The document discusses metallurgy and how understanding metallurgy can help solve problems in metal production and applications. It defines key terms like ferrous metals, microstructure, and processes. It provides examples of how understanding composition, microstructure, and properties allowed engineers to solve issues like warped lawnmower blades, a tractor axle shaft breaking, and fractured lock washers. The document emphasizes that knowledge of metallurgy is useful for many metal-related jobs and industries.

1. Presentations for PowerPoint
Metallurgy
Fundamentals
Ferrous and Nonferrous

2. Metallurgists and Careers
in Metals Industries
Chapter 2

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• Define metallurgy.
• Understand the primary cause-and-effect relationships encountered
in metallurgy.
• Explain why the study of metallurgy can be a valuable asset in jobs
other than direct production.
• Explain why every step in a production process is needed to
produce a good, working part.
Learning Objectives

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• Describe how metallurgical knowledge can be used to solve
industrial problems.
• Explain how research scientists, metallurgical engineers, operations
technicians, and equipment operators all contribute to make
process and product improvements.
Learning Objectives

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• Materials are metals and nonmetals (most are metals).
• Metals are ferrous or nonferrous.
• Ferrous metals’ major component is iron.
• All other metals are nonferrous.
• More than 80 different ones
Classifying Materials
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• Ferrous metals have wide variety of applications.
• Depends on alloying elements added to iron
• Depends on processing used
• Steel contains lower levels of carbon (up to 2%).
• Most common type is mild steel.
• Low carbon
• Lower strength
Ferrous Metals
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• Other commercial grades of steels
• Stainless steels
• Specialty steels
• Cast irons contain roughly 2%–4% carbon.
• Different alloying elements added for desired properties
Ferrous Metals (cont.)

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• Desirable properties in metal achieved
by selecting suitable composition and
processing it properly
• Processes performed create
microscopic structures in metal, called
microstructures.
Composition and Processes Determine
Microstructure and Properties
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• Microstructure determines properties.
• Different processes on same alloy can produce different
microstructures/properties.
Composition and Processes Determine
Microstructure and Properties (cont.)

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• Common processes affecting microstructures and properties
• Forming
• Heating to different temperatures
• Rapid or slow cooling from elevated temperatures
Processes

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• Different processes result in different internal structures.
• Small changes in processes can change metal properties.
• Understanding of these relationships helps to adjust procedures
when something unexpected occurs.
Adjusting Processes

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• Knowledge of metallurgy helps solve metal-related problems.
• Knowledge of metallurgy helps find workable solutions.
• Following slides show examples of how metallurgical knowledge
helps.
• Design better metal parts
• Select best metal for applications
• Troubleshoot manufacturing problems
Practical Examples of Metallurgy

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• Steel sheet formed into desired shape (blades) by stamping and
bending processes.
• Properties obtained by heat treatment.
• One day, reject rate for blades jumped.
• Metallurgical problem
• Mill producing steel sheet had changed processing slightly.
• Additional stresses formed in metal while rolling into sheet.
• When heat-treated, each piece relieved stresses by warping.
Warped Lawnmower Blades

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• Metallurgical solution
• Before forming, heat as-received sheet to elevated temperature for
two hours.
• Relieves internal stresses caused by rolling
Solution to Warped Lawnmower Blades

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• Metallurgical problem
• Bend cultivator steel control arm linkage for easier movement.
• Metallurgical solution
• Heated end to be bent with blowtorch until red hot
• Used hammer and anvil to bend end to better fit
• Reheated linkage to bright yellow and plunged into bucket of water
• Filed off scale on heated end and reheated one last time
Steel Heat Treatment on the Farm

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• Metallurgical problem
• Axle shaft of large tractor must support bending and twisting forces.
• Engineers need to increase strength.
• Conditions to keep costs down
• No increase in diameter
• No alloy change
Tractor Axle Shaft

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• Metallurgical solution
• Current part made by heat-treating axle
shaft
• Careful testing showed higher strength
achievable by adjusting heat treatment.
• Required closer control of heating and
cooling processes
Strengthening a Tractor Axle Shaft
Warner Consulting, Inc.

