement of ligands around a central metal ion can split the energies of the d-orbitals.
Part-2 Leaning to plot Fe-c diagram-BNB-audio.pptBiranchiBiswal3
The document provides information about the iron-iron carbide phase diagram, including:
1) It describes the three allotropic forms of iron that exist at atmospheric pressure - alpha iron, gamma iron, and delta iron.
2) It outlines the three horizontal lines on the phase diagram which indicate isothermal reactions - the peritectic reaction at 1490°C, the eutectic reaction at 1130°C, and the eutectoid reaction at 723°C.
3) It defines several important terms related to the phase diagram including steel, cast iron, pearlite, austenite, and ferrite as well as their properties.
The document discusses heat treatment processes and the iron-carbon phase diagram. It describes the various phases in steel like ferrite, austenite, cementite and pearlite. The critical temperatures on the Fe-C diagram are defined, including eutectoid temperature A1 and eutectic temperature A4. Micrographs show the microstructures of allotriomorphic ferrite, pearlite and ledeburite. The objectives of heat treatment like increasing strength and improving properties are mentioned.
In their simplest form, steels are alloys of Iron (Fe) and Carbon (C). The Fe-C phase diagram is a fairly complex one, but we will only consider the steel and cast iron part of the diagram, up to 6.67% Carbon
Steel is an alloy of iron and other elements like carbon, silicon, and manganese. Modern steelmaking involves two main processes: basic oxygen steelmaking (BOS) and electric arc furnace steelmaking. In BOS, molten iron from a blast furnace is refined in a converter vessel by blowing oxygen and maintaining a basic slag. Impurities like carbon, silicon, phosphorus, and sulfur are oxidized and removed. Electric arc furnace steelmaking uses scrap and direct reduced iron as the raw materials, which are melted using electric arcs. Secondary steelmaking and continuous casting then further refine the steel and cast it into final shapes.
The document discusses different types of alloy steels. It begins by explaining that alloy steels have other elements added to iron beyond just carbon in order to improve properties like strength, hardness, toughness, creep resistance, and corrosion resistance.
It then classifies alloy steels into low, medium, and high alloy steels based on their composition. Low alloy steels are further broken down into low carbon, medium carbon, and high/ultra high carbon steels. High alloy steels include stainless steels and tool steels.
Stainless steels are classified as austenitic, ferritic, martensitic, or precipitation hardening depending on their microstructure. Austenitic stainless steels
This document discusses different types of steels and their manufacturing processes. It begins by classifying engineering materials and discussing ferrous metals like steels. It then defines different types of steels based on carbon content, including plain carbon steels and alloy steels. The document outlines the classification of plain carbon steels and describes common manufacturing processes like Bessemer, open hearth, electric arc furnace. It also discusses stainless steels, their composition diagrams and production methods. World steel production statistics are presented along with microstructure diagrams of plain carbon steels and the iron-carbon phase diagram.
Transition metal carbonyls form when carbon monoxide bonds to a transition metal through both sigma and pi bonding. This synergistic metal-ligand bonding strengthens the metal-carbon bond. Metal carbonyls can be classified based on the ligands present and the number/structure of metal atoms. They exhibit a variety of reactions including substitution, reactions with halogens, and disproportionation. Metal carbonyls display properties related to their toxicity, magnetic behavior, thermal stability, and thermodynamic instability.
This document summarizes Piyush Verma's presentation on the Fe-Fe3C phase diagram for plain carbon steel. It introduces the key phases in iron like ferrite, austenite, cementite and pearlite. It explains how carbon enters the iron crystal lattice and affects its properties. The phase diagram shows the different phases present at various temperatures and carbon concentrations. It also describes the mechanisms of phase transformations like reconstructive and displacive transformations during heating and cooling of steel.
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1. Program: Diploma(Mechanical)
Class: SYME
Course: Mechanical Engineering Materials(22343)
Unit 02: Steel and its Alloys
Lecture 04: Concept of phase, pure metal, alloy and solid
solutions ,Iron Carbon Equilibrium diagram
2. 1. Name of the Trainer :- Prof. S. B. Deshmukh
2. Years of Experience :- 8 Years
3. Domain Expertise :- Mechanical Engineering
www.sandipuniversity.edu.in
Presented By 02
https://www.sandipfoundation.org/
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
3. www.sandipuniversity.edu.in
Unit – 2 Steel and its Alloys 03
https://www.sandipfoundation.org/
Topic to be covered
2.1 Concept of phase, pure metal, alloy and solid solutions.
2.2 i Iron Carbon Equilibrium diagram various phases Critical temperatures and
significance ii. Reactions on Iron carbon equilibrium diagram
2.3 Broad Classification of steels
i. Plain carbon steels: Definition, Types and Properties, Compositions and applications
of low, medium and high carbon steels
ii. Alloy Steels: Definition and Effects of alloying elements on properties of alloy steels.iii.
