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30 Pages

Ch11

Course: EGN 3365, Spring 2012
School: FIU
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Word Count: 1943

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11: Chapter Metal Alloys Applications and Processing 11.1 Introduction ISSUES TO ADDRESS... How are metal alloys classified and how are they used? What are some of the common fabrication techniques? How do properties vary throughout a piece of material that has been quenched, for example? How can properties be modified by post heat treatment? Chapter 11 - 1 Taxonomy of Metals Metal Alloys Ferrous Steels...

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11: Chapter Metal Alloys Applications and Processing 11.1 Introduction ISSUES TO ADDRESS... How are metal alloys classified and how are they used? What are some of the common fabrication techniques? How do properties vary throughout a piece of material that has been quenched, for example? How can properties be modified by post heat treatment? Chapter 11 - 1 Taxonomy of Metals Metal Alloys Ferrous Steels Steels <1.4wt%C <1.4 wt% C Cast Irons CastIrons 3-4.5 wt% 3-4.5 wt%C C Cu Al 1600 d L 1400 g austenite g+L a800 ferrite 600 400 0 (Fe) L+Fe3C 1148C 4.30 1000 727C Eutectoid: 0.76 1 2 Eutectic: g+Fe3C 4 Ti Adapted from Fig. 9.24,Callister 7e. (Fig. 9.24 adapted from Binary Alloy Phase Diagrams, 2nd ed., Vol. 1, T.B. Massalski (Ed.-in-Chief), ASM International, Materials Park, OH, 1990.) Fe3C cementite a+Fe3C 3 Mg microstructure: ferrite, graphite cementite T(C) 1200 Adapted from Fig. 11.1, Callister 7e. Nonferrous 5 6 Co , wt% C 6.7 Chapter 11 - 2 11.1 Ferrous alloys Iron containing Steels - cast irons Nomenclature AISI & SAE 10xx Plain Carbon Steels 11xx Plain Carbon Steels (resulfurized for machinability) 12xx Plain Carbon Steels (Resulfurized and rephosphorized) 13xx Mn (1.6-1.9%) 40xx Mo (0.20 ~ 0.30%) 43xx Ni (1.65 - 2.00%), Cr (0.4 - 0.90%), Mo (0.2 - 0.3%) 44xx Mo (0.5%) where xx is wt% C x 100 example: 1060 steel plain carbon steel with 0.60 wt% C Stainless Steel -- >11% Cr Chapter 11 - 3 http://www.engineershandbook.com/Tables/carbonsteelalloys.htm Steel Alloy Designation System (American Iron and Steel Institute -Society of Automotive Engineering) AISI-SAE Designation Number Type and Description Carbon steels 10xx Plain Carbon (Mn. 1.00% max.) 11xx Resulfurized 12xx Resulfurized and rephosphorized 15xx Plain Carbon (max. Mn. range 1.00-1.65%) Manganese steels 13xx Mn 1.75 Nickel steels 23xx Ni 3.50 25xx Ni 5.00 Nickel-chromium steels 31xx Ni 1.25; Cr 0.65, 0.80 32xx Ni 1.75; Cr 1.07 33xx Ni 3.50; Cr 1.50, 1.57 34xx Ni 3.00; Cr 0.77 Molybdenum steels 40xx Mo 0.20, 0.25 44xx Mo 0.40, 0.52 Chromium-molybdenum steels 41xx Cr 0.50, 0.80, 0.95; Mo 0.12, 0.20, 0.25, 0.30 Nickel-chromium-molybdenum steels 43xx 43BVxx 47xx Ni 1.82; Cr 0.50, 0.80; Mo 0.25 Ni 1.82; Cr 0.50; Mo 0.12, 0.25; V 0.03 min. Ni 1.05; Cr 0.45; Mo 0.20, 0.35 Chapter 11 - 4 81xx Ni 0.30; Cr 0.40; Mo 0.12 86xx Ni 0.55; Cr 0.50; Mo 0.20 87xx Ni 0.55; Cr 0.50; Mo 0.25 88xx Ni 0.55; Cr 0.50; Mo 0.35 93xx Ni 3.25; Cr 1.20; Mo 0.12 94xx Ni 0.45; Cr 0.40; Mo 0.12 97xx Ni 1.00; Cr 0.20; Mo 0.20 98xx Ni 1.00; Cr 0.80; Mo 0.25 Nickel-molybdenum steels 46xx Ni 0.85, 1.82; Mo 0.20, 0.25 48xx Ni 3.50; Mo 0.25 Chromium steels 50xx Cr 0.27, 0.40, 0.50, 0.65 51xx Cr 0.80, 0.87, 0.92, 0.95, 1.00, 1.05 50xxx Cr 0.50; C 1.00 min. 51xxx Cr 1.02; C 1.00 min. 52xxx Cr 1.45; C 1.00 min. Chromium-vanadium steels 61xx Cr 0.60, 