2. 06/06/1706/06/17 22
Selection CriteriaSelection Criteria
Type of MouldType of Mould
Mould life i.e. Number of acceptedMould life i.e. Number of accepted
components produced over itscomponents produced over its
working lifeworking life
Ability to take mirror finish (HighAbility to take mirror finish (High
degree of polishibility)degree of polishibility)
Good machinabilityGood machinability
3. 06/06/1706/06/17 33
Selection CriteriaSelection Criteria
Good hardenabilityGood hardenability
Low distortion during HeatLow distortion during Heat
treatmenttreatment
Corrosion resistantCorrosion resistant
High compressive strengthHigh compressive strength
High toughnessHigh toughness
4. 06/06/1706/06/17 44
Selection CriteriaSelection Criteria
Cost of Steel in a mould consistsCost of Steel in a mould consists
of 10 – 15% of total Tooling Cost.of 10 – 15% of total Tooling Cost.
Selection of suitable steel isSelection of suitable steel is
essential in order toessential in order to
Avoid late delivery penaltiesAvoid late delivery penalties
Loss of Customer goodwillLoss of Customer goodwill
5. 06/06/1706/06/17 55
Selection CriteriaSelection Criteria
Minimize cost of excessiveMinimize cost of excessive
maintenance like repolishing,maintenance like repolishing,
cleaning, replating, replacing orcleaning, replating, replacing or
worn or broken partsworn or broken parts..
6. 06/06/1706/06/17 66
Selection CriteriaSelection Criteria
Proper selection of Steel as perProper selection of Steel as per
required service condition helpsrequired service condition helps
inin
Maximizing life of the mouldMaximizing life of the mould
Optimum mould performanceOptimum mould performance
Lowest possible total tooling cost perLowest possible total tooling cost per
part producedpart produced
8. 06/06/1706/06/17 88
Product Design RequirementsProduct Design Requirements
A moulded Product has to fulfillA moulded Product has to fulfill
Functional requirementsFunctional requirements
High standard of Surface finishHigh standard of Surface finish
Dimensional tolerance over longDimensional tolerance over long
production runsproduction runs
9. 06/06/1706/06/17 99
Product Design RequirementsProduct Design Requirements
To fulfill these requirementsTo fulfill these requirements
we have to havewe have to have
Good product designGood product design
Good mould designGood mould design
Good mould making processGood mould making process
Proper selection of tool steels forProper selection of tool steels for
the mouldthe mould
10. 06/06/1706/06/17 1010
Product Design RequirementsProduct Design Requirements
A product designer has to askA product designer has to ask
various questions to satisfy himselfvarious questions to satisfy himself
for a trouble free production run.for a trouble free production run.
These are:These are:
How important is the surface finishHow important is the surface finish
(Mirror / Optical finish)?(Mirror / Optical finish)?
Whether pattern on the moulding isWhether pattern on the moulding is
required by Photo etching etc.?required by Photo etching etc.?
11. 06/06/1706/06/17 1111
Product Design RequirementsProduct Design Requirements
Whether moulding material is corrosive,Whether moulding material is corrosive,
abrasive or both?abrasive or both?
Requirements of maintaining closeRequirements of maintaining close
tolerance?tolerance?
Quantities to be produced?Quantities to be produced?
Answering these queries will help theAnswering these queries will help the
designer to short list the tool steelsdesigner to short list the tool steels
required for the mould under production.required for the mould under production.
12. 06/06/1706/06/17 1212
Mould Design RequirementsMould Design Requirements
Role and responsibility of a MouldRole and responsibility of a Mould
DesignerDesigner
Economizing tooling of the mould byEconomizing tooling of the mould by
selecting standard steel grades, Standardselecting standard steel grades, Standard
steel sizes and standard machined plates.steel sizes and standard machined plates.
Alongwith the mould maker , he sharesAlongwith the mould maker , he shares
the responsibility for producing a mouldthe responsibility for producing a mould
to produce reliable and economical partto produce reliable and economical part
production as visualized by Productproduction as visualized by Product
designer.designer.
13. 06/06/1706/06/17 1313
Mould Design RequirementsMould Design Requirements
Role and responsibility of a Mould DesignerRole and responsibility of a Mould Designer
Ensures that the mould is fabricated asEnsures that the mould is fabricated as
easily and as economical as possible byeasily and as economical as possible by
the mould maker.the mould maker.
