Chapter 11-

Extra slides are added to the

original powerpoint

Younes Ataiiyan

Chapter 11-

Part I

History of metals

You are not responsible for part I

Chapter 11-

Gold, Silver, Copper

Earliest known metals, Why?

•They can be found in metallic state in

nature (not necessarily pure)

•They are malleable

Chapter 11-

Copper History

The name originates from the Latin word cyprium, after the island of Cyprus. Copper was associated with the goddess named Aphrodite / Venus in Greek and Roman mythology.http://www.facts-about.org.uk/science-element-copper.htm

There are reports of copper beads dating back to 9000BCfound in Iraq.

Methods for refining copper from its ores were discovered around 5000BC and a 1000 or so years later it was being used in pottery in North Africa.

around 5000 years ago it was discovered that when copper is mixed with other metals the resulting alloys are harder than copper itself (BRONZE IS COPPER AND TIN)http://www.webelements.com/webelements/scholar/elements/copper/history.html

Chapter 11-

Copper Properties

• Malleable + Durable

• High Electrical/Thermal conductivity

• High corrosion resistance

• Non-Magnetic

Chapter 11-

Copper Properties Electrical/Thermal conductivity

• Highest electrical conductivity (after Silver)

• Used in electrical wiring, pipes, roofing,

Culinary.

Chapter 11-

Copper

Colors and alloying elements

German Silver

Chapter 11-

Copper Minerals

• Turquoise

• Dioptase

• Cuprite

• Copper pyrite

• Azurite

Chapter 11-

Copper Mines

Chapter 11-

Copper Mines

Chapter 11-

Copper Mines

Chapter 11-

Copper Mines

Chapter 11-

Copper Odd Facts

• Excessive consumption of foods high in copper, such as

organ meats and oysters can cause Wilson's disease .

• The average home today contains about 400 pounds of

copper for electrical wiring, water pipes and appliances.

• Your refrigerator, dishwasher, microwave, washing

machine and clothes dryer are just a few of the

laborsaving devices in your home that contain copper.

Chapter 11-

Copper Odd Facts

• The Statue of Liberty contains 179,000 pounds of

copper.

• One of copper’s major advantages is that it is

recyclable. In North America alone, approximately

one half of the copper consumed annually comes

from recycled material.

• Copper’s recycle value is so great that premium-

grade scrap has at least 95% of the value of primary

copper from newly mined ore.

• http://www.nwma.org/Education/copper_facts.htm

Chapter 11-

GOLD

• Around 6000 BC

• Main usage was for jewelry

• The name originates from the Old English

Anglo-Saxon word 'geolo' meaning yellow.

The Symbol (Au) Origin is from the Latin

word 'aurum' meaning gold.

Chapter 11-

Gold Properties

• It is extremely malleable

Used in electronic for wiring of the circuits

Chapter 11-

Gold Properties

• Has high Thermal/Electrical conductivity

Chapter 11-

Gold Properties

• Corrosion Resistance

- Used in coins and jewelry

- Gold plating to protect against environment

- Dentistry

Chapter 11-

Gold Properties

• High reflectivity (Infra red)

Chapter 11-

Gold Properties

• Medicine

Medieval times: gold leaf in water

Now: Goldwasser (Goldwater) liquor

rheumatoid arthritis

implantable insulin pump

Chapter 11-

FAKE GOLD

HOW?

Alloying: All started with Archimedes!

Plating: Thick plating on heavy metal

Mineral:

Fool’s Gold, Pyrite (Iron Sulfide)

Chapter 11-

Gold supply

• Gold is so dense in volume that the total

amount ever mined could be contained in a

cube measuring 62 feet on each side. The

total amount of gold ever mined is 4.2

billion ounces (since 1996).

• Source:http://www.nwma.org/Education/Gold_Facts.htm

Chapter 11-

Silver History

• 4000 BC The area of Anatolia (modern Turkey) is considered the first major source of mined silver.

Names:English: SilverFrench: ArgentGerman: SilberItalian: ArgentoLatin: ArgentumSpanish: Plata

Argentina is named after Silver

Source:http://www.silverinstitute.org

Chapter 11-

Silver Properties Reflectivity

The most reflective metal (specially UV)

– Used in manufacturing of mirrors

– Used for coating telescope mirrors

– Do you remember “silver screen”?