0.80, 0.95; V 0.10, 0.15 Tungsten-chromium steels 72xx W 1.75; Cr 0.75 Silicon-manganese steels 92xx Si 1.40, 2.00; Mn 0.65, 0.82, 0.85; Cr 0.00, 0.65 High-strength low-alloy steels 9xx Various SAE grades Boron steels xxBxx B denotes boron steels Leaded steels xxLxx L denotes leaded steels Chapter 11 - 5 Steels High Alloy Low Alloy low carbon Med carbon <0.25 wt% C 0.25-0.6 wt% C high carbon 0.6-1.4 wt% C heat plain treatable Cr,V Cr, Ni Additions none none none Ni, Mo Mo Example 1010 4310 1040 43 40 1095 Name plain Hardenability 0 TS EL + Uses auto struc. sheet HSLA + 0 + bridges towers press. vessels plain + + 0 crank shafts bolts hammers blades tool Cr, V, Mo, W 4190 ++ ++ - ++ + - +++ ++ -- pistons gears wear applic. wear applic. drills saws dies increasing strength, cost, decreasing ductility Based on data provided in Tables 11.1(b), 11.2(b), 11.3, and 11.4, Callister 7e. austenitic stainless Cr, Ni, Mo(>11%) 304 0 0 ++ high T applic. turbines furnaces V. corros. resistant Chapter 11 - 6 Cast Iron Ferrous alloys with > 2.1 wt% C more commonly 3 - 4.5 wt%C low melting (also brittle) so easiest to cast Cementite decomposes to ferrite + graphite Fe3C 3 Fe (a) + C (graphite) generally a slow process Chapter 11 - 7 Fe-C True Equilibrium Diagram T(C) 1600 Graphite formation promoted by 1400 Si > 1 wt% 1200 slow cooling L g Austenite Liquid + Graphite g +L 1153C 4.2 wt% C 1000 g + Graphite a+g 800 0.65 740C 600 Adapted from Fig. 11.2,Callister 7e. (Fig. 11.2 adapted from Binary Alloy Phase Diagrams, 2nd ed., Vol. 1, T.B. Massalski (Ed.in-Chief), ASM International, Materials Park, OH, 1990.) 400 (Fe) a + Graphite 0 1 2 3 4 90 Co , wt% C Chapter 11 - 8 100 Types of Cast Iron Gray iron (2.5-4.0wt%C and 1.0-3.0wt%Si) graphite flakes+ferrite weak & brittle under tension stronger under compression excellent vibrational dampening wear resistant Ductile iron add Mg or Ce to Gray iron graphite in nodules not flakes matrix often pearlite - better ductility Adapted from Fig. 11.3(a) & (b), Callister 7e. Chapter 11 - 9 Types of Cast Iron White iron <1wt% Si rapid cooling more cementite instead of graphite + pearlite harder but brittle Adapted from Fig. 11.3(c) & (d), Callister 7e. Malleable iron heat treat white iron at 800900C (cementite decomposes). graphite in rosettes Pearlite or ferrite more ductile (<= cooling rate) Chapter 11 - 10 Production of Cast Iron Adapted from Fig.11.5, Callister 7e. Chapter 11 - 11 Limitations of Ferrous Alloys 1) Relatively high density 2) Relatively low conductivity 3) Poor corrosion resistance Chapter 11 - 12 11.3 Nonferrous Alloys stronger Cu Alloys Al Alloys -lower r: 2.7g/cm3 Brass: Zn is subst. impurity (costume jewelry, coins, -Cu, Mg, Si, Mn, Zn additions corrosion resistant) -solid sol. or precip. Bronze : Sn, Al, Si, Ni are strengthened (struct. subst. impurity aircraft parts (bushings, landing & packaging) gear) NonFerrous Mg Alloys Cu-Be : -very low r: 1.7g/cm3 Alloys precip. hardened -ignites easily for strength -aircraft, missiles Ti Alloys Refractory metals -lower r: 4.5g/cm3 vs 7.9 for steel -reactive at high T -space applic. Noble metals -Ag, Au, Pt -oxid./corr. resistant Based on discussion and data provided in Section 11.3, Callister 7e. -high melting T -Nb, Mo, W, Ta Stong interatomic B Chapter 11 - 13 Metal Fabrication How do we fabricate metals? Blacksmith - hammer (forged) Molding - cast Forming Operations Rough stock formed to final shape Hot working vs. T high enough for recrystallization Larger deformations Risk of