Engineering Materials PDF

Metallurgy 9/17/2021
Metallurgy
Course Code-ME205
By
Dr. Biranchi Narayan Sahoo
Assistant Professor
Department of Mechanical Engineering

SVNIT Surat-359007
17-09-2021
Details Syllabus
INTRODUCTION AND SCOPE (04 Hours)
Various fields of metallurgical engineering, Status of metallurgical industry in
India, Sources of metals, Basic outline of the principles of production of iron
and steel, copper, aluminum. Basic concepts of metallography.
STRUCTURE-PROPERTY CORRELATIONSHIP IN METALS (06 Hours)
Ferrous: Allotropic forms of Iron, Wrought Iron, Cast Irons - Grey, White,
Malleable and Spheroidal Graphite, Steel - Plain carbon steel, Alloying of steels,
Stainless steels, Tool steels, Maraging steels. Non-ferrous: Copper & Copper
alloys - Brass, Bronze, Cupro-Nickel; Aluminum and Aluminum alloys, Titanium
alloys, Nickel based super alloys.
SOLIDIFICATION OF METALS (04 Hours)
Solidification of pure metals, Nucleation, Growth, Applications of controlled
Nucleation & controlled growth.
DEFORMATION OF METALS (06 Hours)
Elastic & plastic deformation of metals, Strengthening mechanisms,
Importance of grain size, directional properties, Recovery, Recrystallization and
grain growth.
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Details Syllabus
EQUILIBRIUM PHASE DIAGRAMS (08 Hours)
Objectives & classification, Basic terms - system, phases & structural
constituent, Phase systems - Isomorphous, Eutectic. Eutectoid, Peritectic.
Interpretation of phase diagrams- s phase rule, Equilibrium phase diagram of
Fe-Fe3C system, Equilibrium phase diagrams of non-ferrous alloys.
HEAT TREATMENT (08 Hours)
Purpose, Definition and Classification of heat-treatment processes for steels,
Heat treatments for bulk materials - Annealing, Normalizing, Hardening,
Tempering, Isothermal cooling transformation diagram (ICT/TTT) and
Continuous cooling transformation (CCT) diagrams for steels, Various surface
hardening heat-treatment of steels; Heat-treatment of Al alloys - Solution
treatment, Solution quenching & Precipitation hardening.
NON-DESTRUCTIVE TESTING TECHNIQUES (06 Hours)
Importance, principle, procedure, equipments, advantages & limitations of
various non-destructive techniques - visual inspection, radiography, ultrasonic
testing, magnetic particle inspection, liquid penetrant inspection, eddy current
testing
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STRUCTURE-PROPERTY CORRELATIONSHIP IN METALS
Ferrous:
 Allotropic forms of Iron, Wrought Iron, Cast Irons - Grey, White,
Malleable and Spheroidal Graphite,
 Steel - Plain carbon steel, Alloying of steels, Stainless steels, Tool
steels, Maraging steels.
Non-ferrous:
 Copper & Copper alloys - Brass, Bronze, Cupro-Nickel;
 Aluminum and Aluminum alloys,
 Titanium alloys,
 Nickel based super alloys.
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Evolution of engineering materials in Products
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Evolution of engineering materials in Products
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Classification of engineering materials

Engineering Materials
Metals Ceramics Polymers Composites
Ferrous Metals Crystalline Ceramics Thermoplastics Metal Matrix

Composites
Nonferrous Metals Glasses Thermosets Ceramic Matrix

Composites
Elastomers Polymer Matrix

Composites
 Their chemistries are different, their mechanical and physical

properties are dissimilar.
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Metals
 There are hundreds of metals which are used in engineering

applications.
 All the metals are extracted from quarries in the form of ores. They
are made pure by some special methods in the industries.
 Metals used in manufacturing are usually alloys, which are

composed of two or more elements, with at least one being a
metallic element.
 Metals are classified into two main groups depending upon

