types of material ie 351 lecture 3. engineering materials
TRANSCRIPT
Further Classification
• Metals– Ferrous– Non-ferrous– Super alloys
• Ceramics– Traditional ceramics– New ceramics– Glass
Further Classification
• Polymers– Thermoplastics– Thermosets– Elastomers
• Composite Materials– Metal Matrix Composites– Ceramic Matrix Composites– Polymer Matrix Composites
Metals
• Ferrous Metals– Cast irons– Steels
• Non-ferrous metals– Aluminum and its alloys– Copper and its alloys– Magnesium and its alloys– Nickel and its alloys– Titanium and its alloys
Metals
• Ferrous Metals– Cast irons
– Steels
• Superalloys– Iron-based
– Nickel-based
– Cobalt-based
• Non-ferrous metals– Aluminum and its alloys
– Copper and its alloys
– Magnesium and its alloys
– Nickel and its alloys
– Titanium and its alloys
– Zinc and its alloys
– Lead & Tin
– Refractory metals
– Precious metals
Heat Treatment of Metals
• Annealing– Full annealing– Normalising (faster rate of cooling)– Recovery annealing (longer holding time, slower
rate of cooling,)– Stress relieving (lower temperature)
• Martensite formation in steel– Austenitizing (conversion to austenite)– Quenching (control cooling rate– Tempering (reduce brittleness)
Heat Treatment of Metals
• Precipitation hardening– Solution treatment (-phase conversion)– quenching– precipitation treatment (aging)
• Surface hardening– Carburizing– Nitriding– Carbonitriding– Chromizing and Boronizing
Furnaces for Heat Treatment
• Fuel fire furnaces– gas– oil
• Electric furnaces– batch furnaces
• box furnaces - door
• car-bottom furnaces - track for moving large parts
• bell-type furnaces - cover/bell lifted by gantry crane
– continuous furnaces
Furnaces for Heat Treatment
• Vacuum furnaces
• Salt-bath furnaces
• Fluidized-bed furnaces
Some of the furnaces have special atmosphere requirements, such as carbon- and nitrogen- rich atmosphere.
Surface Hardening Methods
• Flame hardening
• Induction heating
• High-frequency resistance heating
• Electron beam heating
• Laser beam heating
Ceramics
• Traditional ceramics– clays: kaolinite– silica: quartz, sandstone– alumina– silicon carbide
• New ceramics– oxide ceramics : alumina– carbides : silicon carbide, titanium carbide, etc.– nitrides : silicon nitride, boron nitiride, etc.
Glass
• Glass products– window glass– containers– light bulb glass– laboratory glass– glass fibers– optical glass
• Glass ceramics - polycrystalline structure
Polymers
• Thermoplastics - reversible in phase by heating and cooling. Solid phase at room temperature and liquid phase at elevated temperature.
• Thermosets - irreversible in phase by heating and cooling. Change to liquid phase when heated, then follow with an irreversible exothermic chemical reaction. Remain in solid phase subsequently.
• Elastomers - Rubbers
Thermoplastics
– Acetals– Acrylics - PMMA– Acrylonitrile-Butadiene-Styrene - ABS– Cellulosics– Fluoropolymers - PTFE , Teflon– Polyamides (PA) - Nylons, Kevlar– Polysters - PET– Polyethylene (PE) - HDPE, LDPE– Polypropylene (PP)– Polystyrene (PS)– Polyvinyl chloride (PVC)
Elastomers
• Natural rubber
• Synthetic rubbers– butadiene rubber– butyl rubber– chloroprene rubber– ethylene-propylene rubber– isoprene rubber– nitrile rubber– polyurethanes– silicones– styrene-butadiene rubber– thermoplastic elastomers
Composite Materials
• Metal Matrix Composites (MMC)Mixture of ceramics and metals reinforced by strong,
high-stiffness fibers
• Ceramic Matrix Composites (CMC)Ceramics such as aluminum oxide and silicon carbide
embedded with fibers for improved properties, especially high temperature applications.
• Polymer Matrix Composites (PMC)Thermosets or thermoplastics mixed with fiber
reinforcement or powder.