surface oxidation Cold working well below Tm work hardening smaller deformations better surface finish Chapter 11 - 14 11.4 Metal Fabrication Methods - I FORMING CASTING JOINING Forging (Hammering; Stamping) Rolling (Hot or Cold Rolling) (wrenches, crankshafts) force (I-beams, rails, sheet & plate) roll die A o blank A d often at elev. T Drawing force Ao Ad roll Adapted from Fig. 11.8, Callister 7e. Extrusion (rods, wire, tubing) die Ao Ad (rods, tubing) Ao tensile force die die be must well lubricated & clean force container ram billet die holder Ad extrusion die ductile metals, e.g. Cu,hapter 11 Al (hot) C container 15 11.5 Metal Fabrication Methods - II FORMING CASTING JOINING Casting- mold is filled with metal metal melted in furnace, perhaps alloying elements added. Then cast in a mold most common, cheapest method gives good production of shapes weaker products, internal defects good option for brittle materials Chapter 11 - 16 Metal Fabrication Methods - II FORMING CASTING JOINING Sand Casting (large parts, e.g., auto engine blocks) trying to hold something that is hot what will withstand >1600C? Sand Sand molten metal cheap - easy to mold => sand!!! pack sand around form (pattern) of desired shape Chapter 11 - 17 Metal Fabrication Methods - II FORMING CASTING JOINING Sand Casting (large parts, e.g., auto engine blocks) Investment Casting pattern is made from paraffin. Sand Sand molten metal Investment Casting (low volume, complex shapes e.g., jewelry, turbine blades) plaster die formed around wax prototype mold made by encasing in plaster of paris melt the wax & the hollow mold is left pour in metal wax Chapter 11 - 18 Metal Fabrication Methods - II FORMING CASTING Sand Casting (large parts, e.g., auto engine blocks) Sand Die Casting (high volume, low T alloys) Sand molten metal Investment Casting (low volume, complex shapes e.g., jewelry, turbine blades) plaster die formed around wax prototype JOINING Continuous Casting (simple slab shapes) molten solidified wax Chapter 11 - 19 11.6 Metal Fabrication Methods - III FORMING CASTING Powder Metallurgy (materials w/low ductility) Welding (when one large part is impractical) pressure filler metal (melted) base metal (melted) fused base metal heat area contact densify JOINING unaffected piece 1 heat affected zone unaffected Adapted from Fig. piece 2 11.9, Callister 7e. Heat affected zone: point contact at low T densification by diffusion at higher T (region in which the microstructure has been changed). (Fig. 11.9 from Iron Castings Handbook, C.F. Walton and T.J. Opar (Ed.), 1981.) Chapter 11 - 20 Thermal Processing of Metals 11.7 Annealing: Heat to Tanneal, soak, then cool slowly. Stress Relief: Reduce Spheroidize (steels): Make very soft steels for good machining. Heat just below TE & hold for 15-25 h. of Annealing Process Anneal: Negate effect of cold working (by recovery/ recrystallization, terminate before significant grain growth) Based on discussion in Section 11.7, Callister 7e. Full Anneal (steels): Make soft steels for good forming by heating Above TE to get g, then cool In furnace to get coarse P. softer stress caused by: -plastic deformation -nonuniform cooling -phase transform (Relative low T, not influence other hardening. Types Normalize (steels): For deformed steel with large grains, normalize above critical T, austenitize, then cool in air to make grains small. Chapter 11 - 21 11.8 Heat Treatments 800 a) Annealing Austenite (stable) T(C) TE A b) Quenching P 600 c) Tempered Martensite B A 400 