Properties and Applications of Metals and Alloys

Transcription

1 ENGINEERING MATERIALS Properties and Applications of Metals and Alloys C.P. Sharma

2 ENGINEERING MATERIALS Properties and Applications of Metals and Alloys C.P. SHARMA Department of Metallurgical Engineering Malaviya National Institute of Technology Jaipur (Rajasthan) Delhi

3 ENGINEERING MATERIALS Properties and Applications of Metals and Alloys C.P. Sharma 2004 by PHI Learning Private Limited, Delhi. All rights reserved. No part of this book may be reproduced in any form, by mimeograph or any other means, without permission in writing from the publisher. ISBN The export rights of this book are vested solely with the publisher. Third Printing August, 2007 Published by Asoke K. Ghosh, PHI Learning Private Limited, Rimjhim House, 111, Patparganj Industrial Estate, Delhi and Printed by Mohan Makhijani at Rekha Printers Private Limited, New Delhi

4 Contents Preface List of Figures List of Tables vii ix xi Chapter 1 INTRODUCTION TO ENGINEERING MATERIALS Introduction Elements Engineering Materials Classification of Engineering Materials Properties of Materials Materials Selection 8 Question Answer 8 Chapter 2 CARBON STEELS Introduction Plain Carbon Steels Classification of Carbon Steels Types of Steel Killed, Semikilled and Rimmed Steels Wrought and Cast Steels Effect of Minor Elements on Steel Properties Effect of Carbon on Properties of Steel Specifications for Steels AISI/SAE Specifications British Specifications Indian Specifications 24 Question Answer 27 Chapter 3 ALLOY STEELS Introduction Alloying Elements In Steels Effect of Alloying Elements Classification of Alloy Steels 50 iii

5 iv CONTENTS 3.5 Miscellaneous Alloy Steels Chromium Steels Manganese Steels Molybdenum Steels Nickel Steels Silicon Steels Nickel-Chromium Steels Nickel-Chromium-Molybdenum Steels Nickel-Chromium-Vanadium Steels Chromium-Molybdenum Steels Chromium-Vanadium Steels Silicon-Manganese Steels Structural Steels Spring Steels Ball Bearing Steels Case Hardening Steels High Strength Low Alloy Steels Dual-phase Steels Low Temperature Steels Valve Steels Hadfield Steel Stainless Steels Maraging Steels Tool Steels 61 Question Answer 62 Chapter 4 CAST IRONS Introduction Gray Cast Iron White Cast Iron Nodular Cast Iron Malleable Cast Iron Meehanite Compacted Graphite Cast Iron Alloying Elements in Cast Irons Carbon Silicon Manganese Sulphur Phosphorus Chromium Nickel Molybdenum Copper Vanadium 104

6 CONTENTS v 4.9 Alloy Cast Irons Silal Nicrosilal High Silicon Irons Ni-resist Cast Irons Ni-hard Irons High Chromium Cast Irons 108 Question Answer 108 Chapter 5 LIGHT METALS AND ALLOYS Introduction Aluminium Alloying Behaviour of Aluminium Classificiation of Aluminium Alloys Designation of Aluminium Alloys Characteristics of Aluminium Alloys Magnesium Magnesium Alloys Beryllium Beryllium Alloys Titanium Alloying Elements in Titanium Titanium Alloys 143 Question Answer 145 Chapter 6 COPPER AND ITS ALLOYS Introduction Commercial Grades of Copper Blister Copper Electrolytic Copper Electrolytic Tough Pitch Copper Oxygen-free High Conductivity Copper Copper Alloys Brasses Bronzes Copper-Nickel Alloys 170 Question Answer 171 Chapter 7 NICKEL, COBALT AND THEIR ALLOYS Nickel Nickel Base Alloys Nickel-Copper Alloys Nickel-Chromium Alloys Nickel-Molybdenum Alloys Nickel-Iron Alloys 188

7 vi CONTENTS 7.3 Cobalt Cobalt Base Alloys 189 Question Answer 189 Chapter 8 WHITE METALS AND THEIR ALLOYS Introduction Zinc Cadmium Lead Tin 204 Question Answer 204 Chapter 9 REFRACTORY METALS AND ALLOYS Question Answer 212 Multiple Choice Questions Appendices Index