Chapter 11-

Silver Properties Electrical/Thermal

conductivity

• Highest electrical conductivity

• 2nd highest thermal conductivity

(can you guess what is the 1st?)

Used in electronic circuits

Chapter 11-

Silver PropertiesAntibacterial properties

The ancient Phoenicians carried wine in silver containers to keep it fresh.

Colloidal soap bar is being sold .

Silver based water filter is used to remove water born disease agents.

Silver based cleaner are used in swimming pools.

A number of food and beverage makers use silver in food preparation to keep equipment free from bacteria

Commercial air conditioners utilize silver to prevent the buildup of bacteria that cause legionnaires' disease and other airborne illnesses.

Source: http://www.mincosilver.ca/s/Home.asp

Chapter 11-

Silver Applications

• Electronics

• Medicine

• Jewelry

• Currency

• Explosive materials

• Photography

• Sterling silver:92.5% silver and rest other metals (usually copper).

Chapter 11-

Silver Odd Facts

• In India, food can be found decorated with a thin layer of silver, known as Varak.

• Silver is the whitest color of any metal.

• 1/3 of silver goes to photographic film.

• More than 2/3 of the silver produced worldwide is a by product of lead, copper and zinc mining.

• Silver iodide is often used in cloud seeding. A pound of silver iodide is enough to seed many cubic miles of clouds.

Chapter 11-

Silver Odd Facts

• When miners struck gold in Nevada (The Comstock Lode),

the were really slowed down by the huge amounts of gray

clay. It wasn't until later they found out it was silver in the

mud!

• There are no words in the dictionary that rhyme with orange,

purple and SILVER.

• The Olympic gold medal is mostly made of Silver

Chapter 11-

IRON

Timeline• Source of Iron in pre-historical time was

meteorite.

• Earliest production around 2000BC in Anatolia or the Caucasus using bloomeries.

• Cast iron was first produced in China about 550 BC using blast furnace.

Chapter 11-

Time line

• late 1850s, Henry Bessemer invented a new steelmaking process.

• In the 1860s, a rival appeared on the scene: the open-hearth process,developed primarily by the German engineer Karl Wilhelm Siemens. Use of these furnaces ended in US around 1992.

• basic oxygen steelmaking, developed in the 1950s and being used today.

Chapter 11-

Some definitions

• Iron Ore: Raw material containing Iron

• Pig Iron: Immediate product of smelting containing very

high C (3 to 5%)

• Cast Iron: by product of re-melting Pig Iron with scrap iron

(2 to 4% C)

• Steel: Low C Iron (up to 1.7%C)

• Wrought Iron: Commercially pure iron (up to 0.15%C)

• Stainless Steel: Contains at least 10.5 Chromium.

Chapter 11-

Damascus sword

• You can buy plank

Chapter 11-

Practical

thermomete

r

•White heat •Light Yellow heat•Yellow heat.•Bright red or Light red (Orange) heat.•Full Red heat.•Dark Red or Dull Red heat.•Black heat or Dark Blood Red heat.

Chapter 11-

How expensive is Iron?

• Gold is about $23 per grams.

• How expensive IRON can be?

Chapter 11-

Pure Iron is very expensive!

That is $1600 per grams!

Gold is $38/grams

Chapter 11-

The Iron Pillar from Delhi7.3 m tall, with one meter below the ground; the diameter is 48 centimeters at the foot, tapering to 29 cm at the top, just below the base of the wonderfully crafted capital; it weighs approximately 6.5 tones, and was manufactured by forged welding.

http://www.world-mysteries.com/sar_ironpillar.htm

Chapter 11-

Steel making

Video Link:

http://www.youtube.com/watch?v=9l7Jqonyo

KA

Chapter 11-

Iron Alloys

Steel (carbon) (category:steels)

Stainless steel (chromium, nickel) AL-6XN

Alloy 20

Celestrium

Marine grade stainless

Martensitic stainless steel

Surgical stainless steel (chromium, molybdenum, nickel)

Silicon steel (silicon)

Tool steel (tungsten or manganese)

Bulat steel

Chromoly (chromium, molybdenum)

Crucible steel

Damascus steel

HSLA steel

High speed steel

Maraging steel

Reynolds 531

Wootz steel

Iron Anthracite iron (carbon) Cast iron (carbon) Pig iron (carbon) Wrought iron (carbon) Fernico (nickel, cobalt) Elinvar (nickel, chromium) Invar (nickel) Kovar (cobalt) Spiegeleisen (manganese, carbon, silicon) Ferroalloys (category:Ferroalloys) FerroboronFerrochromeFerromagnesiumFerromanganeseFerromolybdenumFerronickelFerrophosphorusFerrotitaniumFerrovanadiumFerrosilicon

Chapter 11-

Steel producing countries

Chapter 11-

Aluminum (or Aluminum!)

