Engineering materials and

their applications

Group no. 3:
Sayali Shinde - 3754
Vaishnavi Shinde - 3755
Krushna Sisodiya - 3757
 1.CAST IRON
• Alloy of iron and carbon,containing more than 2% of carbon.
• Composition:
1. Carbon: 3-4%
2. Silicon: 1-3%
3. Manganese: 0.5-1%
4. Sulphur , Phosphorus: up to 0.1%
5. Remaining Iron.
• PROPERTIES:
1. Available in large quantities & is produced on a large scale
2. Higher compressive strength.
3. Excellent ability to damp vibrations.
4. More resistance to wear even under the conditions of boundary
lubrications.
5. Low notch sensitivity.
• STRUCTURE: It have matrix structure which may be established either
during cooling from the molten state or as a result of heat treatment.
ADVANTAGES

• It has good casting properties

• It can be given any complex shape and size without using costly machining operations.
• It has three to five times more compression strength compared to steel
• It has good Sensibility
• It has constant Mechanical properties between 20 to 350 degree Celsius
• It has Low stress concentration
• It bears Low cost
• It is Durability

Disadvantages of cast iron

• It is Prone to rusting
• It has poor tensile strength , impact resistance
• Compared to steel it has poor machine ability
• It has High weight to strength ratio
• It has High brittleness

Applications of cast iron

• It is used in making pipes, to carry suitable fluids

• It is used in making different machines , automotive parts
• It is used in making pots pans and utensils
• It is used in making anchor for ships.
• Gray Cast Iron: Cast iron which contain carbon in free form,
known as Gray cast iron
• White Cast Iron: Cast iron in which carbon is present in
combined form or in carbide form known as white cast iron.
• Malleable Cast Iron: This cast iron is obtained from white cast
iron by heat treatment process. It is mostly obtain by annealing of
white cast iron.
• Nodular Cast Iron: It is also known as ductile or high strength
cast iron. It has high strength.
• COMPOSITION :
 2.Plain Carbon Steel

Depending upon percentage of

cabon, plain carbon steel is classified as:
1. Low Carbon Steel : 0.15-0.30% C
2. Medium Carbon Steel: 0.30-0.80%C
3. High Carbon Steel: 0.80-1.5% C
In addition to carbon, these steels also contain upto 1%
manganese, phosphorus upto 0.5%, sulphur upto 3% and
silicon upto 0.03%.
❑Properties and Uses:
(i) Low Carbon Steel: It possesses good formability and
weldeability but lacks in hardness. It is used in making nuts,
bolts, sheets, tubes and machine components not requiring
much high strength. It is also used in making beams and
channels.
(ii) Medium Carbon steel: It has higher strength than low
carbon steel and is harder due to increased content of
carbon. Its properties can be improved by heat treatment
processes and hence is very popular. It is used for making
machine parts such as gears, axles, crank-shafts and parts for
metal working mahinery.
(iii) High Carbon Steel: It has low toughness and formalibility
but hardness and wear resistance are high. It is used generally
for making parts such as cutting tools, cables, springs,etc.
 Guidelines for deciding carbon
content in plain carbon steel:
• Lower the percentage of carbon, higher is the percentage
of elongation or ductility. Eg. Automobile bodies
• In machine tools, spindles and transmission shaft the
surface is heavily stressed while the stress in core has small
magnitude. i.e they require soft core and hard surface
• Spring wires are subjected to severe stress and strength i.e
they require maximum tensile strength
• Higher the percentage of carbon, more difficult it is to weld
• Higher the percentage of carbon, more difficult it is to forge
the part. Eg. Levers, rocker arm, yoke or tie rod
• All steels have essentially same modulus of elasticity. If
rigidity is required they perform equally well, here least
costly steel is selected
❑ Application of Plain Grade Tensile
Strength
Yield
Strength
Hardnes
s
Elongatio
n
Carbon Steel are: (Min.) (Min.) (HR) (%)
(N/mm2) (N/mm2)
▪ 7C4 : Automobile bodies and
hoods
7C4 320 - - 27
▪ 10C4 : Cam and cam shaft,
sprocket and spindle ,etc. 10C4 340 - - 26
▪ 30C8 : Socket, tie rod, yoke, 30C8 500 400 179 21
lever and rocker arm
▪ 40C8 : transmission shaft, crank 40C8 580 380 217 18

shaft, spindle, stud and bolt 45C8 630 380 229 15

▪ 45C8 : transmission shaft,
50C4 660 460 241 13
machine tool spindle, bolt and
gear of large dimension 55C8 720 460 265 13
▪ 50C4 : Transmission shaft, 60C4 750 - 255 11
worm, gear and cylinder
▪ 60C4 : Machine tool spindle, 65C6 750 - 255 10

hardened bolt and pinion

▪ 65C6 : Coil and leaf spring
 Alloy Steel
Alloy is defined as carbon steel to which one or
more alloying elements are added
to obtain certain beneficial effects.

