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Lecture 5 - Processing of Automotive Materials

This document provides an overview of automotive materials and manufacturing processes. It discusses the extraction and manufacturing of common metals used in automobiles like iron, steel, and cast iron. It also covers the processing of other materials like polymers, glass, and composites. Key manufacturing techniques covered include heat treatment processes for metals, sheet metal stamping, welding, and forming composite parts. The document is a useful reference for the various materials and processing methods involved in automotive manufacturing.

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Kamal Suren
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149 views34 pages

Lecture 5 - Processing of Automotive Materials

This document provides an overview of automotive materials and manufacturing processes. It discusses the extraction and manufacturing of common metals used in automobiles like iron, steel, and cast iron. It also covers the processing of other materials like polymers, glass, and composites. Key manufacturing techniques covered include heat treatment processes for metals, sheet metal stamping, welding, and forming composite parts. The document is a useful reference for the various materials and processing methods involved in automotive manufacturing.

Uploaded by

Kamal Suren
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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5501ICBTAE

Automotive Materials & Manufacturing Processes

Lecture 5-Processing of
Automotive Metals
EXTRACTION / MANUFACTURING OF AUTOMOBILE MATERIAL

Common iron ores include:

Hematite - Fe2O3 - 70 % iron ( a common iron ore)

Magnetite - Fe3O4 - 72 % iron


Limonite - Fe2O3 + H2O - 50 % to 66 % iron Siderite - FeCO3 -
48 percent iron
2 C(s) + O2(g) → 2 CO(g)
Fe2O3 + 3CO → 2Fe+3CO2
• Iron-making in a Blast Furnace
•Blast furnace- a refractory-lined chamber with a diameter of about 9 to 11 m (30 to 35 ft) at its widest and a
height of 40 m (125 ft)
• To produce iron, a charge of ore, coke, and limestone are dropped into the top of a blast furnace
• Hot gases are forced into the lower part of the chamber at high rates to accomplish combustion and reduction of
the iron,
Iron Ore Mine

Iron Ore crushing plant


Making iron – Blast Furnace << https://www.youtube.com/watch?v=8sPYEClAb80 >>
Ferrous metals
Wrought Iron
• Has very low strength and low hardness.
• Very ductile and resistant to corrosion.
• Carbon = 0.020%, Silicon = 0.120%, Sulphur =
0.018%, Phosphorus = 0.020%, Slag = 0.070%,
and the remaining is iron.(99.5%)

•Applications:- Sheeting for ships, water


and steam pipes and decorative items
Cast Iron

• Contains about 2% to 6% C and small amount of Si.


Other alloying elements are also contained.
• There are types of cast iron as gray, white,
malleable, ductile and special alloy

Properties:
Lower melting point
Low shrinkage and good fluidity and casting ability
Excellent machinability
High wear resistance
Cast Iron

Application:-
• Car parts – cylinder heads, blocks and gearbox cases
• Because of its high damping capacity and compressive strength, it
is used for frames of large equipment and machinery.
• Because of its good resistance to wear, it is used for engine
blocks, piston rings, brake drums, rolls and crushers
Steel

• Steel is a material composed primarily of iron(Fe)


• Most steel contain more than 90% of iron.
• All type of steel contain a second element of C
• Many other alloying elements are used in most steel, but iron (Fe)
and C are the only elements found in all steels.
• The percentage of C in steel ranges from just above 0% to
approximately 2%.
• However most steel has between 0.15% and 1% of carbon.

Steel Manufacturing - Including Blast Furnace and BOS - YouTube


Major types of steel
Steel

Carbon Other
Alloy steel Stainless
steel Tool steel steel
steel

Low
carbon
Medium
carbon
High
carbon
Microstructure behavior of steel and Cast iron

In steel, Iron dissolves Carbon

In gray cast iron, C precipitate out as small In ductile cast iron, the dissolved C
carbon flakes precipitates as small round nodules
Low Carbon Steel

➢Most abundant grade of steel is low carbon steel –


greatest quantity produced; least expensive.
➢Not responsive to heat treatment; cold working
needed to improve the strength.
➢Good Weldability and machinability. low
hardenability
Medium Carbon Steel
➢Carbon content in the range of 0.3 – 0.6%.
➢Medium carbon steels have low hardenability
➢Addition of Cr, Ni, Mo improves the heat treating
capacity
➢Heat treated alloys are stronger but have lower
ductility
Applications – Railway wheels and tracks, gears,
crankshafts.
High Carbon Steel
➢High carbon steels – Carbon content 0.6 – 1.4%
➢High C content provides high hardness and
strength. Hardest and least ductile.
➢Strong carbide formers like Cr, V, W (Tungsten) are
added as alloying elements to from carbides of
these metals.