•Aluminum is the most abundant metal in the Earth's crust

(8%), although it is not found free in nature.

•Ancient Greeks and Romans used aluminum salts as dyeing

mordants and as astringents for dressing wounds .

•Hans Christian Ørsted created impure metal in 1825 and in

1827 Friedrich Wöhler isolating aluminum by mixing

anhydrous aluminum chloride with potassium.

Chapter 11-

Aluminum pyramid in Washington memorial

•When Frishmuth submitted his bill for the aluminum pyramid it

was for $256.10

•His original quote was $75 for the aluminum pyramid

•The final price of $225 was agreed upon and was paid.

•Millions of people who had never before even heard about

aluminum now knew what it was.

Chapter 11-

Why Aluminum does not

corrode?• Forms a strong, thin protective oxide layer.

Some other metals (for

example Ti, Cr) have the

same protective layer.

Chapter 11-

Electrical/Thermal conductivity

• has 63% of the electrical conductance of

Copper, but less than half the weight.

• It Is used for electrical wires.

• Aluminum wires are not recommended (and

banned in some places) for house wiring.

WHY?

Chapter 11-

Aluminum Applications

• Aluminum is now the

most used metal (2nd is

steel) in cars today.

Chapter 11-

Aluminum Applications

• 15% of global consumption of Aluminum is beverage cans.

• Used extensively in aircrafts (Up to 80%, 777 has 50% Aluminum and 80 percent of the airframe structure of the F-16 is made from Aluminum).

Chapter 11-

Aluminum Applications

• The Space Shuttle itself burns twice as much aluminum (in the solid rocket booster SRBs) as it does hydrogen (total of the elemental hydrogen in the external tank and the chemically combined hydrogen in the SRB fuel).

• Once the solid fuel has been ignited, there is no stopping the reaction until the fuel is spent; solid booster rockets can't be stopped and restarted like liquid fueled ones.

Chapter 11-

Aluminum recycling facts

•Recycling aluminum saves about 95% of the energy it

would take to produce aluminum from its original source,

bauxite.

•Recycling one aluminum can saves enough electricity

to run a TV for three hours.

•Recycling 40 cans conserves the same energy as one

gallon of gasoline.

•Aluminum recycling is so efficient that it can take as few

as 60 days for a can to be collected, melted down and

made into a new can sitting on a grocery store shelf.

•Can be recycled over and over and over again.

Chapter 11-

106,000 aluminum cans, the

number used in the US every

thirty seconds.

From:http://www.chrisjordan.com/current_set2.php?id=7

Chapter 11-

Tin• Tin was known to the ancients and is

mentioned in the Old Testament.

• Early metal workers found it too soft for

most purposes.

• When mixed with copper becomes Bronze.

• Symbol is Sn (Latin: stannum )

Chapter 11-

Tin usage• Bronze• Bronze is the most popular metal for top-quality bells

and cymbals, and more recently, saxophones.

• It is also widely used for cast metal sculpture. Common bronze alloys often have the unusual and very desirable property of expanding slightly just before they set, thus filling in the finest details of a mold. Bronze parts are tough and typically used for bearings, clips, electrical connectors and springs.

• Bronze also has very little metal-on-metal friction, which made it invaluable for the building of cannons where iron cannonballs would otherwise stick in the barrel.

Chapter 11-

Tin usage• Bronze• It is still widely used today for springs, bearings, bushings,

automobile transmission pilot bearings, and similar fittings, and is particularly common in the bearings of small electric motors.

• Phosphor bronze is particularly suited to precision-grade bearings and springs.

• Bronze is typically 88% copper and 12%. Alpha bronze consists of the alpha solid solution of tin in copper. Alpha bronze alloys of 4–5% tin are used to make coins, springs, turbines and blades.