Tool steels: Cold work tool steels, Hot work tool steels, High speed steels(HSS) iv.
Stainless Steels: Types and Applications v. Spring Steels: Composition and Applications
vi. Specifications of steels and their equivalents
2.4 Steels for following: Shafts, axles, Nuts, bolts, Levers, crank shafts, camshafts, Shear
blades, agricultural equipments, house hold utensils, machine tool beds, car bodies,
Antifriction bearings and gears.
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
4. www.sandipuniversity.edu.in
Phase, pure metal, alloy and solid solutions. 04
https://www.sandipfoundation.org/
Phase
It is a form of material having characteristics
structure and properties
It is a form of material which has identifiable
composition, structure, and boundaries separating it
from other phase in material volume
Phase equilibrium diagrams assist in the
interpretation of microstructure of metals
Equilibrium diagrams are presented in the form of
temperature versus composition and represent the
interrelationship between phases, temperature and
composition only under equilibrium conditions
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
5. www.sandipuniversity.edu.in
Phase, pure metal, alloy and solid solutions. 05
https://www.sandipfoundation.org/
Pure metal
It is a substance that contains atoms of only one type of metallic element, such as
aluminum, gold, copper, Iron, zinc, mercury, lead and zinc
. It is made into an alloy to improve the properties of a pure metal.
Most metals very rarely, if ever, appear in their pure form in nature and instead must
be extracted from a metal ore
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
7. 7
Alloy
An alloy is a mixture of two or more elements in which the main component is a metal.
The first alloy made by humans was bronze.
Most pure metals are either too soft, brittle or chemically reactive for practical use.
Combining different ratios of metals as alloys modifies the properties of pure metals to
produce desirable characteristics.
The aim of making alloys is generally to make them less brittle, harder, resistant
to corrosion, or have a more desirable color and luster.
Of all the metallic alloys in use today, the alloys of iron (steel, stainless steel, cast iron,
tool steel, alloy steel) make up the largest proportion both by quantity and commercial
value.
Iron alloyed with various proportions of carbon gives low, mid and high carbon steels,
with increasing carbon levels reducing ductility and toughness.
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
8. 8
Alloy
The addition of silicon will produce cast irons, while the addition of chromium, nickel
and molybdenum to carbon steels (more than 10%) results in stainless steels. Examples o
alloys are 22 Carat gold, brass
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
9. 9
Solid solution
A uniform mixture of substances in solid form.
Solid solutions often consist of two or more types of atoms or molecules that share a
crystal lattice, as in certain metal alloys.
Solid solutions are of two types. They are (a) Substitution solid solutions. (b)
Interstitial solid solutions. Steel used in construction, for example, is actually a solid
solution of iron and carbon.
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
10. 10
Iron Carbon Equilibrium diagram various phases
Phase equilibrium diagrams assist in the interpretation of microstructure of metals.
Equilibrium diagrams are presented in the form of temperature versus composition and
represent the interrelationship between phases, temperature and composition only
under equilibrium conditions.
Iron-carbon phase diagram describes the iron-carbon system of alloys containing up to
6.67% of carbon, discloses the phases compositions and their transformations occurring
with the alloys during their cooling or heating.
Carbon content 6.67% corresponds to the fixed composition of the iron carbide Fe3C. It
shows the changes in phase due to change in composition.
Iron in Iron-Carbon equilibrium diagram is soft and ductile & also it is allotropic in
nature. The Lever rule is used to determine composition of various phases in a phase
diagram. In Eutectic reaction in iron carbon diagram no mushy zone is obtained.
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
11. 11
Iron Carbon Equilibrium diagram various phases
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
The following phases are involved
in the transformation, occurring
with iron-carbon alloys:
L - Liquid solution of carbon in iron;
δ - Ferrite: Solid solution of carbon
in iron.
Maximum concentration of carbon
in δ-ferrite is 0.09% at 2719 °F
(1493°C) – temperature of the
peritectic transformation. The
crystal structure of δ-ferrite is BCC
(cubic body centered).
12. 12
Iron Carbon Equilibrium diagram various phases
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
13. 13
Iron Carbon Equilibrium diagram various phases
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
14. 14
Iron Carbon Equilibrium diagram various phases
Austenite
Interstitial solid solution of carbon in γ-iron.
