Materials Science and

Engineering

ME 112 – MSE
Module 10
Applications and Processing of Metals and
Alloys

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Materials Science and
Engineering Modules/chapters
Introduction
Atomic Structure and Interatomic Bonding
The Structure of Crystalline Solids
Imperfections in Solids
Diffusion
Mechanical Properties of Metals
Failure
Phase Diagrams
Phase Transformations: Development of Microstructure
Applications and Processing of Metals and Alloys
Ceramics
Polymers
Composites
Biomaterials/Electronic Materials
Properties of Materials (Electric, Thermal, Magnetic and Optical)
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Materials Science and
Engineering Introduction
➢ Metal alloys, by virtue of composition, are often grouped into two
classes—ferrous and nonferrous.
➢ Ferrous alloys, those in which iron is the principal constituent, include
steels and cast irons
➢ The nonferrous ones—all alloys that are not iron based

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Ferrous alloys—those in which iron is the prime constituent—are produced in

larger quantities than any other metal type. They are essential as engineering
construction materials.

Their widespread use is accounted for by three factors:

(1) iron containing compounds exist in abundant quantities within the Earth’s
crust;
(2) metallic iron and steel alloys may be produced using relatively economical
extraction, refining, alloying, and fabrication techniques; and
(3) ferrous alloys are extremely versatile in that they may be tailored to have a
wide range of mechanical and physical properties.

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Steels: Steels are iron carbon alloys s that may contain appreciable concentrations of
other alloying elements

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Low carbon Steels: contain less than about 0.25 wt% C and are
unresponsive to heat treatments intended to form martensite; strengthening is
accomplished by cold work.

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Materials Science and
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Materials Science and
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Medium carbon Steels: The medium-carbon steels have carbon

concentrations between about 0.25 and 0.60 wt%. These alloys may be heat-
treated by austenitizing, quenching, and then tempering to improve their
mechanical properties.
.
The Society of Automotive Engineers (SAE), the American Iron and Steel
Institute (AISI), and the American Society for Testing and Materials (ASTM)
are responsible for the classification and specification of steels as well as other
alloys.

The AISI/SAE designation for these steels is a four-digit number: The first two
digits indicate the alloy content; the last two give the carbon concentration. For
plain carbon steels, the first two digits are 1 and 0; alloy steels are designated
by other initial two digit combinations (e.g., 13, 41, 43). The third and fourth
digits represent the weight percent carbon multiplied by 100 NITK, Surathkal
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High carbon Steels: The high-carbon steels, normally having carbon contents between 0.60 and
1.4 wt%, are the hardest, strongest, and yet least ductile of the carbon steels.

The tool and die steels are high-carbon alloys, usually containing chromium, vanadium, tungsten, and
molybdenum. These alloying elements combine with carbon to form very hard and wear-resistant
carbide compounds.

These steels are used as cutting tools and dies for forming and shaping materials, as well as in
knives, razors, hacksaw blades, springs, and high-strength wire.

Stainless steel :The stainless steels are highly resistant to corrosion (rusting) in a variety of
environments, especially the ambient atmosphere.

Their predominant alloying element is chromium; a concentration of at least 11 wt% Cr is required.

Corrosion resistance may also be enhanced by nickel and molybdenum additions.

Stainless steels are divided into three classes on the basis of the predominant phase constituent of
the microstructure—martensitic, ferritic, or austenitic
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Cast iron: s Generically, cast irons are a class of ferrous alloys with carbon contents above 2.14 wt%; in
practice, however, most cast irons contain between 3.0 and 4.5 wt% C and, in addition, other alloying
elements.

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Gray iron: The carbon and silicon contents of gray cast irons vary between 2.5 and 4.0 wt% and 1.0 and
3.0 wt%, respectively. For most of these cast irons, the graphite exists in the form of flakes (similar to corn
flakes), which are normally surrounded by an 𝛼-ferrite or pearlite matrix.

Ductile (or Nodular) Iron: Adding a small amount of magnesium and/or cerium to the gray iron before
casting produces a distinctly different microstructure and set of mechanical properties. Graphite still
forms, but as nodules or spherelike particles instead of flakes.

