Transcript GOVERNMENT COLLEGE OF ENGINEERING AURANGABAD

GOVERNMENT COLLEGE OF ENGINEERING
AURANGABAD
Dr. Sanjay Chikalthankar
Department of Mechanical Engineering
GECA
[email protected]
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Alloys are a great combination of two or more materials.
It is a completely new material with varying properties. Thus,
take a look at all the different types of alloys mentioned for you
in the following article.
You must have heard the term alloy many times, and also
come across a few. These are found very often in nature and are
defined as a mixture of two or more materials, out of which at
least one has to be a metal. Alloys can be a combination of
various metallic and non-metallic components and also a
mixture of different metals. No matter what these combinations
and mixtures are, each component present in an alloy is known
to have its own specific set of properties. There are alloys of all
metals formed under the earth's crust and there can be a large
number of alloys of a single metal. This is because these
combinations of metals with each other as well as non-metallic
components, can go up to any number and types of alloys. Find
out which are the most commonly found different types of alloys
below.Dr. Sanjay Chikalthankar
17mentioned
July 2015
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Alloying a metal is done by combining it with one or more
other metals or non-metals that often enhance its properties. For
example, steel is stronger than iron, its primary element. The physical
properties, such as density, reactivity, Young's modulus, and electrical
and thermal conductivity, of an alloy may not differ greatly from those
of its elements, but engineering properties such as tensile strength and
shear strength may be substantially different from those of the
constituent materials. This is sometimes a result the sizes of the atoms
in the alloy, because larger atoms exert a compressive force on
neighboring atoms, and smaller atoms exert a tensile force on their
neighbors, helping the alloy resist deformation. Sometimes alloys may
exhibit marked differences in behavior even when small amounts of
one element occur. For example, impurities in semi-conducting
ferromagnetic alloys lead to different properties, as first predicted by
White, Hogan, Suhl, Tian Abrie and Nakamura. Some alloys are made
by melting and mixing two or more metals. Bronze, an alloy of copper
and tin, was the first alloy discovered, during the prehistoric period
now known as the bronze age; it was harder than pure copper and
originally used to make tools and weapons, but was later superseded by
metals and alloys with better properties. In later times bronze has been
used for ornaments, bells, statues, and bearings. Brass is an alloy made
from copper and zinc.
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Aluminum
AA-8000
Alnico (aluminum, nickel, copper)
Duralumin (copper, aluminum)
Zamak (zinc, aluminum, magnesium, copper)
Silumin (aluminum, silicon)
Aluminum forms other complex alloys with magnesium,
manganese, and platinum
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Bismuth
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Wood's metal (bismuth, lead, tin, cadmium)
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Field's metal
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Rose metal (bismuth, lead, tin)
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Cobalt
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Stellite (cobalt, chromium, tungsten or molybdenum, carbon)
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Talonite (cobalt, chromium)
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Ultimet (cobalt, chromium, nickel, molybdenum, iron, tungsten)
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Vitallium
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Megallium
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Copper
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Arsenical copper
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Beryllium copper (copper, beryllium)
Brass (copper, zinc)
Billon (copper, silver)
Bronze (copper, tin, aluminum or any other element)
Constantan (copper, nickel)
Cunife (copper, nickel, iron)
Copper-tungsten (copper, tungsten)
Cupronickel (copper, nickel)
Cymbal alloys (Bell metal) (copper, tin)
Electrum (copper, gold, silver)
Heusler alloy (copper, manganese, tin)
Hepatizon (copper, gold, silver)
Manganin (copper, manganese, nickel)
Nickel silver (copper, nickel)
Shakudo (copper, gold)
Nordic gold (copper, aluminum, zinc, tin)
Gold
Tumbaga (gold, copper)
Electrum (gold, silver, copper)
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Heusler alloy (copper, manganese, tin)
Hepatizon (copper, gold, silver)
Manganin (copper, manganese, nickel)
Nickel silver (copper, nickel)
Shakudo (copper, gold)
Nordic gold (copper, aluminum, zinc, tin)
Gold
Tumbaga (gold, copper)
Electrum (gold, silver, copper)
White gold (gold, nickel, palladium, or platinum)
Rose gold (gold, copper)
Iron
Anthracite iron (carbon)
Pig iron (carbon)
Cast iron (carbon)
Wrought iron (carbon)
Ferrous Alloys
Steel (carbon)
Silicon steel (silicon)
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Stainless steel (chromium, nickel)
Tool steel (tungsten or manganese)
Chromoly (chromium, molybdenum)
Find more on ferrous metals list.
