properties+uses-of-metals

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CHAPTER 1 PROPERTIES AND USES OF METAL In the seabees, Steelworkers are the resident experts on the properties and uses of metal. We lay airfields, erect towers and storage tanks, assemble pontoon causeways, and construct buildings. We use our expertise to repair metal items, resurface worn machinery parts, and fabricate all types of metal objects. To accomplish these tasks proficiently, one must possess a sound working knowledge of various metals and their properties. As we learn their different properties and characteristics, we can then select the right type of metal and use the proper method to complete the job. Steelworkers primarily work with iron and steel; however, we also must become familiar with the nonferrous metals coming into use more and more each da y. As Steelworkers, we must be able to identify various metals and to associate their individual properties with their proper application or use. The primary objective of this chapter is to present a detailed explanation of some of the properties of different m eta ls an d to provide instruction on using simple tests in establishing their identity. METAL PROPERTIES There is no simple definition of metal; however, any chemical element ha ving “meta llic properties” is classed as a metal. “Metallic properties” are defined as luster, good thermal and electrical conductivity, and the capability of being permanently shaped or deformed at room temperature. Chemical elements lacking these properties are classed as nonmetals. A few elements, known as metalloids, sometimes behave like a metal and at other times like a nonmetal. Some examples of metalloids are as follows: carbon, phosphorus, silicon, and sulfur. Although Steelworkers seldom work with pure metals, we must be knowledgeable of their properties becau se the alloys w e work wit h a re combinat ions of pure metals. Some of the pure metals discussed in this chapter are the base metals in these alloys. This is true of iron, aluminum, and magnesium. Other metals discussed are t he alloying elements present in sma ll qua ntities but important in their effect. Among these are chromium, molybdenum, titanium, and manganese. An “alloy” is defined as a substance having metallic properties that is composed of two or more elements. The elements used as alloying substances are usually metals or metalloids. The properties of an alloy differ from the properties of the pure meta ls or metalloids th at make up the a lloy and this difference is wha t creates th e usefulness of alloys. By combining metals and metal- loids, manufacturers can develop alloys that have the part icular properties required for a given use. Table 1-1 is a list of various elements and their symbols that compose metallic materials. Table 1-1. —Symbols of Base Metals and Alloying Elements 1 -1

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    CHAPTER 1

    PROPERTIES AND USES OF METAL

    In the seabees, Steelworkers are the resident

    experts on the properties and uses of metal. We lay

    airf ields, erect towers and storage tanks, assemble

    pontoon causeways, and construct buildings. We use

    our expertise to repair metal i tems, resurface worn

    machinery parts, and fabricate all types of metal

    objects. To accomplish these tasks proficiently, one

    must possess a sound working knowledge of va rious

    metals and their properties. As we learn their different

    properties and characteristics, we can then select the

    right type of metal and use the proper method to

    complete the job. Steelworkers primarily work with

    iron and steel; however, we also must become familiar

    with the nonferrous metals coming into use more and

    more each da y. As St eelworkers, we must be able to

    ident i f y var ious meta l s and to assoc ia te the i r

    individual properties with their proper application or

    use.

    The primary objective of this chapter is to present

    a detailed explanation of some of the properties of

    different m eta ls an d to provide instruction on using

    simple tests in establishing their identity.

    METAL PROPERTIES

    There is no simple definition of metal; however,

    an y chemical element ha ving meta llic properties is

    cla ssed as a meta l. Meta llic properties are defined

    as luster, good thermal and electrical conductivity, and

    the capab i l i ty o f be ing permanent ly shaped or

    deformed at room temperature. Chemical elements

    lacking these properties are classed as n onmetals. A

    few elements, known as metalloids, sometimes behave

    like a metal and at other times l ike a nonmetal . Some

    examples of metal loids are as fol lows: carbon,

    phosphorus, silicon, and sulfur.

    An alloy is defined as a substan

    properties that is composed of two

    The elements used as alloying subs

    metals or metalloids. The properties

    from the properties of the pure meta l

    make up the a lloy a nd this difference

    usefulness of alloys. By combining

    loids, manufacturers can develop al

    part icular properties required for a g

    Table 1-1 is a l ist of various e

    symbols that compose metallic mat

    Table 1-1.Symbols of Base Metals and

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    Figure 1-1.Stress applied to a materiaI.

