Ferrous Materials

Mr. Amir D. Patel

Assistant Professor
Mechanical Engineering Department
 Introduction
• Ferrous material contains iron.
• Ferrous materials are most important metals /
alloys in metallurgical and mechanical
industries because of their expensive uses.
Classification of Metals
 Pig Iron
• It is a raw material for all iron and steel
products.
• Raw material for pig iron is ore. (Iron Oxide,
Carbonate Lime stone and coke)
• It produces in blast furnace, is the first
product in the process of converting ore into a
useful metals.
• The iron ore becomes pig iron when
impurities are burn out in blast furnace.
 Composition
• Carbon : 3 to 4 %
• Silicon : 1 to 3 %
• Manganese : 0.1 to 1 %
• Phosphorus : 0.3 to 1.7 %
• Sulphur : Under 1 %
• Remaining is Iron
 Classification of Pig Iron
1. Basic Pig Iron :
• Used for steel making and having low silicon
(upto 1.5 %) to prevent attack of refractory
lining.
• Having low sulpher (0.04 %)
• Phosphorous : < 1 %
• Manganese : 1 – 2 %
• Carbon : 3.5 – 4.4 %
 2. Foundry Pig Iron
• Used for production of castings.
• C:3–4%
• Si : 0.5 – 3.5 %
• Mn : 0.4 – 1.25 %
• P : 0.035 – 0.9 %
• S : < 0.05 %
 3. Ferrous Alloys
• Alloys of Pig Iron – each rich in specific
elements
• Ferrosilicon – Si (5 – 17 %)
• Ferromanganese – Mn (74 - 82 %)
• Used as additives in Iron and Steel Industries
to control the properties of iron and steels.
 Wrought Iron
• Mechanical mixture (very pure iron + silicate
slag
• Manufacturing Steps:
1. Melt and refine base metal.
2. Produce and keep molten a proper slag.
3. Disintegrate the base metal and mechanically
incorporate with desire amount of slag.
 Properties of Wrought Iron
• Never Cast. Shaped by hammering, pressing,
forging etc.
• High Ductility
• Ultimate strength ca be increased by cold
working followed by period of aging.
• High resistance towards corrosion
• Mechanical Properties are largely of pure iron
 Applications of Wrought Iron
• Available in the forms of plates, sheets, bars,
forging blooms and billets, rivets etc.
• Building Construction: Service Lines,
Electrical conduits, soil waste etc.
• Public Works : Bridges, Rails, Blast Plates,
towers etc.
• Industrial : Condenser Tubes, Heat
Exchangers, Acid and alkali process lines
• Rail road & Marine : Diesel exhaust, air brake
piping
 Gray Cast Iron
• Low cost material can be used for many
purpose.
 Properties
• High Compressive Strength
• Low Tensile Strength
• High Rigidity
• High stability after weathering
• High fluidity and ability to make sound casting
• Low melting point – 1130ᵒ C – 1250ᵒ C
• Easily machined to a good finish
• Self Damping – Does not vibrate
• Self Lubricating
• Good anti friction properties
 Characteristics
• Alloy of carbon and silicon with iron
• Readily cast into desire shape into sand mould
• C : 2.5 – 3.8 %, Si : 1.1 – 2.8 %, Mn : 0.4 – 1 %, S : 0.1 %, P : 0.15 %
• Marked by presence of graphite flakes in ferrite and pearlite.
• Graphite flakes occupies 10 % of metal volume
• Length of Flakes : 0.05 – 0.1 mm
• When fractured gives gray appearance
• Lowest melting point of ferrous metals
• High resistance to wear
• Low ductility and low impact strength compared to steel
• Shrinkage of 1 mm / 100 mm
• Low cost combined with hardness and rigidity
 Applications
• Machine tool structure (bed, frame & details)
• Gear, Pump & Turbine housing
• Motor Frame
• Gas & water pipes fro underground purpose
• Manhole cover
• Cylinder Blocks, Heads for IC Engine, Piston rings
• Tunnel Segments
• Sanitary wares
• Rolling Mills & General machinery parts
• Household Applications
 Malleable Cast Iron
• The purpose of malleablisation is to convert all
combine carbon in white iron into irregular nodules
of graphite and ferrite.
• Step I & II of annealing
 Characteristics
• Can be hammered and rolled to obtain desire shape
• It can be obtain from hard and brittle white iron
through controlled heat conversion process.
• Ferritic Malleable CI has ferrite metrix.
• Pearlite Malleable CI has pearlite metrix.
• High yield strength
• Good wear resistance and damping capacity
• High young ‘s modulus and low co-efficient of thermal
expansion
• Shrinkage is 1.5 mm / 100 mm
• Low moderate cost
 Chemical Composition
• C:2–3%
• Si : 0.6 – 1.4 %
• P : < 0.18 %
• Mn : 0.25 – 0.55 %
• S : 0.05 %
 Applications
• Axle & Differential Housing
• Cam shaft and Crank shaft in automobile
• Gears, chain link, sprockets, elevator brackets
• Pumps, Nozzles, Cam, Rocker arms as machine
parts
• Gun mounts, tank parts, pistol parts etc.
• Hammers wrenches etc.
 Nodular Cast Iron
• Known as ductile iron or spheroidal CI
• Graphite is in the form of spheroids or tiny
balls.
 Characteristics
• Very good machinability
• Soft grades can be turned at very high speeds and
feeds.
• Properties depends on metal composition and cooling
rate.
• Damping capacity between cast iron and steel
• Excellent castability and wear resistance
• C : 3.2 – 4.2 %
• Si : 1.1 – 3.5 %
• Mn : 0.3 – 0.8 %
• P : 0.08 %
• S : 0.2 %
 Applications
• Tractor and implement parts
• Crankshaft, piston and cylinder heads
• Switch box, motor frame and circuit breaker
parts
• Hoist drum, drive pulley, flywheel, elevator
parts
• Steel mill rolls
• Furnace doors
• Bearing, tool and dies, wrenches
 White Cast Iron
• Freshly broken surface shows a bright white
fracture.
 Characteristics
• Excellent abrasive wear resistance
• Brittle and not machinable in normal circumstances
• Casting can be made in sand mould
• C : 1.8 – 3.6 %
• Si : 0.5 - 2 %
• Mn : 0.2 – 0.8 %
• P : 0.18 %
• S : 0.10 %
• Shrinkage 1 mm/100 mm
• White CI is the first step in production of malleable CI
 Applications
• For producing malleable cast iron
• Manufacturing of components which require
hard and abrasion resistance
 Steels

