Properties of Steel he aesistance of a mafenial +o + Tensile strength > f voce person and hardness as axes ting function of carbon content in plain carbon steel (hot rolled) 2012 John Wiley & Sons, Inc. MP Groover, Introduction to “Manufacturing Processes Plain Carbon Steels ~tow carbon steels - less than.20% 9 + Applications: automobile sheetmetal parts, plate steel for fabrication, railroad rails Medium carbon steels - between (0.20% and 0.50% C) + Applications: machinery components and engine parts such as crankshafts and connecting rods High carbon steels - greater than 0.50% C *** + Applications: gpringg, cutting tools and blades, wear-resistant parts AISI-SAE Designation Scheme + Specified by a 4-di number system:OXx%) where 0 indicates plain carbon steel) and XX indicates carbon % in hundredths of percentage points + For example, 1020 steel contains 0.20% C + Developed by American Iron and Steel Institut (AISI) and Society of Automotive Engineers (SAE), so designation often expressed as AISI 1020 or SAE 1020 ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes Low Alloy Steels Iron-carbon alloys containing additional alloying elements in amounts totaling less than ~ 5% by weight - Mechanical properties superior to plain carbon steels for given applications -~Higher strength-tardness-hot hardness“wear resistance, andtoughness. + Heat treatment is often required to achieve these improved propertiesPANG SM RETIGUTE SEEET aPPHCAUONS IN NEW IMIErCEGES: Benz structure descent of all the bodyshell panels for thedMlercedes-Benz E-Clas3e.g. are itra:high-strength steel - a new record in passenger-car development. Three 's the tensile strength of conventional high-strength steel grades. They are its where the material can be exposed to exceptionally high stresses during as a material forthe B-pillars and the side roof frames to provide side xtion, Staifif€s Steel (SS) hly alloyed steels designed for corrosion resistance rincipal alloying element is chromium, usual Jreater than 15% om Cr forms a thindgipeniouSovide film that protects surface from corrosion Nickel (Ni) is another alloying ingredient in certain SS O increase corrosion protection Zarbon is used to strengthen and harden SS, but ligh C content reduces corrosion protec chromium carbide forms to reduce available free Cr AISI-SAE Designation 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: _-13XX - Manganese steel _-20XX - Nickel steel _ 31XX - Nickel-chrome steel ~40XxX - Molybdenum steel ~41XX - Chrome-molybdenum steel (©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes Properties of Stainless Steels + In addition to corrosion resistance, stainless steels are noted for their combination of strength and S generally make stainless steel difficult to work in manufacturing + But not impossible! (Jim comment) + Significantly more expensive than plain C or low alloy steelsa row cy resittant panes on : Fe th? > peo yor Feo iho > Fe, +? Foxy 4 Hj@ > FeO), nla? Ly v Comosion proce? Ch 4%0y.02 Cen Me impen vious faye Crd ye -D Cat 4 C0, \ (igke the 38 bendNickel and Its Alloys = Similar to iron in some respects: . must vids i + Applications: stainless steel alloying ingredient, plating metal for steel, applications requiring high temperature and corrosion resistance ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes Applications of Titanium + Inthe commercially pure state, Ti is used for corrosion resistant components, such as marine eet components and prosthetic implants > yerT=, GA, + Titanium alloys are used as high strength were we components at temperatures ranging up to above (550°C J1000°F), especially where its excellent stréngth-to-weight ratio is exploited loying elements used with titanium include aluminum, manganese, tin, and vanadiumZinc and Its Alloys ow melting poindmakes it attractive as a casting especially die casting . Also provides corrosion protection when coated conto steel or iron + The term Qalvanizedstee! refers to steel coated with zinc . Widely used as alloy with copper (brass) cael Ad a 2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes Superalloys > ™' jigh-performance alloys designed to meet demanding requirements for strength and resistance to surface degradation at high service temperatures Many superalloys contain substantial amounts of three or more metals, rather than consisting of one base metal plus alloying elements Commercially important because they are ver expensive — Technologically important because of their unique Properties My first car - 1970 Camaro — 90,000 miles At6 years old, rusted wheelwells, surface rust all over. Before Auto Industry started to use zinc plated steel Laghic > Lead Feet Six tre . tate reaee 9 ripe Amp © HH Why Superalloys are Important Room temperature strength properties are good) but not outstanding -~—¥ss——— . h temperature performance is ex« strength, hot hardness; créép resistance, and corrosion resistance at very elevated temperatures - Operating temperatures often ~{100°C\2000°F) Applications: gas turbines - jet and rocket engines, 32cam turbines, and nuclear power plants (systems that operate more efficiently at high temperatures) (0211? Inhn Wiley & Sans ine MP Grnaver Intrachiction to.Three Groups of Superalloys _Aton-based alloys - in some case: of total composition lloyed with Ni, Cr, Co Nickel-based alloys - better high temperature strength than alloy steels a lloyed with Cr, Co, Fe, Mo, Ti _Lobalt-based alloys - ~ 40% Co and ~ 20% chromium lloyed with Ni, Mo, and W Virtually all superalloys strengthen by precipitation hardening (hold at high temp for longer periods of time to optimize grain structure) 2012 John Wiley & Sons, Inc. M P Groover, Introduction to anufacturing Processes on is less than 50% Properties of Ceramic Materials High hardness, electrical and thermal insulating, chemical stability, and high melting temperatures Brittle, virtually no ductility - can cause problems both processing and performance of ceramic. gyas* products ol ie gicet Some ceramics ar translucent) window glass (based on silica) being the clearest example ota. lite EOF gles sH a Cerdmic Defined gy, simply > medal ovide putt An inorganic compound con: semi-metal) and one or more nonmetals «Important examples: Silica {silicon dioxide ( most glass products + Alumina - aluminum oxide (AI203), used in various applications from abrasives to artificial bones + More complex compounds such as hydrous aluminum silicate (AI2Si205(OH)4), the main ingredient in most clay products ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes 2)) the main ingredient in Three Basic Categories of Cerai 1 Traditional ceramics - clay products such as pottery, bricks, common abrasives, and cement ret sa, New ceramics - more recently developed ceramics based on oxides, carbides, etc., with better mechanical or physical properties than traditional ceramics 3 Glasses - based primar distinguished by their @oncrystaling structureOxide Ceramics Most important oxide ceramic is alumina Al203 Products of Oxide Ceramics ~~ Abrasives (grinding wheel grit) Alumina is also produced synthetically from aun» ale . 219, Bioceramics (artificial bones and teeth) Control of particle size and impurities, refinements in processing methods, and blending with small amounts of other ceramic ingredients, strength and toughness of alumina are improved substantially compared to its natural counterpart Alumina also has good hot hardness, low thermal conductivity, and good corrosion resistance 212 John Wiley & Sons, Inc. M P Groover, Introduction to ufacturing Processes bente > : ween mmisFanee > 25 a fom by sere 7 aqbusion aed +, umina ceramic components (photo courtesy of 3aco Inc.) Ines VAdiees Came ine tf O Cenmeses intent — Electrical insulators and electronic components » Refractory brick Cutting tool inserts - REALLY hard ©2012 John Wiley & Sons, Inc. M P Groover, Introduction to Manufacturing Processes Carbide Ceramics titanium carbide (TiC), tantalum carbide (TaC), ant chromium carbide (Cr3C2) ~~ + Production of SiC dates from a century ago, and itis generally included among traditional ceramics + WC, TIC, and TaC are hard and We pnd are used in applications such as cut Gearressian - WC, TiC, and TaC must be combined with a metallic binder such as cobalt or nickel in order to fabricate a