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• Metallurgical problem
• Cutting tool losing its edge
• Cutting tool must be harder than
workpiece being cut.
• Frictional heat can soften hardened
steel tools.
• Soft tools do not cut well and must
be replaced.
Cutting Tool
PERO studio/Shutterstock.com

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• Metallurgical solution
• Changing to different steel type reduces problem.
• Some steel types withstand higher temperatures.
• Tools last longer.
• Machinists maintain higher production rate.
Improving Cutting Tool Durability

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• Metallurgical problem
• Sometimes strength is not only
requirement.
• Metallurgical solution
• High-strength aluminum alloy is strong
enough.
• Made from heat-treatable alloy
• Aluminum can be polished to look good.
Hood Lifters for Show Car
Ringbrothers

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• Manufacturer’s problem
• Entire shipment of lock washers
rejected after over 50%
fractured when installed
• Salesperson explained
customer’s viewpoint.
Fractured Compression Lock Washers
Jay Warner; Goodheart-Willcox Publisher

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• Product engineer and production supervisor explained process for
making lock washers.
• Stamped from sheet steel
• Twisted slightly to lock against nut when installed
• Finally, electroplated
• Plant metallurgist determined failures were brittle fractures.
• Likely caused by hydrogen embrittlement
Compression Lock Washers

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• Metallurgical solution
• Electroplating drives hydrogen into the steel.
• Baking drives hydrogen out of the steel.
• Check of production records spotted missed process step of baking.
• Corrective actions
• Explain importance of baking process to drive out hydrogen.
• Develop ways to assure step is not missed again.
Compression Lock Washers (cont.)

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• Radiators extract heat from hot fluids flowing through tubes.
• Heat flows from tubes, to metal fins, to surrounding air.
• Aluminum or copper foil used for metal fins
• The thin foil is called fin stock.
Cooling Fins for Automobile Radiators
Sunti Wongyai/Shutterstock.com; Goodheart-Willcox Publisher

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• Dialysis uses blood coolers to control blood temperature while blood
is removed from patient.
• Fin stock for blood coolers is similar to that used in automotive
industry.
• Manufacturer of fin stock for automobile radiators expands business
by producing fin stock for blood coolers.
Cooling Fins for Blood Coolers

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• Problem
• Order rushed out without checking all specifications
• Order rejected for surface imperfections (gouges and tears)
• Cause: difference in performance requirements
• No scratches, gouges, or perforations acceptable for blood cooler fin
stock
• Technician who made order not aware of different specifications
Different Specifications for Cooling Fins

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• Artist’s concept
• Large, physically simple, reflective object showing surroundings (land
and sky)
• Effect similar to liquid mercury
• What material to accomplish concept?
• Ordinary steel rusts.
• Chrome-plated steel does not maintain shine at welds.
• Aluminum requires frequent repolishing.
Outdoor Sculpture: Chicago’s Cloud Gate

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• Metallurgical solution
• Used weldable stainless steel and
filler metal that matched in color
• Used arc and laser welding
• Welds polished and ground, leaving
no marks on surface
Outdoor Sculpture: Chicago’s Cloud Gate
(cont.)
Jay Warner

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• Everyone associated with metal manufacturing operations can
benefit from a knowledge of metallurgy.
• People directly involved in manufacturing need a great deal of
information.
• General technicians, maintenance people, and troubleshooters can
recognize problems that occur.
• Those who do not make metal products use metals to do their work.
Metals Are Everywhere

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• Metallurgy is improving, with new innovations and breakthroughs all
the time.
• Example: changing how oil is spread on a metal sheet
• May reduce number of rejected parts
• May allow increase in speed of stamping and forming
• May result in reduction of production cost
Advancing Metallurgy

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• Increased use of computer control and reporting
• Understanding the connections between composition, processes,
microstructure, and properties will continue to be important.
Advancing Metallurgy (cont.)
Goodheart-Willcox Publisher