    Very ra rely do Steelworkers work wit h elements

    in their pure state. We primarily work with alloys and have

    to understand their characteristics. The characteristicsof elements and alloys are explained in terms of

    p h y s i c a l , c h e m i c a l , e l e c t r i c a l , a n d m e c h a n i c a l

    properties. Physical properties relate to color, density,

    weight, and heat conductivity . Chemical properties

    involve the behavior of the metal when placed in

    contact with the atmosphere, salt water, or other

    substances. Electrical properties encompass the

    electrical conductivity , resistance, and magnetic

    qualities of the metal. The mechanical properties

    re l a te to load-ca r ry ing ab i l i t y , wear res i s t ance ,

    hardness, and elastici ty.

    When selecting stock for a job, your main

    concern is the mechanical properties of the metal.

    The various properties of metals and alloys were

    determined in the laboratories of manufacturers and

    by var ious societ ies in teres ted in meta l lurgica ldevelopment. Cha rts presenting the properties of a

    particular metal or al loy are available in many

    commerci a l l y publ i shed re f e rence books . The

    charts provide information on the melting point,

    tensile strength, electrical conductivity, magnetic

    properties, and other properties of a particular metal

    or alloy. Simple tests can be conducted to determine

    some of the properties of a metal ; however, we

    norma l l y use a meta l t e s t on ly a s an a id f o r

    identifying apiece of stock. Some of these methods

    of testing are discussed lat er in this chapt er.

    MECHANICAL PROPERTIES

    Common types of stress are com

    shear, torsion, impact, 1-2 or a com

    stresses, such as fatigue. (See fig.

    Compression stresses develop

    when forces compress or crush the

    that supports an overhead beam is i

    the internal stresses that develop wit

    compression.

    Tension (or tensile) stresses

    material is subject to a pulling load;using a w ire rope to li f t a load or w

    guy to anchor an antenna. Tensile s

    as resistance to longitudinal stress

    measured in pounds per square inc

    Shearing stresses occur within

    external forces are applied along

    opposite directions. Shearing for

    material by sliding part of it in one

    rest in the opposite direction.

    Some materials are equally stron

    tension, and shear. However, man

    marked differences; for example, cu

    maximum strength of 2,000 psi in

    only 400 psi in tension. Carbon ste

    strength of 56,000 psi in tension an

    a maximum shear s trength o f o

    therefore, when dealing with maxim

    should always state the type of load

    A material tha t is stressed repea

    at a point considera bly below i ts ma

    tension, compression, or shear. Fo

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    Table 1-2.Mechanical Properties of Metals/Alloys

    Strength Rockwell C number. On nonferrou

    Strength is the property that enables a metal to resist

    deformation under load. The ultimate strength is the

    maximum strain a materia l can withstand . Tensi le

    strengt h is a measurement of the resista nce to being

    pulled apart when placed in a tension load.

    Fatigue strength is the ability of material to resistvar ious kinds of rapidly changing st resses and is ex-

    pressed by the magnitude of alternating stress for a

    specified number of cycles.

    Impa ct strength is the a bility of a met al to resist

    suddenly a pplied loads an d is mea sured in foot-pounds

    of force.

    Hardness

    Hardness is the property of a material to resist

    permanent indentation. Because there are several meth-

    ods of measuring hardness, the hardness of a material is

    always specified in terms of the particular test that was

    softer, a metal ball is used and the ha

    by a Rockwell B number. To g

    property of hardness, compare lead a

    be scratched with a pointed woode

    cannot because it is harder than lead

    A full explanation of the variou

    determine the hardness of a matercommercial books or books located in

    Toughness

    Toughness is the property t ha t en

    withstand shock and to be deformed

    Toughness may be considered as s trength a nd plast ici ty. Tab le 1-2s

    some of the more common material

    well as other properties.

    Elasticity

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    Plasticity

    Plasticity is the ability of a material to deform

    permanently without breaking or rupturing. This prop-

    erty is t he opposite of strengt h. B y careful a lloying of

    metals, th e combination of plasticity and strength is used

    to manufacture large structural members. For example,

    should a member of a bridge structure become over-

    loaded, plasticity allows the overloaded member to flow

    allowing the distribution of the load t o other pa rts of the

    bridge structure.

