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OVER VIEW ON METALLIC MATERIALS-1

OVER VIEW ON METALLIC MATERIALS-1. PART 1: PROPERTIES & APPLICATIONS. ALLOY SYSTEMS. STEELS ALUMINUM ALLOYS TITANIUM ALLOYS NICKEL BASE SUPERALLOYS. TYPES OF STEELS. STRUCTURAL STEELS Carbon Steels Free Cutting Steels Case Hardening Steels Spring Steels High Temperature Steels

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OVER VIEW ON METALLIC MATERIALS-1

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  1. OVER VIEW ON METALLIC MATERIALS-1 PART 1: PROPERTIES & APPLICATIONS

  2. ALLOY SYSTEMS • STEELS • ALUMINUM ALLOYS • TITANIUM ALLOYS • NICKEL BASE SUPERALLOYS

  3. TYPES OF STEELS STRUCTURAL STEELS Carbon Steels Free Cutting Steels Case Hardening Steels Spring Steels High Temperature Steels Nitriding Steels Bearing Steels Valve Steels TOOL STEELS Carbon tool steels Shock resisting steels Deep Hardening steels Cold work steels Hot Die Steels File steels HIGH SPEED STEELS Tungsten base Molybdenum base STAINLESS STEELS Austenitic Ferritic and martensitic HEAT RESISTANT STEELS Super Austenitic Super Ferritic SPECIAL STEELS PH stainless steels Maraging steels

  4. ALLOYING ELEMENTS AND IMPURITIES • Any alloy containing Fe & C is called Steel. • Other Alloying elements are Mn, Si, Cr, Mo, Ni, V, W, Al. • Cu, Ti, Nb are added in small quantities. • S, P, AS, Bi and Sb are present as impurities. • Sometimes Sulphur is added intentionally.

  5. EFFECT OF ALLOYING ELEMENTS Contd…

  6. EFFECT OF ALLOYING ELEMENTS Contd…

  7. EFFECT OF ALLOYING ELEMENTS

  8. EFFECT OF IMPURITY ELEMENTS

  9. STEEL GRADES COMPOSITIONS AND APPLICATIONS

  10. STRUCTURAL STEELS • Carbon Steels • Free Cutting Steels • Case Hardening Steels • Spring Steels • High Temperature Steels • Nitriding Steels • Bearing Steels • Valve Steels

  11. PLAIN CARBON STEELS APPLICATIONS Heat treated condition - automotive and general engineering applications; parts requiring better wear resistance such as brakes, camshafts, axles, spring bolts, roller bearing etc. Higher carbon steels - for making fodder cutting blades, knives, plough etc.

  12. FREE CUTTING STEELS APPLICATIONS • Machine parts subjected to comparatively light loads • such as bolts, nuts screws intended for easy machining.

  13. CASE HARDENING STEELS APPLICATIONS Ni free steels are used for medium core strength and wear resistance – piston rings, bushes, drilling machine spindles and general engineering works. Ni containing steels have high tensile strength and toughness of core. Used for components in automobiles and aircrafts and general engineering where blows and shocks are involved. For heavy duty gearing such as transport vehicles and air crafts high Ni steels (>3.5%) are used.

  14. GENERAL HARDENING AND TEMPERING STEELS APPLICATIONS General engineering applications. For parts where high tensile and impact strengths are required such as crank shafts, stub axles, connecting rods etc., Ni, Mo steels are used.

  15. SPRING STEELS APPLICATIONS Spiral , Helical , Torsion, Leaf , volute , plate springs requiring good endurance , bending and fatigue strengths.

  16. HIGH TEMPERATURE STEELS APPLICATIONS Steam boiler plants, super heaters, receivers, superheated steam lines, up to 530-5500 C

  17. NITRIDING STEELS APPLICATIONS Construction members with high surface wear resistance; small ruling sections such as bolts, needle beds, precision measuring tools; parts of higher ruling section-cams, crank shafts, worms, big measuring tools.

  18. BEARING STEELS APPLICATIONS Balls, rollers, cylinders, races etc

  19. VALVE STEELS Surfaces nitrided for good wear resistance APPLICATIONS Scaling resistant, suitable for outlet and inlet valves in aircraft and high duty engines

  20. TOOL STEELS • Carbon tool steels • Shock resisting steels • Deep Hardening steels • Cold work steels • Hot Die Steels • Die block steels • File steels

  21. CARBON TOOL STEELS APPLICATIONS Heavy Forge hammers, sledge hammers, blanking tools, dies blacksmith, chisels, Scissors knife blades, hot and cold trimming tools, threading tools, cutting dies, milling cutters, boring tools taps, threading dies etc.

  22. HOT WORK STEELS APPLICATIONS Heavy duty hot work tools, Extrusion mandrel dies, hot impact extrusion tools, forming dies, die inserts, hot shear blades etc. Austenitic PH steel of high strength used for extrusion dies.

  23. COLD WORK STEELS APPLICATIONS Highly wear resistant application such as spinning tools, bending rolls, punches and dies, spiral drills, center bits, cold upsetting and cold extrusion tools, Drawing tools, engraving tools, press tools, cold punches, knives, milling cutters, taps, Hacksaw blades, reamers etc.