Austenite has FCC (cubic face centered)
crystal structure, permitting high solubility of
carbon up to 2.06% at 2097 °F (1147°C).
Austenite does not exist below 1333 °F
(723°C) and maximum carbon concentration at
this temperature is 1.7%.
Martempering & Marquenching permit the
transformation of austenite to martensite,
throughout the cross-section of a component
without cracking or distortion
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
15. 15
Iron Carbon Equilibrium diagram various phases
α-ferrite
It is the solid solution of carbon in α-
iron.
α-ferrite has BCC crystal structure.
Ferrite is steels is softest and least
strong
It has low solubility of carbon, up to
0.025% at 1333 °F (723°C).
α-ferrite exists at room temperature.
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
16. 16
Iron Carbon Equilibrium diagram various phases
Cementite
It is the iron carbide,
intermetallic compound, having
fixed composition Fe3C.
Cementite is a hard and brittle
substance, influencing on the
properties of steels and cast irons.
In Iron-Carbon equilibrium
diagram, at 210oCtemperature
cementite is changes from
ferromagnetic to paramagnetic
character.
This phase has a complex
orthorhombic crystal structure
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
17. 17
Iron Carbon Equilibrium diagram various phases
Pearlite
It is the last phase obtained
after completing heat treatment
cycle in patenting process.
The mixture of α-ferrite and
cementite is called as Pearlite
Bainite
This phase is obtained as the
end product, after complete heat
treatment cycle in austempering
process
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
18. 18
Iron Carbon Equilibrium diagram various phases
Phase Transformations The following phase transformations occur with iron-carbon
alloys:
As iron starts cooling from it molten state it undergoes changes in phases .At 2912
°F it is in molten state. When it cools it forms delta ferrite, then austenite and finally
alpha ferrite.
Hypoeutectoid steels (carbon content from 0 to 0.83%) consist of primary
(proeutectoid) ferrite and pearlite.
Eutectoid steel (carbon content 0.83%) entirely consists of pearlite.
Hypereutectoid steels (carbon content from 0.83 to 2.06%) consist of primary
(proeutectoid) cementite (according to the curve ACM) and pearlite.
Iron-Carbon alloys, containing up to 2.06% of carbon, are called Steels.
In practice only hypoeutectic alloys are used.
These alloys (carbon content from 2.06% to 4.3%) are called Cast Irons.
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
19. 19
Iron Carbon Equilibrium diagram various phases
Critical temperatures
Upper critical temperature (point) A3 is the
temperature, below which ferrite starts to form as a result of
ejection from austenite in the hypoeutectoid alloys.
Upper critical temperature (point) ACM is the temperature,
below which cementite starts to form as a result of ejection
from austenite in the hypereutectoid alloys.
Lower critical temperature (point) A1 is the temperature of
the austenite-to-pearlite eutectoid transformation. Below this
temperature austenite does not exist.
Magnetic transformation temperature A2 is the temperature
below which α-ferrite is ferromagnetic.
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
20. 20
Summary
In this lesson, We have learned
Concept of phase, pure metal, alloy and solid solutions ,
Iron Carbon Equilibrium diagram
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
23. 1. Name of the Trainer :- Prof. S. B. Deshmukh
2. Years of Experience :- 8 Years
3. Domain Expertise :- Mechanical Engineering
www.sandipuniversity.edu.in
Presented By 02
https://www.sandipfoundation.org/
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
24. 24
Broad Classification of steels
Steel
An iron base alloy, malleable under proper conditions, containing up to 2% carbon.
Alloys with high proportion of other elements and a relatively small amount of iron,
are also called as steel if the iron and carbon are important influencing elements.
Iron is a major component and primary element in steel. Carbon is the major alloying
element. 90% of the steels produced throughout the world are referred to as carbon
steel.
Pure iron is soft, malleable, and ductile and has very useful property of being
magnetic.
Small amounts of some elements such as manganese, sulphur, silicon, chromium,
molybdenum, phosphorus are also added to steel to improve its properties.
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
25. 25
Broad Classification of steels
Steel
Hardness of steel depends on the shape and distribution of the car-bides in iron.
Copper does not impart hardness to steel.
Steel made from phosphatic iron is brittle
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
26. 26
Broad Classification of steels
Types of Steel
Steels can be classified by a variety of different systems depending
The composition, such as carbon, low-alloy or stainless steel.
The manufacturing methods, such as open hearth, basic oxygen process, or electric
furnace methods.
