METALS Composition and Microstructure Ferrous Metals and Alloys
- Slides: 57
METALS Composition and Microstructure Ferrous Metals and Alloys Non-Ferrous Metals and Alloys Specifications and Proof Testing Corrosion
Composition and Microstructure Metal: element that readily loses electrons to form positive ions, characterized by high electrical conductivity and malleable Alloy: combinations of metals in a crystalline structure
Structure of Metals Microstructural properties determine all of the material properties of metals and alloys. Different from Covalent and Ionic Bonds
Alloying Structure 3 -D lattice in metalic bonds provides n n opportunity for other element to occupy some of the positions. or for small element to enter the lattice
Interstitial Alloy Between atomic lattice location < 60% of the size of the lattice atoms only a small % can fit interstitially For Transition metals only a few fit H, B, C, N
Substitutional Alloy Replacing elements in the lattice + 15% radius of lattice atoms large percentage is possible [ Alloys may contain both interstitial and substitutional elements
Forming a Crystalline Structure Liquid: large degree of disorder Freezing Point: order begins to form Grain Initiation: initiation energy Solidification: ordered lattice structures form Grain Boundary: separate lattices collide FCC: BCC or FCC: FCC with different angle
Forming a Crystalline Structure Grain Structure: each grain has its own lattice structure (FCC, BCC, HCP).
Introduction to Steel Production Commercial Forms Applications Microstructure Strengthening Mechanisms Corrosion
Metal Processing Crushing and Calcining, or Separation Extraction n Smelting w Ore is melted and separated in solution n Electrolytic processing w electric furnace or process is used to separate metal n Leaching (liquid processing) w metal is recovered from leachate
Ferrous Metals principle element is iron, cast iron, steel, wrought iron. Metals come from ore, "minerals" ore consists of metal and gangue (valueless extra) Mining n n open pit underground
Refining the Metal n n oxidizing impurities distillation chemical agents electrolysis
Iron Production Blast Furnace n n Reduces iron ore to metal Separates metal from impurities Molten Iron Slag
Processing of Virgin Steel 1) first step in reducing iron ore, 2) separates impurities 3) absorbs carbon (leaves 2. 5 - 4. 5 % carbon) End product is cast in bars, "pigs".
Ferrous Metals Pig Iron n Iron ore is combined with coke, and limestone (fluxing agent). Blasts of hot air are forced through the material to ignite the coke and melt the iron ore. The impurities in the iron are absorbed by the limestone and forms blast furnace slag.
Forms of Ferrous Alloys Cast Iron n cast iron is pig iron is any other shape. Remelted and cast into desired shape. Malleable Cast Iron n annealed (heating then slow cooling to encourage refined grains and soften mechanical properties, removes internal stresses, removes gases) cast iron that has been made more ductile and formable.
Forms of Ferrous Alloys Wrought Iron n a form of iron that contains slag, and virtually no carbon. making it workable when it is hot but hardens very rapidly when cooled rapidly. Ingot Iron n low carbon steel or iron cast from a molten state.
Forms of Ferrous Alloys Steel n n Iron - Carbon alloy which is cast from a molten mass in a form which is malleable. Carbon steel is steel with less than 1. 5% carbon. Alloy steel is steel which has properties controlled by elements other than carbon. Steel has the best structural properties of these materials
Carbon Steels Carbon steels have between. 008 and 1. 7 percent C (most are between 0. 1 and 0. 8%) Carbon may be substitutional or interstitial depending upon the amount present Alloys with greater than 1. 7 percent carbon become very brittle and hard, i. e. cast iron properties.