Specifies best mould steels withSpecifies best mould steels with
optimum hardness required for differentoptimum hardness required for different
mould parts.mould parts.
14. 06/06/1706/06/17 1414
Mould Design RequirementsMould Design Requirements
Role and responsibility of a Mould DesignerRole and responsibility of a Mould Designer
Selection of standard parts such asSelection of standard parts such as
guide pillars, Guide bushes, ejector pinsguide pillars, Guide bushes, ejector pins
etc, standard mould bases considerablyetc, standard mould bases considerably
reduces time and cost.reduces time and cost.
Helps in better planning, prompt mouldHelps in better planning, prompt mould
delivery as well as minimizing initialdelivery as well as minimizing initial
machining cost and material losses.machining cost and material losses.
15. 06/06/1706/06/17 1515
Mould Design RequirementsMould Design Requirements
Some of the commonly used steels are:Some of the commonly used steels are:
Pre hardened Mould SteelsPre hardened Mould Steels
Through hardened mould steelsThrough hardened mould steels
Corrosion resistant mould steelsCorrosion resistant mould steels
16. 06/06/1706/06/17 1616
Pre hardened Mould SteelsPre hardened Mould Steels
Applications:Applications:
Large mouldsLarge moulds
Moulds with lower wear resistanceMoulds with lower wear resistance
requirementrequirement
High strength holder paltesHigh strength holder paltes
Moulds with moderate production runMoulds with moderate production run
17. 06/06/1706/06/17 1717
Pre hardened Mould SteelsPre hardened Mould Steels
AdvantagesAdvantages
Available in the hardened and temperedAvailable in the hardened and tempered
condition having hardness about 25 – 30condition having hardness about 25 – 30
HRCHRC
No heat treatment is necessary beforeNo heat treatment is necessary before
the mould is put into use.the mould is put into use.
Surface hardness can be furtherSurface hardness can be further
increased by flame hardening orincreased by flame hardening or
nitriding.nitriding.
18. 06/06/1706/06/17 1818
Through hardened steelsThrough hardened steels
AdvantagesAdvantages
Available in soft annealed & stressAvailable in soft annealed & stress
relieved condition.relieved condition.
Also available in hardened andAlso available in hardened and
tempered to the required hardnesstempered to the required hardness
level (48 – 60 HRC)level (48 – 60 HRC)
Better wear resistance, resistance toBetter wear resistance, resistance to
deformation and indentationdeformation and indentation
Better polishibilityBetter polishibility
19. 06/06/1706/06/17 1919
Corrosion resistant mould steelsCorrosion resistant mould steels
ApplicationsApplications
Suitable for a mould likely to beSuitable for a mould likely to be
exposed to corrosive atmosphere.exposed to corrosive atmosphere.
In these cases, Stainless steel isIn these cases, Stainless steel is
strongly recommended.strongly recommended.
Higher initial cost of steel will be lessHigher initial cost of steel will be less
than the cost involved in repolishing /than the cost involved in repolishing /
replating of mould parts affected byreplating of mould parts affected by
corrosion.corrosion.
20. 06/06/1706/06/17 2020
Mould making requirementsMould making requirements
Substantial part of the total mould costSubstantial part of the total mould cost
is that incurred in machining of theis that incurred in machining of the
mould.mould.
It is to be ensured that the mouldIt is to be ensured that the mould
making process is as straightforward asmaking process is as straightforward as
possible.possible.
