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)
www.google.com 2 www.wikiepedia.com 3
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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
4 www.giessereilexikon.com 13
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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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