    Brittleness

    Brittleness is the opposite of the property of plastic-

    ity. A brittle metal is one that breaks or shatters before

    it deforms. White cast iron and glass are good examples

    of brittle material. Generally, brittle metals are high in

    compressive strength but low in tensile strength. As an

    example, you would not choose cast iron for fa bricat ing

    support beams in a bridge.

    Ductility and Malleability

    Ductili ty is the property tha t enables a ma terial to

    stretch, bend, or twist without cracking or breaking. This

    property ma kes it possible for a mat erial to be draw n out

    into a thin wire. In comparison, malleability is the

    property that enables a material to deform by compres-

    sive forces without developing defects. A malleable

    material is one that can be stamped, hammered, forged,

    pressed, or rolled into thin sheets.

    CORROSION RESISTANCE

    Corrosion resista nce, a lthough not a mecha nical

    property, is importa nt in th e discussion of meta ls. Cor-

    rosion resistance is the property of a metal that gives it

    the ability to withstand attacks from atmospheric,

    chemical, or electrochemical conditions. Corrosion,sometimes called oxidation, is illustrated by the rusting

    of iron.

    Ta ble 1-2 lists four mechanical properties and the

    corrosion resistance of various metals or alloys. The first

    metal or alloy in each column exhibits the best charac-

    METAL TYPES

    The metals that Steelworkers wo

    into two general classifications: ferro

    Ferrous metals are those composed p

    iron alloys. Nonferrous metals are th

    ma rily of some element or element

    Nonferrous metals or alloys sometimamount of iron as a n a lloying elemen

    FERROUS METALS

    Ferrous metals include all form

    alloys. A few examples include wrou

    carbon steels, alloy steels, and tool s

    als are iron-base a lloys w ith sma ll peand other elements added to achiev

    ties. Normally, ferrous metals are m

    rous metals are nonmagnetic.

    Iron

    Pur e iron r arely exists outside of

    is produced by reducing iron ore to p

    use of a blast furnace. From pig iron

    of iron and steel are produced by the

    of car bon an d a lloys. The following p

    the different types of iron and stee

    from iron ore.

    PIG IRON. P ig iron is comp

    iron, from 3%to 5%car bon, a nd v

    other elements. Pig iron is compar

    brittle; therefore, i t ha s a limited use

    ninety percent produced is refined

    Cast-iron pipe and some fittings an

    factured from pig iron.

    WROUGHT IRON. Wrought

    pig iron with some slag mixed in du

    Almost pure iron, the presence of sl

    iron to resist corrosion and oxidatanalyses of wrought iron and mild s

    the same. The difference comes fr

    contr olled during the ma nufactur ing

    iron can be gas and arc welded, mac

    easily formed; however, i t has a lo

    low-fatigue strength

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    hardness . A mal leable cas t i ron is produced through a eas ily as the low-carbon s tee ls . They

    prolonged a nnea ling process. hooks, a xles, sha ft s, set screw s, a nd s

    INGOT IRON. Ingot iron is a commercially pure

    iron (99.85% iron) th at is easily formed a nd possesses

    good ductilit y a nd corrosion resist a nce. The chemical

    an alysis a nd properties of this iron and the lowest carbon

    steel are practically the same. The lowest carbon steel,

    known as dead-soft, has about 0.06%more carbon than

    ingot iron. In iron the carbon content is considered an

    impurity a nd in st eel it is considered a n a lloying ele-

    ment. The primary use for ingot iron is for galvanized

    and enameled sheet.

    Steel

    Of all the different metals and materials that we use

    in our trade, steel is by far the most important. When

    steel was developed, it revolutionized the American iron

    industry. With it came skyscrapers, stronger and longer

    bridges, and railroad tracks that did not collapse. Steel

    is ma nufactured from pig iron by decreasing t he a mountof carbon and other impurities and adding specific

    amounts of alloying elements.

    Do not confuse steel with the two general classes of

    iron: cast iron (great er tha n 2% carbon) a nd pure iron

    (less than 0.15%carbon). In steel manufacturing, con-

    trolled amounts of alloying elements are added during

    the molten stage to produce the desired composition.

