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CLASS 2
MATERIALS IN METAL MANUFACTURING
CRYSTALLINE STRUCTURE
Almost all metals have a crystalline structure. This means that the atoms arrange
themselves in an ordered manner, in which a small repeat unit called a unit cell can
be identified.
This unit cell, which in some cases contains just several atoms, is repeated in all three
directions, and in this way, the entire structure is built up.
Three principal types of lattice
BCC Strong and ductile materials (Fe, Cr, W, Ti, V, Ta)
FCCLowto moderate strength and high ductility (Fe, Al, Cu, Au, Pb)
HCP Difficult to deform, brittle materials (Mg, Zn, Cd)
DEFECTS & DISLOCATIONS
The unit cell description of a crystalline structure implies the atoms are arranged in
perfect order, which is only true in an ideal solid.
All crystalline solid structures contain missing atoms called defects, impurity atoms of
other elements, and misaligned planes of atoms called dislocations.
Dislocations are rather common in many systems you encounter everyday
Example: corn cob
Source: http://mrsec.wisc.edu/edetc/amorphous/
Dislocation (rowof kernels
insertedintotheregular
arrangement of rows)
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GRAIN STRUCTURE
grain structure: arrangement of the grains in a metal
grain boundary: the outside area of a grain that separates it fromthe other grains
size of the grain: determines the properties of the metal
NON-CRYSTALLINE MATERIALS
Amorphous materials are formed by cooling the liquid material quickly enough to
prevent crystallization; the atoms do not have time to arrange themselves into an
ordered structure
The atoms in an amorphous material are not arranged in any ordered structure,
rather they have a tightly-packed, but randomarrangement.
http://www.liquidmetal.com/technology/default.asp
METALS AND METAL ALLOYS
Pure metals - rarely used because of their limited material properties
Alloys- materials that combines elements of two or more chemical components
(one of which is a metal)
ferrous - based on iron-carbon alloys (steel, cast iron)
nonferrous - alloys of all other metals (Cu-based alloys, Al-based alloys, etc.)
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FERROUS ALLOYS: STEELS
Fe + 0.02%to 2.11 %C with or without other alloying elements.
cast &wrought steel; hot-rolled steel (HRS) &cold-rolled steel
Alloying elements - Mn, Cr, Si, Ni, Mo, etc.
SAE systemto designate various steels (except stainless steel):
The first two digits indicate the alloying elements and their percentage, the last two
digits indicate the carbon content. Examples:
AISI 1020: plain Csteel, 0.20%C
AISI 3130: 1.25%Ni, 0.65%Cr, 0.3%C
Number Type
1xxx Carbonsteels
2xxx Nickel steels
3xxx Nickel-chromiumsteels
4xxx Molybdenumsteels
5xxx Chromiumsteels
6xxx Chromium-vanadiumsteels
7xxx Tungstensteels
8xxx Nickel-chromium-vanadiumsteels
9xxx Silicon-manganesesteels
TYPES OF STEEL
Three major groups:
Carbon steels (plain carbon steels): higher the carbon content - higher the strength,
hardness and brittleness
Alloy steels: more than 1.65%Mn, 0.60%Si, or 0.60%Cu
less than 5%- low-alloy steels, mostly Cr
Stainless steels: high-allowsteel with >15%Cr
three-digit SAEnumbering system(older); Unified Numbering System(UNS)
example: UNSS31600 is SAE316
Number Properties
LowCarbon
1006-12 soft andplastic
1015-22 soft andtough
1023-32 medium
MediumCarbon
1035-40
1041-50
1052-55
HighCarbon
1060-70 shockresistant
1074-80 toughandhard
1084-95
FERROUS ALLOYS: CAST IRONS
Iron-carbon alloy, containing carbon (2.11%to 4%or 5%) in addition to 1%to 3%
silicon.
Types of cast iron:
Gray cast iron
Ductile cast iron
White cast iron
Graphite flakes
in the gray cast
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Spheroidal
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NON-FERROUS ALLOYS
Aluminumalloys: light weight, corrosion resistance
Copper alloys: thermal and electrical conductivities, corrosion resistance
brass (Cu + Zn), bronze (Cu + Sn)
Titaniumalloys: strong as steel, but 45%lighter; twice as strong as Al but only 60%
heavier
Nickel alloys: corrosion and heat resistance
Series UNS number Primary Alloying Element
1xxx A91xxx Aluminum- 99.00%or greater
2xxx A92xxx Copper
3xxx A93xxx Manganese
4xxx A94xxx Silicon
5xxx A95xxx Magnesium
6xxx A96xxx MagnesiumandSilicon
7xxx A97xxx Zinc
8xxx A98xxx Unspecifiedalloy
Type UNS Number
ElectrolyticToughPitchCopper C11xxx
RedBrass C23xxx
CartridgeBrass C26xxx
Free-CuttingBrass C36xxx
Architectural Bronze C385xx
Naval Brass C46xxx
Phosphor Bronze C51xxx
Free-CuttingPhosphor Bronze C54xxx
LowSiliconBronze C65xxx
Nickel Silver C74xxx
PHASES
Physically distinctive, homogeneous part of the material that differs fromanother
part of the same material in composition, structure, or both.
Phase transformations: change of metal crystal structure with temperature.
Example: phase transformations in iron
face-centered
PHASE DIAGRAMS IN ALLOYS
Represents the physical structure and
composition of an alloy with respect to
temperature
This very simple case is the Cu-Ni alloy.
The liquidus line separates the liquid phase from
solid or solid + liquid phases. That is, the solution
is liquid above the liquidus line.
The solidus line is that belowwhich the solution is
completely solid (does not contain a liquid phase.)
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IRON-CARBON PHASE DIAGRAM
Eutectic steel (4.3 %C)
Eutectoid steel (0.78 %C)
Mechanical properties of steels depend on
which phase predominates
soft and ductile (ferrite predominates)
hard and brittle (cementite, Fe
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C,
predominates)
Reading assignment for the next class: Chapter 7
Questions?