A mould maker will like to see that theA mould maker will like to see that the
steels he is going to use has followingsteels he is going to use has following
properties:properties:
21. 06/06/1706/06/17 2121
Mould making requirementsMould making requirements
Free from any manufacturingFree from any manufacturing
defectsdefects
Good machinabilityGood machinability
Good polishibilityGood polishibility
Good hardenabilityGood hardenability
Good dimensional stabilityGood dimensional stability
22. 06/06/1706/06/17 2222
Moulding requirementsMoulding requirements
A processor expects certain features in hisA processor expects certain features in his
mould such as:mould such as:
Uniform and high rate of productionUniform and high rate of production
Uniform moulding qualityUniform moulding quality
Longer mould lifeLonger mould life
Low mould maintenance costLow mould maintenance cost
Lowest possible production costLowest possible production cost
Easy component and materialEasy component and material
replacementreplacement
24. 06/06/1706/06/17 2424
ALLOY STEELSALLOY STEELS
More stronger, tougher and fatigueMore stronger, tougher and fatigue
resistant than carbon steelresistant than carbon steel
Sufficient formability, ductility and weldSufficient formability, ductility and weld
abilityability
Corrosion and abrasion resistantCorrosion and abrasion resistant
Typical application areTypical application are
Structural applicationsStructural applications
25. 06/06/1706/06/17 2525
ALLOY STEELSALLOY STEELS
Railroad passenger and freight carsRailroad passenger and freight cars
Transmission towersTransmission towers
Long span bridgesLong span bridges
Columns of high rise buildingsColumns of high rise buildings
parts of tankers, small barragesparts of tankers, small barrages
agricultural and earth moving machineryagricultural and earth moving machinery
partsparts
26. 06/06/1706/06/17 2626
HIGH STRENGTH LOWHIGH STRENGTH LOW
ALLOY STEELSALLOY STEELS
Group of steels exhibiting significantlyGroup of steels exhibiting significantly
higher strength than carbon steelhigher strength than carbon steel
Small amount of alloying elementsSmall amount of alloying elements
such as manganese, aluminum, silicon,such as manganese, aluminum, silicon,
vanadium, titanium, molybdenum,vanadium, titanium, molybdenum,
nitrogen, calcium and other rare earthnitrogen, calcium and other rare earth
elements are added.elements are added.
Steel is processed through specialSteel is processed through special
process.process.
27. 06/06/1706/06/17 2727
HIGH STRENGTH LOWHIGH STRENGTH LOW
ALLOY STEELSALLOY STEELS
Carbon content is less than 0.3 % byCarbon content is less than 0.3 % by
weight.weight.
Toughness, Strength, Formability andToughness, Strength, Formability and
corrosion resistance increases.corrosion resistance increases.
These are different from alloy steel asThese are different from alloy steel as
they achieve their high strength withoutthey achieve their high strength without
separate heat treatment after finishing.separate heat treatment after finishing.
28. 06/06/1706/06/17 2828
HIGH CARBON HIGHHIGH CARBON HIGH
CHROMIUM STEELCHROMIUM STEEL
Contains C – 1.5 – 2.25 %, Cr – 12 %, MoContains C – 1.5 – 2.25 %, Cr – 12 %, Mo
– 1 %, V – 0.25%– 1 %, V – 0.25%
Deep hardeningDeep hardening
Low thermal conductivityLow thermal conductivity
Require slow heating and careful heatRequire slow heating and careful heat
treatment to avoid decarburization.treatment to avoid decarburization.
29. 06/06/1706/06/17 2929
TOOL STEELSTOOL STEELS
Special steel developed to cut / changeSpecial steel developed to cut / change
shape of a material into a finished orshape of a material into a finished or
semi finished product.semi finished product.
Slight change of form during hardeningSlight change of form during hardening
Little risk of cracking during hardeningLittle risk of cracking during hardening
Good toughnessGood toughness
30. 06/06/1706/06/17 3030
TOOL STEELSTOOL STEELS
Good wear resistanceGood wear resistance
Very good machinabilityVery good machinability
Definite hardening temperature andDefinite hardening temperature and
cooling ratecooling rate
Resistance to softening on heating (RedResistance to softening on heating (Red
hardness)hardness)
31. 06/06/1706/06/17 3131
STAINLESS STEELSTAINLESS STEEL
Iron based alloy containing 10.50 % or moreIron based alloy containing 10.50 % or more
chromium.chromium.
Stainless characteristics is achieved due toStainless characteristics is achieved due to
formation of chromium rich oxide film formedformation of chromium rich oxide film formed
on the surface of the materialon the surface of the material
Self forming and self healing oxide film in theSelf forming and self healing oxide film in the
presence of oxygenpresence of oxygen
Other alloying elements are – nickel,Other alloying elements are – nickel,
molybdenum, copper, titanium, silicon,molybdenum, copper, titanium, silicon,
manganese aluminum etc,manganese aluminum etc,
Carbon content varies from 0.3 – 1.0 %.Carbon content varies from 0.3 – 1.0 %.