    The composition of a steel is determined by its applica-tion and the specifications that were developed by the

    following: American Society for Testing and Materials

    (ASTM), the American Society of Mechanical Engi-

    neers (ASME), the Society of Automotive Engineers

    (SAE), and the American Iron and Steel Institute (AISI).

    Car bon steel is a term applied to a broad range of

    steel that falls between the commercially pure ingot iron

    an d the cast irons. This ra nge of ca rbon steel ma y beclassified into four groups:

    HIGH-CARBON STEEL/VE

    BON STEEL. Steel in these class

    heat treatment and can be welded. W

    cial electrodes must be used along w

    stress-relieving procedures to prevent

    ar eas. These steels are u sed for dies

    tools, ra ilroad car w heels, chisels, kn

    LOW-ALLOY, HIGH-STR

    PERED STRUCTURAL STEEL.

    carbon steel, containing specific

    alloying elements, that is quenched aa yield strength of greater than 50,0

    str engths of 70,000 to 120,000 psi. St

    made from these high-strength steels

    cross-sectional a reas tha n common

    and sti l l have equal or greater s tren

    these steels are normally more corros

    resistan t. High-strengt h st eels a re

    specifications.

    NOTE: This type of steel is m

    low-ca rbon steels. Shear ing ma chin

    steel must ha ve twice the capacity tha

    low-carbon steels.

    STAINLESS STEEL. This ty

    sified by the American Iron and Ste

    into two general series named the 2

    400 series. Each series includes sevwith different characteristics.

    The 200-300 series of sta inless

    AUSTENITIC. This type of steel

    ductile in the as-welded condition; th

    for welding an d requires no a nnea l

    atmospheric conditions. The most w

    steel in this series are the 302 and 3

    monly ca lled 18-8 beca use t hey a re

    chromium a nd 8% nickel. The chromLow-Carbon Steel . . . . . . . . 0.05%to 0.30%carbon ar e the most widely used a nd a re norm

    Medium-Ca rbon S teel . . . . . . 0.30%t o 0.45%car bonThe 400 series of steel is su bdiv

    High -Ca rbon St eel . . . . . . . . 0.45%t o 0.75%ca rbon their crystalline structure into two ge

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    and frequently used for decorative trim and equipment

    subjected to high pressures and temperatures.

    Martensitic Chromium. These steels ar e ma g-

    netic and are readily hardened by heat treatment. They

    conta in 12% to 18% chromium, 0.15% to 1.2% carbon,

    a nd u p to 2.5%nickel. This gr oup is used w here high

    strength, corrosion resista nce, a nd ductility a re required.

    ALLOY STEELS. Steels that derive their prop-

    erties primarily from the presence of some alloying

    element other than carbon are called ALLOYS or AL-

    LOY STEELS. Note, however, that alloy steels always

    contain traces of other elements. Among the more com-

    mon alloying elements are nickel, chromium, vana-

    dium, silicon, and tungsten. One or more of these

    elements may be added to the steel during the manufac-

    tur ing process to produce the desired cha ra cteristics.

    Alloy steels may be produced in structural sections,

    sheets, plates, a nd ba rs for use in the a s-rolled condi-

    tion. Better physical properties are obtained with these

    steels than are possible with hot-rolled carbon steels.

    These alloys a re used in str uctures where t he strength of

    material is especially important. Bridge members, rail-road ca rs, dump bodies, dozer blades, and crane booms

    a re ma de from alloy steel. Some of the common alloy

    steels are briefly described in the paragraphs below.

    Nickel Steels. These steels contain from 3.5%

    nickel to 5% nickel. The nickel increases t he str ength

    and toughness of these steels. Nickel steel containing

    more than 5%nickel has an increased resistance to

    corrosion and scale. Nickel steel is used in the manufac-

    ture of aircraft parts, such as propellers and airframe

    support members.

    Chromium Steels. These steels have chromium

    added to improve hardening a bility, wea r resistan ce, an d

    strength. These steels contain between 0.20%to 0.75%

    chromium and 0.45%carbon or more. Some of these

    steels are so highly resistant to wear that they are used

    for t he races and ba lls in a ntifriction bear ings. Chro-

    mium steels are highly resistant to corrosion and t o

    scale.