• Another useful property of bronze is that it is non-sparking. That is, when struck against a hard surface, unlike steel, it will not generate sparks. This is used to advantage to make hammers, mallets, wrenches and other durable tools to be used in explosive atmospheres or in the presence of flammable vapors.

Chapter 11-

Tin usage• Bell metal: hard alloy used for making bells (78%

copper, 22% tin).

• Babbitt metal:

Also called white metal, is an alloy used to provide

the bearing surface in a plain bearing. It was invented

in 1839 by Isaac Babbitt .

Common compositions for Babbitt alloys:

90% tin 10% copper

89% tin 7% antimony 4% copper

80% lead 15% antimony 5% tin

Chapter 11-

Tin usage• Die casting (because of low melting temp.)

• pewter1. between 85 and 99 percent tin, with the remainder consisting of 1-15

percent copper. Some other alloys may contain Lead.

2. Physically, pewter is a bright, shiny metal that is very similar--if not

identical--in appearance to silver.

3. Pewter is a very malleable alloy, being soft enough to carve with hand

tools, and it also takes good impressions from punches or presses.

4. Lead poisoning death could result, leading many to believe tomatoes

(high in acid content) were poisonous for several centuries.

Chapter 11-

Tin usage• Solder: (with a melting point or melting range of

180-190°C )

• Tin plate: sheet steel covered with a thin layer

of tin. Before the advent of cheap mild steel

the backing metal was iron. While once more

widely used, the primary use of tinplate now is

the manufacture of tin cans.

Chapter 11-

Tin usage• Battery grids: Lead-calcium-tin alloys have

been developed for storage-battery grids

largely as replacements for antimonies lead

alloys.

• Dental alloys: or making amalgams contain

silver, tin, mercury, and some copper and zinc.

Chapter 11-

Tin facts• Tin Cry: breaking of the crystals

https://www.youtube.com/watch?v=kzIsvbKHgfU

At temperatures below 13.2oC (55.8oF) the gray powder allotrope begins to show more stability than the white metal allotrope. As temperatures decrease below 13.2oC, the shift from the metallic allotrope to the non-metallic allotrope progresses, reaching a maximum at about -30oC (-22oF).

The gradual disintegration of shiny tin metal into a crumbly, gray powder was observed hundreds of years ago on tin organ pipes housed in unheated northern European cathedrals. With allotropy unknown, the phenomenon was attributed to the work of the Devil

Chapter 11-

Tin facts

The story is often told of Napoleon's men freezing in the bitter Russian winter, their clothes falling apart as tin pest ate the buttons. Most think this is just a story!

Tin ingots stored in St. Petersburg became worthless gray powder following a Russian winter. (Chemists restored the valuable white tin metal by melting the gray allotrope.)

Chapter 11-

Tin facts• Tin foil was once a common wrapping

material for foods and drugs; replaced in the early 20th century by the use of aluminum foil.

• Tin becomes a superconductor below 3.72 K Tin becomes a superconductor below 3.72 K. the Meissner effect was first discovered in superconducting tin crystals.

Chapter 11-

Tin pest https://www.youtube.com/watch?v=FUoVEmHuykM

Tin whisker 1: https://www.youtube.com/watch?v=pGZUdnPoU_I

Tin Whisker 2: ttps://www.youtube.com/watch?v=o758FoVY_8w

Tin whisker 3: https://www.youtube.com/watch?v=goyWEYGKPrQ

Tin whisker 4:

https://www.youtube.com/watch?v=nO-7aFZ8c3E

Chapter 11-

Mercury•Named after the Roman god Mercury, known for speed and mobility

•Also called quicksilver

•Chemical symbol : Hg (Latinized Greek: hydrargyrum, meaning watery or liquid silver .

•Mercury was known to the ancient Chinese and Hindus, and was found in Egyptian tombs that date from 1500 BC.

•China's first emperor, Qin Shi Huang Di —said to have been buried in a tomb that contained rivers of flowing mercury, representative of the rivers of China — was driven insane and killed by mercury pills intended to give him eternal life.

Chapter 11-

Mercury

•The ancient Greeks used mercury in ointments

•Romans used it in cosmetics

•By 500 BC mercury was used to make amalgams with other metals.