presence of iron content.
(1) Ferrous and
(2) Nonferrous.
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Properties Mg Al Cu Steel
Physical Properties
Density (gm/cm3) 1.74 2.7 8.9 7.8
 Density - The mass per unit volume of a material.
 Electrical Resistivity - This is a measure of a material’s ability to
conduct electricity. A material with a low resistivity will conduct
electricity well.
 Thermal Conductivity - A measure of how fast heat is conducted
through a slab of material with a given temperature difference
across the slab.
 Thermal Expansion - A measure of the degree of increase in
dimensions when an object is heated. This can be measured by an
increase in length, area or volume. The expansivity can be
measured as the fractional increase in dimension per Kelvin
increase in temperature.
 Hardness - The resistance a material offers to penetration or
scratching.
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Mechanical Properties
 Tensile Strength - The ability of a material to withstand pulling forces.
 Stiffness - The ability of a product to withstand bending.
 Ductility - The ability of a material to be drawn or extruded into a

wire or other extended shape.
 Toughness - The ability of a material to resist the propagation of

cracks. (Tough guys don’t crack)
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Metals Ferrous Alloy
Steel Cast Iron
 containing 0.02% to 2.11% carbon  iron and carbon (2% to 4%)
 manganese, chromium, nickel, and  Silicon in amounts from 0.5% to 3%),

molybdenum and other elements are often added
also, to obtain desirable properties in
 construction (bridges, I-beams, and the cast part.
nails), transportation (trucks, rails,
and rolling stock for railroads), and  Blocks and heads for internal
consumer products (automobiles and combustion engines.
appliances)
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Nonferrous Alloy
 Nonferrous metals include the other metallic elements and their

alloys.
 In almost all cases, the alloys are more important commercially than
the pure metals.
 The nonferrous metals include the pure metals and alloys of
aluminum, copper, gold, magnesium, nickel, silver, tin, titanium, zinc,
and other metals.
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Cast Iron
 Contains 2%-4% of carbon
 Very hard and brittle
 Strong under compression
 Suitable for casting [can be pour at a relatively low temperature]
 Engine block, engineer vices, machine parts
Types of cast iron
 Gray cast iron

 White cast iron
 Malleable cast iron
 Nodular cast iron
 Alloy cast iron
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Cast Iron
Gray Cast Iron Designation
 Compositions- (other than iron)
Carbon= 3 - 4.5 %  FG20, FG35
 The numbers indicate ultimate tensile
Silicon= 1 – 2.75 % strength in MPa and
Manganese = 0.4 – 1 %  FG35Si15 -15 indicates 0.15%
silicon.
Phosphorous = 0.15 – 1 %
Sulphur = 0.02 - 0.15 %
 Uses –
cylinder blocks , fly wheel , pipes , etc
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Cast Iron
White Cast Iron
 Compositions –
– carbon = 1.75 – 2.5 %
– silicon = 0.85 – 1.2 %
– manganese = 0.1 - 0.4 %
– phosphorous = 0.05 - 0.2 %
– sulphur = 0.12 – 0.35 %
 Uses-
– Use as raw materials , break shoes , pumps
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Cast Iron
Malleable Cast Iron
 Obtain from white cast iron by annealing process

It separate free graphite into nodular form
 Uses-
– hubs of wagon wheel , pipes fittings , etc
Nodular Cast Iron

 Also known as ductile cast iron
 Can be produced in thicker part than malleable cast iron
 uses –
– in cast parts where density and pressure tightness is highly desired
quality
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Cast Iron
Alloy Cast Iron
 Produced by adding alloying elements such as Ni ,
Cr , Mo , Cu , Si etc
 These elements provide more strength,
corrosion resistance etc
 Uses-
– piston , piston rings , parts of crushing and grinding etc
Wrought Iron
 Purest form of iron contain at least 99.5% iron
 It is tough , malleable ,ductile but cannot withstand
sudden and excessive shocks
 Uses –
– crane hooks , railway cuppling , etc
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Types Steel Classification of Plain carbon steels
1. Low carbon steels (Less than 0.25% carbon)
 Plain Carbon Steel 2. Medium carbon steels (Between 0.25 to 0.60%)
 Alloy Steel 3. High carbon steels (More than 0.60% carbon)
Alloy Steels
 Any steel other than carbon steel is called alloy steels.
 Alloying elements : chromium, nickel, molybdenum, vanadium,
tungsten, cobalt, boron, copper and others.
Classification of Alloy steels
1. Low alloy steels (Having 3 to 4% alloying element)
2. High alloy steels (Having more than 5% alloying element)
Classification of Low Alloy steels Classification of High Alloy steels
1. AISI(American Iron and 1. Tool and die steels
Steel Institute) steels 2. Stainless steels
2. HSLA(High – strength Low- Alloy)
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steels
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Designation of engineering materials