    Chrome Vanadium Steel. This steel has the

    maximum a mount of s trength with the least amount of

    h S l f h f % %

    to cut after it becomes red-hot. A goo

    conta ins from 13%t o 19%tungste

    dium, 3%t o 5%chromium, a nd 0.6

    Because this alloy is expensive to

    largely restricted to the ma nufacture

    milling cutters, and similar cutting t

    Molybdenum. This is often u

    agent for steel in combination wi

    nickel. The molybdenum adds tough

    can be used in place of tungst en to

    grades of high-speed steel and in ca

    high-pressure tubing.

    Manganese Steels. The am o

    used depends upon the properties des

    product. Small amounts of mangane

    free-machining steels. Larger amo

    a nd 10%) produce a somew ha t brit t

    la rger a mount s (11%t o 14%) prod

    tough and very resistant to wear afte

    ment .

    NONFERROUS METALS

    Nonferrous metals contain eith

    insignificant amounts used as a n a lloy

    common nonferrous metals Steelwor

    as follows: copper, brass, bronze, co

    lead, zinc, tin, aluminum, and Dural

    NOTE: These metals are nonma

    Copper

    This metal and its a lloys ha ve m

    erties. Among th e commercial meta

    most popular. Copper is ductile, mal

    strong, wear resistant, machinable,

    rosion resista nt. I t also has high-tens

    strength, and thermal and electrical

    per is one of the easier metals to w ork

    because it easily becomes work-harde

    condition can be remedied by heatin

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    True Brass sinks or protect bench tops where a la

    is used. Lead-lined pipes are used in

    This is an alloy of copper and zinc. Additional corrosive chemicals. Frequently, lead

    elements, such as aluminum, lead, tin, iron, manganese, form to increase its low-tensile stre

    or phosphorus, are added to give the alloy specific tin, lead produces a soft solder. Wh

    properties. Naval rolled brass (Tobin bronze) contains alloys, lead improves their machinababout 60% copper, 39%zinc, a nd 0.75% tin. This bra ss

    is highly corrosion-resistant and is practically impurity

    free. CAUTION

    Bra ss sheets a nd s tr ips are a vai lable in several

    gra des: soft, 1/4 ha rd, 1/2 ha rd, full h a rd, a nd s pring When working with lead, y

    g ra d es . Ha rd nes s i s crea te d by the proces s of cold rol l- proper preca u t ions beca us e the d

    ing. All grades of brass can be softened by annealing at vapors from it ar e highly poison

    a temperature of 550F to 600F then allowing it to coolby itself without quenching. Overheating can destroy

    the zinc in the alloy. Zinc

    Bronze

    B ronze is a combinat ion of 84%copper an d 16%t in

    and was the best metal available before steel-making

    techniques were developed. Many complex bronze al-

    loys, containing such elements as zinc, lead, iron, alu-

    minum, silicon, and phosphorus, a re now ava ilable.

    Today, the name bronze is applied to any copper-based

    alloy that looks like bronze. In many cases, there is no

    real distinction between the composition of bronze and

    that of brass .

    Copper-Nickel Alloys

    Nickel is used in t hese alloys t o make th em strong,

    tough, and resistant to wear and corrosion. Because of

    their high resistance to corrosion, copper nickel alloys,

    conta ining 70% copper a nd 30% nickel or 90% copper

    and 10%nickel, are used for saltwater piping systems.

    Small storage tanks and hot-water reservoirs are con-

    You often see zinc used on iron o

    of a protective coating called galvan

    used in soldering fluxes, die castings

    making brass and bronze.

    Tin

    Tin has ma ny importa nt uses as

    a lloyed wit h lead t o produce softer

    copper to produce bronze. Tin-based

    resistance to corrosion, low-fat igue st

    pressive strength that accommodate

    loads. Tin, like lead, has a good resiand has the added advantage of not

    however, w hen subjected t o extrem

    tures, it h as a tendency to decompos

    Aluminum

    strutted of a copper-nickel alloy that is available in sheetThis metal is easy to work wit

    form. Copper-nickel alloys should be joined by metal-appearance. Aluminum is light in wearc welding or by brazing.strength per unit w eight . A disadv

    Leadtensile strength is only one third of t

    fifth of that of annealed mild steel.