•Alchemists often thought of mercury as the First Matter from which all metals were formed

Chapter 11-

Mercury facts• The triple point of mercury, -38.8344 °C, is a

fixed point used as a temperature standard for the International Temperature Scale (ITS-90).

Alexander Calder built a mercury fountain for the Spanish Pavilion at the 1937 World's Fair in Paris.

https://www.youtube.com/watch?v=3OIeEU29kEk

Chapter 11-

Mercury Facts• Mercury was once used as a gun barrel bore

cleaner.

• Mercury was used inside wobbler fishing lures.

• Mercury was used for gold and silver mining.

• Liquid mercury was sometimes used as a coolant

for nuclear reactors.

• Mercury was a propellant for early ion engines in

electric propulsion systems

Chapter 11-

Mercury Facts

• Mercury compounds are found in some over-

the-counter drugs, including topical

antiseptics, stimulant laxatives, diaper-rash

ointment, eye drops, and nasal sprays.

Chapter 11-

Applications

Hat making

• From the mid-18th to the mid-19th centuries, a

process called "carroting" was used in the making of

felt hats. Animal skins were rinsed in an orange

solution of the mercury compound mercuric nitrate,

Hg(NO3)2·2H2O. This process separated the fur

from the pelt and matted it together.

Chapter 11-

ApplicationsMedicine

• Mercury (I) chloride (Hg2Cl2 has traditionally been used as a diuretic, topical disinfectant, and laxative. •Mercury (II) chloride (HgCl2) was once used to treat syphilis (along with other mercury compounds), although it is so toxic that sometimes the symptoms of its toxicity were confused with those of the syphilis it was believed to treat. It was also used as a disinfectant. •Blue mass, a pill or syrup in which mercury is the main ingredient, was prescribed throughout the 1800s for numerous conditions including constipation, depression, child-bearing and toothaches. •In the early 20th century, mercury was administered to children yearly as a laxative and de-wormer, and it was used in teething powders for infants. Since the 1930s some vaccines have contained the preservative thiomersal, which is metabolized or degraded to ethyl mercury. Although it was widely speculated that

Chapter 11-

ApplicationsMedicine:Germicidal lamp for producing UV light.

Chapter 11-

Applications

Dentistry•Elemental mercury is the main ingredient in dental amalgams. •Controversy over the health effects from the use of mercury amalgams began shortly after its introduction into the western world, nearly 200 years ago. •In 1845, The American Society of Dental Surgeons, concerned about mercury poisoning, asked its members to sign a pledge that they would not use amalgam. The ASDS disbanded in 1865. •The American Dental Association formed three years after and currently takes the position that "amalgam is a valuable, viable and safe choice for dental patients,“. •In 1993, the United States Public Health Service reported that "amalgam fillings release small amounts of mercury vapor," but in such a small amount that it

Chapter 11-

Applications

INDUSTRIAL:

•The red mercury oxide is used in mercury batteries, developed during II World War, which are compact and stable energy sources.

•The major applications of mercury are in electrical equipment and in control devices, where the fluidity stability, high density and electrical conductivity are essential.

Chapter 11-

Applications

Motor

https://www.youtube.com/watch?v=1fRC7V3KMA4

Chapter 11-

Mercury Poisoning

• Symptoms included tremors, emotional

lability, insomnia, dementia and

hallucinations.

Video Link:

http://www.youtube.com/watch?v=JABbof

wD3MI

Chapter 11-

Part II

Different Metals

Chapter 11- 2

Adapted from Fig. 9.21,Callister 6e.

(Fig. 9.21 adapted from Binary Alloy Phase Diagrams, 2nd ed.,

Vol. 1, T.B. Massalski (Ed.-in-Chief),

ASM International, Materials Park,

OH, 1990.)

Adapted from

Fig. 11.1,

Callister 6e.

TAXONOMY OF METALS

Chapter 11- 3Based on data provided in Tables 11.1(b), 11.2(b), 11.3, and 11.4, Callister 6e.

