Master of Engineering

(Mechanical)

MME501: Materials for Engineers

Tutorial

Topic 5
Metals and Alloys

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Topics
1. Metal alloys
2. Structure and properties of iron-based alloys
3. Stainless steel and cast irons
4. Carbon equivalence
5. Aluminum alloys
6. Copper alloys
7. Titanium and refractory materials

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
 Metal Alloys

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Metal Alloys
List four common applications of high carbon steel.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Metal Alloys
List four common applications of high carbon steel.

Answer:
– Cutting tools and dies for forming and shaping materials
– Knives and razors
– Springs
– High-strength wire

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Metal Alloys
Match the alloy with their respective application.
1. Copper
2. Aluminium
3. Magnesium
4. Titanium
5. Stainless steel

a) Packaging
b) Missiles
c) Space applications
d) Automotive exhaust components
e) Bushing
CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Metal Alloys
Answer:
Match the alloy with their respective application.

1) Copper e) Bushing
2) Aluminium a) Packaging
3) Magnesium b) Missiles
4) Titanium c) Space applications
5) Stainless steel d) Automotive exhaust components

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Structure and Properties of Iron-based Alloys

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Structure and Properties of Iron-based Alloys
Relatively soft and weak with outstanding ductility, toughness and is
machinable and weldable.
The above statement refers to which class of steel?

a) Low carbon steel

b) Medium carbon steel
c) High carbon steel
d) Stainless steel

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Structure and Properties of Iron-based Alloys
Relatively soft and weak with outstanding ductility, toughness and is
machinable and weldable.
The above statement refers to which class of steel?

a) Low carbon steel

b) Medium carbon steel
c) High carbon steel
d) Stainless steel

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
Which of these is the most corrosion resistant class of steel?

a) Ferritic
b) Martensitic
c) Austenitic

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
Which of these is the most corrosion resistant class of steel?

a) Ferritic
b) Martensitic
c) Austenitic

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
Stainless Steel Case Study Example 1:
• Stonecutters Bridge Towers Stonecutters Bridge, Hong Kong, is a
cable stayed structure with a total length of 1596 m and a main span
of 1018 m.
• It crosses the Rambler Channel and is the main entrance to the busy
Kwai Chung Container Port.
• The most striking features of the bridge are the twin tapered mono
towers at each end supporting the 50 m wide deck.
• These tapered towers rise to 295 m above sea level; the lower
sections are reinforced concrete while the upper 115 m are
composite sections with an outer stainless steel skin and a reinforced
concrete core.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
Stainless Steel Case Study Example 1:

General view
Mono tower and stay cables

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
Stainless Steel Case Study Example 1:
• The design life of the bridge is 120 years. A highly durable material
was required for the upper sections of the bridge towers because of
the harsh marine and polluted environment.
• Duplex steel 1.4462 (S32205) was chosen as it has high strength (460
N/mm2) with good corrosion resistance and tolerance on surface
finish.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
Stainless Steel Case Study Example 2:
• The Pavilion marks the new western entrance into Regent's Place, a
13-acre development in the heart of London which features retail,
leisure and public spaces.
• It is a structure made entirely of stainless steel in which a field of
vertical columns supports a roof canopy 8 m above street level.
• The pavilion is 20 m by 5 m in plan, with 258 highly slender
rectangular hollow sections supporting a roof plane, reflecting
sunlight during the day and projecting light at night from lights
integrated into the paving.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
Stainless Steel Case Study Example 2:

The Pavilion, Regent’s Place, illuminated View of underside of roof

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
Stainless Steel Case Study Example 2:
• A design life of 50 years was specified for this structure. Initially
carbon steel with a painted or galvanised finish was considered, but
stainless steel was preferred because it provided superior durability
coupled with an attractive appearance.
• Austenitic grades were considered and finally grade 1.4404 (S31603)
was chosen.
• This grade has similar corrosion resistance to 1.4362 in atmospheric
exposure but a lower strength (about 220 N/mm2).

