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Types of Metal Alloys

Ferrous and Nonferrous

Types of Ferrous Alloys

Iron based:


Steels and Cast Irons

Steels

<1.4 wt% C




Low Alloys and High Alloys




increasing strength decreases ductility

Low Alloy, Low Carbon Steels

<0.25 wt% C




plain: (auto structural sheets)




HSLA: additions are Cr, V, Ni, and Mo (bridges, towers)

Low Alloy, Medium Carbon Steels

0.25-0.6 wt% C




plain: (crank shafts, bolts)




heat treatable: additions are Cr, Ni, Mo (pistons, gears)



Low Alloy, High Carbon Steels

0.6-1.4 wt%




tool: additional are Cr, V, Mo, W (drills, saws, dies)

High Alloy

stainless steel: additions are Cr, Ni, and Mo (high temperature applications, very corrosion resistant)

Refinement of Steel from Ore

coke, limestone, and iron ore goes into blast furnace and molten iron comes out


(1) heat generation


(2) reduction of iron ore to metal


(3) purification

Cast Irons

-Ferrous Alloys with >2.1 wt% C (3-4.5)


-Low melting - relatively easy to cast


-generally brittle


-cementite=ferrite+graphite (general a slow process)



Types of Cast Iron

Gray Iron, Ductile Iron, White Iron, Malleable Iron, Compacted Graphite Iron

Gray Iron

Type of Cast Iron


-graphite flakes


-weak and brittle in tension


-stronger in compression


-excellent vibrational dampening


-wear resistant

gray=old/hypertension=weak and brittle in tension

Ductile Iron

Type of Cast Iron


-add Mg and or Ce


-graphite as nodules not flakes


-matrix often pearlite - stronger but less ductile

White Iron

Type of Cast Iron


-<1 wt% Si


-pearlite + cementite


-very hard and brittle

white=pearlite=pearls=hard and brittle

Malleable Iron

Type of Cast Iron


-heat that white iron at 800-900


-graphite in rosettes


-reasonably strong and ductile

Compacted graphite iron

Type of Cast Iron


-relatively high thermal conductivity


-good resistance to thermal shock


-lower oxidation at elevated temperatures

Limitations of Ferrous Alloys

(1) Relatively high densities


(2) Relatively low electrical conductivity


(3) Generally poor corrosion resistance

Types of Nonferrous Alloys

Mg Alloys, Cu Alloys, Al Alloys, Ti Alloys, Noble Metals, Refractory metals

MCAT=Mg,Cu,Al,Ti

Nonferrous Mg Alloys

-very low density (1.7 g/cm3)


-ignites easily


-aircraft, missiles

Nonferrous Cu Alloys

-Brass: Zn is subst. impurity (costume jewelry, coins, corrosion resistant)


-Bronze: Sn, Al, Si, Ni are subst. impurities (business, landing gear)


-Cu-Be: precip hardened for strength

Nonferrous Al Alloys

-low density (2.7 g/cm3)


-Cu, Mg, Si, Mn, Zn additions


-solid sol. or precip. strengthened (structure air craft parts and packaging)

Nonferrous Ti Alloys

-relatively density (4.5 g/cm3)


-reactive at high temperatures


-space applications

Noble Metals (nonferrous alloys)

-Ag, Au, Pt


- oxid./corr. resistant

Refractory Metals

-high melting temperatures


-Nb, Mo, W, Ta

Types of Ceramics

Glass, Clay products, Refractories, Abrasives, Cements, Advanced Ceramics

Glasses

Ceramic Material


-optical


-composite reinforce


-containers/household

Clay Products

Ceramic Material


-whiteware


-structural



Refractories

Ceramic Material


-bricks for high T (furnaces)


-Silica-Alumina System: small additions of alumina depress melting temperature



Abrasives

Ceramic Material


-sandpaper


-cutting


-polishing


APPLICATION: Cutting Tools


-for grinding glass, tungsten, carbide, ceramics/cutting Si wafers/oil drilling



Cements

Ceramic Material


-composites


-structural

Advanced ceramics

Ceramic Material


-engine rotors,


-valve bearings


-sensors

Advantages of Advanced Ceramics

-operate at high temperatures (high efficiencies)


-low frictional losses


-operate without a cooling system


-lower weights what current engines

Disadvantages of Advanced Ceramics

-ceramic materials are brittle


-difficult to remove internal voids (that weaken structures)


-ceramic parts are difficult to form and machine

Types of Polymers

Fibers, Miscellaneous (Coatings, Adhesives, Films, Foams), Advanced Polymers

Fibers

polymer type


-primary use in textiles


-high tensile strengths


-high degrees of crystallinity


-structures containing polar groups



Spinning

polymer fabrication


(1) extrude polymer through a spinneret (a die containing many orifices)


(2) the spun fibers are drawn under tension


(3) leads to highly aligned chains -fibrillar structure

Coatings

miscellaneous polymer type


thin polymer films applied to surfaces (paint/varnish)


-protects from corrosion and degradation


-decorative


-improves electrical insulation





Adhesives

miscellaneous polymer type


bongs two solid materials (adherands)


two bonding types:


(1) Secondary: van der Waals forces


(2) Mechanical: penetration into pores/crevices

Films

miscellaneous polymer type


-produced by blown film extrusion



Foams

miscellaneous polymer type


-gas bubbles incorporated into plastic

Advanced Polymer: Ultrahigh Molecular Weight Polyethylene (UHMWPE)

-molecular weight = 4E6 g/mol


outstanding properties:


-high impact strength


-resistance to wear/abrasion


-low coefficient of friction


-self-lubricating


(bullet proof vests, golf call covers, hip implants)