 Designation or identification of material class by a
number, letter, symbol, name or a combination is called
specification.
 Normally based on mechanical properties or chemical

composition.
 Materials classified and designated as per following
standard
 BIS- Beauro of Indian Standard

 AISI- American Iron and Steel Institute
 SAE- Society of Automotive Engineers
 BS- British Standards
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 Designation of following materials are considered---( as
per IS)
 Cast iron
 Plain C steels
 Tool steels
 Low and medium alloy steels
 High alloy steels
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DESIGNATION OF CAST IRONS
 First symbol for type of cast iron
Number – indicates minimum tensile strength
FG – GRAY CI
WM – WHITE HEART MALLEABLE CI
PM – PEARLITIC MALLEABLE CI
SG – SPHEROIDAL GRAPHITE CI
Examples
FG150
GRAY CI TS 150 N/SQ.MM
IT IS GRAY CAST IRON WITH MIN. TS 150 N/SQ.MM OR MPa

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DESIGNATION OF CAST IRONS
WM250- White heart malleable CI with min. TS=250
N/SQ.MM
SG150- Spheroidal graphite with min. TS=150

N/SQ.MM
 Designation on The Basis Of Mechanical Propertie
DESIGNATED BY TENSILE OR YIELD STRENGTH

Fe- INDICATES STEEL
E – INDICATES YIELD STRENGTH
K- KILLED STEEL
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if E is not shown then TS is considered.
Example
Fe 350 – STEEL WITH MIN. TS 350 N/SQ.MM
Fe E 380 – STEEL WITH MIN. YIELD STRENGTH 380
N/SQ.MM
E- FOR YIELD STRENGTH
Fe 410 K – KILLED STEEL WITH MIN TS 410 N/SQ.MM
K- KILLED AND Fe FOR STEEL i.e. KILLED STEEL

KILLED STEEL IS DEOXYDIZED FULLY SO THAT
CASTING ARE SOUND AND FREE FROM BLOW HOLES.
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DESIGNATION AS PER CHEMICAL COMPOSITION:
PLAIN C STEELS:
e.g.
40C8
0.4 % CARBON AND 0.8 % Mn
 NUMBER AFTER C IS PERCENT OF Mn
 FOR Mn MULTIPLYING FACTOR IS 10 i.e. 10/100=1/10
SO 8/10=0.8 %
 NUMBER BEFORE C SHOWS % CARBON 40/100=0.4%
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45 C 10 S 18
0.45 % C, 1.0 % Mn, 0.18 % S

PLAIN C STEELS HAVE C, P, S, Mn, Si AS INGREDIENTS
Except Mn all elements are considered 100%
i.e. divide by 100, as 18/100 = 0.18 %
DESIGNATION OF TOOL STEELS:
10 T 4
TOOL STEEL CONTAINING 0.1 % C , 0.4 % Mn

T- INDICATES TOOL STEEL
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FIRST NUMBER --- INDICATES % CARBON
SECOND, FOURTH, SIXTH – INDICATES ALLOYING
ELEMENTS
THIRD, FIFTH, SEVENTH – INDICATES MULTIPLYING
FACTOR/100
ALLOYING ELEMENTS MULTIPLYI

NG FACTOR
Cr, Co, Ni, Mn, Si, W 4
Al, Pb, Cu, Be, V, Nb, Ti, Mo 10
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P, S, N 100
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40 Cr 4 Mo 3
LOW ALLOY STEEL 0.4 % C , 1 % Cr, 0.3 % Mo

DIVIDE BY MULTIPLYING FACTOR
i.e. 4/4=1 % FOR Cr,
AND 3/10=0.3 % FOR Mo
35 Mn 6 Mo 3
ALLOY STEEL WITH 0.35 % C, 1.5 % Mn, 0.3 %Mo
ALLOYING ELEMENTS MULTIPLYING
FACTOR
Cr, Co, Ni, Mn, Si, W 4
Al, Pb, Cu, Be, V, Nb, Ti, Mo 10
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DESIGNATION OF
ALLOY STEEL & HIGH ALLOY TOOL STEEL
X- INDICATES HIGH ALLOY STEEL
XT – INDICATES HIGH ALLOY TOOL STEEL
MULTIPLYING FACTOR NOT USED
FOR ALLOYING ELEMENTS NUMBER GIVES % OF
ELEMENTS
e.g. X 15 Cr 25 Ni 12
HIGH ALLOY STEEL 0.15 % C, 25 % Cr, 12 % Ni
XT 75 W 18 Cr 4 V 1
HIGH ALLOY TOOL STEEEL 0.75 % C , 18 % W, 4 % Cr, 1 % V
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STATE THE MEANING OF THE FOLLOWING …
T 70 TOOL STEEL HAVING 0.7 % C