The finishing method, such as hot rolling or cold rolling
The product form, such as bar plate, sheet, strip, tubing or structural shape
The de-oxidation practice, such as killed, semi-killed, capped or rimmed steel
The microstructure, such as ferritic, pearlitic and martensitic
The heat treatment, such as annealing, quenching and tempering, and thermo
mechanical processing
Main types are
1.Carbon Steels 2.Alloy Steels 3.Tool Steels 4.Stainless Steels
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
27. 27
I ) Plain carbon steels:
.
The American Iron and Steel Institute (AISI) define carbon steel as follows:
Steel is carbon steel when it is doesn't contain Aluminum, Boron, Chromium, Cobalt,
Columbium, Molybdenum, Nickel, Titanium, Tungsten, Vanadium or Zirconium. Copper
does not exceed 0.40% or when the maximum content specified does not exceed the
percentage noted -Manganese 1.65%,Silicon 0.6%,Copper 0.6%
Carbon steels are different from cast iron as regards the percentage of carbon.
Carbon contains 0.10 to 1.5% carbon whereas cast iron possesses from 1.8 to 4.2%
carbon
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
28. 28
Classification of carbon steels
Carbon steels contain up to 2% total alloying elements and can be subdivided into
according to their carbon content.
1. Low-carbon steels.
2. Medium-carbon steels.
3. High-carbon steels.
Carbon steel can be classified, according to various de-oxidation practices, as rimmed,
capped, semi-killed, or killed steel.
De-oxidation practice and the steelmaking process will have an effect on the
properties of the steel.
Variations in carbon have the greatest effect on mechanical properties.
As carbon percent increased, it increases the hardness and strength of steel.
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
29. 29
a) Low Carbon Steels or mild steel
Characteristics of Low Carbon Steels
It contains up to 0.30% carbon.
Low carbon steels are not hardened appreciably by hardening process of heat
treatment.
A decrease in carbon content improves ductility.
Low carbon steels are not hardened appreciably by hardening process of heat
treatment.
The ultimate tensile strength of low carbon steel by working at a high strain rate will
increase.
Mild steel belongs to the Low carbon steel.
Advantages of Low Carbon Steels
It has good tensile strength.
It has good magnetizing properties.
It can be easily machined, welded or forged.
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
30. 30
a) Low Carbon Steels or mild steel
Advantages of Low Carbon Steels
It is soft, ductile and malleable.
It has good toughness.
It is cheaper.
It has wide variety available with different properties
It has high stiffness.
Disadvantages of Low Carbon Steels
The corrosion resistance is poor.
So they should not be used in a corrosive environment unless some form of
protective coating is used.
Uses of Low Carbon Steels
Its typical uses are in automobile body panels, tin plate, and wire products
These materials may be used for stampings, forgings, seamless tubes, and
Boiler plate
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
31. 31
a) Low Carbon Steels or mild steel
Uses of Low Carbon Steels
It is used for rods, steel joints, channels and angles, structural sections, drop forgings.
It is used in motors and electrical appliances
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
32. 32
b) Medium carbon steels
Characteristics of Medium carbon steels
It contains 0.30 to 0.60% carbon.
It is used for machine components requiring high strength and good fatigue
resistance.
Medium steels are stronger than low carbon steels and can be further strengthened
by heat treatment.
It contains manganese from 0.60 to 1.65%.
Advantages of Medium Carbon Steels
It has better ductility.
It has better strength.
It has good wear resistance.
It can be easily machined and forged.
It possesses good formability.
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
33. 33
b) Medium carbon steels
Disadvantages of Medium Carbon Steels
More costly than mild steel.
Uses of Medium Carbon Steels
It is used for making shafts, axles, gears, crankshafts, couplings and forgings.
It is used for railway wheels and rail axles.
It is also used for making Drop forging dies, Die blocks, Set screws, Clutch discs, Plates
punches, Valve Springs, Cushion rings, Thrust washers.
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
34. 34
c) High carbon steels
Characteristics of High carbon steels
It contains 0.7% to 1.5% carbon.
These steels have high hardness and low toughness.
The combination of these properties makes it ideal for bearing applications where wear
resistance is important and compressive loading minimize brittle fracture that might
develop on tensile loading.
Strength to hardness increase with increase in carbon contents.
As the carbon is increased hardness increases and strength starts decreasing.
Advantages of High carbon steels
It has high hardness.
It has high wear resistance.
Compressive strength is highest.
It has fair formability.
It can be magnetized easily.
It can be hardened and tempered easily.
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
35. 35
c) High carbon steels
Disadvantages of High Carbon Steels
It has low impact strength.
These cannot weld easily.