Steels

Low Carbon Medium High Carbon

Steel Carbon Steel Steel
 Plain Carbon Steel
• Alloy of iron and carbon and is malleable
• Different from CI in % of carbon
• Carbon Steel : 0.1 – 1.50 % C
• Cast Iron : 1.80 – 4.20 % C
 Low Carbon Steel

Low Carbon
Steels

Dead Mild
Mild Steel Mild Steel
Steel
 Dead Mild Steel
• C : 0.05 – 0.15 %
• Used in steel wires, sheets, rivets, screw, pipe,
chain
• Tensile Strength : 390 N/mm2
• Hardness : 115 BHN
 Mild Steel
• C : 0.15 – 0.20 %
• Used in Camshafts, Sheets, strips for fans,
welded turbine, forgings, drag lines etc.
• Tensile Strength : 420 N/mm2
• Hardness : 125 BHN
 Mild Steel
• C : 0.2 – 0.3 %
• Used in valves, gears, crankshafts, connecting
rods, railway axles, fish plates, small forgings
etc.
• Tensile Strength : 555 N/mm2
• Hardness : 140 BHN
 Medium Carbon Steel
• C : 0.3 – 0.7 %
 750 N/mm2 – 0.35 – 0.45 % C
Connecting Rods, gear shaft, spring clips, small
and medium forgings
 1000 N/mm2 – 0.45 – 0.55 % C
Axle, Spline shaft, railway coach, crankshaft
 1230 N/mm2 & 400 to 450 BHN – 0.6 – 0.7 % C
Dia blocks, punch plates, drop forging dies, valve
springs, set screws
 High Carbon Steel
• C : 0.7 – 1.5 %
 1400 N/mm2 & 450 to 500 BHN – 0.7 – 0.8 % C
cold chisels, pneumatic drill, jaw of vices,
Shear blades
 660 N/mm2 & 500 to 600 BHN – 0.8 – 0.9 %
C
Rock Drills, Railways rail, Punch and Die,
Clutch Disc, Leaf springs etc.
 580 N/mm2 & 550 to 600 BHN – 0.9 – 1 % C
Keys, Pins, Shear blades, punch and sie etc.
 1 – 1.1 % C
Railways springs, mandrels, machine tools etc.
1.1 – 1.2 % C
Taps, Twist drills, Knives, Thread metal dies etc.
1.2 – 1.3 % C
Files, Reamers, Metal cutting tools etc.
1.3 – 1.5 % C
Wire drawing dies, paper knives, hack saws etc.
 Alloy Steels
• Steels are considered to be alloy steel when
max. of the range given for content of alloying
elements exceeds one or more of following
limits.
• Mn : 1.65 %
• Si : 0.6 %
• Cu : 0.6 %
 Composition of Alloy Steels
• C : 0.2 – 0.4 %
• Si : 0.3 – 0.6 %
• Cr : 0.4 – 0.6 %
• Mn : 0.3 – 1 %
• Ni : 0.4 – 0.7 %
• Mo : 0.15 – 0.3 %
• Fe : Remaining
• Alloying element alter the properties of steel and
put it into slightly different class from ordinary.
 Purpose of Alloying
• Increase Hardenability
• Improve strength at ordinary temperature
• Improve Mechanical properties at low and high
temperatures
• Improve toughness
• Increase wear resistance
• Increase corrosion resistance
• Increase magnetic properties
• Increase Ductility
• Better grain size control
 Advantages of Alloy Steels
• Greater Hardenability
• Less distortion and cracking
• Greater stress relief at given hardness
• Less grain growth
• Higher elastic ratio and endurance limit
• Greater high temperature strength
• Better machinability at high hardness
• Greater ductility at high strength
 Disadvantages of Alloy Steel
• Higher Cost
• Special Handling
• Brittleness in certain grades
 Effect of Alloying Elements
• C:
Hardness, Tensile Strength, Machinability,
Melting Point
• Ni:
Increase Toughness & Resistance to impact
Lessens distortion in quenching
Lowers the critical temperature
Increase strength
Does not unite with carbon
• Cr:
Joined with carbon and forms chromium