Phase Diagrams relate the n n composition & temperature to the crystalline structure (“phase”) Inverse Lever Law n determines the percentage of each crystalline phase
Two Component (Binary) Phase Diagram for Temperature, °C completely soluble elements or compounds Melting Temperature of A Liquid Components Liquid + Solida Solid a Melting Temperature of B Percent A by weight 0 10 20 30 40 50 60 70 80 90 100 Percent B by weight 100 90 80 70 60 50 40 30 20 10 0
Two Component (Binary) Phase Diagram: Ni - Cu 1700 Nickel - Copper Alloy Temperature, °C 1600 Liquid 1500 Liquidus Line 1455°C 1400 1300 Liquid + Solida 1200 1100 Solidus Line Solid a 1084°C 1000 Percent Ni by weight 0 10 20 30 40 50 60 70 80 90 100 Percent Cu by weight 100 90 80 70 60 50 40 30 20 10 0
Binary Phase Diagram for Temperature. °C insoluble elements or compounds Liquid A + B Liquid + A Liquid + B Solid A + B Composition of A Actual atomic form will depend on the composition of formation (will discuss later for steel) Composition of B
Definitions Eutectic Reaction – Eutectic Point – Eutectic Solid –
Water - Na. Cl Phase Diagram 15 10 Temperature. °C 5 Liquid – Brine (Water + Dissolved Na. Cl) 0 -5 Eutectic Point -10 Salt + Brine Ice + Brine -15 -20 -25 Ice + Salt -30 0 -21 o. C (-5. 8°F) 5 10 15 Weight Percent Na. Cl 20 25 23. 3% 30
Binary Phase Diagram for Temperature. °C partially soluble elements or compounds Liquid Eutectic Point a + Liquid b a Solid a + b Composition of A Composition of B
Lead-Tin Phase Diagram 327°C Liquid a Liquid + a 19. 2% Liquid +b 61. 9% 183°C a+b 232°C b 97. 5%
Definitions Eutectoid Reaction – Eutectoid Point – Eutectoid –
Steps to Analyzing a Phase Diagram 1. Determine the phase/phases present at the point (composition vs. temperature) 2. The mass percentage composition of each phase at the point can be determined by the drawing a horizontal through the point for the length of the entire region. 3. The intersection of the horizontal line and a line on the phase diagram defines the composition of the solution.
A Point with 2 Phases 4. If the point is located in a region with more 2 phases, the mass percentage of each phase within the region can be determined by the inverse lever law.
Inverse Lever Law (Derivation on pgs 56 + 57 of text) The mass percentage of a phase present in a two phase region is the length along the “tie line” portion from the state point to the other phase region divided by the total “tie line” length. Compositions are used as a measure of length. State Point y Phase I + Phase II Region (e. g. Solid + Liquid) Phase II Region (e. g. Liquid) Mass percentage of Phase II In the two-phase region: x/(x+y) x Phase I Region (e. g. Solid) Mass percentage of Phase I in the two-phase region: y/(x+y)
Example: Ni-Cu For a 1000 kg block of Ni-Cu metal at a defined state point of 53% Nickel and 47% Copper at 1300 o. C, determine the following: Compositions (%) of both the liquid and solid phases Mass percentages of the liquid and solid phases The mass of Nickel in the Liquid Phase
Example: Ni - Cu 1700 Nickel - Copper Alloy Temperature, °C 1600 1500 Liquid + Solida State Point 53% Ni, 47 % Cu 1400 1300 1200 Solid a 1100 1000 Percent Ni by weight 0 10 20 30 40 50 60 70 80 90 100 Percent Cu by weight 100 90 80 70 60 50 40 30 20 10 0
Phase diagram for Fe-C Cementite: n n n above 4. 35 to 6. 67 very hard and brittle alloy forms 6. 67% Carbon 93. 33% Iron "iron carbide" Ferrite: n iron which contains very little carbon. this is soft ductile material
Phase diagram for Fe-C Pearlite: n n combination of ferrite and cementite structures intermediate property structure Austinite: n solid state gamma phase iron-carbon combination.