Lead
Antimonial lead (lead, antimony)
Solder (lead, tin)
Molybdochalkos (lead, copper)
Type metal (lead, tin, antimony)
Nickel
Alumel (nickel, manganese, aluminum, silicon)
Cupronickel (nickel, bronze, copper)
Chromel (nickel, chromium)
German silver (nickel, copper, zinc)
Hastelloy (nickel, molybdenum, chromium, sometimes
tungsten)
 Monel metal (copper, nickel, iron, manganese)
 Inconel (nickel, chromium, iron)
 Zinc
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Zamak (zinc, Dr.
aluminum,
magnesium, copper)
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Good corrosion resistance.
Medium to high mechanical strength.
Good fatigue strength.
Good elongation/fracture Toughness.
Excellent machining properties.
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1.
Automotive Industry
Wheels
Components for
Suspension
Strut
Brake system
Power train
Car body and
Interior
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General Engineering
Impeller wheels
• Connecting rods
• Hydraulic bodies
• Large-size-pistons
• Motor casings
• Special-designed
•extrusions
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3.
Construction Industry
Door and window
•extrusions
• Insulating extrusions
• Facade extrusion
•elements
• Scaffold planks
• Lamp posts
•and flagpoles
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4.
Aerospace Industry
Structural parts in
•fuselage and wings
• Undercarriage
•components
• Hydraulic bodies
• Engine components for
•aircraft, helicopters and
•missiles
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IN AUTOMOTIVE INDUSTRY:
Since materials play a decisive role with regard to both the
quality and cost of a car, selection of the correct materials at the
earliest possible stage of the development process is of vital
importance.
The materials used in vehicles nowadays are selected so as to
optimally fulfill the specific requirements. It is the job of the
materials engineer in a car-manufacturing company to ensure that
this optimum will be reached. However, the corporation, itself, must
decide what "optimal" actually means in practice. As well as
considering the general economic framework, external influences
such as the customers selected as the target group, and legal
requirements and regulations are
particularly relevant here.
Newly developed or modified conventional materials on the
market represent competition for materials already in use. The
application potential of such materials is dependent on how well
they satisfy the requirements placed on them.
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Aircraft half wheel
2214-T6, 60 kg
Passenger window frame
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2015kg
7175-T74,
Main Fitting Nose Landing
Gear
7175-01, 112 kg
Fin-to-fuselage fitting
Dr. Sanjay
Chikalthankar
7175-T73,
82 kg
Large-scale die forgings for the
automotive industry
Spoiler Manifold
7175-T73, 7 kg
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ALLUMINIUM(A Strong Marine & Armor Plate Material):AL-Mg Alloys in General: Among all aluminum alloys, the nonheat treatable Al-Mg alloys (5xxx series) are the most suitable
material for marine applications. Magnesium, as the main
alloying constituent, lends itself to reasonable strength for
marine applications. More important, however, is the corrosion
resistance of Al-Mg alloys which makes them the most suitable
material for shipbuilding.
Effect of Mg on Strength: The relationship between
Magnesium content of 5xxx alloys and its mechanical properties,
i.e. yield strength, tensile strength, and elongation, is given in
slide 7. The main reason for increasing strength is the formation
of Al-Mg intermetallic particles which reinforce the alloy.
Effect of Mg on Corrosion Resistance: Theoretically,
increasing the Mg content will add to strength. However, when
Mg% is raised above approximately 4%, the corrosion resistance
of the alloy will gradually decrease. The reason for this
phenomenon is that at higher Mg%, the Al-Mg intermetallic
particles will start precipitating at the grain boundaries. These
particles are anodic relative to Aluminum and thus they cause
electrochemical imbalance in the grains which leads to “Inter
Granular Corrosion”. This causes pitting and weight loss.
Furthermore, IGCDr.may
lead to “Stress Corrosion Cracking”.