Usually joined by brazing with low temperature silver alloy making it possible to repair
or fabricate tool-steel parts without affecting their heat treated condition.
Uses of High Carbon Steels
It is used for hardness and high tensile strength, springs, cutting tools,
Press tools, and striking dies.
It is used for drills, taps, milling cutters, knives.
It is used for cold cutting dies, wood working tools.
It is used for reamers, tools for cutting wood and brass.
It is used where a keen cutting edge is necessary, razors, saws, and where wear
resistance is important.
High carbon steel is used in transmission lines and microwave towers
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
36. 36
ii) Alloy steels
Steel is a metal alloy consisting mostly of iron, in addition to small amounts of carbon,
depending on the grade and quality of the steel.
Alloy steel is any type of steel to which one or more elements besides carbon have
been intentionally added, to produce a desired physical property or characteristic.
Common elements that are added to make alloy steel are molybdenum, manganese,
nickel, silicon, boron, chromium, and vanadium.
Alloy steel is steel alloyed with a variety of elements in total amounts of between
1.0% and 50% by weight to improve its mechanical properties.
Alloy steel may be classified according to their chemical compositions, structural class
and purpose.
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
37. 37
Purpose of alloying:
Steels are alloyed for-
Strengthening of the ferrite.
Improved corrosion resistance.
Better hardenability
Grain size control
Greater strength
Improved machinability
Improved ductility
Improved toughness
Better wear resistance
Improved cutting ability
Improved case hardening properties etc.
Improved high or low temperature stability.
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
38. 38
Alloy Steel
Advantages of Alloy Steel
It has greater hardenability
It has less distortion and cracking
It has greater ductility at high strength
It has greater high temperature strength
It has greater stress relief at given hardness
It has better machinability at high hardness
It has high elastic ratio and endurance strength.
Disadvantages of Alloy Steel
It has higher cost
It needs special handling
Effect of elements in Alloy steels
Alloying elements are added to achieve certain properties in the material
Alloying elements are added in lower percentages (less than 5%) to increase
strength or hardenability,
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
39. 39
Effect of Various Alloying Elements on Steel
Alloying elements are added in larger percentages (over 5%) to achieve special
properties, such as corrosion resistance or extreme temperature stability
Following are some common alloying elements
Chromium :-
It provides corrosion resistance.
It increases hardenability or the depth to which steel can be hardened.
It adds hardness, toughness and resistance to wear.
Prevent formation of austenite
Nickel
It increases strength and toughness.
It helps to resist corrosion.
Cobalt
Improves cutting ability
Reduce hardenability
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
Chromium
Nickel
Cobalt
40. 40
Effect of Various Alloying Elements on Steel
Nickel
It improves shock resistance.
It increases strength of steels.
Manganese
It is used in steel to produce a clean metal. If manganese exceeds 1.65 -2.10%, the
product is classed as alloy steel.
It increases hardenability and strength.
It also adds to the strength of the metal and helps in heat treating.
It counteracts brittleness from sulphur
It lowers both ductility and weldability if present in high percentage with high carbon
content in steel.
Molybdenum
It adds toughness and higher strengths to steel.
It promotes hardenability of steel.
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
Manganese
Molybdenum
41. 41
Effect of Various Alloying Elements on Steel
Molybdenum
It makes steel fine grained.
It increases toughness.
It increases tensile and creep strength at high temperatures.
It enhances corrosion resistance in stainless steels.
It forms abrasion resisting particles.
They have good creep resistance.
It is used for making high speed steels. It forms stable carbides resulting in fine grain
size.
Tungsten
It is added in the form of tungsten carbide
It gives steel high hardness even at red heats.
It promotes fine grains
It increases heat resistance.
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
Tungsten
42. 42
Effect of Various Alloying Elements on Steel
Tungsten
It increases strength at elevated temperatures.
It is used with chromium, vanadium, molybdenum, or manganese to produce high
speed steel used in cutting tools.
Tungsten steel is said to be "red-hard" or hard enough to cut after it becomes red-
hot.
Vanadium:
It gives steel a fine-grained structure.
It increases toughness.
It is often used in tool steels because of its increased resistance to impact.
It increases hardenability
It increases imparts strength and toughness to heat-treated steel.
It increases shock resistance.
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
Vanadium:
43. 43
Effect of Various Alloying Elements on Steel
Titanium
It is a very strong, very lightweight metal that can be used
alone or alloyed with steels.
It is added to steel to give them high strength at high temperatures.
It prevents formation of austenite in high chromium steels.
It reduces martensitic hardness and hardenability in medium chromium steels.