Adapted from Fig. 10.22, Callister 7e. 0% M+A 200 50% M+A 90% a) b) 10 -1 10 10 time (s) 3 10 5 Chapter 11 - 22 c) Hardenability--Steels Ability to form martensite Jominy end quench test to measure hardenability. specimen (heated to g phase field) 24C water flat ground (0.015) Adapted from Fig. 11.11, Callister 7e. (Fig. 11.11 adapted from A.G. Guy, Essentials of Materials Science, McGraw-Hill Book Company, New York, 1978.) Rockwell C hardness tests 1/16 (0-1/2) 1/8 (1/2-2) Hardness, HRC Hardness versus distance from the quenched end. Adapted from Fig. 11.12, Callister 7e. Distance from quenched end Chapter 11 - 23 Why Hardness Changes W/Position Hardness, HRC The cooling rate varies with position. 60 40 20 0 1 2 3 distance from quenched end (in) T(C) 0% 100% 600 Adapted from Fig. 11.13, Callister 7e. (Fig. 11.13 adapted from H. Boyer (Ed.) Atlas of Isothermal Transformation and Cooling Transformation Diagrams, American Society for Metals, 1977, p. 376.) 400 200 M(start) AM 0 M(finish) 0.1 1 10 100 1000 Time (s) Chapter 11 - 24 Hardenability vs Alloy Composition Adapted from Fig. 11.14, Callister 7e. (Fig. 11.14 adapted from figure furnished courtesy Republic Steel Corporation.) "Alloy Steels" (4140, 4340, 5140, 8640) --contain Ni, Cr, Mo (0.2 to 2wt%) --these elements shift the "nose". --martensite is easier to form. 100 Hardness, HRC Jominy end quench results, C = 0.4 wt% C 10 3 60 2 Cooling rate (C/s) 100 4340 80 %M 50 40 4140 8640 20 5140 0 10 20 30 40 50 Distance from quenched end (mm) 800 T(C) 600 A 400 200 0 -1 10 10 B TE shift from A to B due to alloying M(start) M(90%) 103 105 Time (s) Chapter 11 - 25 Quenching Medium & Geometry Effect of quenching medium: Medium air oil water Severity of Quench low moderate high Hardness low moderate high Effect of geometry: When surface-to-volume ratio increases: --cooling rate increases --hardness increases Position center surface Cooling rate low high Hardness low high Chapter 11 - 26 Mildly agitated water Mildly agitated oil Chapter 11 - 11.9 Precipitation Hardening Particles impede dislocations. 700 Ex: Al-Cu system T(C) Procedure: 600 --Pt A: solution heat treat (get a solid solution) --Pt B: quench to room temp. --Pt C: reheat to nucleate small q crystals within a crystals. Other precipitation systems: Cu-Be Cu-Sn Mg-Al 500 400 a a+L q+L A q a+q C 300 0 B 10 (Al) CuAl2 L 20 30 40 50 wt% Cu composition range needed for precipitation hardening Adapted from Fig. 11.24, Callister 7e. (Fig. 11.24 adapted from J.L. Murray, International Metals Review 30, p.5, 1985.) Temp. Pt A (soln heat treat) Pt C (precipitate q) Adapted from Fig. 11.22, Callister 7e. Pt B Time Chapter 11 - 28 Precipitate Effect on TS, %EL 2014 Al Alloy: 400 300 200 100 149C 204C 1min 1h 1day 1mo 1yr precipitation heat treat time %EL reaches minimum with precipitation time. 2017 Al Alloy: large precipitate can occur at RT. %EL (2 in sample) tensile strength (MPa) TS peaks with precipitation time. Increasing T accelerates process. 30 20 10 0 204C 149C 1min 1h 1day 1mo 1yr precipitation heat treat time Adapted from Fig. 11.27 (a) and (b), Callister 7e. (Fig. 11.27 adapted from Metals Handbook: Properties and Selection: Nonferrous Alloys and Pure Metals, Vol. 2, 9th ed., H. Baker (Managing Ed.), American Society for Metals, 1979. p. 41.) Chapter 11 - 29 Summary Steels: increase TS, Hardness (and cost) by adding --C (low alloy steels) --Cr, V, Ni, Mo, W (high alloy steels) --ductility usually decreases w/additions. Non-ferrous: --Cu, Al, Ti, Mg, Refractory, and noble metals. Fabrication techniques: --forming, casting, joining. Hardenability --increases with alloy content. Precipitation hardening --effective means to increase strength in Al, Cu, and Mg alloys. Chapter 11 - 30