Fe 470 W STEEL WITH MIN TS 470 N/SQ.MM
AND HAVING GOOD WELDABILITY
45 C 10 S 18 STEEL WITH 0.45 % C, 1.0 % Mn,
0.18 % S
XT 60 W 12 Cr 4 V 1 HIGH ALLOY TOOL STEEL WITH

0.6 % C, 12 % W, 4 % Cr, 1 % V
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AISI- AMERICAN IRON STEEL INSTITUTION DESIGNATION

• 35C8 i.e. 0.35 %CARBON, 0.8 % Mn.
• AISI1035 i.e. plain carbon steel containing 0.35 % carbon.
(Digit 1 indicates plain c steel.)
• AISI5140, AISI4140,AISI6150,AISI8640.
1st digit indicates type of steel.

2nd digit for predominant alloying element.
3rd &4th digit indicates% of carbon in hundredth.
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e.g. 1 for plain carbon steel,

2 nickel series,
3 for nickel chromium,
31 for manganese steel.
4 for chromium steel.
41 for chromium-molybdenum steels,
51 for medium chromium,
61 Chromium-vanadium series.
92XX FOR SILICON SERIES.
AISI5140 i.e. medium cr steel with 0.40%c.
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Nonferrous Metals
ALUMINUM (Al):
It is more commonly used non-ferrous metal. It is widely used in every
field of Engineering. Due to improved strength and durability, aluminum
is a versatile material for use by Engineers.
Properties
(1) Its colour is silvery white.
(2) It shows bright luster on a freshly broken surface.
(3) It is ductile material,
(4) It is very light in weight.
(5) It also resists atmospheric corrosion,
(6) It is very good conductor of electricity,
Uses:
(1) It is used for making door and window frames,
(2) It is also used in roofing, piping, etc,
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is also used in electric wires, cables.
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Designation of Al
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Application of Al
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Copper and its alloys

 Copper (Cu) atomic weight 63.546 is a soft, malleable and ductile
metal with very high thermal and electrical conductivity from the
group of Coinage metals in the modern periodic table.
 There are 29 isotopes of copper.
 Cu and Cu are stable, with Cu comprising approximately 69% of
naturally occurring copper.
 The other isotopes are radioactive.
 Copper is present in the Earth's crust at a concentration of about 50
parts per million (ppm)
 Copper occurs as native copper or in mineral such as the copper
sulfides chalcopyrite and chalcocite, copper carbonates azurite and
malachite and the copper(I) oxide mineral cuprite.
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COPPER:
It is one of the most widely used non-ferrous metals. It is not widely
used in Engineering due to its high cost.
Properties:
(1) It is crystalline in structure,
(2) Its color is reddish brown,
(3) It is highly ductile,
(4) It is excellent conductor of electricity,
(5) When exposed to sun, its colour turns greenish,
(6) It with stands corrosion,
(7) It is soft and highly flexible,
(8) It is light in weight,
(9) Dents in copper can be hammered out without any damage to it.
Uses:
(1) It is used for winding electric motors, generators and for
transmission
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of electricity,
(2) Its sheets are used as damp proofing in buildings.
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Nonferrous Metals COPPER:
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Alloys of Copper
1. Brasses 2. Bronzes, 3. Cupronickel
Class Cupper Zink
Alpha >65 <35 Alpha brasses are malleable, can be worked cold, and are used in pressing,
Brasses forging, or similar applications. They contain only one phase, with FCC
structure. With their high proportion of copper, these brasses have a more
golden hue than others
Alpha- 55-65 35-45 Also called duplex brasses, these are suited for hot working. They contain
beta both α and β' phases; the β'-phase is BCC and is harder and stronger than α.
Brasses Alpha-beta brasses are usually worked hot. The higher proportion of zinc
means these brasses are brighter than alpha brasses.
Beta 50-55 45-50 Beta brasses can only be worked hot, and are harder, stronger, and suitable
Brasses for casting. The high zinc-low copper content means these are some of the
brightest and least-golden of the common brasses
Gamma 33-39 61-67 There are also Ag-Zn and Au-Zn gamma brasses, Ag 30–50%, Au 41%.
Brases
White <50 >50 These are too brittle for general use. The term may also refer to certain
Brases types of nickel silver alloys as well as Cu-Zn-Sn alloys with high proportions
(typically 40%+) of tin and/or zinc, as well as predominantly zinc casting
alloys with copper additives. These have virtually no yellow coloring at all,
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Alloys of Copper
Brasses
• The alloy of copper and zinc is referred as brasses
• There are two type of brasses
1. Single phase brasses (alpha phase)
a. Yellow alpha brasses
b. Red alpha brasses
2. Alpha plus beta phase brass
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Alloys of Copper
Yellow alpha brasses
• This contain Zinc 20 to 36% Applications
Few examples Automotive
Cartridges brass(70Cu and 30Zn) Radiators core , tanks , headlight
Electrical
Yellow brass (65 Cu and 35 Zn) Flash lamps ,sockets shells,
Properties of yellow alpha brasses screw shells
• Good strength Hardware
• High ductility Eyelets, fasteners, gromenmets,
gear, watch parts Spring,
Problem of yellow alpha brasses reverts
1. Season cracking
2. Residual stress
3. Pitting corrosion
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Alloys of Copper
Alpha plus beta brasses
It contains about 38 to 46 %of Zn
Properties of alpha plus beta brasses
1. More harder
2. More brittle at room temperature
3. Excellent hot working properties
Example
• Muntz metal is a form of alpha-beta brass with about 60% copper,
40% zinc. Have very huge application in ship building industries.
• Free cutting brass 61.5%Cu,35.5%Zn and 3 Pb. Used in making gears,
automatic high speed screw
• Naval brass 60 %Cu,39.25%Zn and 0.75%Sn . Propeller shafts, piston
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and valve steams.