34. 06/06/1706/06/17 3434
Designation of STEELDesignation of STEEL
High Alloy Tool SteelHigh Alloy Tool Steel
TT W – High Speed SteelW – High Speed Steel
MM Mo – High Speed SteelMo – High Speed Steel
DD High C, high Cr SteelHigh C, high Cr Steel
AA Air hardening SteelAir hardening Steel
OO Oil hardening SteelOil hardening Steel
WW Water hardening SteelWater hardening Steel
HH Hot Work SteelHot Work Steel
SS Shock resisting SteelShock resisting Steel
35. 06/06/1706/06/17 3535
Composition of STEELComposition of STEEL
SerieSerie
ss
CC MnMn SiSi MoMo CrCr NiNi
EN 8EN 8 0.400.40 0.900.90 0.250.25 ------ ------ ------
EN 9EN 9 0.500.50 0.900.90 0.250.25 ------ ------ ------
ENEN
1616
0.350.35 1.251.25 0.250.25 0.250.25 ------ ------
ENEN
1818
0.400.40 0.800.80 0.250.25 ------ 1.101.10 ------
ENEN
1919
0.400.40 0.750.75 0.250.25 0.300.30 1.251.25 ------
ENEN 0.400.40 0.700.70 0.250.25 0.300.30 1.251.25 1.501.50
37. 06/06/1706/06/17 3737
Composition of STEELComposition of STEEL
SeriesSeries CC MnMn SiSi MoMo CrCr NiNi
EN 57EN 57 0.200.20 0.900.90 0.500.50 ------ 15.0015.00 1.001.00
EN 58EN 58 0.150.15 1.501.50 0.150.15 ------ 18.0018.00 8.008.00
EN 100EN 100 0.400.40 1.201.20 0.300.30 0.200.20 0.500.50 0.900.90
EN 202EN 202 0.150.15 1.201.20 0.250.25 ------ ------ ------
EN 353EN 353 0.180.18 0.750.75 0.350.35 0.100.10 1.001.00 1.501.50
38. 06/06/1706/06/17 3838
Effect of Alloying ElementsEffect of Alloying Elements
An alloying element is added toAn alloying element is added to
a metal for improvement in theira metal for improvement in their
Mechanical & PhysicalMechanical & Physical
properties.properties.
Common alloying elements are:Common alloying elements are:
C, Ni, Mo, V, W, Mn, Cu, Bo, Al,C, Ni, Mo, V, W, Mn, Cu, Bo, Al,
Co, Si, Ti, Cr etc.Co, Si, Ti, Cr etc.
39. 06/06/1706/06/17 3939
Effect of Alloying ElementsEffect of Alloying Elements
Addition of alloying elements toAddition of alloying elements to
steel results insteel results in
Improved tensile strength withoutImproved tensile strength without
lowering ductility.lowering ductility.
Improved toughness.Improved toughness.
Increases hardenabilityIncreases hardenability
40. 06/06/1706/06/17 4040
Effect of Alloying ElementsEffect of Alloying Elements
Retain physical properties atRetain physical properties at
elevated temperatureelevated temperature
Improved corrosion resistanceImproved corrosion resistance
Improved wear resistanceImproved wear resistance
Improved grain size to steelImproved grain size to steel
Improved surface hardnessImproved surface hardness
characteristicscharacteristics
41. 06/06/1706/06/17 4141
Effect of Alloying ElementsEffect of Alloying Elements
CarbonCarbon Increases HardnessIncreases Hardness
Increases Tensile strengthIncreases Tensile strength
and Yield strengthand Yield strength
Decreases Weldability,Decreases Weldability,
Ductility and ToughnessDuctility and Toughness
Decreases MachinabilityDecreases Machinability
Increases Melting PointIncreases Melting Point
42. 06/06/1706/06/17 4242
Effect of Alloying ElementsEffect of Alloying Elements
ManganeseManganese Increases Strength andIncreases Strength and
Hardness ( lesser thanHardness ( lesser than
Carbon)Carbon)
Counteracts brittleness dueCounteracts brittleness due
to Sulpherto Sulpher
Lowers Ductility andLowers Ductility and
WeldabilityWeldability
Increases HardenabilityIncreases Hardenability
43. 06/06/1706/06/17 4343
Effect of Alloying ElementsEffect of Alloying Elements
PhosphorusPhosphorus Increases Strength andIncreases Strength and
Hardness of Carbon steelHardness of Carbon steel
Reduces Ductility &Reduces Ductility &
Toughness in high carbonToughness in high carbon
steelsteel
Improves machinabilityImproves machinability
44. 06/06/1706/06/17 4444
Effect of Alloying ElementsEffect of Alloying Elements
SulfurSulfur Lowers transverse ductilityLowers transverse ductility
and notch impact toughnessand notch impact toughness
Decreases WeldabilityDecreases Weldability
Detrimental to surfaceDetrimental to surface