It is used in modern jet engines used titanium steels.
Phosphorus and Lead
They are added to steel to increase its machinability.
They increase hardness, strength and corrosion resistance.
They improve resistance to atmospheric corrosion.
Sulphur
Lowers the toughness and transverse ductility
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
Titanium
:
Phosphorus Lead
:
Sulphur
44. 44
Effect of Various Alloying Elements on Steel
Silicon
It is often used to increase the resiliency of steel for making springs.
It increases the strength properties especially elastic limit
without loss of ductility.
Increasing silicon increases resiliency of steel for spring applications.
It is used for magnetic circuits in electrical equipments.
It is the principal deoxidizing used in steel making.
It improves oxidation resistance
It strengthens low alloy steels
Niobium
Greatly increases tensile strength of steel.
Only 40 lb of niobium per ton of steel will increase
the tensile strength by 10,000 to 15000 lb/in2.
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
Silicon
Niobium
45. 45
iii) Tool steels
Tool steel refers to a variety of carbon and alloy steels that are particularly well-suited
to be made into tools.
Their suitability comes from their distinctive hardness, resistance to abrasion, their
ability to hold a cutting edge, and/or their resistance to deformation at elevated
temperatures (red-hardness).
Tool steel is generally used in a heat-treated state.
Tool steels are steels that are primarily
used to make tools used in manufacturing
processes as well as for machining metals, woods, and plastics.
Cemented carbide tools are not found to
be suitable for cutting non-ferrous alloys.
Department Of Mechanical Engineering,Sandip Polytechnic,Nashik
46. 46
iii) Tool steels
Characteristics Tool steels
It is generally used in a heat-treated state.
It has carbon content between 0.7% and 1.5%.
Tool steels are manufactured under carefully controlled conditions to produce the
required quality.
The manganese content is often kept low to minimize the possibility of cracking
during water quenching.
Advantages of Tool steels
It has good abrasion resistance.
It has good toughness.
It has good machinability.
It has good wear resistance.
It has ability to hold a cutting edge at elevated temperatures.
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iii) Tool steels
Disadvantages of Tool steels
They are brittle, especially at their higher hardness.
It has high cost.
Uses of Tool steels
It is used for stamping dies.
It is used for metal cutting tools.
It is used for injection molding moulds.
Types of Tool steels
1. High speed steel (HSS or HS) :-
The first alloy that was formally classified as high speed steel was introduced in
1910.
Tungsten-type High speed steel grades contains 0.65–0.80% carbon, 3.75–4.00%
chromium, 17.25–18.75% tungsten and 0.9–1.3% vanadium.
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Summary
In this lesson, We have learned
Carbon Steels
1. Low-carbon steels.
2. Medium-carbon steels.
3. High-carbon steels.
Alloy Steels
Introduction to Tool steels
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1. High speed steel (HSS or HS)
1.High speed steel (HSS or HS) :-
Characteristics High speed steel (HSS or HS) :-
It is a subset of tool steels.
It includes all molybdenum and tungsten class alloys.
It is usually used in tool bits and cutting tools.
It is often used in power saw blades and drill bits.
It is superior to the older high carbon
steel tools used extensively through the
1940s in that it can withstand higher
temperatures without losing its temper (hardness).
This property allows HSS to cut
faster than high carbon steel, hence the
name high speed steel
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1. High speed steel (HSS or HS)
Advantages of High speed steel:-
It has good toughness.
It has excellent red hardness.
It can be hardened to 62-67 HRC.
It retains cutting ability up to 540°c.
It has good abrasion resistance.
It has good compressive strength.
It has good wear resistance.
Disadvantages of High speed steel
It has poor resistance to decarburization.
They are not easy for machining.
It is brittle, snaps before it will bend.
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1. High speed steel (HSS or HS)
Uses of High speed steel :-
It is mainly used for manufacture of various cutting tools: drills, taps, milling cutters, too
bits, gear cutters, saw blades, etc.
It is used for punches and dies manufacturing.
It is used making files, chisels, hand plane blades, and high quality kitchen and pocket
knives.
Types of HSS
a)18:4:1 High Speed Steel
It is one of the best known High speed tools steel.
It contains 18% tungsten, 4% chromium and 1% vanadium.
It has excellent red hardness.
It has good abrasion resistance.
It has good compressive strength.
It is used for milling cutters, punches, dies.
It is also used for reamers, broaches, and drills.