Alloys of Copper
Red brasses
• Red brasses consist of 5to 20 %Zinc
• This don’t have the problem of season corrosion
• Have excellent work hardening capacity due the low
percentage of zinc present.
Example
Gilding metal (95%Cu and 5%Zn)
Commercial brasses (10%Zn)
Red brass(15%Zn)
Low brass (20%Zn)
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Alloys of Copper
BRONZE:
 Bronze is an alloy of 90 % copper and 10 % tin.

 It can be easily machined and cast.
Properties:
 It resists corrosion.
 It takes a fine polish.
Uses:
 It is used for manufacturing of house hold utensils.
 Phosphorous bronze is used for making radio aerials and certain
other instruments
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Alloys of Copper
Cu-Ni Alloy:
 Alloys of Cu & Ni , contains upto 30 % Ni
 Cupronickels Alloys are single phase alloys
 No heat treatment is required
 Properties are improved only by cold working
 They have high fatigue resistance , high corrosion & erosion
resistance toward sea water
 These are widely used in condenser , heat exchanger tubes ,
coastal power plants
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LEAD:
It is widely used in building construction and has draw back of being
poisonous.
Properties:
(1) It is bluish grey metal,
(2) It is soft as it can be cut with a knife,
(4) It is a good conductor of heat and electricity,
(5) It does not corrode,
(6) Its specific gravity is 11.35.
Uses:
(1) It is used as a base in paints,
(2) Lead pipes and lead joints in sanitary fittings are extensively used.
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Nonferrous Metals
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TIN:
It is one of the mostly used protective metals used in construction
activities.
Properties:
(1) It is lustrous silvery white metal,
(4) It is soft and has good plasticity,
(5) Its specific gravity is 7.3.
Uses:
It is used to give protective coatings to iron and steel sheets.
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(5) ZINC:
It is commonly used in building construction either as a base for paints
or as protective coverings for metals.
Properties:
(1) It is bluish white crystalline metal,
(2) It is brittle metal at ordinary temperature,
(3) It becomes ductile between 100-150 ⁰C,
(5) It resists corrosion.
Uses:
(1) It is used for galvanizing iron sheets and pipes, for batteries and
printing blocks,
(2) It is also used for preparing paints.
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Physical & Mechanical Properties of Nonferrous Metals
Mg Al Cu Sn Pd
Atomic Number 12 13 29 50 82
Atomic Mass 24.30 26.98 63.5 118.7 207.2
Colour Shiny Silvery Reddish Silvery Bluish grey
Grey White Orange white
Density (gm/cm3) 1.73 2.70 8.96 5.769 11.34
Melting Temperature (°C) 650 660 1085 232 328
Thermal Conductivity 156 237 401 66.8 35.3
(W/m.K)
Hardness (Hv) 44-150 160-350 40-110 50-440 38-50
Strength (MPa)
Young modulus (GPa) 45 70 110 50 16
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Titanium and its alloys