    A hea vy meta l tha t w eighs about 710 pounds per

    cubic foot. In spite of its weight, lead is soft and malle-

    Aluminum alloys usually conta in

    minum. The addition of silicon, ma

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    Table 1-3.Surface Colors of Some Common Metals

    Duralumin Monel

    One of the first of the strong structural aluminum

    alloys developed is called Duralumin. With the devel-

    opment of a variety of different wrought-aluminum

    alloys, a num bering system wa s a dopted. The digits

    indicat e the ma jor a lloying element a nd t he cold-worked

    or heat-treated condition of the metal. The alloy, origi-nally called Duralumin, is now classified in the metal

    working indust ries a s 2017-T. The lett er T indicates tha t

    the metal is heat-treated.

    Alclad

    Monel is an alloy in which n

    element. It contains from 64%to 68%

    copper, and small percentages of ir

    cobalt. Monel is harder and stronge

    or copper and has high ductility. It

    steel in appearance and has many ostrength, combined with a high resi

    make Monel an a cceptable substitute

    where corrosion resistan ce is the prim

    bolts, screws, and various fittings a

    This a lloy can be w orked cold and

    welded If worked in the tempera t

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    comparable to heat-treated steel. K-monel is used for

    instrument parts that must resist corrosion.

    Inconel

    This high-nickel alloy is often used in the exhaust

    systems of aircraft engines. Inconel is composed of

    78.5% nickel, 14% chromium, 6.5% iron, a nd 1% of

    other elements. It offers good resistance to corrosion and

    retains its strength at high-operating temperatures.

    METAL IDENTIFICATION

    Many methods are used to identify a piece of metal.

    Identification is necessary when selecting a metal for

    use in fabrication or in determining its weldability.

    Some common m ethods used for field identification a re

    surface appearance, spark test, chip test, and the use of

    a magnet.

    SURFACE APPEARANCE

    Sometimes it is possible to identify metals by their

    surface appearance. Table 1-3 indicates the surface col-

    ors of some of the more common metals. Referring to

    the table, you can see that the outside appearance of a

    metal helps to identify and classify metal. Newly frac-

    tur ed or freshly filed surfaces offer a dditional clues.A surface examination does not always provide

    enough information for identification but should give us

    enough information to place the metal into a class. The

    color of the meta l an d th e distinctive ma rks left from

    manufacturing help in determining the identity of the

    metal . Cast iron and malleable iron usually show evi-

    dence of the sand mold. Low-carbon steel often shows

    forging marks, and high-carbon steel shows either forg-ing or rolling marks. Feeling the surface may provide

    a nother clue. Sta inless steel is slightly r ough in the

    unfinished state, and the surfaces of wrought iron, cop-

    per, brass, bronze, nickel, and Monel are smooth. Lead

    also is smooth but has a velvety appearance.

    Figure 1-2.Terms used in sp

    SPARK TEST

    The spark test is made by hold

    material against an abrasive wheel.

    ing the spark stream, an experience

    identify the metals with considerable

    is fast, economical, convenient,

    plished, and there is no requiremen

    ment. We can use this test for identi

    from scrap. Identification of scrap is

    ta nt when selecting material for ca

    hea t t r ea t ment .

    When y ou hold a piece of iron

    with a high-speed abrasive wheel, sm

    metal are torn loose so rapidly that th

    As th ese glowing bits of meta l lea

    follow a path (trajectory) called th

    carrier line is easily followed with

    when observed against a dark backg

    The spar ks given off, or the la ck

    identif ication of the metal. The l

    strea m, the color, a nd the form of theyou should look for. Figure 1-2 illustr

    in referring to various basic spark

    spark testing.

    Steels having the same carbon c

    alloying elements are difficult to id

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    by tiny blocks of brilliant white light. Silicon suppresses

    the carbon burst even more than nickel. When silicon is

    present, t he carrier line usually ends abruptly in a white

    f lash of light.