STEELS

Chapter 11-76

Ferrous Alloys

Iron-based alloys

Nomenclature for steels (AISI/SAE)

10xx Plain Carbon Steels

11xx Plain Carbon Steels (resulfurized for machinability)

15xx Mn (1.00 - 1.65%)

40xx Mo (0.20 ~ 0.30%)

43xx Ni (1.65 - 2.00%), Cr (0.40 - 0.90%), Mo (0.20 - 0.30%)

44xx Mo (0.5%)

where xx is wt% C x 100

example: 1060 steel – plain carbon steel with 0.60 wt% C

Stainless Steel >11% Cr

• Steels

• Cast Irons

Chapter 11- 4

NonFerrous Alloys

• Cu AlloysBrass: Zn is subst. impurity (costume jewelry, coins, corrosion resistant)Bronze: Sn, Al, Si, Ni are subst. impurity (bushings, landing gear)Cu-Be: precip. hardened for strength

• Al Alloys-lower : 2.7g/cm3

-Cu, Mg, Si, Mn, Zn additions -solid sol. or precip. strengthened (struct.

aircraft parts & packaging)

• Mg Alloys-very low : 1.7g/cm3

-ignites easily -aircraft, missles

• Refractory metals-high melting T -Nb, Mo, W, Ta• Noble metals

-Ag, Au, Pt -oxid./corr. resistant

• Ti Alloys-lower : 4.5g/cm3

vs 7.9 for steel -reactive at high T -space applic.

Based on discussion and data provided in Section 11.3, Callister 6e.

NONFERROUS ALLOYS

Chapter 11-

Cast Iron:

Past Semester Project

Chapter 11-79

Cast Irons

• Ferrous alloys with > 2.1 wt% C

– more commonly 3 - 4.5 wt% C

• Low melting – relatively easy to cast

• Generally brittle

• Cementite decomposes to ferrite +

graphite

Fe3C 3 Fe (α) + C (graphite)

– generally a slow process

Chapter 11-80

Types of Cast Iron

Gray iron

• graphite flakes

• weak & brittle in tension

• stronger in compression

• excellent vibrational dampening

• wear resistant

Ductile iron

• add Mg and/or Ce

• graphite as nodules not flakes

• matrix often pearlite – stronger

but less ductile

Figs. 11.3(a) & (b),

Callister &

Rethwisch 9e.[Courtesy of C. H.

Brady and L. C. Smith,

National Bureau of

Standards, Washington,

DC (now the National

Institute of Standards

and Technology,

Gaithersburg, MD]

Chapter 11-81

Types of Cast Iron (cont.)

White iron

• < 1 wt% Si

• pearlite + cementite

• very hard and brittle

Malleable iron

• heat treat white iron at 800-900°C

• graphite in rosettes

• reasonably strong and ductile

Figs. 11.3(c) & (d),

Callister &

Rethwisch 9e.

Co

urtesy

of A

mcast In

dustrial C

orp

oratio

n

Rep

rinted

with

perm

ission o

f the

Iron C

astings S

ociety

, Des P

laines, IL

Chapter 11-82

Types of Cast Iron (cont.)

Compacted graphite iron

• relatively high thermal conductivity

• good resistance to thermal shock

• lower oxidation at elevated

temperatures

Fig. 11.3(e), Callister & Rethwisch 9e.

Co

urtesy

of S

inter-C

ast, Ltd

.

Chapter 11-83

Production of Cast Irons

Fig.11.5, Callister & Rethwisch 9e.(Adapted from W. G. Moffatt, G. W.

Pearsall, and J. Wulff, The Structure and

Properties of Materials, Vol. I, Structure, p.

195. Copyright © 1964 by John Wiley &

Sons, New York. Reprinted by permission of

John Wiley & Sons, Inc.)

Chapter 11-84

Limitations of Ferrous Alloys

1) Relatively high densities

2) Relatively low electrical conductivities

3) Generally poor corrosion resistance

Chapter 11-

More comprehensive information at:

http://en.wikipedia.org/wiki/Cast_iron

Chapter 11-

Part III

Manufacturing

Techniques

Chapter 11-87

Metal Fabrication

• How do we fabricate metals?