•Alloy steels are low alloy

steel containing 1-4% alloying element.
•Stainless and heat resisting steels
are called high alloy steel
Advantages of Alloy Steels:
• High strength, hardness and toughness
• High hardenability, which is important in heat
treatment of components
• Retain their strength and hardness at elevated
temperatures
• Higher resistance to corrosion and oxidation
Effect of major alloying element:
• Silicon
• Manganese
• Nickel
• Chromium
• Tungsten
• Molybdenum
Guidelines for selecting alloy steels are follows:

• Spring wires are subjected to severe stress and strength.

Silicon increases strength. Eg. 55Si7
• In highly stressed screw, bolts and axles high strength and
toughness is required. Nickel increases strength and
toughness without loss of ductility. Eg. 40Ni14
• In gear, surface hardness, wear resistance, response to heat
treatment is important consideration. Chromium increase
hardness and wear resistance. Eg. 40Cr4
• In gears, cam, camshafts, transmission shaft combined
properties like hardness, toughness, strength and ductility
are required which are achieved by nickel and chromium as
alloying element. Eg. 16Ni3Cr2
 B.I.S. Designation of Steels
Steel are Designated by a group of letters or number
indicating :
1. Tensile strength
2. Carbon content
3. Composition of alloying elements
Examples- Fe 360, FeE 250
• Plain Carbon steel-
55 C 4 (0.55%C and0.4%Mn)

• Unalloy Free Cutting Steel-

25C12S14 (0.25%Carbon, 1.2% Mn and 0.14% S)
20C12Pb15(0.20%Carbon,1.2% Mn,0.15%Pb)
• Low and Medium alloy steel is used for containing total
alloying element <10%
Elements Multiplying Factor
Cr, Co, Ni, Si and W 4
Al, Be, V, Pb, Cu, Nb, Ti, Ta, Zr and Mo 10
P, S, N 100

Example- 25Cr4Mo2 (0.25%C, 1% Cr, 0.2%Mo)

40Ni8Cr8V2(0.40%C, 2%Ni, 2%Cr, 0.2%V)

• High alloy Steel is used For containing total alloying

elements >10%
Example- X15Cr25Ni12 (0.15%C, 25%Cr, 12%Ni)
X20Cr18Ni2 (0.20%C, 18%Cr, 2%Ni)
 Aluminium Alloy
• Advantages - Low specific gravity
Corrosion Resistance
Ease of Fabrication
High thermal conductivity
• Types Of Aluminium alloy:
1) Wrought Aluminium alloy
2) Cast Aluminium Alloy

• Designation System
Cast Al alloy by 4 Digit and Wrought al alloy by 5 Digit
Example- 9.8%Cu, 1.0%Fe,0.25%Mg
1. Identification of Cu-2
2. Average percetage alloying element-(9.8/2=4.5~5)
3. Identification of Fe-8
4. Identification of Mg-5
Designation : 2585
Applications:
❑ Cast Aluminium Alloy
• Alloy 4450: Engine cylinder block
• Alloy 4600: Pump Casting
• Alloy 2280: Connecting rod, Flywheel
• Alloy 2285: piston, cylinder Head

❑ Wrought Aluminium Alloy

• Alloy 54300: Welded structure, Tank
• Alloy 74530: Welded Pressure vessels
• Alloy 2534: Stressed components of aircraft
 Copper Alloys
• Copper has excellent thermal and electrical conductivity.
Easily Cast, machined and Brazed

• Types
❑Brass:- Alloy of Copper and Zinc(best proportion30%)
▪ Advantages –high Tensile strength, cheaper, Excellent
corrosion resistance ,Better machinability , Good Thermal
Conductivity
▪ Application-tubes for condenser and Heat exchanger, rivets,
valve stem, bellow spring
❑ Bronze:- alloy of copper and elements other than zinc
▪ Types –
i. Aluminium bronze(5-10% Al)
ii. Phosphorous Bronze(0.2%)
iii. Tin bronze(18%Sn)
▪ Advantages:
Excellent corrosion resistance , low coefficient of friction high
tensile strength
❑Gun metal –alloy of copper 10% tin and 2% zinc
▪ Applications: Used for bearings
❑Monel metal –alloy of copper(32%) and nickel (65%)
▪ Advantages: Excellent corrosion resistance to acid,s
alkalis,brine water,sea water and other chemicals
▪ Applications: Used for handling H2SO4 and HCL, pump and
Valves