carbides, thus increase hardenability with
improved resistance to abrasion and wear.
• Ti:
Prevents localized depletion of Cr in SS during
long heating
Prevents formation of austenite in high Cr steel
Reduces hardness in medium Cr steels
 Molybdenum
• Promotes hardenability of steel
• Makes steel fine grained
• Increases toughness at various hardness levels
• Increases creep and tensile strength at high
temperatures
• Enhances corrosion resistance
• Forms abrasion resisting particles
 Vanadium
• Promotes fine grains in steel
• Increases hardenability
• Imparts strength and toughness to heat
treated steels
• Causes marked secondary hardening
 Tungsten
• Increases hardness (Also red hardness)
• Promotes fine grain
• Resist heat
• Promotes strength at elevated temperature
 Manganese
• Contributes markedly to strength and
hardness
• Counteracts brittleness from sulphur
• Lowers ductility and weldability if it is present
in high % with high carbon content in steel
 Copper
• Increases resistance to atmospheric corrosion
• Act as strengthening agent
Boron:
Increase hardenability when quenched.
 Aluminium
• Act as deoxidizer
• Produces fine austenite grain size
• If present in amount of 1 %, it promotes
nitriding
 Cobalt
• Contributes red hardness by hardening ferrite
• Improves Mechanical properties
• Refines the graphite and pearlite
• Mild stabilizer of carbides
• Improves heat resistance
• Retards transformation of austenite and thus
increases hardenability and freedom from
cracking and distortion
 Popular Alloy Steels
• Nickel Steel
• Chromium Steel
• Manganese Steel
• Molybdenum Steel
 Nickel Steel
• C : 0.35 % , Ni : 3.5 %
• Addition of Ni in Structural steel results in
increase of strength, without decrease in
ductility
• Used for storage cylinder for liquefied gas and
other low temperature application
• Other uses are heavy forging, turbine blades,
high stress screws, bolts and nuts
 Chromium Steel
• Cr is less expensive then Ni
• Forms simple or complex carbides
• Carbides have high hardness and wear
resistance
• It increases tensile strength and corrosion
resistance of alloy steel
• 8 % Cr : Electrical use
• 15 % Cr : Spring ball and roller bearing
 Manganese Steel
• Mn : 1.6 – 1.9 %
• Si : 0.2 – 0.35 %
• C : 0.18 – 0.48 %
• Mn increases hardness and tensile strength.
• Secondary effect is increase in resistance to
abrasion
• Used for Power shovel buckets, Grinding and
crushing machinery, Railway tracks etc.
 Molybdenum Steel
• C : 0.35 % , Mo : 0.76 %
• Relatively expensive element
• Strong effect on hardenability
• Increases hot hardness and strength of steel
• Uses for aircraft landing gear, Coil and leaf
springs, Transmission gears, Pressure vessels
 Tool Steels
• Special steel used for cutting and forming
purpose.
Properties:
• Excellent red hardness
• Good shock resistance
• Good non deforming properties
• Good wear resistance
• Fair machinability
• Resistance to decarburizing
• Good Toughness
 Classification of Tool Steel
Group Symbol and Type
Water Hardening W
Shock Resistance S
Cold Work O – Oil Hardening
A – Medium Alloy Air Hardening
D – High Carbon, High Chromium steel
Hot Work H
H1 – H19 : Chromium Base