quality of steelquality of steel
Increases machinabilityIncreases machinability
45. 06/06/1706/06/17 4545
Effect of Alloying ElementsEffect of Alloying Elements
SiliconSilicon Acts as a deoxidizerActs as a deoxidizer
Increases Strength andIncreases Strength and
HardnessHardness
Impairs Machinability andImpairs Machinability and
Cold formingCold forming
46. 06/06/1706/06/17 4646
Effect of Alloying ElementsEffect of Alloying Elements
AluminumAluminum One of the importantOne of the important
deoxidizerdeoxidizer
Produces fine austeniticProduces fine austenitic
grain sizegrain size
Helps in Nitriding in case ofHelps in Nitriding in case of
surface hardeningsurface hardening
47. 06/06/1706/06/17 4747
Effect of Alloying ElementsEffect of Alloying Elements
NickelNickel Increases Toughness &Increases Toughness &
Impact resistanceImpact resistance
Reduces distortion duringReduces distortion during
quenchingquenching
Lowers critical temperatureLowers critical temperature
of steel ( widening heatof steel ( widening heat
treatment range)treatment range)
Improves StrengthImproves Strength
48. 06/06/1706/06/17 4848
Effect of Alloying ElementsEffect of Alloying Elements
ChromiumChromium Joins with carbon formingJoins with carbon forming
Chromium carbideChromium carbide
Increases depthIncreases depth
hardenability and resistancehardenability and resistance
to abrasion & wearto abrasion & wear
Helps preventing corrosionHelps preventing corrosion
& oxidation& oxidation
Adds strength at elevatedAdds strength at elevated
temperaturetemperature
49. 06/06/1706/06/17 4949
Effect of Alloying ElementsEffect of Alloying Elements
MolybdenumMolybdenum Promotes hardenabilityPromotes hardenability
Makes steel fine grainedMakes steel fine grained
Improves toughness atImproves toughness at
various toughness levelvarious toughness level
Reduces temper brittlenessReduces temper brittleness
Improves creep and tensileImproves creep and tensile
strength at elevatedstrength at elevated
temperaturetemperature
Enhances corrosionEnhances corrosion
50. 06/06/1706/06/17 5050
Effect of Alloying ElementsEffect of Alloying Elements
VanadiumVanadium Promotes fine grains in steelPromotes fine grains in steel
Increases hardenabilityIncreases hardenability
Imparts strength andImparts strength and
toughness to heat treatedtoughness to heat treated
steelsteel
Resists tempering and provideResists tempering and provide
secondary hardeningsecondary hardening
Increases mechanicalIncreases mechanical
properties of hot rolled steelsproperties of hot rolled steels
51. 06/06/1706/06/17 5151
Effect of Alloying ElementsEffect of Alloying Elements
TungstenTungsten Increases hardness as well asIncreases hardness as well as
red hardness ( by formingred hardness ( by forming
tungsten carbides)tungsten carbides)
Promotes fine grainsPromotes fine grains
Increases heat resistanceIncreases heat resistance
Promotes strength at elevatedPromotes strength at elevated
temperaturetemperature
52. 06/06/1706/06/17 5252
Effect of Alloying ElementsEffect of Alloying Elements
CopperCopper Added up to 0.2 to 0.5 %Added up to 0.2 to 0.5 %
Increases resistance toIncreases resistance to
atmospheric corrosionatmospheric corrosion
Acts as a strengthening agentActs as a strengthening agent
53. 06/06/1706/06/17 5353
Effect of Alloying ElementsEffect of Alloying Elements
BoronBoron Increases hardenabilityIncreases hardenability
Increases depth of hardnessIncreases depth of hardness
when quenchedwhen quenched
54. 06/06/1706/06/17 5454
Effect of Alloying ElementsEffect of Alloying Elements
CobaltCobalt Contributes to red hardnessContributes to red hardness
Decrease hardenability forDecrease hardenability for
steels with more than 0.4 %steels with more than 0.4 %
carboncarbon
Improves hardenability for lowImproves hardenability for low
carbon chromium steelscarbon chromium steels
55. 06/06/1706/06/17 5555
Effect of Alloying ElementsEffect of Alloying Elements
TitaniumTitanium Prevents localised depletionPrevents localised depletion