Application:

➢Used as tool and die steels owing to the high


hardness and wear resistance property
Tool steel
• Tool steel is a high carbon alloy steel that has ideal characteristics
including high hardness, abrasion resistance, a good ability to
retain its shape, even in higher temperatures
Alloy steel
Corrosion resistance
Easy to fabrication
High thermal conductivity
Stainless steel
• Extremely corrosive resistant
• Cost more than carbon steel
• Harder to cut and machine
• Use commonly to meet special sanitation
requirements, transfer chemical through pipes
• Contains of high quantities of chromium and many
types contain high quantities of nickel alloys
Heat Treatments of Alloys (Steel)
Heat treatment is defined as “the process of heating and cooling of solid steel
under carefully controlled conditions”.
During heat treatment certain physical properties are altered without changes
in chemical composition.

Purpose of Heat treatment:


• Improvement in magnetic and electrical
properties.
• Refinement of grain structure.
• Removal of imprisoned trapped gases.
• Removal of internal stresses.
• Improves fatigue and corrosion
resistance.
AUTOMOTIVE MATERIALS AND MANUFACTURING PROCESSES-AE--ICBT-2021
Heat treatment processing methods for steel

Heat treatment processes for Ion-Carbon phase diagram


Types of Heat Treatment of Alloys (Steel)
1) Annealing:

• It is done by heating the metal to high temperature followed by slow cooling in a


furnace. Annealing is also known as softening.
• Purpose of annealing:
❑ It increases the machinability.
❑ It also removes imprisoned
gases.
Types of annealing:
Annealing can be done in two ways
1. Low temperature annealing or process annealing
It involves heating the steel to a temperature below the lower critical temperature followed by
slow cooling.

2. High temperature annealing or full annealing


It involves heating the steel to a temperature above the highest critical temperature and holding
it at that temperature for sufficient time to allow the internal changes to take place and then
cooled to room temperature.
AUTOMOTIVE MATERIALS AND MANUFACTURING PROCESSES-AE--ICBT-2021
Effects of Annealing Temperature on Alloy
2) Hardening or Quenching:
It is the process of heating steel beyond the critical temperature and then suddenly cooling it
either in oil or brine-water or some other fluid. Hardening increases the hardness of steel.
The faster the rate of cooling harder will be the steel produced.
Purpose of Hardening:
• Increases the resistance to wear, ability to cut other metals and strength.
• Increase in abrasion resistance, so that it can used for cutting tools.
https://www.youtube.com/watch?v=c39CeMRc6Gg

3) Tempering:
It is the process of heating the already hardened steel to a temperature lower than its own
hardening temperature and then cooling it slowly.
Purpose of Tempering:
• It removes any stress and strain that might have developed during quenching.
• It reduces the brittleness and some hardness, ductility, and toughness are simultaneously
increased.
Cutting-tools like blades, cutters, tool-bites always require tempering.

AUTOMOTIVE MATERIALS AND MANUFACTURING PROCESSES-AE--ICBT-2021


4) Normalizing:
It is the process of heating steel to a definite temperature (above its higher critical temperature) and allowing
it to cool gradually in air.
Purpose of Normalizing:
• It refines grains.
• It removes internal stresses.
• It increases the toughness.
• Normalized steel is suitable for use in engineering work.

5) Carburizing:
A mild steel article is taken in a cast iron box containing small pieces of charcoal (carbon material).
It is then heated to about 900 to 950⁰C and kept for sufficient time, so that the carbon is absorbed to the required
depth. The article is then allowed to cool slowly within the iron box itself.
The outer skin of the article is conveíted into high carbon steel containing about 0.8-1.2%
carbon.
Purpose of Carburizing: To produce a hard-wearing surface on steel article.

6) Nitriding:
Similar to carburizing, nitriding is the process of heat treatment of alloys in presence of ammonia at a temperature
of about 550⁰C. The nitrogen (obtained by the dissociation of ammonia) combines with the surface of the alloy to
form hard nitride.
Puípose of Nitriding: To get super-hard surface

AUTOMOTIVE MATERIALS AND MANUFACTURING PROCESSES-AE--ICBT-2021


Sheet metal material assembled together to
manufacture a vehicle body.
Body panels, doors, hoods, floor pans and other parts
are stamped out of sheet metal

Fully automated transfer presses cut out blanks from


the metal sheets.

Laser welding consists in assembling metal sheets


each having a different thickness or strength, into one
part.

Dies are used in heavy duty stamping machines to


shape the metal, trim excess, bend edges and pierce
holes.
Types of Polymers
Automotive glass manufacturing Process
<< https://www.youtube.com/watch?v=-UzruiYwCcc>>
Automotive Hybrid batteries manufacturing process
Automotive Hybrid batteries manufacturing/ Recycling process
Processing of Composites
• A variety of methods for producing composite parts are used,
depending on the application and materials.
• Short fiber-reinforced composites are normally formed by mixing the
fibers with a liquid or plastic matrix, then using relatively
conventional techniques such as injection molding for polymer-base
composites or casting for metal-matrix composites.
• Polymer matrix composites can also be produced by a spray-up
method, in which short fibers mixed with a resin are sprayed against
a form and cured.
Hand Layup
https://www.youtube.com/watch?v=bLyjhLBTcFw

Spray up
https://www.youtube.com/watch?v=0iYnfglPkkU
Transfer Molding
What are the applications
of Composites????
30

Thank you!

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