  24. HOT DIE STEELS APPLICATIONS Very tough coining tools used for manufacturing cutlery and plastic moulding

  25. HIGH SPEED STEELS • Molybdenum base • Tungsten base

  26. HIGH SPEED STEELS MOLYBDENUM BASED APPLICATIONS Excellent cutting efficiency & tough. Twist Drills, Taps, Profile Tools, Milling Cutters, Cold work tools and tool bits.

  27. HIGH SPEED STEELS TUNGSTEN BASED APPLICATIONS Milling cutters, Taps, twist Drills, Reamers, Planning tools. High strength and hard steels. 

  28. STAINLESS STEELS • Austenitic • Ferritic and martensitic

  29. STAINLESS STEELSAUSTENITIC APPLICATIONS Corrosion resistant, cold hardened, utensils, lining food processing industry, dairies and breweries, chemical industries, blunt surgical instruments (Good deep drawability) photo & film industry, Textile industry etc. 

  30. STAINLESS STEELSFERRITIC& MARTENSITIC APPLICATIONS Ferritic steels used for spoons, forks, cutlery, steam turbine shafts, axles, screws, bolts, nuts, which are non-heat treatable.  Martensitic steels used for corrosion resistant cutting tools, surgical instruments, knives, meat mincing components, needle valves, nozzle blades.

  31. HEAT RESISTANT STEELS • Super Austenitic • Super Ferritic

  32. SUPER AUSTENITIC STEELS APPLICATIONS Requiring resistance to pitting corrosion . Rails, rams, roller axles, shafts, super heater suspensions, burner nozzles, valves, spindles, thermo couple protectors, nuts, rivets

  33. SUPER FERRITIC STEELS APPLICATIONS Food handling equipment, heat exchangers, piping systems, furnace parts, automobile exhausts etc.

  34. SPECIAL STEELS • PH Stainless steels • Maraging steels

  35. PH STAINLESS STEELS APPLICATONS Jet engine parts like turbine buckets, discs fasteners, undercarriage parts, honeycomb panels ,chemical equipment, fluid control systems etc.

  36. MARAGING STEELS APPLICATIONS Landing gears, rocket motor cases, engine shafts, cams , pistons, clutch discs, hot forging dies, springs, cold heading dies, gear box etc.

  37. STRENGTHENING PRECIPITATES

  38. ALUMINIUM ALLOYSCOMPOSITIONSPROPERTIES

  39. CLASSIFICATION WROUGHT ALLOYS CAST ALLOYS 1xx.x : Pure aluminium 2xx.x : copper principal alloying element+ other alloying elements like Si, Mg,Mn etc 3xx.x : Si principal alloying element +others like Cu, Mg etc. 4xx.x : Si principal alloying element 5xx.x: Mg principal alloying element 6xx.x : not used 7xx.x : Zn principal alloying element+ other alloying elements like Cu, Mg ,Cr, Zr etc. 8xx.x : Sn principal alloying element • 1xxx : Pure aluminium • 2xxx : copper principal alloying element+ other alloying elements like Si, Mg, Mn etc • 3xxx : Mn principal alloying element • 4xxx : Si principal alloying element • 5xxx: Mg principal alloying element • 6xxx : Mg + Si principal alloying elements • 7xxx : Zn principal alloying element+ other alloying elements like Cu, Mg, Cr, Zr etc

  40. AGE HARDENABLE ALLOYS

  41. SOLID SOLUTION ALLOYS

  42. SOLID SOLUTION STRENGTHENING IN AL ALLOYS Effect of Solute Concentration on Yield Strength

  43. MECHANICAL PROPERTIES OFSOME Al ALLOYS

  44. EFFECT OF ALLOYING ELEMENTS Cu : One of the most important alloying additions. Appreciable solubility. Strengthening through solution treatment and aging when added as principal alloying element, and through solid solution strengthening in secondary additions Mn:It has limited solubility. It is added in the limit of about 1% in non heat treatable wrought alloys(3xxx). It is used as supplementary addition in both heat treatable and non heat treatable alloys Mg:Provides substantial strengthening and improvement of work hardening characteristics of Al. High solubility in solid solution but not amenable to heat treatment. Zn:Zn is added in conjunction with Mg in wrought alloys to make it suitable for heat treatment(7xxx). Mg produces the highest solid solution strength among all Al alloys Contd…

  45. EFFECT OF ALLOYING ELEMENTS Si:It lowers the melting point and increases fluidity of Al. Some increase in strength is also achieved Mg+Zn :Mg and Zn are added in appropriate proportions to form Mg2Si precipitate which is the basis for age hardening in both wrought(6XXX) and cast(3XXX) alloys. Sn : Improves the anti friction characteristics of Al. Cast Al-Sn alloys(8XX.X) alloys are used for bearings. Li : added to some Al alloys in concentrations approaching 3wt% to decrease density and increase elastic modulus. Eg. Al-Cu-Li alloys (2091) , Al-Cu-Li-Mg alloys(8090).

  46. TITANIUM AND ITS ALLOYS • Introduction • Extraction and melting of titanium • Classification of titanium and its alloys • α+β titanium alloys • β titanium alloys • Properties of titanium alloys

  47. APPLICATIONS

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