Material Specification
• Chemical composition
• Mechanical properties – Strength, hardness (under various conditions: temperature, humidity, pressure)
• Physical properties – density, optical, electrical, magnetic
• Environmental – green, recycling
Typical Selection of Carbon and Alloy Steels for Various Applications
TABLE 5.1Product Steel Product SteelAircraft forgings,
tubing, fittingsAutomobile bodiesAxlesBall bearings and racesBoltsCamshaftsChains (transmission)Coil springsConnecting rodsCrankshafts (forged)
4140, 8740
10101040, 4140521001035, 4042, 48151020, 10403135, 314040631040, 3141, 43401045, 1145, 3135, 3140
Differential gearsGears (car and truck)Landing gearLock washersNutsRailroad rails and wheelsSprings (coil)Springs (leaf)TubingWireWire (music)
40234027, 40324140, 4340, 87401060313010801095, 4063, 61501085, 4063, 9260, 615010401045, 10551085
Mechanical Properties of Selected Carbon and Alloy Steels in Various Conditions
TABLE 5.2 Typical Mechanical Properties of Selected Carbon and Alloy Steels in the Hot-Rolled,Normalized, and Annealed ConditionAISI Condition Ultimate
tensilestrength(MPa)
YieldStrength(MPa)
Elongation in50 mm (%)
Reduction ofarea (%)
Hardness(HB)
1020
1080
3140
4340
8620
As-rolledNormalizedAnnealedAs-rolled
NormalizedAnnealed
NormalizedAnnealed
NormalizedAnnealed
NormalizedAnnealed
448441393
1010965615891689
1279744632536
346330294586524375599422861472385357
363536121124192412222631
596766172045575036495962
143131111293293174262197363217183149
AISI Designation for High-Strength Sheet Steel
TABLE 5.3Yield Strength Chemical
CompositionDeoxidation
Practice
psi x 103 MPa
35404550607080
100120140
240275310350415485550690830970
S = structural alloy
X = low alloy
W = weathering
D = dual phase
F = killed plus sulfide inclusion control
K = killed
O = nonkilled
Room-Temperature Mechanical Properties and Applications of Annealed Stainless Steels
TABLE 5.4 Room-Temperature Mechanical Properties and Typical Applications of Selected AnnealedStainless Steels
AISI(UNS)
Ultimatetensile
strength(MPa)
Yieldstrength(MPa)
Elongationin 50 mm
(%) Characteristics and typical applications303(S30300)
550–620 240–260 53–50 Screw machine products, shafts, valves, bolts,bushings, and nuts; aircraft fittings; bolts; nuts;rivets; screws; studs.
304(S30400)
565–620 240–290 60–55 Chemical and food processing equipment,brewing equipment, cryogenic vessels, gutters,downspouts, and flashings.
316(S31600)
550–590 210–290 60–55 High corrosion resistance and high creep strength.Chemical and pulp handling equipment,photographic equipment, brandy vats, fertilizerparts, ketchup cooking kettles, and yeast tubs.
410(S41000)
480–520 240–310 35–25 Machine parts, pump shafts, bolts, bushings, coalchutes, cutlery, tackle, hardware, jet engine parts,mining machinery, rifle barrels, screws, andvalves.
416(S41600)
480–520 275 30–20 Aircraft fittings, bolts, nuts, fire extinguisherinserts, rivets, and screws.
Basic Types of Tool and Die Steels
TABLE 5.5Type AISIHigh speed
Hot work
Cold work
Shock resisting
Mold steels
Special purpose
Water hardening
M (molybdenum base)T (tungsten base)H1 to H19 (chromium base)H20 to H39 (tungsten base)H40 to H59 (molybdenum base)D (high carbon, high chromium)A (medium alloy, air hardening)O (oil hardening)SP1 to P19 (low carbon)P20 to P39 (others)L (low alloy)F (carbon-tungsten)W
Processing and Service Characteristics of Common Tool and Die Steels
TABLE 5.6 Processing and Service Characteristics of Common Tool and Die Steels
AISIdesignation
Resistance todecarburization
Resistance tocracking
Approximatehardness(HRC) Machinability Toughness
Resistance tosoftening
Resistance towear
M2 Medium Medium 60–65 Medium Low Very high Very highT1 High High 60–65 Medium Low Very high Very highT5 Low Medium 60–65 Medium Low Highest Very highH11, 12, 13 Medium Highest 38–55 Medium to high Very high High MediumA2 Medium Highest 57–62 Medium Medium High HighA9 Medium Highest 35–56 Medium High High Medium to
highD2 Medium Highest 54–61 Low Low High High to very
highD3 Medium High 54–61 Low Low High Very highH21 Medium High 36–54 Medium High High Medium to
highH26 Medium High 43–58 Medium Medium Very high HighP20 High High 28–37 Medium to high High Low Low to
mediumP21 High Highest 30–40 Medium Medium Medium MediumW1, W2 Highest Medium 50–64 Highest High Low Low to
medium
Source: Adapted from Tool Steels, American Iron and Steel Institute, 1978.