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Alloys AA5083 and AA5456: Alloy 5083 has been a popular
shipbuilding alloy for a couple of decades. With the average Mg
content of 4.4%, it provides a yield strength of 31 KSI, ultimate
tensile strength of 44 KSI and an elongation of 10%. The
corrosion resistance of AA5083 has been quite satisfactory for
marine applications. However, the need for a higher strength
marine alloy gradually became apparent as more aluminum
vessels were built; specially for fast ferries and catamarans where
weight saving and higher speed became an important issue. An
alternative high strength alloy was AA5456 which is mainly used
for military applications and coast guard vessels. The Mg level in
this alloy is up to 5.5% which produces a yield strength of about
35 KSI and UTS of about 48 KSI with somewhat lower elongation
(less formability). However, the lower corrosion resistance
became evident as no special treatment for corrosion resistance
was done. Although this alloy is still recommended in military
and government specifications, Its use has drastically affected
the design and maintenance of the vessels. For example, coast
guard rescue bots made of this alloy have a very tight service
interval. Also, for vessels operating in sea water (salt water), the
lower part of the hull is painted with multiple layers of epoxy
paint.
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Alloy AA5383: Alloy AA5383 was developed in the nineties,
in an effort to increase strength. The Mg content of this
alloy is slightly higher than that of AA5083 and this has
increased the yield strength to 32 KSI or 220 MPa (about 1
KSI more than AA5083) while the UTS and Elongation
remain the same. The yield strength and UTS after welding
is 20 KSI and 42 KSI respectively and this is about 2 KSI
higher than AA5083. There has been no official reports of
reduced corrosion resistance as due to minimal increase in
Mg content and strength, the difference in corrosion
resistance with that of AA5083 may appear in several years.
We are aware of one case where this alloy was used in a
Catamaran which was exposed to elevated temperature
(200 F) for a couple of months (the vessel was under
extreme sunlight) and significant amount of pitting was
reported. This was attributed to sensitization due to added
Magnesium. Currently, several vessels made of AA5383 are
in service. However, the slight increase in strength has not
been used for down gauging and subsequent weight saving.
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ALLUMINIUM ALLOY
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1. SAE 1010: formed sheet-metal parts
2. SAE 1020: general machine applications
3. SAE 1040: flame- or induction-hardened parts
4. ASTM A36: structural steel
5. SAE 4140: high-strength machine parts
6. SAE 4340: high-strength machine parts
7. SAE 8620: carburized wear parts
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Type
Designation
Uses
Carbon Tool Steel
T 118
T 70
Engg. Tools, fields, razors,
shappingtools,drills,chiesel,
press tools etc.
Carbon-Chromium Tool
Steel
T 60 & T 85
T 105 Cr 1 Mn 60
T 105 Cr 1
Die blocks. hand
tools,gardenand agricultural
tools. Cold forming rolls,
lathe centre's, knurling
tools, press tools
High Carbon High
Chromium Tool Steels
T 215 Cr 12
T160 Cr 12
High quality press tools ,
drawing and cutters dies,
shear blades, thread rollers,
cold rolls
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Types
Designation
Uses
Fast finishing tool steel
T 140 W 4 Cr 50
Finishing tool with high
feeds , marking tools etc
Non- deforming tool steel
T110 W2 Cr 1
T90 Mn 2 W50 Cr 45
Engraving tools , press tools
, gauge ,tape, hard reamers,
milling centre's, cold
punches, knives,etc.
Shock resisting tool steels
T50 Cr 1 V23
Chisels , rivet shape shear
blades ,scarfing tools,
trimming dies, heavy duty
punches, pneumatic
chisels, etc
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What is a code?
A code is a standard that has been adopted by one
or more governmental bodies and has the force of law, or
when it has been incorporated into a business contract.
What is the involvement of ASME
in codes and standards today?
Since the beginning of industrialization, ASME
and many other standards developing organizations have
worked to fulfill the growing need for standards in
today’s world. Through a voluntary, consensus process
ASME standards are developed to protect the health and
welfare of the public. In addition to developing these
standards ASME provides conformity assessment
processes which help to ensure that manufacturers live
up to the relevant specifications and that certain
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personnel are properly
trained.