of chromium in stainlessof chromium in stainless
steels during long heatingsteels during long heating
Acts as a deoxidizer and limitsActs as a deoxidizer and limits
grain growthgrain growth
Increases hardenability inIncreases hardenability in
case of boron steelcase of boron steel
56. 06/06/1706/06/17 5656
Non Ferrous Metals &Non Ferrous Metals &
AlloysAlloys
Commonly used Non ferrousCommonly used Non ferrous
metals as Mould material aremetals as Mould material are
AluminumAluminum
CopperCopper
57. 06/06/1706/06/17 5757
Non Ferrous Metals &Non Ferrous Metals &
AlloysAlloys
ALUMINUMALUMINUM
Most abundant metallic elementMost abundant metallic element
Light metal with bright silvery lustureLight metal with bright silvery lusture
Melting point : 660 CMelting point : 660 C
Specific gravity : 2.8Specific gravity : 2.8
( density : 2.77 gm / cm³)( density : 2.77 gm / cm³)
Weighs only one third that of an equalWeighs only one third that of an equal
volume of steelvolume of steel
58. 06/06/1706/06/17 5858
Non Ferrous Metals &Non Ferrous Metals &
AlloysAlloys
ALUMINUMALUMINUM
Very ductile and soft in natureVery ductile and soft in nature
Can be hardened by cold working andCan be hardened by cold working and
alloyingalloying
Strength increases considerably onStrength increases considerably on
alloyingalloying
Commonly used alloying elements are Cu,Commonly used alloying elements are Cu,
Mg, Mn, and ZnMg, Mn, and Zn
Iron & Silicon are commonly present asIron & Silicon are commonly present as
impuritiesimpurities
59. 06/06/1706/06/17 5959
Non Ferrous Metals &Non Ferrous Metals &
AlloysAlloys
ALUMINUMALUMINUM
Excellent conductor of heat & electricityExcellent conductor of heat & electricity
( next to gold, silver and copper)( next to gold, silver and copper)
Highly reflective of light & heatHighly reflective of light & heat
Light in weight, yet some of the alloys haveLight in weight, yet some of the alloys have
strengths greater than that of structural steelstrengths greater than that of structural steel
High resistance to corrosion under majority ofHigh resistance to corrosion under majority of
service conditionsservice conditions
Can easily be worked into many forms withCan easily be worked into many forms with
wide variety of surface finishwide variety of surface finish
60. 06/06/1706/06/17 6060
Non Ferrous Metals &Non Ferrous Metals &
AlloysAlloys
COPPERCOPPER
Comparatively heavy materialComparatively heavy material
Melting point : 1083 CMelting point : 1083 C
Salomon pink in colour with bright metallicSalomon pink in colour with bright metallic
lusturelusture
Specific gravity : 8.96Specific gravity : 8.96
Non magneticNon magnetic
High thermal conductivity and electricalHigh thermal conductivity and electrical
conductivityconductivity
61. 06/06/1706/06/17 6161
Non Ferrous Metals &Non Ferrous Metals &
AlloysAlloys
COPPER & AlloysCOPPER & Alloys
Corrosion resistanceCorrosion resistance
Ease of forming, joiningEase of forming, joining
Low strength to weight ratioLow strength to weight ratio
Low strength at elevated temperaturesLow strength at elevated temperatures
Susceptible to stress corrosion crackingSusceptible to stress corrosion cracking
Can be hot or cold worked to increaseCan be hot or cold worked to increase
strengthstrength
Ductility can be restored by annealingDuctility can be restored by annealing
64. 06/06/1706/06/17 6464
Commonly used ALLOYSCommonly used ALLOYS
BRASSBRASS
Alloy of Copper & ZincAlloy of Copper & Zinc
Most widely & least expensive copperMost widely & least expensive copper
based alloysbased alloys
Relatively good corrosion resistanceRelatively good corrosion resistance
Moderately high strengthModerately high strength
Good ductility and excellent formingGood ductility and excellent forming
characteristicscharacteristics
65. 06/06/1706/06/17 6565
Commonly used ALLOYSCommonly used ALLOYS
BRASSBRASS
Alpha brass contains copper at 64 %Alpha brass contains copper at 64 %
or above.or above.
