17.11.
2019
Introduction
Materials –> substance -> use for certain application(s)
ENGINEERING MATERIALS Number of materials around us – anything here in the
room to a spacecraft
Dr. M. Atif Makhdoom
Lectures – 1 & 2
www.flisom.com 1
Introduction Classification
Materials –> Important aspect of engineering design &
analysis
Crystalline
Civil work
Crystalline SiO2
Mechanical work (Quartz)
Electrical work
Polymer
etc.. Non-crystalline
(Amorphous)
Amorphous SiO2
(Glass)
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Classification Classification
Engineering Materials Engineering Materials
Metallic Materials Non-metallic Materials Metallic Materials
Ferrous Non-Ferrous Organic Inorganic Ferrous
Iron-carbon alloy
Steels Cast Irons Steels C = 0.01 – 2.0 %
%age of carbon defines its properties
• Plain • White • Al • Plastic • Minerals • Plain Increasing carbon reduces ductility and toughness
• Carbon • Grey • Cu • Wood • Cement • Carbon Certain heat-treatment processes can change these properties
• Alloy • Malleable • Mg • Paper • Glass • Alloy In addition to carbon, steels also contain alloying elements
• Ductile • Sn • Rubber • Ceramic
Plain carbon steel contains only residual concentration of
• CGCI • Zn • Leather • Graphite
impurities other than carbon and little Mn
• Alloy • Pb • Petroleum
• Ni & its alloys In alloy steels, more alloying elements are intentionally added
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Classification Classification
Engineering Materials Engineering Materials
Metallic Materials Metallic Materials
Low carbon Plain Low carbon Plain
Ferrous
(0.01 – 0.25% C)
HSLA Ferrous
(0.01 – 0.25% C)
HSLA
Steels Plain Steels
Low alloy Medium carbon Low alloy Greatest quantity produced – low cost
(0.25 – 0.55% C)
Heat treatable
• Plain • Plain No response to HT
• Carbon • Carbon
Plain Cold working – for strengthening
• Alloy High carbon • Alloy Good weldability & machinability
(0.55 – 2.0% C)
Tool HSLA – high strength low alloy steel
High alloy Alloying elements e.g. Cu, V, Ni & Mo
Stainless (up to 10%), have high strengths
( > 11% Cr)
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Classification Classification
Engineering Materials Engineering Materials
Metallic Materials Plain Metallic Materials Plain
Medium carbon High carbon
Ferrous
(0.25 – 0.55% C)
Heat treatable Ferrous
(0.55 – 2.0% C)
Tool
Steels Steels
Low alloy Heat treatable Low alloy High %C gives high strength & hardness
• Plain Addition of Cr, Ni & Mo improves HT • Plain but low ductility
• Carbon response • Carbon Used in hardened and tempered condition
• Alloy HT improves strength but reduce ductility • Alloy Carbide forming elements e.g. Cr, V, W are
Applications: added to form carbides in it
Gears, Railway wheels and their High wear & hardness property – tool and
tracks die steel
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Classification Classification
Engineering Materials Engineering Materials
Metallic Materials Metallic Materials
Low carbon Plain Extra ordinary corrosion resistance due to Cr2O3
HSLA
(0.01 – 0.25% C) formation
Ferrous Ferrous Types:
Steels Plain Steels
Ferritic SS – alpha iron
Low alloy Medium carbon Martensitic SS – heat treatable
(0.25 – 0.55% C)
Heat treatable Austenitic SS – gamma phase brought to room
• Plain • Plain
temp. by alloying. Highly corrosion resistance
• Carbon • Carbon
Plain Precipitation hardening SS – Ultra high
• Alloy High carbon • Alloy
strength due to precipitation hardening
(0.55 – 2.0% C)
Tool Duplex SS – dual phase (alpha + gamma)
High alloy High alloy
Stainless Stainless
( > 11% Cr) ( > 11% Cr)
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Steel Designation Steel Designation
Within each group of alloy – classification can be made: Example: AISI 1045
First two digit shows alloy system
Chemical composition – %C or any other alloy present
Last two or three digits show carbon
Finishing method – Hot/cold rolled
percentage in hundredths
Product made – bar, plate etc.
Production method – cast / wrought alloy
SAE designation Type
1xxx Carbon Steel
Designation is actually assigning a particular identification number, 2xxx Nickel steels
letter, symbol or a combination to a specific class/group of alloy. 3xxx Nickel-chromium steels
4xxx Molybdenum steels
Normally based on chemical composition or mechanical properties 5xxx Chromium steels
6xxx Chromium-vanadium steels
7xxx Tungsten steels
8xxx Nickel-chromium-molybdenum steels
9xxx Silicon-manganese steels
11 www.wikipedia.com, www.totalmateria.com 12
Classification Classification
Engineering Materials Engineering Materials
Metallic Materials Non-metallic Materials Metallic Materials
Cast irons contain %C = 2.0 – 6.67 %
Ferrous Non-Ferrous Organic Inorganic Ferrous Produced by re-melting of pig iron with coke, lime
stone& steel scrap in a furnace – cupola
Steels Cast Irons Steels Cast Irons
• Plain • White • Al • Plastic • Minerals • Plain • White
• Carbon • Grey • Cu • Wood • Cement • Carbon • Grey
• Alloy • Malleable • Mg • Paper • Glass • Alloy • Malleable
• Ductile • Sn • Rubber • Ceramic • Ductile
• CGCI • Zn • Leather • Graphite • CGCI
• Alloy • Pb • Petroleum • Alloy
• Ni & its alloys
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Inputs for Ferrous Materials Inputs for Ferrous Materials
Pig Iron
Ore – It is an aggregate of minerals from which a valuable constituent, especially a
Raw material for all kinds of steels and cast irons products
metal, can be profitably mined or extracted
High value product in foundry & steel making processes
Constituents of an Ore – Structurally an ore is heterogeneous hard rock containing:
Smelting process in Blast furnace- input materials consists of:
Mineral of 1. Principal metal 2. Other metal
Iron ore , Coke (acts as fuel), Lime stone (acts as flux/catalysis)
Gangue – Earthy impurities like silica, mud etc. associated with ore. also called waste.
