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Materials

This document provides an overview of materials used to form final products through classification and manufacturing codes. It discusses the crystal structures and basic metal structures of ferrous and non-ferrous materials. Specific steel grades and their alloying elements are covered, along with the selection of steel grades. The document also summarizes various welding processes, types of welds and joints, elements of welding symbols, weld discontinuities, and destructive and non-destructive testing methods.

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143 views30 pages

Materials

This document provides an overview of materials used to form final products through classification and manufacturing codes. It discusses the crystal structures and basic metal structures of ferrous and non-ferrous materials. Specific steel grades and their alloying elements are covered, along with the selection of steel grades. The document also summarizes various welding processes, types of welds and joints, elements of welding symbols, weld discontinuities, and destructive and non-destructive testing methods.

Uploaded by

horascanman
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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MATERIALS

TO FORM FINAL PRODUCT


CLASSIFICATION:
1. FERROUS MATERIALS
2. NON FERROUS MATERIALS

Crystal Structures
In a solid metal, the atoms tend to align themselves into
orderly lines, rows, and layers to form three dimensional
crystalline structures.
"Unit cell".
Body-centered cubic (BCC),
Face-centered cubic (FCC),
Body centered tetragonal (BCT), and
Hexagonal close-packed, (HCP).

Basic Metal
Structures
I. Simple Cubic

II. Body Centered Cubic

III. Face Centered Cubic

(BCC)

(FCC)

Fe, Cr

Al, Cu, Ni

STEEL MATERIALS
IRON & CARBON
MOST COMMONLY USED
INCREASE HARDNESS , WEAR RESISTANCE ETC.
LOW , MEDIUM, HIGH CARBON
ALLOYING ELEMENTS
ELEMENTS WHICH IS ADDED TO ENHACE THE
PROPERTIES OF THE MATERIAL

MOST COMMON ALLOYING ELEMENTS


1. CARBON
2. MANGANESE
3. CHROMIUM
4. SILICON
5. NICKEL
6. MOLYBDENUM
7. VANADIUM
8. TUNGSTEN
9. COPPER

Manufacturing Codes

I S -Indian Standard
IBR Indian Boiler regulations
BS British Standard
DIN German Standard
JIS - Japan Standard
GHOST Russian Standard
ASME American Society for Mechanical Engineers
ASTM American Society for Testing Materials
AWS American Welding Society

P.No
P1
P3
P4
P5A
P5B
P5B

Material Specification Product


Plate
Pipe
Tube
SA178 Gr.D
Carbon steel SA 515 Gr.60/70
SA 106 Gr.B SA210 Gr.A1
(C,Mn,Si,S,P) SA 516 Gr.60/70
SA210 Gr.C
SA204 Gr.A
0.5%Mo
SA335 P1
SA209 T1
SA204 Gr.B
1.25%cr,
SA387 Gr 11/12 SA 335 P12 SA213 T11
0.5%MO
2.25%Cr,
SA387 Gr22
SA335 P22
SA213 T22
1%Mo
5%Cr,
SA 387 Gr5.Cl.1 SA335 P5
SA213 T5
0.5%Mo
9%Cr,
SA387 Gr.91.Cl2 SA335 P91
SA213 T91
1%Mo,V

Chemical
Composition

Chemical
P.No Composition
P8

P8

Material Specification Product


Plate
Pipe

Tube

18%Cr,8%Ni

SA240Type304
SA240Type304L
SA240Type304H

SA312TP304
SA312Tp304L
SA312Tp304H

SA213TP304
SA213Tp304L
SA213Tp304H

25%Cr,20%Ni

SA240Type310s
SA240Type310H

SA312Tp310S
SA312Tp304H

SA213Tp310S
SA213Tp310H

SA240Type316
16%Cr,12%Ni,2
SA240Type316L
Mo
SA240Type316H

SA312Tp316
SA312Tp316L
SA312Tp316H

SA213TP304
SA213Tp304L
SA213Tp304H

SA240Type321
SA240Type321H

SA312Tp321
SA312Tp321H

SA312Tp321
SA312Tp321H

18%Cr,8%Ni

18%Cr,10%Ni,
P6/P Cb
7
13 % Cr

SA240Type347
SA240Type347H
SA240Type321
SA240Type321H

SA312Tp321
SA312Tp321H
-

SA213Tp321
SA213Tp321H
-

SELECTION OF STEEL GRADES

Strength/ weight ratio.