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
Stainless Steel Case Study Example 3:
• The Helix Bridge is a landmark pedestrian bridge in Singapore,
comprising a walkway surrounded by opposing double helix
structures made from stainless steel.
• The design was inspired by the geometric helicoidal arrangement of
DNA, which is seen as a symbol of continuity and renewal.
• The 280 m long bridge is the first double-helix bridge in the world.
• It is a very lightweight structure built almost entirely using duplex
stainless steel.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
Stainless Steel Case Study Example 3:

General view of the Helix Bridge Pedestrian view through the bridge

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
Stainless Steel Case Study Example 3:
• The vast majority of the material used for the bridge, including the
helices and support structures, was duplex stainless steel grade
1.4462 (S31803).
• This grade provides improved mechanical properties compared to
austenitic steels.
• Duplex steels have a 0.2 % proof stress of 450 N/mm2 compared to
220 N/mm2 for austenitic steels.
• Where the strength of duplex steels can be utilized in the design, it
results in more efficient, lightweight and economic structures and can
lead to weight savings compared with carbon steels.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
Stainless Steel Case Study Example 3:
• Duplex steels, in common with the austenitic stainless steels, are
available with a range of durable architectural finishes.
• This steel has excellent long term corrosion resistance and provides
more than adequate resistance while meeting other requirements of
good availability, cost effectiveness, ease of fabrication and
structural/architectural requirements.
• It also provides good fatigue strength as well as high resistance to
stress corrosion cracking.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
Cast Iron Case Study Example
Problem:
• In 1985, the Cast Iron Waterboxes at the San Juan Station of Puerto
Rico Electric Authority, after being subjected to many years of salt
water attack, were corroded to the failure point and were leaking in
numerous areas.
• Replacement of the old waterboxes, if even possible, would take
about 2-3 years, but the power generation was needed immediately.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
Cast Iron Case Study Example
Solution:
• DUROMAR, INC. was contracted to rebuild/reprofile the surface with
their thick film, permeation and abrasion resistant epoxy lining, SAR.
• After completely removing the thick crust of scale and digging out the
graphitized pits, the surface was steamed to remove chlorides, dried
and sandblasted to white metal.
• The rough surface was reprofiled with SAR which in some areas
required over 1″ of material.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
Cast Iron Case Study Example
Solution cont.
• Large sections of the water box severely weakened from metal loss
were reinforced with carbon steel plates glued in with SAR.
• Then the complete surface was covered with additional SAR to a
minimum film thickness of 80 mils DFT.
• To decrease drag and improve impact resistance, a topcoat of high-
performance lining HPL-2510@ 40 mils DFT was added.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
Cast Iron Case Study Example
Results:
• The DUROMAR lining of approximately 120 mils of heavily
filled, SAR and HPL-2510, was found to add considerable strength to
the now thinner cast iron surfaces.
• It has been shown that at this thickness, 1/3 to 1/2 the original
strength can be added back to the lined surface.
• The project was completed on schedule and immediately returned to
service.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
Plain carbon steel is:

a) A steel alloy which contain the plain flake type of carbon

b) A steel alloy which contain very little amount of carbon, typically
less than 0.25% wt
c) A steel alloy in which carbon is the main alloying element and no
or very little alloy residues
d) A type of cast iron which has plain properties

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
Plain carbon steel is:

a) A steel alloy which contain the plain flake type of carbon

b) A steel alloy which contain very little amount of carbon, typically
less than 0.25% wt
c) A steel alloy in which carbon is the main alloying element and no
or very little alloy residues
d) A type of cast iron which has plain properties

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
Other than carbon, the most significant alloying element in tool steels is:

a) Chromium
b) Manganese
c) Vanadium
d) Aluminium

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
Other than carbon, the most significant alloying element in tool steels is:

a) Chromium
b) Manganese
c) Vanadium
d) Aluminium

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
What is true about cast iron?

a) Grey, white, malleable and nodular are some of its variants

b) Has a relatively high melting point compared with plain carbon
steels
c) Generally has a low ductility compared with steel
d) Does not undergo corrosion
e) Has a carbon content more than common steels
f) Is lighter in colour than steels

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Stainless Steel and Cast Irons
What is true about cast iron?

