IT 111 MANUFACTURING MATERIALS

Lecture 3 Thomas E. Scott

Standards Organizations
American Society for Testing and Materials (ASTM) American Iron and Steel Institute (AISI) Society of Automotive Engineers (SAE) American Institute of Astronautics and Aeronautics (AIAA) NASA Department of Defense (DOD)
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ASTM Standards provide:

Letter designation for standards that include: specifications, test methods, definitions, classification, suggested practices
A. Ferrous Metals B. Nonferrous Metals C. Cement, ceramics D. Miscellaneous materials E. Miscellaneous Subjects

F. Specific applications of materials G. Corrosion, deterioration H. Emergency Standards

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Ferrous Metals (Iron)

In industry, iron is mainly used in the form of steel Steel an iron carbon alloy with less than 2% carbon Cast Iron more that 2% but less than 4% carbon

Production of Iron
Very little pure iron produced
Usually ingot or iron powders

Mostly steels with alloys carbon, silicon, nickel, chromium, manganese

Plain carbon steel less that 1% alloying element of carbon, silicon, and/or manganese Low-alloy steel have small quantities of the above plus nickel, chromium, molydenum or others that alter the properties of steel High-alloy steel have more than 5% of alloying elements
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Source of Iron (Fe)

Ores of iron
Magnetite contains 65% iron
Ferric oxide (Fe2O3) and Ferrous oxide (FeO) Highly magnetic (Lodestone)

Hermatite contains 50% iron

Ferric oxide (Fe2O3) Commonly know as rust Blood red

Taconite contains 30% iron

Green colored Contains a lot of silica
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Refining Iron Ore

Heat ore in a furnace where air (oxygen) has been removed
Produces coke

Blast furnace force air at 1100 F to permit carbon oxygen combustion

Iron melts Slag provides a protective barrier for purified iron Pure iron captured as ingots (Pigs) Contains roughly 4% carbon (cast iron)

Yield is about 50% - 6000 tons of ore to produce 3000 tons of pig iron
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Production of Steel (Conversion)

Burn off carbon
Blow hot air across the pigs and scrap iron Let the carbon burn Add exact amounts of carbon and alloys Draw off liquid into ingots

Open Hearth 200 tons in 12 hours Bessemer 25 tons in 15 minutes Electric arc Expensive because of energy used (for finishing)
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Commercial Shapes of Steel

Ingots
Blooms
Beams Channels Tubes

Slabs
Plates Pipe Sheets Coils

Billets
Bars Rods Wire

Commercial Shapes of Steel

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Carbon in Steel
NAME Low Medium % Carbon 0.05-0.32 0.35-0.55 Example
Sheet, Structural Machinery, Re-bar, auto, aerospace

High
Cast Iron

0.60-1.50
>2.00

Machine tools, knives, hammers

Castings
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Effect of carbon addition

(Small increase approx 0.1%)
More expensive Less ductile more brittle Harder Loses machinability Higher tensile strength Lower melting point Easier to harden Harder to weld
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Characteristics of Carbon Steels

Cold working
Plastic deformation at room temp
Decrease thickness 4% Increase tensile strength 50% Work hardening results May require heat treating

Examples
Cold rolled steel Cold drawn tubing
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Other elements in steel

Aluminum
Oxygen remains in steel undesirable Adding aluminum (killed steel) causes oxygen to react with aluminum and negates rust formation (good for forging and piercing) Aluminum also promotes small grain size and therefore, toughness

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Other elements in steel

Manganese
Sulfur accumulates at grain boundaries undesirable Causes the steel to lose strength at high temp Manganese ties up the sulfur Increases strength, hardenability, and hardness

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Other elements in steel

Boron increases hardenability Copper increases corrosion resistance Chromium corrosion resistance and hardenability Niobium increases strength Titanium high strength at high temp Tungsten carbide high hardness Vanadium toughness and impact resistance
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Steel
Free Cutting (High sulfur)
e.g., AISI 1111 up to 1151 Easy machining Higher carbon XX44 for example, greater hardness and flame case hardening

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Nomenclature for steels

Steel AISI and SAE Four digit designator describes alloy content
Number Type of Steel
Plain Carbon Sulfurized Leaded Manganese Nickel Nickel-Chromium Molybdenum Chrome Molybdenum
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Number Type of Steel

10-11-12L-13-2--3--40-41--

43-46-5--6--7--8--9---

Ni Cr Moly Ni Moly Chromium Chrom Van Unused Low-Ni Cr Moly Ni Cr small -Moly

Nomenclature for steels

Examples 1010 Plain carbon (C = 0.1%) 4030 Steel with 0.30% Molybdenum

Standards table required to determine actual content, suggested use and properties
Web access to clarify material properties - Often have to pay for it
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Nomenclature for steels

Table 3-B of Kazanas Table 3-C of Kazanas Table 3-D of Kazanas Table 3-E of Kazanas Table 3-F of Kazanas Table 3-G of Kazanas Table 3-H of Kazanas
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Tool Steels
High carbon high alloy High wear and heat resistance High strength hard Letter classification

Type AOW H M-T P S D L-F

Purpose Air or Oil or Water hardening Hot working High-speed containing Moly or Tungsten Mold (plastic) Steels Shock resistant, med carbon, low alloy High Chromium Special Purpose 29

Tool Steels
Examples
W-1 Water hardening 1% carbon used for cold working of metals D3 High chromium with 2.25% carbon for cold working applications S2 Shock resistant hammer or chisel steel
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Tool Steels
Table 3-I of Kazanas Table 3-J of Kazanas Table 3-K of Kazanas

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Tool Steels
Must sustain high loads Often loads concentrated on surface May have elevated temperatures Often substantial shock loading Must be immune to cracking

Often particular steel alloy types Seven basic types of tool steel
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Tool Steels
Properties for tool steels
Wear resistance Impact resistance High temperature capability Toughness

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Alloys in tool steels

Carbon hardenability (>0.6%) Manganese reduce brittleness (<0.6%) Silicon for hot forming, strength and toughness (<2%) Tungsten hot hardness Vanadium hardness and wear resistance Molybdenum deep hardening, toughness Cobalt hot hardness Chromium hardenability (up to 12%) Nickel toughness and wear resistance
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Cast Iron
More than 2% carbon Lower strength since carbon flakes produce minute cracks Very susceptible to breaking (brittle) Grey cast iron almost no ductility White cast iron 1% silicon making it hard

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Nodular Cast Iron

Nodular cast iron small amounts of calcium, cerium, lithium, magnesium, sodium Slow cooling produces spheres instead of plates Improves ductility 60:40:20
Tensile 60K, Yield 40K, 20% elongation

Engine blocks, pistons, crankshafts

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Stainless Steel
Normal Steels corrode rapidly if left uncoated Higher temperature, more rapid corrosion Chromium and nickel slow corrosion Stainless steels have Cr > 12%

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Stainless Steel
Ferritic can be strengthened by work hardening
Jewelry, utensils, automotive trim

Austenitic non-magnetic
18/8 18% Cr, 8% Ni Low carbon low strength Food utensils

Martensitic High strength

Knives,

Maraging superalloys, contain Moly and Titan

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Stainless Steel
Numbering system
200s and 300s Austenitic 400s Ferritic and Martensitic

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Corrosion (Rust)
Galvanic corrosion (electrolytic process) Corrosion sped up by
Temperature Metal fatigue Cold working

Retarded by
Alloys Coatings
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