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COMD2050:Chapter5Etymology:thestudyoftheoriginandhistoryofawordHowarenewwordscreated?Wecreatenewwordsbecausetheremaynotbeanotherwaytoexpressourselveswedontknoworcantrememberthewordtouse.Theinventionofatotallynewword.Itdoesnothappenoften.Itsusually
LSU - FINANCE - 3717
Chapter 6: MorphologyMorphology is the study of the formsor structure of words and their parts.Understanding the basic forms in alanguage, not just understandingwords--Morphologyunderstanding the basic forms inlanguage-conversations, sentences,
LSU - FINANCE - 3717
CHAPTER 7GrammarGrammarA way of describing the structure ofphrases and sentences which willaccount for all of the grammaticalsequences and rule out all theungrammatical sentences.Book, in, theGrammar*chapter perplexed the reread studentsthe* t
LSU - FINANCE - 3717
Chapter10PragmaticsPragmatics Pragmatics:thestudyofintendedmeaningwhenthereissomethingmoretoorsomethingdifferentfromtheliteralmeaningisconveyed,andweexplainthosesituationsusingpragmatics.Invisiblemeaning PragmaticstendstofocusonwhatYulecallsinv
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Discourse AnalysisDiscourse Analysis How do we make sense of texts that we read?How do we understand what speakers mean despitewhat they say? (how do we interpret ambiguous orunclear statements embedded within texts orconversations?)What makes us t
LSU - FINANCE - 3717
COMD 2050COMDChapter 13: Language and the BrainThere is no sense of pain in thebrain.2Language and the brainLanguageNeurolinguistics:field that studies therelationship between language andthe brain Neurologists Psychologists Speech-language
LSU - FINANCE - 3717
StudyofLanguageStudyofLanguageCOMD2050Chapter16:DevelopmentofwritingWhichismorepermanentthewrittenorspokenword?QuestionQuestionWrittenmorepermrecordedinaphysicalwayandcanbepassedalongSpokenwordisgoneassoonasthesoundwaveendsorisit?Onceuhavesaid
LSU - FINANCE - 3717
The study of behavioral economics aims to understand how psychological phenomenalike emotions and group dynamics influence economic decisions. Studies have found thatpeople often make decisions that are not in their best interest - or at least whatecon
LSU - FINANCE - 3717
CMST 1061Rhetorical Analysis PaperChengting Hu7/12/2011http:/www.youtube.com/watch?v=TkHA2pf1gvcI found this video on YouTube. I was deeply touched by the beautiful commercialview with sound. Its one of the Coca Cola commercials named sleepwalker.I
Maryland - CCJS - 100
Limiting Procedural LawProcedural law defines how procedures and laws should be enforced. Althoughprocedural law allows the criminal justice system to investigate and process cases and specifiesthe defendants rights, in essence this isnt necessary beca
FSU - GEOLOGY (G - 1000
Journey to the Center of the EarthThe Van Allen Belts The solar wind is deflected by the magnetosphere. Near the Earth, the stronger magnetic field forms the VanAllen belts, which arrest deadly solar &amp; cosmic radiation.Earth: Portrait of a Planet, 3r
FSU - ACG - 2021
Chapter 3 Handout1. Name the Steps in the Accounting Cycle:2. What is the Matching Principle?Offset expenses with the associated revenue.Recognize expenses as incurred.3. What is the Realization Principle?Revenue is recognized when goods are sold or