Can withstand considerable coldCan withstand considerable cold
working without annealingworking without annealing
Beta brass contains 60% or lessBeta brass contains 60% or less
coppercopper
Excellent hot working characteristicsExcellent hot working characteristics
66. 06/06/1706/06/17 6666
Commonly used ALLOYSCommonly used ALLOYS
BRASSBRASS
The strength and elongation of theseThe strength and elongation of these
brass vary depending upon content ofbrass vary depending upon content of
Zinc & CopperZinc & Copper
Adding 0.5 to 4 % lead results in freeAdding 0.5 to 4 % lead results in free
machining (cutting) alloysmachining (cutting) alloys
Relatively low ductility but otherRelatively low ductility but other
properties remain unaffectedproperties remain unaffected
67. 06/06/1706/06/17 6767
Commonly used ALLOYSCommonly used ALLOYS
TIN BRONZETIN BRONZE
Contains 8 – 10 % Sn and 2 – 4 % Zn,Contains 8 – 10 % Sn and 2 – 4 % Zn,
remaining copperremaining copper
General utility structural bronzeGeneral utility structural bronze
Used for Pressure casting, Bushing &Used for Pressure casting, Bushing &
BearingsBearings
68. 06/06/1706/06/17 6868
Commonly used ALLOYSCommonly used ALLOYS
ALUMINIUM BRONZEALUMINIUM BRONZE
Contains 1 – 4 % Fe, 9 – 11% Al,Contains 1 – 4 % Fe, 9 – 11% Al,
remaining copperremaining copper
Sometimes may contain upto 4% NiSometimes may contain upto 4% Ni
Used for heavy duty parts, marineUsed for heavy duty parts, marine
equipments, gears, bearings,equipments, gears, bearings,
bushings, valve seals, guides, acidbushings, valve seals, guides, acid
resisting pums etc.resisting pums etc.
69. 06/06/1706/06/17 6969
Commonly used ALLOYSCommonly used ALLOYS
LEADED NICKEL BRONZELEADED NICKEL BRONZE
Contains 4 – 5 % Sn, 1.5 – 4% Pb, 2 –Contains 4 – 5 % Sn, 1.5 – 4% Pb, 2 –
8 % Zn, 20 – 25 % Ni and remaining8 % Zn, 20 – 25 % Ni and remaining
coppercopper
Used for marine casting, hardware,Used for marine casting, hardware,
valve, dairy equipments etc.valve, dairy equipments etc.
70. 06/06/1706/06/17 7070
Commonly used ALLOYSCommonly used ALLOYS
LEADED YELLOW BRASSLEADED YELLOW BRASS
Contains 1% Sn, 1 – 3% Pb, 24 – 36 %Contains 1% Sn, 1 – 3% Pb, 24 – 36 %
Zn and remaining copperZn and remaining copper
0.3 % Al may also be present0.3 % Al may also be present
Used for hardware, valve, fittingsUsed for hardware, valve, fittings
ornamental casings etc.ornamental casings etc.
71. 06/06/1706/06/17 7171
Commonly used ALLOYSCommonly used ALLOYS
GUN METALGUN METAL
Contains 5 – 10 % Sn, 2 – 5 % Zn andContains 5 – 10 % Sn, 2 – 5 % Zn and
remaining copperremaining copper
Possesses good tensile strength andPossesses good tensile strength and
corrosion resistancecorrosion resistance
Used for bearings, steam pipe fittings,Used for bearings, steam pipe fittings,
marine castings, hydraulic valve &marine castings, hydraulic valve &
gears etc.gears etc.
72. 06/06/1706/06/17 7272
Commonly used ALLOYSCommonly used ALLOYS
PHOSPHOR BRONZEPHOSPHOR BRONZE
Contains 8 – 12 % Sn with smallContains 8 – 12 % Sn with small
addition of phosphorous and remainingaddition of phosphorous and remaining
coppercopper
Used for springs, condenser tubes,Used for springs, condenser tubes,
bearings, bushings, diaphrams etc.bearings, bushings, diaphrams etc.
73. 06/06/1706/06/17 7373
Commonly used ALLOYSCommonly used ALLOYS
GERMAN SILVERGERMAN SILVER
Alloy of Copper, Nickel & ZincAlloy of Copper, Nickel & Zinc
Contains 52 – 80 % Cu, 5 – 30 % Ni andContains 52 – 80 % Cu, 5 – 30 % Ni and
5 – 35 % Zn5 – 35 % Zn
Nickel gives a silvery colour, improvesNickel gives a silvery colour, improves
strength and corrosion resistancestrength and corrosion resistance
Used in silver plated tableware, jewellery,Used in silver plated tableware, jewellery,
springs, marine fixtures. Plumbingsprings, marine fixtures. Plumbing
fixtures, architectural applications.fixtures, architectural applications.