Phase Diagram for C-Fe
Microstructure Phases of Steel n n Ferrite (BCC) Austenite (FCC) Cementite (Orthorhombic) Delta Iron (BCC) Grain Size
Time-Temperature-Transition Curves Critical Temp. Fine Pearlite Coarse Pearlite Bainite Martinsite
Heat Treatments Annealing n n n heated above critical temperature and cooled slowly softens structure Quenching n n n heated above critical temperature and cooled rapidly in water or oil improves hardness and strength
Heat Treatments Tempering n n n heated below critical temperature, held and quenched improves ductility and toughness while retaining hardness
Mild Steel Grades A 992 “Low Alloy” Carbon Steel n n n <0. 23% Carbon Common Structural Sections Replaced A 36 steel A 572 “High-Strength Low-Alloy Columbium-Vanadium Steel” n n Grades 42, 50, 65 Structural sections and bolts. . .
Mild Steel Grades A 615 Billet Reinforcing Steel n n low alloy, high ductility steel reinforcing bars A 588 Weathering Steel n n should not be used in Cl water environments Free from moisture 40% of the time; avoid extreme humid environments
Corrosion Oxidation of metal requires n n oxygen, water, two different metals connected electrically electrolyte
Corrosion Major problem with steel Control Methods n n Protective Coatings Galvanic Protection Cathodic Protection Corrosion-resistant Steels
S-N Curve
Strengthening Mechanisms Alloying Heat Treating Cold Working
Alloying Forming Solid Solution with Iron n Carbon, Chromium, Manganese, Nickel, Copper, and Silicon Formation of Carbide n Titanium, Vanadium, and Molybdenum Formation of an Undissolved, second phase n Lead, Sulfur, and Phosphorus
Heat Treatments Full Annealing Process Annealing Normalizing Quenching
Cold Working Plastic deformation Done below recrystallization temperature
Other Properties of Steel Impact n resistance to dynamic loadings (toughness) Creep n time dependent deformation due to sustained loads Ductility n n mild steels may yield at = 0. 002 and fracture at > 0. 200
Forms of Steel Structural Shapes n n Wide flange sections, Channels, Tubing, Plate Reinforcing Steel Cold Rolled forms, pans, sheet Pipe
Structural Grades ASTM n n n A 36 & A 572 (being phased out) A 992 Structural Shapes A 325 Bolts AISI - SAE n 10 XX w XX defines Carbon content n 13 XX w 13 defines a manganese alloy steel
Applications Structural Members Bolts, Connectors Reinforcement Tools Machines
Steel Grades
- Examples of alloy metals
- Microstructure of ferrous metals
- Development of microstructure in isomorphous alloys
- Non ferrous alloys definition
- Hinduminium
- Classification of ferrous metals
- 5 ferrous metals
- What is macrostructure
- Hypereutectoid microstructure
- Market microstructure trading strategies
- High frequency market microstructure
- Roll's model bid ask spread
- What is the percent yield of ferrous sulfide
- Ferrous scrap
- Uses of ferrous sulphate
- Metal categories
- Non metals periodic table
- Density of metalloids
- Matter and materials grade 7
- Technology grade 7 term 3 notes
- Reactivity periodic table
- Application and processing of metal alloys
- Applications and processing of metal alloys
- Aluminum and its alloys
- Aluminum and its alloys
- Moscow institute of steel and alloys
- Microfusion cast & alloys
- Trituration definition in dentistry
- Substitutional alloy examples
- Shape memory alloys lecture notes
- Wrought metal in cast rpd is used for
- Interstital alloys
- Magnesium barium alloys
- Titanium alloys
- Advanced copper alloys
- Adaptive alloys
- Chemical properties of alloys
- "re alloys"
- Memory shape
- Lightweight alloys
- Ferromagneti
- San precision alloys pvt ltd
- Semimetals periodic table
- Least reactive non-metal
- What separates metals from nonmetals
- Nonmetals vs metals periodic table
- The physical properties of metals include luster and
- Metals nonmetals and metalloids answer key
- Compare metals nonmetals and metalloids
- Difference between metals nonmetals and metalloids
- Classification of metalloids
- Melting point of nonmetals
- Brass vs bronze
- Metals nonmetals and metalloids chart
- Non metals and uses
- Chapter 17 elements and their properties
- Optical properties of metals and nonmetals
- Alkali metals periodic table