White iron: For low-silicon cast irons (containing less than 1.0 wt% Si) and rapid cooling rates, most of
the carbon exists as cementite instead of graphite. A fracture surface of this alloy has a white
appearance, and thus it is termed white cast iron.

Malleable Iron: Due to large amounts of the cementite phase, white iron is extremely hard but also very
brittle, to the point of being virtually unmachinable. Its use is limited to applications that necessitate a very
hard and wear-resistant surface, without a high degree of ductility—for example, as rollers in rolling mills.
Generally, white iron is used as an intermediary in the production of yet another cast iron, malleable iron

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Materials Science and
Engineering NONFERROUS ALLOYS

Steel and other ferrous alloys are consumed in exceedingly large quantities because they have such a
wide range of mechanical properties, may be fabricated with relative ease, and are economical to
produce. However, they have some distinct limitations, chiefly (1) a relatively high density, (2) a
comparatively low electrical conductivity, and (3) an inherent susceptibility to corrosion in some common
environments.

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Copper and its alloy : Copper and copper-based alloys possessing a desirable
combination of physical properties have been used in quite a variety of applications.

The most common copper alloys are the brasses, for which zinc, as a substitutional
impurity, is the predominant alloying element.

The bronzes are alloys of copper and several other elements, including tin, aluminum,
silicon, and nickel. These alloys are somewhat stronger than the brasses, yet they still have
a high degree of corrosion resistance.

The most common heat-treatable copper alloys are the beryllium coppers. They possess a
remarkable combination of properties: tensile strengths as high as 1400 MPa (200,000 psi),
excellent electrical and corrosion properties, and wear resistance when properly lubricated

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Aluminiun and its alloy: Aluminum and its alloys are characterized by a relatively low
density (2.7 g/cm3 as compared to 7.9 g/cm3 for steel), high electrical and thermal
conductivities, and a resistance to corrosion in some common environments, including the
ambient atmosphere.

Principal alloying elements include copper, magnesium, silicon, manganese, and zinc.

Magnesium and its alloys; The most outstanding characteristic of magnesium is its
density, 1.7 g/cm3 , which is the lowest of all the structural metals; therefore, its alloys are
used where light weight is an important consideration.

Aluminum, zinc, manganese, and some of the rare earths are the major alloying elements

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Refractory Metals: Metals that have extremely high melting temperatures are classified as refractory
metals. Included in this group are niobium (Nb), molybdenum (Mo), tungsten (W), and tantalum (Ta).
Melting temperatures range between 2468°C (4474°F) for niobium and 3410°C (6170°F), the highest
melting temperature of any metal, for tungsten.

The Superalloys :The superalloys have superlative combinations of properties. Most are used in
aircraft turbine components, which must withstand exposure to severely oxidizing environments and
high temperatures for reasonable time periods. These materials are classified according to the
predominant metal(s) in the alloy, of which there are three groups: iron–nickel, nickel, and cobalt.
Other alloying elements include the refractory metals (Nb, Mo, W, Ta), chromium, and titanium.

Noble Metals: The noble or precious metals are a group of eight elements that have some physical
characteristics in common. They are expensive (precious) and are superior or notable (noble) in
properties—characteristically soft, ductile, and oxidation resistant. The noble metals are silver, gold,
platinum, palladium, rhodium, ruthenium, iridium, and osmium.

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Miscellaneous Non ferrous alloy:

Nickel and its alloys are highly resistant to corrosion in many environments, especially those that are
basic (alkaline). Nickel is often coated or plated on some metals that are susceptible to corrosion as a
protective measure. Monel, a nickel-based alloy containing approximately 65 wt% Ni and 28 wt% Cu
(the balance is iron), has very high strength and is extremely corrosion resistant; it is used in pumps,
valves, and other components that are in contact with acid and petroleum solutions.

Lead, tin, and their alloys find some use as engineering materials. Both lead and tin are
mechanically soft and weak, have low melting temperatures, are quite resistant to many corrosion
environments, and have recrystallization temperatures below room temperature.

Zinc alloy : soft metal having a low melting temperature and a subambient recrystallization
temperature.Chemically, it is reactive in a number of common environments and, therefore,
susceptible to corrosion.

Zirconium alloy
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Metal fabrication techniques

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Thank You

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