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Specifications
SAE-AISI
Society of Automotive Engineers – American Iron and
Steel Institute
ASTM
American Society for Testing and Materials
ASME
American Society of Mechanical Engineers
MIL
U.S. Department of Defense
AMS
Aerospace Materials Specification
BS
British Standards Institution
EN
European Committee for Standardization
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American Iron and Steel Institute (AISI)
classifies alloys by chemistry
4 digit number
1st number is the major alloying element
2nd number designates the subgroup
alloying element OR the relative percent of
primary alloying element.
last two numbers approximate amount of
carbon (expresses in 0.01%)
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•letter prefix to designate the process used to produce the
steel
E = electric furnace
X = indicates permissible variations
•If a letter is inserted between the 2nd and 3rd number
B = boron has been added
L = lead has been added
•Letter suffix
H = when harden ability is a major requirement
•Other designation organizations
ASTM and MIL
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Material
SAE or AISI
Number
Carbon steels
1XXX
Plain carbon
10XX
Free cutting, screw stock
11XX
Chromium steels
5XXX
Low chromium
51XX
Medium chromium
52XXX
Corrosion and heat resisting
51XXX
Chromium-nickel-molybdenum steels
86XX
Chromium-nickel-molybdenum steels
87XX
Chromium-vanadium steels
6XXX
1.00 % Cr
61XX
Manganese steels
13XX
Molybdenum steels
4XXX
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40XX
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Chromium-molybdenum
41XX
Chromium- nickel-molybdenum
43XX
Nickel-molybdenum;1.75% Ni
46XX
Nickel-ml-olybdenum;3.50%Ni
48XX
Nickel-chromium steels
3XXX
1.25%Ni,0.60%Cr
31XX
1.75%Ni,1.00%Cr
32XX
3.50%Ni, 1.50%Cr
33XX
Silicon-manganese steels
9XXX
2.00% Si
92XX
Nickel steels
2XXX
3.5% Ni
23XX
5.0% Ni
25XX
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BIS designation
En Number
SAE
AISI
DIN
7C4
2A
1010
C1010
17210
10C4
32A
1012
C1012
17155
30c8
5
1030
C1030
-
45C8
43B
1045
C1045
17200
50C4
43A
1049,1050
C1049,C1050
-
55C8
43J,9K
1055
C1055
-
60C4
43D
1060
C1060
17200
65C6
42B
1064
C1064
17222
10c8s10
-
1109
C1109
-
14C14S14
7A,202
1117,1118
C1117,C1118
-
Plain-carbon steels
Free cutting steels
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40C1010S18
8M
1140
C1140
-
40C15S12
15AM
1137
C1137
-
40Cr4
18
5135
5135
-
40Ni14
22
2340
2340
-
35Ni5Cr2
111
3140
3140
1662
30Ni16Cr5
30A
-
-
-
40Ni6Cr4Mo2
110
4340
4340
17200
27C15
14B
1036
C1036
17200
37C15
15,15A
1041,1036
C1041,C1036
17200
50Cr4V2
47
6150
6150
17221
25C12S14x
7
1126
C1126
2
Alloy steels
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Mechanical properties for forging alloys, like
physical properties, are listed in standard reference
sources. In some cases they are not affected by
subsequent manufacturing operations, and can be
used with reasonable confidence to predict real world
performance. In other cases, mechanical properties are
altered by subsequent processes, in varying amounts
and with varying degrees of predictability in the end
product. Variations are caused by factors such as:
► Forging temperature
► Forging reduction (deformation) which, in turn,
affects grain size
► Heat treatment.
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Mechanical properties of alloy steel forgings
designat conditio
ion
ns
Tensile strength
Mpa
20 Mn 2
Hardened
&
tempered
Kgf/mm
Elongati Izod
on
impact
value
Brinell
hardnes
s no.
Limitin
g ruling
section
588-736
60-75
18
47.1
217 Max
63
Refined &
quenched
588 Min
60 Min
10
34.3
-
-
Refined&
20MnCr 1 quenched
981 Min
100Min
8
37.3
317+Max
60
15 Cr 65
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The die casting process consists of forcing the
molten metal into closed metal die. This process is used
for metals with a low melting point. The advantages of
casting process are as follows :
1. Small parts can be made economically in large
quantities.
2. Surface finish obtained by this method is excellent
and requires no further finishing.
3. Very thin section or complex shapes can be
obtained easily.
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