Ferrous and non-ferrous materialsmaterials

Dr Bertram MalliaRoom 221, Faculty of Engineeringbertram.mallia@um.edu.mt

Course description:

Introduction to a wide range of ferrous and non-ferrous materialsnon-ferrous materials

The role of alloying elements and other factors effecting the properties of these materials

Suggested reading Engineering Materials by R. L. Timing, Volume 1, second

edition, ISBN 978-0-582-31928-8

Light alloys by Ian Polmear, fourth edition, ISBN 0-7506-6371-5

Physical Metallurgy by William F. Hosford, ISBN 0-8247-2321-6 Physical Metallurgy by William F. Hosford, ISBN 0-8247-2321-6

Steels Microstructure and Properties by R.W.K Honeycombeand H.K.D.H. Bhadeshia, second edition, ISBN 0-340-58946-9

Materials Science and Engineering by W.D. Callister, sixth edition, ISBN 0-471-22471-5

Course material:

Website: http://www.um.edu.mt/vle

Engineering Materials

Metals Non-ferrous

Ferrous metals

Engineering materials

Non-metallic materials

Natural materials

Synthetic materials

ferrous metals

Ferrous Alloys

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Ferrous metalsClassification:

Steel

Carbon steel (low)

Carbon steel (meduim)

Carbon steel (high)

Alloy steel

Ferrous material Cast iron

Wrought iron

Grey cast iron

White cast iron

Malleable cast iron

Alloy cast iron

Spheriodal cast iron

Non-Ferrous metals

Metals

AluminiumCadmiumChromiumCobaltCopperGoldLead MagnesiumManganeseMolybdeniumNickel

Brass (copper and zinc)

Tin bronzePhosphor bronze

Gun metal

Aluminium bronze (Cu-Al)

Non-Ferrous material

Alloys

NickelPlatiniumSilverTinTitaniumVanadiumZinc

Aluminium bronze (Cu-Al)

Cupro-nickel alloys (Cu-Ni)

Aluminium alloys

HT (wrought)HT (cast)Non HT (wrought)Non HT (cast)

Magnesium alloys

Zinc based die casting alloys

Tin-lead soldersSoft solders

Bearing metals

...... all metals not classified as ferrous

Pure non-ferrous metalsGenerally have poor mechanical properties and Generally have poor mechanical properties and

are used for applications where special properties are required

Ex corrosion resistance (Cu, Al, Pb, Zn); electric conductivity (Cu, Al), thermal conductivity (Cu, Al)

Metal Density

(kg/m3)Tm

(oC)Properties Uses

Aluminium 2700 660 Lightest of commonly used metals, high electrical and thermalconductivity, Soft, ductile and low TS (93MPa)

Base of many engineering alloys, lightweight electrical conductors

Copper 8900 1083 Soft, ductile, low TS Base of brass and Copper 8900 1083 Soft, ductile, low TS (232MPa), High conductivity (2nd to silver), easier to join by brazing or soldering than Al.

Base of brass and bronze alloys, electrical conductors and heat exchangers

Lead 11 300 328 Soft ductile, very low TS, high corrosion resistance

Electric cable sheets, base of solder alloys, lining in chemical plants, added to other metals to make them free cutting

Metal Density (kg/m3)

Tm (oC)

Properties Uses

Titanium 4510 1678 Good creep, excellent corrosion-resistant

Base of many engineeringalloys, Aerospace, chemical industry, biomedical, power generation, automotive, marine, sportsmarine, sports

Silver 10 500 960 Soft, ductile, and very low TS. Highest electrical conductivity of metals

Used in electrical and electronic engineering for switch and relay contacts

Tin 7 300 232 Corrosion resistant Tin plate, soft solders, one of the bases for white metal bearings, An alloying element in bronzes.

Metal Density (kg/m3)

Tm (oC)

Properties Uses

Zinc 7100 420 Soft, ductile and low TS, Corrosion resistant

Alloying element in brass, galvanising, base of die casting alloys

Chromium 7500 1890 Resists corrosion, Increase strength but

Alloying element in high strength and corrosion Increase strength but

lowers ductility of steels. Improves heat treatment

strength and corrosion resistant steels, electroplating

Cobalt 8900 1495 Improves wear resistance and hot hardness of high speed steels

Alloying element in high speed steels and in permanent magnet alloys

Metal Density

(kg/m3)

Tm (oC)