H20 – H39 : Tungsten Base
H40 – H59 : Molybdenum Base
High Speed T – Tungsten Base
M – Molybdenum Base
Mold P – Mold Steel
Special Purpose L – Low Alloy
F – Carbon Tungsten
 Indian Standards (IS)
• It is for designation of Plain and Alloy steel.
• Steel have been classified on basis of
1. Mechanical Properties
2. Chemical Composition
 Method of Deoxidation
• R – Rimming Steel
• K – Killed Steel
• No Symbol – Semi Killed Steel
Quality of Steel
• Q1 – Non – aging quality
• Q2 – Freedom from flakes
• Q3 – Given size control
• Q4 – Inclusions control
• Q5 – Internal Homogeneity guaranteed
 Surface Condition
• S1 – Deseamed or scarfed
• S2 – Descaled
• S3 – Pickled
• S4 – Shot ,Grid and sand blasted
• S5 – Peeled
• S6 – Bright drawn or cold rolled
• S7 - Ground
 Formability
• D1 – Drawing ability
• D2 – Deep drawing quality
• D3 – Extra deep drawing quality
• No symbol – Commercial quality
 Surface Finish
• F1 – General purpose finish
• F2 – Full finish
• F3 – Exposed
• F4 – Unexposed
• F5 – Matt finish
• F6 – Bright finish
• F7 – Plating finish
• F8 – Unpolished finish
• F9 – Polished finish
• F10 – Polished and coloured blue
• F11 - Polished and coloured yellow
• F12 – Mirror finish
• F13 – Vitreous enamel finish
• F14 – Direct annealed finish
 Treatment
• No symbol – Hot rolled
• T1 – Shot peened
• T2 – Hard drawn
• T3 – Normalizing
• T4 – Controlled rolled
• T5 – Annealed
• T6 – Patented
• T7 – Solution treated
• T8 – Solution treated and aged
• T9 – Controlled cooled
• T10 – Bright annealed
• T11 – Spherodized
• T12 – Stress relived
• T13 – Case hardned
• For guarantee with regard to elevated
temperature properties letter ‘H’ is used.
• For guarantee with regard to low temperature
properties letter ‘L’ is used
On basis of Chemical Composition
1. Unalloyed Steel (IS : 7598 – 1974)
XCYZ
• X – 100 times % of C
• C – Carbon
• Y – 10 times % of Mn
• Z – Special characteristics
e.g - 25C5B0 – Semi killed steel with 0.25 % C,
0.5 % Mn and resistance to fracture grade B0
 Unalloyed tool steel
• XTY
• T – Tool steel
• X and Y have same meanings
• E.g – 80T11 – Unalloyed tool steel
0.80 % C
1.1 % Mn
 Unalloyed free cutting steels
• XCYWW1Z
• W – free cutting
• W1 – 100 times % of element
• X,C,Y and Z – Same as above
• E.g – 20 C12 Pb15 T14 – Free cutting steel
0.2 % C, 1.2 % Mn, 0.15 % Pb
T14 – harden and tempered
 Alloy Steel (IS : 7598 – 1974)
1.Low and Medium Alloy Steel
• 1st Symbol – 100 times % of C
• 2nd,4th, 6th – Elements
• 3rd, 5th, 7th - % of elements, multiplied by
factors
• Cr, Co, Ni, Si, Mn, W – 4
• Al, Be, V, Pb, Cu, Mb, Ti, Ta, Zr, Mo – 10
• P, S, N - 100
• E.g – 40 Ni 8 Cr 8 V 2
• 0.4 % C
• 2 % Cr
• 2 % Ni
• 0.2 % V
• Hot rolled steel (no symbol at last)
 High Alloy Steel
• Total alloying elements > 10 %
• X 10 Cr18 Ni9 S3
• X – High alloy steel
• 10 – 0.10 % C
• Cr18 – 18 % Cr
• Ni9 – 9 % Ni
• S3 – Pickled condition
 Alloy Tool Steel
• XT 98 W6 Mo5 Cr4 V1
• XT – High alloy tool steel
• 98 – 0.98 % C
• W6 – 6 % Tungsten
• Mo5 – 5% Molybdenum
• Cr4 – 4 % Chromium
• V1 – 1 % Vanadium
 Free Cutting Alloy Steel
• X 15 Cr25 Ni15 S40
• X – High Alloy Steel
• 15 – 0.15 % C
• Cr25 – 25 % Cr
• Ni15 – 15 % Ni
• S40 – 0.4 % Sulphur