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Types of HSS
Types of HSS
b) Tungsten High speed steel.
c) Molybdenum High speed steel.
d) Moly Tungsten High speed steel.
e) Chrome Moly Vanadium High speed steel.
f) Chrome Moly Tungsten High speed steel.
g) Chrome Moly High Vanadium High speed steel.
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Effect of alloying elements on the properties of HSS
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Alloying element Effect of alloying elements on the properties of HSS
Carbon
It forms carbides, increases wear resistance, is responsible for
the basic matrix hardness.
Tungsten and
molybdenum
It improves red hardness, retention of hardness and high
temperature strength of the matrix, form special carbides of
great hardness.
Vanadium
It forms special carbides of supreme hardness, increases high
temperature wear resistance, retention of hardness and high
temperature strength of the matrix.
Chromium It promotes depth hardening, produces readily soluble carbides.
Cobalt
It improves red hardness and retention of hardness of the
matrix.
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Types of Tool steels
2. Hot-work Tool Steels :-
Hot-work tool steels include all chromium, tungsten, and molybdenum alloys.
They are typically used for forging, die casting, heading, piercing, trim, extrusion,
and hot-shear and punching blades.
3. Cold-work Tool Steels
Cold-work tool steels include all high-chromium, medium-alloy air-hardening,
water hardening, and oil hardening alloys.
Typical applications include cold working operations such as stamping dies, draw
dies, burnishing tools, coining tools, Pipes for bicycle and shear blades.
Cold rolled steel sheets contain 0.1% carbon
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iv) Stainless Steels
Characteristics of Stainless Steels :-
Stainless steel does not stain, corrode, or rust as easily as ordinary steel, but it is
not stain-proof so called as “Stain-less”.
It is also called corrosion-resistant steel or CRES.
Stainless steel is a generic term for a family of corrosion resistant alloy steels
containing 10.5% or more chromium.
All stainless steels have a high resistance to corrosion.
This resistance to attack is due to the naturally occurring chromium-rich oxide film
formed on the surface of the steel.
Although extremely thin, this invisible, inert film is tightly adherent to the metal
and extremely protective in a wide range of corrosive media.
The film is rapidly self repairing in the presence of oxygen, and damage by
abrasion, cutting or machining is quickly repaired.
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iv) Stainless Steels
Advantages of Stainless Steels :-
All stainless steels have a high resistance to corrosion.
It resists scaling and maintains high strength at very high temperatures.
It shows exceptional toughness.
The majority of stainless steels can be cut, welded, formed, machined and
fabricated readily.
It is available in many surface finishes.
It is easily and simply maintained resulting in a high quality, pleasing appearance.
The cleanability of stainless steel makes it the first choice in hospitals, kitchens,
food and pharmaceutical processing facilities.
Stainless steel is a durable.
It is low maintenance material.
It has good thermal conductivity.
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iv) Stainless Steels
Types of Stainless Steels :-
In addition to chromium, nickel, molybdenum, titanium, niobium and other
elements may also be added to stainless steels in varying quantities to produce a
range of stainless steel grades, each with different properties. There are a number
of grades to choose from, but all stainless steels can be divided into following basic
categories:
1. Austenitic Stainless Steels
2. Ferritic Stainless Steels
3. Martensitic Stainless Steels
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Types of Stainless Steels
Types of Stainless Steels :-
1.Austenitic Stainless Steels :-
Characteristics of Austenitic Stainless Steels :-
When nickel is added to stainless steel in sufficient amounts the crystal structure changes to
"austenite".
The basic composition of austenitic stainless steels is 18% chromium and 8% nickel.
Chromium carbide precipitates at the grain boundaries, when austenitic stainless steel is
heated at 900 oC.
Advantages of Austenitic Stainless Steels
It has excellent corrosion resistance in organic acid, industrial and marine environments.
It has excellent weldability (all processes)
It has excellent formability, fabricability and ductility
It has excellent cleanability, and hygiene characteristics
It is non-magnetic (if annealed)
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Types of Stainless Steels
Disadvantages of Austenitic Stainless Steels :-
These alloys are not hardenable by heat treatment.
Uses of Austenitic Austenitic Stainless Steels
It is used for computer floppy disk shutters.
It is used for computer keyboard key springs.
It is used for kitchen sinks.
It is used for food processing equipment
It is used for architectural applications
It is used for chemical plant and equipment
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Types of Stainless Steels
2. Ferritic Stainless Steels
Characteristics Ferritic Stainless Steels :-
This group of alloys generally containing only chromium, with the balance mostly iron.
These are plain chromium stainless steels with varying chromium content between 12
and 18%, but with low carbon content.
Advantages of Ferritic Stainless Steels
It has good corrosion resistance.
