MECH 421 Manufacturing Processes I

MAKING BASE MATERIAL &

ENGINEERING MATERIAL
Rami Fayad

Office: IOEC_OXY - 411

Extension: 3465
E-mail: [email protected]
 Making Base Material & Engineering Material

Big Picture – Revision Lecture 3

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 Making Base Material & Engineering Material

Classification of Metallic Material

• End of Lecture 3

• They have properties that satisfy a wide variety of design

requirements.
• The manufacturing processes by which they are shaped into
products have been developed and refined over many
years.
• Engineers understand metals

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 Making Base Material & Engineering Material

Why Metals are Important

 High stiffness and strength - can be alloyed for high rigidity, strength, and
hardness.
• Provide structural framework for most engineered products.
 Toughness - capacity to absorb energy better than other classes of materials.
 Good electrical conductivity
 Good thermal conductivity - conduct heat better than ceramics or polymers.

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 Making Base Material & Engineering Material

Ferrous Metals
 Based on iron, one of the oldest metals known
 Ferrous metals of engineering importance are alloys of iron and carbon

These alloys divide into two major groups:

• Steel
• Cast iron
Together, they constitute approximately 85% of the metal tonnage in the United
States

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 Making Base Material & Engineering Material

Ferrous Metals
 Based on iron, one of the oldest
metals known
 Ferrous metals of engineering
importance are alloys of iron and
carbon

These alloys divide into two major

groups:
• Steel
• Cast iron
Together, they constitute
approximately 85% of the metal
tonnage in the United States
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 Making Base Material & Engineering Material

Steel
 Iron-Carbon alloy containing 0.02% to 2.11% carbon by weight

May contain other alloying elements

Steel alloys can be grouped into four categories:

1. Plain carbon steels

2. Low alloy steels
3. Stainless steels
4. Tool steels

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1. Plain Carbon Steel

 Carbon is the principal alloying element, with
only small amounts of other elements (about
0.4% of manganese is normal)

 Strength of plain carbon steels increases with

carbon content, but ductility is reduced

Tensile strength and hardness as a function of

carbon content in plain carbon steel

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 Making Base Material & Engineering Material

1. Plain Carbon Steel - LCS

Low Carbon Steels (LCS)
1. Contain less than 0.2% C
2. Relatively soft (yield strength of 40,000 psi) and weak
(tensile strengths 60-80 ksi)
3. Outstanding ductility (25% EL) and toughness.
4. Machinable & weldable.
5. Produced in the greatest quantities and are the least
expensive steels to produce.

Applications
Automobile body components, railroad rails, and structural shapes (I-beams, channel iron, ..)
that are used in construction.

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 Making Base Material & Engineering Material

1. Plain Carbon Steel - MCS

Medium Carbon Steels (MCS)
1. Contain between 0.2% and 0.5% C
2. Higher strength than Low Carbon Steels
3. May be heat-treated
4. Additions of Chromium, Nickel and Molybdenum give
rise to a variety of strength-ductility combinations

Applications
Machinery components and engine parts such as crankshafts, gears and connecting rods.
High strength structural components calling for a combination of high strength, wear resistance, and
toughness.
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1. Plain Carbon Steel - HCS

High Carbon Steel (HCS)

1. Contain more than 0.5% C
2. Hardest and strongest Carbon Steels
3. Least Ductile – toward brittle material

Applications
Springs, Cutting tools and blades, and wear-resistant parts.

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 Making Base Material & Engineering Material

1. Plain Carbon Steel – AISI Scheme

AISI-SAE Designation Scheme
 Specified by a 4-digit number system: 10XX, where 10
indicates plain carbon steel, and XX indicates carbon % in
hundredths of percentage points (1/100 % of C)
 Example:
 1020 steel contains 0.20% C

 Developed by American Iron and Steel Institute (AISI) and Society of Automotive Engineers (SAE), so
designation often expressed as AISI 1020 or SAE 1020

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2. Low Alloy Steel

 Iron-carbon alloys containing additional alloying elements in amounts totaling less than  5% by weight
• Mechanical properties greater to plain carbon steels

Element Improves/Increases Reduces/Decreases

Carbon 1. Strength & hardness 1. Ductility
2. Wear Resistance 2. Weldability
 Heat treatment (HT) 3. Strain Hardening
is often required to
Chromium and Nickel 1. Strength & hardness
achieve these 2. Wear & corrosion
improved properties Resistance
3. High temp strength
Manganese 1. Strength & hardness
Sulfur 1. Machinability 1. Surface quality
2. Strength

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2. Low Alloy Steel – AISI Scheme

 AISI-SAE designation uses a 4-digit number system:

YYXX, where YY indicates alloying elements, and XX indicates

carbon % in hundredths of % points
 Examples:  Remember Plain Carbon
• 13XX - Manganese steel Steel are designated as
• 20XX - Nickel steel 10XX
• 31XX - Nickel-chrome steel
• 40XX - Molybdenum steel
• 41XX - Chrome-molybdenum steel

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AISI – SAE Designation Scheme Steel

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3. Stainless Steel
 Highly alloyed steels designed for corrosion resistance
 Principal alloying element is chromium, usually greater than 15%
 Cr forms a thin impervious oxide film that protects surface from corrosion
 Nickel (Ni) is another alloying ingredient in certain SS to increase corrosion protection
 Carbon is used to strengthen and harden SS, but high C content reduces corrosion protection
since chromium carbide forms to reduce available free Cr

 In addition to corrosion resistance, stainless steels are noted for their combination of strength
and ductility
 These properties generally make stainless steel difficult to work with in manufacturing
 Significantly more expensive than plain C or low alloy steels

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3. Stainless Steel – AISI Designation Scheme

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4. Tool Steel
 A class of (usually) highly alloyed steels designed
for use as industrial cutting tools, dies, and molds
 To perform in these applications, they must
possess high strength, hardness, hot hardness,
wear resistance, and toughness under impact
 Tool steels are mostly heat treated
 T, M High-speed tool steels
Classification of

 H Hot-working tool steels - hot-working dies

Tool Steels

 D Cold-work tool steels - cold working dies

AISI

 W Water-hardening tool steels

 S Shock-resistant tool steels - tools needing high toughness,
for applications such as sheet metal punching
 P Mold steels - for molding plastics and rubber

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Cast Iron

 Carbon contents from 2.14% to 6.17% (typically 3

to 4.5%) and silicon (graphite formation is promoted
by the presence of silicon in concentrations greater
than 1%).

 Other alloying elements are manganese, sulfur, and phosphorus.

 Lower Viscosity: Easily casted into molds.
 Turn into molten liquid at temperatures between 1150 and l300 oC which also makes them amenable to casting.

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Classification of Engineering Material

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Non Ferrous Material

Metal elements and alloys NOT based on IRON (FE)
Most important - aluminum, copper, magnesium, nickel, titanium, and zinc,
and their alloys
Although not as strong as steels, certain nonferrous alloys have
strength-to-weight ratios that make them competitive with steels in some
applications
Many nonferrous metals have properties other than mechanical that make
them ideal for applications in which steel would not be suitable

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End of Lecture 4

See You Next Time

Thank You

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