    Spark testing may be done with either a portable or

    stationary grinder. In either case, the speed on the outer

    rim of the wheel should not be less than 4,500 feet per

    minute. The abrasive wheel should be rather coarse,

    very hard, and kept clean to produce a true spark

    To conduct a spark test on an abrasive wheel, hold

    the piece of metal on the wheel in a position that allows

    the spark st ream t o cross your line of vision. By t rial a nd

    error, you soon discover what pressure is needed to get

    a stream of the proper length without reducing the speedof the grinder. Excessive pressure increases the t em-

    perature of the spark stream. This, in turn, increases the

    temperature of the burst and gives the appearance of a

    higher carbon content than actually is present. When

    ma king the test , wa tch a point a bout one third of the

    distance from the tail end of the spark stream. Watch

    only those sparks that cross your line of vision and try

    to forma mental image of the individual spark. Fix thisspark image in your mind a nd th en examine the w hole

    spark picture.

    While on the subject of abrasive wheels, it is a good

    idea to discuss some of the safety precautions associated

    with this tool.

    Never use an abra sive wh eel tha t is cracked or

    out of balance because the vibration causes the wheel toshatter. When an abrasive wheel shatters, i t can be

    disastrous for personnel standing in line with the wheel.

    Always check the wheel for secure mounting andcracks before putting it to use. When you install a new

    wh eel on a grinder, be sure tha t it is t he correct size.

    Remember, as you increase the wheel radius, the periph-

    eral speed a t t he rim a lso increases, even th ough the

    driving motor rpm remains the same. Thus, if you should

    use an oversized wheel, there is a distinct danger the

    peripheral speed (and consequent centrifugal force) can

    become so great that the wheel may f ly apart . Use

    wheels that are designed for a specific rpm. Guards are

    l d d h l h ld

    Never overload a grinder or sure aga inst t he wh eel, unless i t is

    withstand such use.

    Always wear appropriate safetshield while using the grinder. Ensu

    (the device that helps the operator

    adjusted to the minimum clearance f

    the work across the entire face of the

    grooving a nd t o minimize wheel d

    prolongs the life of the wheel.

    Keep your fingers clear of thand do not allow rags or clothing to

    in the wheel.

    Do not wear gloves while wheel.

    Never hold metal with tongs

    Never grind n onferrous mettended for ferrous metals because su

    pores of th e abra sive mat erial. Th

    may cause i t to become unbalanced

    Grinding wheels require freing. Dressing is the term used to des

    cleaning the periphery. This cleanin

    abra sive gra ins and smooths the su

    the grooves. The wheel dresser sho

    used for dressing grinding wheels on

    grinders. For more information on g

    should consult chapter 5 of NAV

    (Tools and T heir U ses).

    Referring now to figure 1-4,

    carbon steel (view A), the spark s

    inches long and the volume is m

    high-carbon steel (view B), the strea

    55 inches) and the volume larger. Th

    may occur at any place in low-carbo

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    Table 1-4.Metal Identification by Chip Test

    and in high-carbon steel, they a re small a nd repeating. these metals must be distinguished fr

    Both metals produce a spark stream white in color.

    Gray cast iron (view C) produces a stream of sparks

    b t 25 i h i l gth Th kl ll d

    some other method.

    St ainless steel (view E ) produce

    about 50 inches in length moderate

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    One way to become proficient in spark testing fer-

    rous metals is to gather an assortment of samples of

    known metals and test them. Make all of the samples

    about the same size and shape so their identities are not

    revealed simply by the size or shape. Number each

    sample and prepare a list of names and corresponding

    numbers. Then, without looking at the number of the

    sample, spark test one sample at a time, calling out its

    name to someone assigned to check it against the names

    and numbers on the list. Repeating this process gives

    you some of th e experience you n eed to become profi-

    cient in identifying individual samples.

    CHIP TEST

    from small, broken fragments to a co

    chip may have smooth, sharp edge

    grained or fine-grained; or it may h

    The size of the chip is important in id

    The ease with which the chipping c

    should also be considered. The in

    table 1-4can help you identify var

    chip test.

    MAGNETIC TEST

    The use of a magnet is another

    in the general identification of meta

    ferrous meta ls, being iron-based aAnother simple test used to identify an unknown

    piece of metal is the chip test. The chip testis made by

    removing a small amount of material from the test piece

    with a sharp, cold chisel. The material removed varies

    magnetic, and nonferrous metals are

    test is not 100-percent accurate bec

    steels are nonmagnetic. In this in

    substitute for experience.

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