a) Grey, white, malleable and nodular are some of its variants

b) Has a relatively high melting point compared with plain carbon
steels
c) Generally has a low ductility compared with steel
d) Does not undergo corrosion
e) Has a carbon content more than common steels
f) Is lighter in colour than steels

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
 Carbon Equivalence

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Carbon Equivalence
Which of these statements regarding Carbon equivalence is not true?

a) It is an empirical value in weight percent, relating the combined

effects of different alloying elements used in the making of carbon
steels to an equivalent amount of carbon.
b) Carbon equivalent determines the ability to form hard metallurgical
constituents such as martensites or any other hard phases.
c) With the carbon equivalent number, properties of the metal such as
application suitability can be determined.
d) Higher the carbon equivalent value, the slower the cooling rate and
lower the tendency for hard, brittle phases to form during cooling.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Carbon Equivalence
Which of these statements regarding Carbon equivalence is not true?

a) It is an empirical value in weight percent, relating the combined

effects of different alloying elements used in the making of carbon
steels to an equivalent amount of carbon.
b) Carbon equivalent determines the ability to form hard metallurgical
constituents such as martensites or any other hard phases.
c) With the carbon equivalent number, properties of the metal such as
application suitability can be determined.
d) Higher the carbon equivalent value, the slower the cooling rate and
lower the tendency for hard, brittle phases to form during cooling.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
 Aluminium Alloys

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Aluminium Alloys
Aluminium Case Study Example:
Project
• Select the material to use for a 1/2-inch diameter, six-foot-long drive
shaft used to run a power tool attached to one end of a pole assembly.
Description
The main requirements for the shaft material were:
• Yield strength > 30 ksi
• 5 years before failure – corresponds to 3,500 hours actual use
• Lightweight
• Easy to manufacture
• Corrosion resistant
CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Aluminium Alloys
Aluminium Case Study Example:
• Based on these requirements, only aluminum alloys were
considered.
• Steel alloys were not considered because of their weight.
• Copper alloys were not considered because of their weight and cost.
• Though plastics were available that met the yield strength
requirement, there was concern about the ability to obtain uniform
properties in the small shaft splines.

Drive shaft cross-section

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Aluminium Alloys
Aluminium Case Study Example:
• The most cost-effective option to consider was extruded 6061
aluminum in a T6 temper condition.
• The Aluminum Association specification for 6061-T6 requires a
minimum yield strength of 35 ksi.
• 6061 is a commonly extruded alloy that is less expensive to purchase
and easy to extrude compared to other aluminum alloys that meet
the strength requirement.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Aluminium Alloys
Aluminium Case Study Example:
Material Evaluation Process: Part of selecting a material to use for a
component involves the following steps:
– Evaluating prototypes to determine whether the material can meet
the application performance and reliability requirements.
– Evaluating potential suppliers of the component to determine
whether they are capable of producing components that meet the
specifications.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Aluminium Alloys
Aluminium Case Study Example:
Evaluating Prototypes
• Prototype evaluation involved machining 6061-T6 rod stock into shaft
samples.
• Samples were tested using accelerated test conditions to simulate
3,500 hours use.
• Two other aluminum alloys that had higher yield strength than 6061-
T6 were also evaluated, just in case testing indicated that options
were required.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Aluminium Alloys
Aluminium Case Study Example:
Evaluating Prototypes cont.
• The testing revealed that minor changes in the shaft cross-section
dimensions were required to prevent failure before 3,500 hours.
• Also, it was determined that 6061-T6 was suitable.
• Since tooling for the shaft had not begun, the dimension changes
were easy to make.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Aluminium Alloys
Aluminium Case Study Example:
Supplier Evaluation
• Evaluating suppliers did not require obtaining samples of the shaft,
which was a good thing because the tooling needed to make the
shaft would not have been ready until later in the development
cycle.
• Production samples of extruded 6061-T6 components that were
similar to the shaft were obtained from two extrusion companies and
were evaluated to see whether they met the composition and
strength requirements for 6061-T6.
• Metallographic examination of one sample from each supplier was
also performed to verify that the microstructure was correct.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Aluminium Alloys
Aluminium Case Study Example:
• One company’s samples were good and met the strength
requirement and was selected as the product supplier of the shafts.
• Later, when tooling for making the shaft was ready, samples were
made and evaluated composition, strength, and microstructure.
• Based on the results, some minor modifications were made to the
extrusion process to get the desired microstructure and strength.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
 Copper Alloys