74. 06/06/1706/06/17 7474
Commonly used ALLOYSCommonly used ALLOYS
MONELMONEL
Alloy of Copper, Nickel & IronAlloy of Copper, Nickel & Iron
Contains 68 % Ni, 27 % Cu and 6 % FeContains 68 % Ni, 27 % Cu and 6 % Fe
Some amount of manganese may alsoSome amount of manganese may also
be present.be present.
Less magnetic, corrosion resistant springLess magnetic, corrosion resistant spring
for light loadfor light load
75. 06/06/1706/06/17 7575
Commonly used ALLOYSCommonly used ALLOYS
BERYLLIUM COPPERBERYLLIUM COPPER
Alloy of Copper and BerylliumAlloy of Copper and Beryllium
Contains up to 2 % Beryllium by weightContains up to 2 % Beryllium by weight
and rest is Copperand rest is Copper
Small amount of cobalt or nickel may alsoSmall amount of cobalt or nickel may also
be addedbe added
Addition of small amount of berylliumAddition of small amount of beryllium
makes the alloy as strong as alloy steelmakes the alloy as strong as alloy steel
76. 06/06/1706/06/17 7676
Commonly used ALLOYSCommonly used ALLOYS
BERYLLIUM COPPERBERYLLIUM COPPER
Excellent response to precipitationExcellent response to precipitation
hardening treatmentshardening treatments
Excellent corrosion and fatigueExcellent corrosion and fatigue
resistanceresistance
Moderate to good electrical and thermalModerate to good electrical and thermal
conductivityconductivity
Resistance to stress relaxation.Resistance to stress relaxation.
77. 06/06/1706/06/17 7777
Commonly used ALLOYSCommonly used ALLOYS
BERYLLIUM COPPERBERYLLIUM COPPER
Good performance at elevatedGood performance at elevated
temperaturestemperatures
Maximum long time operatingMaximum long time operating
temperature should not exceed 204 Ctemperature should not exceed 204 C
Available in 02 categoriesAvailable in 02 categories
High strength with moderateHigh strength with moderate
conductivityconductivity
High conductivity with moderateHigh conductivity with moderate
strengthstrength
78. 06/06/1706/06/17 7878
Commonly used ALLOYSCommonly used ALLOYS
BERYLLIUM COPPERBERYLLIUM COPPER
Available in all forms like strip, rod, bar,Available in all forms like strip, rod, bar,
plate, tube, wire, cast or forged billet,plate, tube, wire, cast or forged billet,
special shape and casting ingotsspecial shape and casting ingots
General heat treatment temperatureGeneral heat treatment temperature
range is 316 C to 482 C for 2 – 3 hours.range is 316 C to 482 C for 2 – 3 hours.
Relatively high strength and ease ofRelatively high strength and ease of
manufacturing, joiningmanufacturing, joining
Typical applications areTypical applications are
80. 06/06/1706/06/17 8080
Common Attributes of Be - CuCommon Attributes of Be - Cu
Galling ResistanceGalling Resistance
It has inherently good wear resistance.It has inherently good wear resistance.
Allows contact with other materials withAllows contact with other materials with
minimum friction and surface damageminimum friction and surface damage
Threaded joints of the alloy with stainlessThreaded joints of the alloy with stainless
steel are not damaged even understeel are not damaged even under
overload conditionoverload condition
81. 06/06/1706/06/17 8181
Special Attributes of Be - CuSpecial Attributes of Be - Cu
Elevated Temperature StrengthElevated Temperature Strength
( Welding rods, Injection mould( Welding rods, Injection mould
components)components)
Reflectivity ( Mirrors)Reflectivity ( Mirrors)
Dimensional StabilityDimensional Stability
Appearance (Decorative components)Appearance (Decorative components)
82. 06/06/1706/06/17 8282
Special Attributes of Be - CuSpecial Attributes of Be - Cu
Special Surface TreatmentSpecial Surface Treatment
Surface modification by localisedSurface modification by localised
hardening, laser and electron beamhardening, laser and electron beam
techniques produces various surfacetechniques produces various surface
states.states.
Coatings can be applied to increaseCoatings can be applied to increase
emissivity, hardening or appearanceemissivity, hardening or appearance
