Aluminum, Copper, Iron, Lead, Zinc, Tin, Magnesium, Nickel

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Engineering Materials Metals

• Michael Hubbard

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Key Concepts

• There are a number of basic properties that are
  important to classifying a metal for use with a
  particular manufacturing process and product
  application.
• These properties are the materials density,
  color, electrical conductivity and reaction when
  exposed to heat.

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Key Concepts

• There are a four major types or classifications
  of metals Ferrous, Nonferrous, High Temperature
  Super alloy and refractory.
• The two major types of ferrous metals are iron
  and steel.

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Key Concepts

• Since they are resistant to corrosion, nonferrous
  metals are more durable than iron and steel.
• Super alloys are classified according to the base
  metal used (typically Iron, Nickel, or Cobalt).
• There are three major methods used to identify
  types of steel AISI numbering, grinding and
  color coding.

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Pure Metals

• Aluminum, Copper, Iron, Lead, Zinc, Tin,
  Magnesium, Nickel Titanium are pure Metals.
• Metals are not used in pure state very often.
  Titanium is used in a 99.5 pure state where
  corrosion resistance is the most important factor.

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Steel

• Steel in the simplest form is an alloy of Iron
  and Carbon. This is known as Carbon Steel.
• For higher strength it is alloyed with Magnesium,
  Vanadium, Nickel, Chromium, Molybdenum and other
  elements.
• When alloys are used with carbon the steel is
  called Alloy Steel.

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Carbon Steel

• 1018 Cold Drawn - .16 - .2 Carbon, .6 - .9 Mn,
  28 Elongation. Chip control is difficult.
• 1018 Hot Rolled - .16 - .2 Carbon, .6 - .9 Mn,
  25 Elongation. Chip control is difficult!
• 1117 Cold Drawn .16 - .2 Carbon, 1 - 1.3 Mn, .08
  - .13 Sulphur 16 Elongation, good chip control
• 12L14 Cold Drawn - .15 - .35 LEAD 10
  Elongation!!! Great machining, poor forming

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Aluminum

• Aluminum is commonly alloyed with Silicon,
  Copper, Manganese, Magnesium, Zinc and Titanium.
  
• The alloys provide a wide range of strength and
  corrosion resistance. Properties of aluminum
  alloys.

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Aluminum Alloys

• 2000 Series Alloys Copper (Cu) is primary
  alloying element.
• 3000 Series Alloys - Manganese (Mn) is primary
  alloying element.
• 4000 Series Alloys - Silicon (Si) is primary
  alloying element.
• 5000 Series Alloys - Magnesium (Mg) is primary
  alloying element.

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Aluminum Alloys

• 6000 Series Alloys - Magnesium and Silicon (Mg
  and Si) is primary alloying element.
• 7000 Series Alloys - Zinc (Zn) is primary
  alloying element.
• 8000 Series Alloys - Varius alloying elements are
  used.

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Physical Properties

• Specific Heat The amount of energy required to
  raise the temperature of a mass of material 1
  degree.
• Aluminum .902
• Brass .382
• Steel .473.
• Notice how high the specific heat of aluminum is!
  

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Physical Properties

• Thermal Conductivity is the ease with which heat
  flows through a material. The higher the
  conductivity the more heat that is conducted.
• Copper 400
• Aluminum 236
• Brass 114
• Steel 43
• SS 14

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Physical Properties

• Thermal Expansion is the amount a material
  expands when heated. Notice there are no units!
• Aluminum .00001244
• Copper .000009
• Iron .00000655
• Steel .00000655
• Titanium .000004

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Physical Properties

• Density - Mass per cubic volume
• Mild Steel - .284 lbs/in3
• Aluminum - .0975 lbs/in3
• 316 Stainless Steel - .33 lbs/in3
• Hastelloy Super Alloy .35 lbs/in3
• Magnetic Properties

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Mechanical Properties

• Hardness tests - Rockwell, Brinell
• Charpy impact
• Tensile strength
• Ductility
• Toughness
• Elasticity

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Mechanical Properties

• Plastic deformation - Doesnt return to original
  shape.
• Ductility - Elongation less 5 is brittle, More
  than 5 is Ductile.
• Mild steel is 20-30
• 316 SS is 40-50

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Ferrous Metals

• Steel has less than 1.7 percent carbon
• Mild steel has 0.05 -0.3 percent carbon
• Medium carbon steel has 0.3-0.7 percent carbon
• High Carbon Steel has 0.7 - 1.3
• 1020 - 1 is Carbon Steel, 0 is percent alloy, 20
  is tenths of carbon (.2)

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Non-Ferrous Metals

• Copper - Soft, easy to form, resists corrosion,
  good conductor
• Aluminum - Soft, easy to form, resists corrosion,
  good conductor

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High Temperature Alloys

• Iron Based
• Nickel Based - Hastelloy
• Cobalt Based - Thermospan

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Refractory Metals

• Niobium 4474º
• Tungsten 6170º
• Uses - Incandescent Light filaments, welding
  electrodes

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Homework Answers

• Why are alloys so popular? Because the addition
  of alloy provides the mechanical properties
  needed for strength, corrosion resistance and
  ductility.

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Homework Answers

• Discuss the concept of plasticity in terms of a
  materials ability to withstand changes in its
  shape when being formed under pressure. A
  material that can be formed under pressure
  (forged) must have Plasticity. For example
  Aluminum can be formed under pressure but cast
  iron cant.

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Homework Answers

• How do Plasticity and Ductility differ?
  Plasticity is the ability to be formed by force,
  ductility is a measure of how much the shape can
  change.
• 5 or less elongation is considered brittle,
  greater than 5 is considered ductile.

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Homework Answers

• List some products made with Refractory metals.
  How are the metals made?
• Light bulb filaments, electrodes, gas turbines,
  crucibles. These metals are pure elements.

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Homework Answers

• Explain how the AISI numbering system is used in
  classifying steels.
• The first two letters of the 4 digit number are
  the type of steel and the last two are the
  percent of carbon.

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• First two numbers Type of Steel
• 10 Carbon Mn to 1 Max
• 11 Resulfurized
• 12 Resulfurized Rephosphorized
• 15 Plain carbon Mn range 1 - 1.65
• 13 Manganese Steel Mn 1.75
• 23 Nickel Steel up to 3.5
• 25 Nickel Steel up to 5.00
• 31 Ni 1.25 Cr .65-.80
• 32 Ni 1.75 Cr 1.07
• 33 Ni 3.50 Cr 1.50-1.57
• 34 Ni 3.00 Cr .77
• 40 Molybdenum Steel Mo .2-.25
• 44 Molybdenum Steel Mo .4-.52
• 41 Chromium-Molybdenum
• 43, 47, 81, 86, 87, 88, 93, 94, 97, 98 Nickel
  Chromium-Molybdenum
• 50, 51, 50xxx, 51xxx, 52xxx Chromium Steels