Ore = Mineral (Valuables) + Gangue (Valueless) Smelting & Melting
Wrought Iron Chemical reduction of ore in the presence of reducing materials (flux) – chemical
Primarily composed of iron (very low contents of %C) with 1 to 2% of slag — reaction (separation of metal from gangue in melted form)
mixture of Si, S, P & aluminum oxides. Temperature below the melting point of respective metal
A soft product suitable for metal forming processes rather than casting Melting is just transformation of a substance from solid to liquid – phase change
Formed by puddling of pig iron – heating and stirring it frequently in a furnace
in the presence of oxidizing materials
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Classification Classification
Engineering Materials Engineering Materials
Metallic Materials Non-metallic Materials Metallic Materials Non-metallic Materials
Ferrous Non-Ferrous Organic Inorganic Ferrous Non-Ferrous Organic Inorganic
Steels Cast Irons Steels Cast Irons
• Plain • White • Al • Plastic • Minerals • Plain • White • Al • Plastic • Minerals
• Carbon • Grey • Cu • Wood • Cement • Carbon • Grey • Cu • Wood • Cement
• Alloy • Malleable • Mg • Paper • Glass • Alloy • Malleable • Mg • Paper • Glass
• Ductile • Sn • Rubber • Ceramic • Ductile • Sn • Rubber • Ceramic
• CGCI • Zn • Leather • Graphite • CGCI • Zn • Leather • Graphite
• Alloy • Pb • Petroleum • Alloy • Pb • Petroleum
• Ni & its alloys • Ni & its alloys
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Classification Classification
Engineering Materials Engineering Materials
Metallic Materials Metallic Materials Non-metallic Materials
Do not contain iron
Generally non-magnetic
Ferrous Non-Ferrous Ferrous Non-Ferrous Organic Inorganic
Comparative properties:
Steels Cast Irons Good electrical and thermal Steels Cast Irons
conductivities
• Plain • White • Al Resistance to corrosion • Plain • White • Al • Plastic • Minerals
• Carbon • Grey • Cu Good modulus of elasticity • Carbon • Grey • Cu • Wood • Cement
• Alloy • Malleable • Mg Better welding properties • Alloy • Malleable • Mg • Paper • Glass
• Ductile • Sn • Ductile • Sn • Rubber • Ceramic
Light weight
• CGCI • Zn • CGCI • Zn • Leather • Graphite
Good castability
• Alloy • Pb • Alloy • Pb • Petroleum
• Ni & its alloys • Ni & its alloys
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Classification Classification
Engineering Materials Engineering Materials
Non-metallic Materials Non-metallic Materials
Do not contain metal Naturally occurring materials but now lab synthesized
versions are also included
Can be solids, liquids or gases (only Bromine is liquid)
Organic Inorganic Organic Inorganic
Bad conductors (except graphite) Carbon is an essential component
Non-malleable – a property by which a substance can be Other main elements are H, N & O
drawn into sheets Possesses degradation tendency e.g. yellowing,
Non-ductile – a property by which a substance can be • Plastic • Minerals embrittlement, fading – long exposure to light (radiation) • Plastic • Minerals
drawn into wires (except carbon fiber)
• Wood • Cement due to breakdown of covalent bonded structures • Wood • Cement
• Paper • Glass • Paper • Glass
Allotropy: Carbon (Diamond, graphite, coke) If flammable – decomposes to CO2, CO & C
• Rubber • Ceramic • Rubber • Ceramic
Phosphorous (yellow P, red P, Violet P, etc..) Insoluble in water but soluble in some organic liquids
• Leather • Graphite • Leather • Graphite
Sulphur (Monoclinic, rhombic, plastic) • Petroleum Continued …….
• Petroleum
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Classification Classification
Engineering Materials Engineering Materials
Non-metallic Materials Rarely contains carbon but no C-H, C-C covalent bonding Non-metallic Materials
Low melting & boiling point
Usually smaller length of chains than organic compound –
Covalent molecular structure
Organic Inorganic don’t contain carbon chains Inorganic
High melting & boiling points
Further classification – based on their source
Usually soluble in water but insoluble in organic liquids
Cellulose materials – Living matter made of cellulose &
If flammable – don’t decomposes to CO2, CO & C
lignin e.g. wood, leaves etc. • Plastic • Minerals • Minerals
Ionic & covalent molecular structure
Proteinaceous materials – Have animal origin e.g. • Wood • Cement • Cement
• Paper • Glass • Glass
leather, wool, silk etc.
• Rubber • Ceramic • Ceramic
Organic polymers – derived from fossil fuels or other
• Leather • Graphite • Graphite
oils e.g. proteins, nucleic acids, natural resins etc.
• Petroleum
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Material Selection
Materials –> selection –> properties, specific application,
advantages & disadvantages
Non-metallic
- alumina (ceramic)
electrically insulating
Spark electrode must resist:
• Thermal fatigue – fast changing temperature Tungsten alloys
• Wear – spark erosion for electrodes
• Oxidation & Corrosion – hot gases containing Sulphur
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