Titanium is named after the Titans, the powerful sons of the
earth in Greek mythology.
Titanium is the forth abundant metal on earth crust (~ 0.86%)
after aluminium, iron and magnesium.
Not found in its free, pure metal form in nature but as oxides,
i.e., ilmenite (FeTiO3) and rutile (TiO2).
Found only in small amount in Thailand.
Have similar strength as steel but with a weight nearly
half of steel.
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Physical properties of titanium
 Experiences allotropic transforma on (α→β) at 882.5oC.

 Highly react with oxygen, nitrogen, carbon and hydrogen.
 Difficult to extract expensive.
 Used mainly in wrought forms for advanced applications
where cost is not critical.
 High strength and toughness
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Advantages of titanium alloys
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Applications of titanium alloys
Used mainly in aerospace, marine, chemical, biomedical
applications and sports.
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Production of titanium alloys
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Alloying system of titanium alloys
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Classification of titanium alloys
 Commercially pure (CP) titanium alpha and near alpha titanium alloys
 Generally non-heat treatable and weldable
 Medium strength, good creep strength, good corrosion resistance
 Alpha-beta titanium alloys

 Heat treatable, good forming properties
 Medium to high strength, good creep strength
 Beta titanium alloys

 Heat treatable and readily formable
 Very high strength, low ductility
 Different crystal structures and properties allow manipulation of heat

treatments to produce different types of alloy microstructures to suit
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required mechanical properties.

Commercially pure (CP) titanium alpha and near alpha titanium alloys
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Ni based superalloys
 A superalloy is a metallic alloy which is developed to resist most of all
high temperatures, usually in cases until 70 % of the absolute melting
temperature.
 All of these alloys have an excellent creep, corrosion and oxidation
resistance as well as a good surface stability and fatigue life.
 The main alloying elements are nickel, cobalt or nickel – iron, which
can be found in the 8th group of the periodic system of the elements.
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 Fields of application are found particularly in the aerospace industry
and in the nuclear industries, e.g. for engines and turbines
All superalloys have an austenitic face-centered cubic, which delivers

advantages such as:
 better mechanical properties
 higher modulus
 higher solubility of alloying elements
 systems
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of gliding plane
Fundamentals of nickel-base Superalloys
 Nickel-based superalloys can be strengthened through solid-solution
and precipitation.
 The solid-solution strengthens superalloys, such as Hastelloy X are
used for burner and combustor applications in gas turbine engines.
 They have particularly high-temperature corrosion resistance,
excellent fabricability and weldability but lower mechanical strength.
 The precipitation-strengthened alloys are constituted in applications
requiring high temperature strength and good corrosion and creep
resistance, for instance as turbine blades and vanes in the gas
turbine.
 Nickel-based superalloys can be used for a higher fraction of melting
temperature and are therefore more favourable than cobalt-based
and iron-nickel-based superalloys at service temperatures close to
the melting temperature of the materials.
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Dr. B.N.Sahoo 35
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 A two-phase equilibrium microstructure is generated, consisting of
gamma (γ) and gammaprime (γ´) with a very unusual crystallographic
relationship between the γ and γ´ phases.
 Both phases are face-centered-cubic, have almost identical lattice
dimensions and also similar orientation.
 Consequently the two phases are almost coherent.
 The lattice sites in the γ-phase are totally equivalent and the atoms
constituting the solid solution being distributed randomly ( Figure 3 ).
 The continuous phase γ is nonmagnetic. Because nickel has a nearly
filled 3rd electronic shell which allows alloying with solid solution
strengthening elements without losses in phase stability.
 The alloy elements assembling mainly the gamma matrix belong to
Group V, VI and VII and are cobalt, iron, chromium, molybdenum and
tungsten
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Dr. B.N.Sahoo 36
17-09-2021
 A super alloy is an alloy that exhibits several key characteristics like
excellent mechanical strength, resistance to thermal creep
deformation, good surface stability, and resistance to corrosion or
oxidation.
 The crystal structure is typically face-centered cubic .
 Examples:- Hastelloy , Inconel , Waspaloy, Rene alloys, Haynes alloys,