They are magnetic.
It has good ductility.
They can be welded or fabricated without difficulty.
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Types of Stainless Steels
Disadvantages of Ferritic Stainless Steels :-
These are not hardenable by heat treatment.
It has poor weldability.
Formability not as good as the Austenitic Stainless Steels.
Uses of Ferritic Stainless Steels
It is used for computer floppy disk hubs.
It is used for automotive trim.
It is used for automotive exhausts.
It is used for colliery equipment.
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Types of Stainless Steels
3. Martensitic Stainless Steels :-
Characteristics of Martensitic Stainless Steels :-
Martensitic stainless steels were the first stainless steels commercially developed (as
cutlery) and have relatively high carbon content (0.1 - 1.2%) compared to other stainless
steels.
They are plain chromium steels containing between 12 and 18% chromium. Hardness of
lower Bainite (tempered martensite) is about RC 57 & Hardness of martensite is about RC
65.
Hardness of upper Bainite (acicular structure) is about RC48.
Disadvantages of Martensitic Stainless Steels
It has poor weldability.
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Types of Stainless Steels
Advantages of Martensitic Stainless Steels
It has moderate corrosion resistance
It can be hardened by heat treatment.
Therefore high strength and hardness levels can be achieved.
It is magnetic in nature.
Uses of Martensitic Stainless Steels
It is used for Knife blades
It is used for surgical instruments
It is used for shafts and spindles.
It is used for pins
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v) Spring Steels:
These steels are generally low-alloy Manganese, medium-carbon steel or high-carbon
steel with a very high yield strength.
EN45 is a manganese spring steel.
It is a steel with a high carbon content, traces of manganese that effect the metal’s
properties, and that it is generally used for springs (such as the suspension springs on
old cars).
It is suitable for oil hardening and tempering.
When used in the oil hardened and tempered condition EN45 offers excellent spring
characteristics.
EN45 is commonly used in the automotive industries for the manufacture and repair
of leaf springs.
Untempered EN45 is harder than mild steel, and will not suffer as much from burs or
require as much repair and therefore have a longer life.
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v) Spring Steels:
Composition:
Carbon, C 0.50 - 0.60 Manganese, Mn 0.70 1.10 Silicon, Si 1.5 2.0 Nickel, Ni
EN45 is used widely in the motor vehicle industry and many general engineering
applications. Typical applications include leaf springs, truncated conical springs, helical
springs and spring plates
Applications of spring steel:
Applications include piano wire (also known as[11] music wire) such as ASTM
A228 (0.80–0.95% carbon), spring clamps, antennas, springs, and vehicle coil springs,
leaf springs, and s-tines.
Spring steel is also commonly used in the manufacture of metal swords for stage
combat due to its resistance to bending, snapping or shattering.
Spring steel is one of the most popular materials used in the fabrication
of lockpicks due to its pliability and resilience.
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v) Spring Steels:
Applications of spring steel:
Tubular spring steel is used in the landing gear of some small aircraft due to its ability
to absorb the impact of landing.
It is also commonly used in the making of knives, especially for the Nepalese kukri.
It is used in binder clips.
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vi) Specifications of steels and their equivalents
They are differing in their chemical composition, structure and applications.
Designation: identification of each material class by a number, letter, symbol, name or a
combination,Normally based on chemical composition or mechanical properties
These are classified and designated according to following standards.
AISI- American Iron and Steel Institute
SAE- Society of Automotive Engineers
IS- Indian Standards
Designation of steel on the basis of mechanical properties
These are designated by Tensile or Yield strength. First character “Fe” indicates –Steel.
“E” indicates minimum yield strength.
The examples are:1) Fe 350 - Steel with minimum tensile strength 350 MPa.
2) Fe 410 K - Killed Steel with minimum tensile strength 410 MPa.
3) Fe E 380 - Steel with minimum yield strength 380 MPa.
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Applications of Steels
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Application Steel used
Shafts Mild steel, alloy steel
Axles Chrome-molybdenum steel, carbon steel
Nuts, bolts Carbon steel
Levers, crank shafts, Medium-carbon steel alloys ) 0.55 to 1.0%
Camshafts Carbon steel- en8/en9, alloyed steels
Shear blades High speed tool steel W6Mo5Cr4V2
Agricultural equipments Stainless steel
House hold utensils Stainless steel
Machine tool beds Cast iron
Car bodies Alloy steel
Antifriction bearings Alloy Steel
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Summary
In this lesson, We have learned
Tool steels
Stainless Steels
Spring Steels
Specifications of steels
Applications of Steels
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