Properties Uses

Manganese 7200 1260 High affinity for oxygen and sulphur

De-oxidise steel, offset ill effects of sulphur impurities, large amounts improve wear resistance

Molybdenum 9550 2620 A heavy heat resistant metal

Alloying element in high strengthnickel-chrome steels to improve resistant metal

that alloys readily with other metals

nickel-chrome steels to improve mechanical and heat treatment prop. Reduces mass effect and temper brittleness

Nickel 8900 1458 Strong, tough, corrosion resistant metal

Alloying element to improve strength, and mechanical properties of steel. Tends to unstabilise carbon during heat treatment and Cr has to be added to counter this effect in medium and high carbon steels

Non-ferrous alloys

Copper alloys:

Bronze (Cu-Sn) High corrosion resistance; easily machined; relative high melting temperature. Heavy and expensive compared to ferrous materialsexpensive compared to ferrous materials

Applications: steam and hydraulic valve components; marine applications

Brass (Cu and Zn) Weaker and less corrosion resistant compared to bronzes. Easily hot formed and can be easily machined to good finish.

Applications: Manufacture of electrical components and Applications: Manufacture of electrical components and domestic water fittings.

Aluminium alloys

Generally less strong than ferrous and copper-based alloys however they are lighter in weight. based alloys however they are lighter in weight. More corrosion resistant than ferrous materials (except stainless steels). The strength of these alloys fall rapidly with temperature

Titanium alloys

Strong as steel and light in weight as aluminium. Titanium retains its strength at high Titanium retains its strength at high temperatures and is very corrosion resistant. On the negative side, titanium is very costly and is difficult to shape

Group Project 8 groups

Deliverables : (1) Present a group report on an assigned ferrous or non-ferrous materialassigned ferrous or non-ferrous material

(2) Presentation (23 mins)

(Carry 15% of the exam mark)

Group 1 Tool steels- Introduction- Main groups of tool steels- Alloy design and heat treatment- Alloy design and heat treatment- Shock resistant tool steels; Hot work tool steels;

High speed steels; Cold work tool steels; Moldsteels ....

- Applications

Group 2 Cast iron- Into/ History- Iron-carbon system- Types of cast iron (Grey cast Iron, White cast

Iron, Spheroidal cast iron, Malleable cast iron, - Types of cast iron (Grey cast Iron, White cast

Iron, Spheroidal cast iron, Malleable cast iron, Alloy cast iron)

- Effect of alloying elements/ impurities and cooling rate on microstructure development

- Properties - Applications

Group 3 Aluminium and its alloys- History / Intro- Wrought Aluminium alloys (Heat treatable and

non-heat treatable)non-heat treatable)- Cast Aluminium alloys (Heat treatable and non-

heat treatable)- Hydrogen porosity - Hardening mechanisms- Properties and applications

Group 4 Nickel and nickel base alloys- Introduction / Historical development- Physical metallurgy (solid solution hardening,

carbide strengthening, precipitation hardening)carbide strengthening, precipitation hardening)- Various Nickel alloys such as superalloys and

their properties and applications (ex. Heat resistant applications; corrosion resistance; low expansion alloys; electrical resistance alloys; soft magnetic alloys; shape memory alloys)

Group 5 Copper and copper base alloys- History / Intro- Commercial pure copper and characteristics- High copper content alloys- High copper content alloys- Cu-Zn alloys (Brasses)- Cu-Sn alloys (Bronzes)- Cu-Ni (cupronickel) alloys - Aluminium-bronze alloys- Properties and Applications

Group 6 Titanium and its alloys- History / Introduction- alloys- Near alloys- Near alloys- + alloys- alloys- Properties and applications

Group 7 Magnesium alloys- Introduction/ History- Casting alloys- Wrought alloys- Wrought alloys- Corrosion and mechanical properties- Applications

Group 8 Stainless steels- Introduction / History- Effect of composition on stainless steel microstructure

(ferrite/ austenite stabilsers, martensite start temperature)temperature)

- Ferritic stainless steels- Martensitic stainless steels- Austenitic stainless steels - Precipitation hardening steels- Duplex stainless steels - Applications, properties and corrosion characteristics

Presentation date: Friday 30th October 2015 Group 1 Group 2

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More Project details 1 report (not longer than 18 A4 pages, font 12

excluding title page and references) Indicate individual contributions Reference work and abide with the University of Reference work and abide with the University of

Malta Plagiarism policy Submit 1 hard and 1 soft copy Submission deadline: Friday 27th November 2015