Cost per mass or per area.
Melting point.
Corrosion and oxidation resistance.
Stress Corrosion.
Corrosion Fatigue.
Compatibility.
Electrical and magnetic properties.
Fabrication properties..
Complexity, section and thickness, weldability.

Miller Electric Mfg. Co.

10

WELDING CLASSIFICATION
1. FUSION WELDING
The surfaces of two components to be joined
are cleaned, placed close together and
heated while being protected from oxidation.
2. SOLID PHASE PROCESS
Friction welding is the main process in this
class and is widely used to join asymmetric
components in two different types of steels.

Types of welding
welding
Solid state welding

1.
2.
3.
4.
5.
6.

Resistance welding
Friction welding
Diffusion welding
Flash welding
Ultrasonic welding
Explosion welding
Consumable
electrode

1.
2.
3.
4.
5.
6.

Gas metal arc welding


Shielded metal arc welding
Submerged arc welding
Flux cored arc welding
Electrogas welding
Electroslag welding

Fusion welding
Chemical energy

Electrical energy

Non consumable
electrode

1. Gas tungsten arc


welding
2. Atomic hydrogen
welding
3. Plasma arc
welding

1. Oxyacetylene welding
2. Oxyfuel gas welding

Other processes

1. Laser beam
welding
2. Thermit welding
3. Electron beam
welding

SHIELD METAL ARC WELDING

GAS METAL ARC WELDING

GAS TUNSTEN ARC WELDING

Types of Welded Joints

Butt joint
Corner joint
Edge joint
Lap joint
T joint

TYPES OF WELDS
1.
2.
3.
4.
5.
6.
7.

GROOVE WELD
FILLET WELD
FLANGE WELD
EDGE WELD
SPOT WELD
SEAM WELD
PLUG WELD

8. SLOT WELD
9. SURFACING WELD
10. BACK WELD
11. BACKING WELD

PARTS OF A GROOVE WELD

PARTS OF A FILLET WELD

ELEMENTS OF WELDING SYMBOLS


1.
2.
3.
4.
5.
6.
7.
8.

REFERENCE LINE
ARROW
BASIC WELD SYMBOLS
DIMENSIONS AND OTHER DATA
SUPPLEMENTARY SYMBOLS
FINISH SYMBOLS
TAIL
SPECIFIC PROCESS

WELDING SYMBOLS

WELD SYMBOLS

WELD DISCONTIUITIES
1.
2.
3.
4.
5.
6.
7.

POROSITY
CRACKS
INCOMPLETE PENETRATION
LACK OF FUSION
UNDERCUTS
INCLUSIONS
SPATTER

TESTING
DESTRUCTIVE TESTING

NON DESTRUCTIVE TESTING

NON DESTRUCTIVE TESTING


REASONS FOR USING NDT
1. ENSURES PRODUCT RELIABILITY
2. CUSTOMER SATISFACTION
3. CONTROLLING MANUFACTURING PROCESS &
COST
4. MAINTAIN UNIFORM QUALITY LEVEL
5. AIDS IN PRODUCT DESIGN
6. SAFETY & PREVENTS ACCIDENTS

NDT APPLICATION
POWER GENERATION
PIPELINE
AUTOMOBILES
AEROSPACE
DEFENCE
REFINERY
SHIPPING ETC.

NDT METHODS
1.
2.
3.
4.
5.
6.
7.

VISUAL TESTING
LIQUID PENETRANT
MAGNETIC PARTICLE
RADIOGRAPHY TESTING
ULTRASONIC TESTING
EDDY CURRENT TECHNIQUES
ACOUSTIC EMISSION TECHNIQUES

VISUAL INSPECTION
APPEARANCE OF THE FINISHED PRODUCT
DETECT SURFACE DISCONTINUITIES
PROCEDURES TO BE FOLLOWED

PENETRANT TESTING
PRINCIPLE
CAPILLARITY & REVERSE CAPILLARITY

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