Incoloy, MP98T, TMS alloys, and CMSX single crystal alloys.
 Super alloys develop high temperature strength through solid
solution strengthening
 Another important strengthening mechanism is precipitation
strengthening which forms secondary phase precipitates such as
gamma prime and carbides.
 Oxidation or corrosion resistance is provided by elements such as
aluminium and chromium.
 Alloying
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increases the strength and temperature capability
Dr. B.N.Sahoo 37
Properties
 Heat resistant and high strength at high temperature (760-

980◦C).
 Good corrosion resistance.
 Good oxidation resistance.
 High toughness and ductility
 Good surface stability
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 Super alloys are classified into three based on the predominant metal
present in the alloy. They are
 Nickel based Super alloy

 Iron based Super alloy
 Cobalt based Super alloy
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Dr. B.N.Sahoo 38
 Nickel based Super alloys can be strengthened by either Solid
solution strengthening or Precipitation hardening.
 Most Ni based alloy contain 10-20% Cr, up to 8% Al and Ti, 5-10% Co,
and small amounts of B , Zr and C
 Other common additions are molybdenum, niobium, and tungsten,
all of which play dual roles as strengthening solutes and carbide
formers.
 Chromium and aluminium improves surface stability through the
formation of Cr2O3 and Al2O3
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Dr. B.N.Sahoo 39
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Dr. B.N.Sahoo 40
17-09-2021
Dr. B.N.Sahoo 41

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Metallurgy 9/17/2021

Department of Mechanical Engineering

STRUCTURE-PROPERTY CORRELATIONSHIP IN METALS

Evolution of engineering materials in Products

Evolution of engineering materials in Products

Classification of engineering materials

Metals Ceramics Polymers Composites

Ferrous Metals Crystalline Ceramics Thermoplastics Metal Matrix

Nonferrous Metals Glasses Thermosets Ceramic Matrix

Elastomers Polymer Matrix

 Their chemistries are different, their mechanical and physical

Classification of engineering materials

 There are hundreds of metals which are used in engineering

 Metals used in manufacturing are usually alloys, which are

 Metals are classified into two main groups depending upon

Classification of engineering materials

Classification of engineering materials

 Tensile Strength - The ability of a material to withstand pulling forces.

 Stiffness - The ability of a product to withstand bending.

 Ductility - The ability of a material to be drawn or extruded into a

 Toughness - The ability of a material to resist the propagation of

Classification of engineering materials

 containing 0.02% to 2.11% carbon  iron and carbon (2% to 4%)

 manganese, chromium, nickel, and  Silicon in amounts from 0.5% to 3%),

Classification of engineering materials

 Nonferrous metals include the other metallic elements and their

Classification of engineering materials

 Gray cast iron

Classification of engineering materials

Classification of engineering materials

Classification of engineering materials

 Obtain from white cast iron by annealing process

Nodular Cast Iron

Classification of engineering materials

Classification of engineering materials

Designation of engineering materials

 Normally based on mechanical properties or chemical

 BIS- Beauro of Indian Standard

Designation of engineering materials

Designation of engineering materials

GRAY CI TS 150 N/SQ.MM

IT IS GRAY CAST IRON WITH MIN. TS 150 N/SQ.MM OR MPa

Designation of engineering materials

SG150- Spheroidal graphite with min. TS=150

DESIGNATED BY TENSILE OR YIELD STRENGTH

Designation of engineering materials

K- KILLED AND Fe FOR STEEL i.e. KILLED STEEL

Designation of engineering materials

Designation of engineering materials

0.45 % C, 1.0 % Mn, 0.18 % S

TOOL STEEL CONTAINING 0.1 % C , 0.4 % Mn

Designation of engineering materials

ALLOYING ELEMENTS MULTIPLYI

Designation of engineering materials

LOW ALLOY STEEL 0.4 % C , 1 % Cr, 0.3 % Mo

HIGH ALLOY STEEL 0.15 % C, 25 % Cr, 12 % Ni

STATE THE MEANING OF THE FOLLOWING …

T 70 TOOL STEEL HAVING 0.7 % C

XT 60 W 12 Cr 4 V 1 HIGH ALLOY TOOL STEEL WITH