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Copper Alloys
Most copper alloys cannot be hardened or strengthened by heat-
treating procedures.

a) True
b) False

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Copper Alloys
Most copper alloys cannot be hardened or strengthened by heat-
treating procedures.

a) True
b) False

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Copper Alloys
Case Study Involving Copper Alloys
• Copper makes vehicles safe and comfortable.
• The cars we see on today’s roads are very different to those being
driven just a decade ago.
• It is also quite likely that the vehicles that will be around in ten years’
time are almost unthinkable today.
• Automotive manufacturers are continually striving to make their
products more fuel efficient and environmentally friendly, more
comfortable and attractive and to add novel features that will inspire
their customers.
• But, they need to achieve all this without adding extra weight.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Copper Alloys
Case Study Involving Copper Alloys
• Brass alloys have been used for decades in the automotive and
industrial equipment sectors.
• However, as the operating temperature of combustion engines has
continued to increase, new alloys are required to deliver the
necessary performance.
• The copper industry has designed an innovative, brass alloy
specifically to meet the high-performance requirements of
automotive and machine building applications.
• It consists of 70% copper along with smaller amounts of manganese,
aluminium, silicon, iron and zinc.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Copper Alloys
Case Study Involving Copper Alloys
• The new alloy offers the potential to realise light weight construction
and space savings, supporting the downsizing trend in automotive
engine technology.
• It has a far better resistance to heat, compared to other competing
materials, and shows no signs of softening even up to 400°C.
• It also has outstanding wear resistance, is more environmentally
friendly, in both production and end-use, but retains the advantages
of other brass alloys, such as superior machinability and workability.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Titanium and Refractory Materials

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Titanium and Refractory Materials
Which of these statements regarding Titanium properties is not true?

a) High melting point

b) High tensile strength
c) Difficult to forge and machine
d) High ductility

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Titanium and Refractory Materials
Which of these statements regarding Titanium properties is not true?

a) High melting point

b) High tensile strength
c) Difficult to forge and machine
d) High ductility

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Titanium and Refractory Materials
Titanium Application Case Study Example 1:
Titanium for bicycles:
Challenge:
• A custom bicycle manufacturer wanted to enhance the cycling
experience for their customers by providing a light-weight, more
durable bicycle frame to withstand diverse terrains.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Titanium and Refractory Materials
Titanium Application Case Study Example 1:
Titanium for bicycles:
Solution:
• Titanium proved to be the optimal material for this innovative
manufacturer to utilize as a component in their bicycle frames.
• The manufacturer is provided with the titanium they need in order to
improve the strength, agility and aesthetics of their high-end bicycles
that are then sold to over 200 retailers nationwide.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Titanium and Refractory Materials
Titanium Application Case Study Example 2:
Titanium Suppressors
Challenge:
• Firearm users shooting with a suppressor were experiencing
suppressor performance failure caused by excessive heat, corrosion,
lack of material strength and excessive weight.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
Titanium and Refractory Materials
Titanium Application Case Study Example 2:
Titanium Suppressors
Solution:
• Shooters needed a lightweight, durable suppressor to improve overall
performance and accuracy.
• The suppressor utilizes titanium baffles providing a light-weight
solution that dramatically increases suppressor performance,
durability, and accuracy.

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
References
• Materials Science and Engineering – William D. Callister and David G.
Rethwisch.com
• Websites:
http://www.steel-stainless.org
http://www.duromar.com/cast-iron-waterbox-rebuild
http://iieng.org/images/proceedings_pdf/8177E0415042.pdf
https://www.imetllc.com/material-selection-for-drive-shaft/
https://copperalliance.org.uk/about-copper/innovating-copper/case-
studies/
https://tmstitanium.com/moving-you-forward/case-studies/

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971
 End of Topic 5
Any questions or comments?

CRICOS Provider Number: 03567C | EIT Institute of Higher Education PRV14008 | RTO Provider Number: 51971