8 Preface Materials have always been the necessity of man. In fact, civilization of mankind is the story of development of materials, which is why materials are considered to be the building blocks for all technological advances. During the last century, tremendous developments have taken place in understanding and analyzing the structure-property correlation for almost all types of materials from metals, wood, ceramics, to semiconductors, polymers and composites. These developments have eased the task of materials designers and engineers who need to choose the right material for an engineering application, after analyzing the properties as well as behaviour and performance of the material during manufacturing processes. Hence, unlike in the past, it has become essential for all engineering graduates to undergo a basic course in materials in order to understand their nature, properties and applications which are influenced to a great deal by the structure of materials. Organized into nine chapters, the book deals with the fundamentals of metallic materials and presents the metallurgy of a large number of metals and alloys used in engineering design in a simple and logical manner. It exposes the reader to the inherent characteristic properties of metals and then goes into the details of the applications and manufacture. The distinctive feature of the book is that it discusses relationships between the physical metallurgy of metals and their engineering applications, through a large number of questions and answers given at the end of the related chapters. These questions are framed on the same pattern of the university examinations, and thus cater to the needs of students who generally find it difficult to format compact and to-the-point answers. The multiple-choice questions further aid the students to prepare for competitive examinations. To make the book useful and interesting, the text is supplemented with eight appendices that include conversion of units and various AISI/SAE steel compositions. Though the book is primarily intended for students of metallurgical engineering, it will be of great help to students pursuing various engineering as well as polytechnic courses and to the practising engineers dealing with materials. I am greatly indebted to my teacher Prof. T.V. Rajan, Emeritus Fellow for his constructive suggestions, and my friend, Dr. A.K. Bhargava for his support and encouragement. I wish to thank Mr. Ashish Dutt Sharma, Mrs. Sunita Sharma and their enthusiastic team for their help in giving the manuscript its final shape. I express my sincere gratitude to my wife Usha, and my children, vii

9 viii PREFACE Avantika, Anu Ayam, son-in-law, Anand and granddaughter, Avni Sharma who had shown great patience while I worked on the book. Finally, I appreciate the dedicated efforts of the members of Prentice-Hall of India, for their help in steering the publication process in a timely manner. C.P. SHARMA

10 List of Tables Table 1.1 Some Important Properties of Materials 5 Table 1.2 Structure-sensitive and Structure-insensitive Properties 6 Table 1.3 Definition of Some Mechanical Properties 6 Table 1.4 Description of Some Physical Properties 7 Table 2.1 Microconstituents in Iron-Cementite Binary System 15 Table 2.2 Important Temperatures and Compositions in Iron-Cementite Binary System 15 Table 2.3 AISI/SAE Designation for Steels 24 Table 2.4 Symbols Exhibiting Specific Characteristics 25 Table 2.5 Multiplying Factors for Indian Designation of Alloy Steels 26 Table 2.6 Indian Designation for Some Steels 27 Table 3.1 Solid Solubility of Some Elements in Alpha- and Gamma-iron 44 Table 3.2 Effects of Alloying Elements in Steels 44 Table 3.3 Amounts of Some Elements for Stabilization of Ferrite 46 Table 3.4 Amounts of Elements for Elimination of Austenitic Region 46 Table 3.5 Compositions of Some Chromium Steels 51 Table 3.6 Compositions of Some Manganese Steels 52 Table 3.7 Compositions of Some Molybdenum Steels 52 Table 3.8 Compositions of Some Nickel Steels 53 Table 3.9 Compositions of Some Silicon Steels 53 Table 3.10 Compositions of Some Nickel-Chromium Steels 54 Table 3.11 Compositions of Some Nickel-Chromium-Molybdenum Steels 55 Table 3.12 Compositions of Some Chromium-Molybdenum Steels 55 Table 3.13 Compositions of Some of Chromium-Vanadium Steels 56 Table 3.14 Compositions of Some Silicon-Manganese Spring Steels 56 Table 3.15 Compositions of Some Low Alloy Spring Steels 57 Table 3.16 Compositions of Ball Bearing Steels 58 Table 3.17 Compositions of Some Flame and Induction Hardening Steels 59 Table 3.18 Compositions of Some Valve Steels 60 Table 3.19 Compositions of Some Stainless Steels 61 Table 3.20 AISI Classification of Tool Steels 62 Table 3.21 Composition of a Weathering Steel 68 Table 3.22 Composition of Pearlitic Heat Resisting Steels 75 Table 3.23 Compositions of Martensitic Heat Resisting Low Alloy Steels 75 xi

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