– Blacksmith - hammer (forged)

– Cast molten metal into mold

• Forming Operations

– Rough stock formed to final shape

Hot working vs. Cold working• Deformation temperature

high enough for

recrystallization

• Large deformations

• Deformation below

recrystallization

temperature

• Strain hardening occurs

• Small deformations

Chapter 11- 6

Ao Ad

force

die

blank

force

• Forging

(wrenches, crankshafts)

FORMING

• Drawing

(rods, wire, tubing)

often at

elev. T

• Rolling

(I-beams, rails)

• Extrusion

(rods, tubing)

Adapted from

Fig. 11.7,

Callister 6e.

tensile force

Ao

Addie

die

METAL FABRICATION METHODS-I

Chapter 11-

Forging:

http://www.youtube.com/watch?v=mRA6RY2o9Lg

Rolling:

https://www.youtube.com/watch?v=wBXexkRsAJg

Drawing:

https://www.youtube.com/watch?v=2ph3AOxvcR4

Extrusion:

https://www.youtube.com/watch?v=Y75IQksBb0M

Chapter 11-

Extrusion

Chapter 11-

Extrusion

Chapter 11-

Forging

Chapter 11-

Forging

Chapter 11-

Drawing

Chapter 11-

HOT/Cold Rolling

Chapter 11-

plaster

die formed

around wax

prototype

8

CASTING

• Sand Casting

(large parts, e.g.,

auto engine blocks)

• Investment Casting

(low volume, complex shapes

e.g., jewelry, turbine blades)

• Die Casting

(high volume, low T alloys)

• Continuous Casting

(simple slab shapes)

METAL FABRICATION METHODS-II

Chapter 11-

Sand Casting

Chapter 11-

Investment Casting

https://www.youtube.com/watch?v=tyrXq_u1OH0

Chapter 11-

Continuous Casting

Chapter 11-

Powder Metal/MIM

Chapter 11- 9

CASTINGFORMING JOINING

• Powder Processing

(materials w/low ductility)

• Welding

(when one large part is

impractical)

• Heat affected zone:

(region in which the

microstructure has been

changed).

Adapted from Fig.

11.8, Callister 6e.

(Fig. 11.8 from

Iron Castings Handbook, C.F.

Walton and T.J.

Opar (Ed.), 1981.)

piece 1 piece 2

fused base metal

filler metal (melted)base metal (melted)

unaffectedunaffectedheat affected zone

METAL FABRICATION METHODS-III

Chapter 11-

Laser

Video Links:

http://www.youtube.com/watch?v=PlF_oXvbu4s

http://www.youtube.com/watch?v=N7NofmHWWPQ

http://www.youtube.com/watch?v=JKHXxLvsAMA

http://www.youtube.com/watch?v=1IhpaVRbMvA

Chapter 11-

Friction Welding

https://www.youtube.com/watch?v=tyrXq_u1OH0

Chapter 11- 10

Annealing: Heat to Tanneal, then cool slowly.

Based on discussion in Section 11.7, Callister 6e.

THERMAL PROCESSING OF METALS

Chapter 11-

FROM: http://www.materialsengineer.com/E-Steel%20Properties%20Overview.htm

Chapter 11-

Chapter 11-107

Hardenability -- Steels• Hardenability – measure of the ability to form martensite

• Jominy end quench test used to measure hardenability.

• Plot hardness versus distance from the quenched end.

Fig. 11.12, Callister &

Rethwisch 9e. (Adapted from A.G. Guy,

Essentials of Materials Science,

McGraw-Hill Book Company,

New York, 1978.)

Fig. 11.13, Callister &

Rethwisch 9e.

24°C water

specimen (heated to γ

phase field)

flat ground

Rockwell C

hardness tests

Hard

ness,

HR

C

Distance from quenched end

Chapter 11-

Video

• https://www.youtube.com/watch?v=qjsZVi

vfzcg

• https://www.youtube.com/watch?v=nEV6R

qDr9CA

Chapter 11-109

Hardenability vs Alloy Composition

• Hardenability curves for

five alloys each with,

C = 0.4 wt% C

• "Alloy Steels"(4140, 4340, 5140, 8640)

-- contain Ni, Cr, Mo

(0.2 to 2 wt%)

-- these elements shift

the "nose" to longer times

(from A to B)

-- martensite is easier

to form

Fig. 11.15, Callister & Rethwisch 9e. (Adapted from figure furnished courtesy

Republic Steel Corporation.)

Cooling rate (°C/s)

Ha

rdn

ess, H

RC

20

40

60

100 20 30 40 50Distance from quenched end (mm)

210100 3

4140

8640

5140

50

80

100

%M4340

T(°C)

10-1

10 103

1050

200

400

600

800

Time (s)

M(start)

M(90%)

BA

TE

Chapter 11-110

• Effect of quenching medium:

Medium

air

oil

water

Severity of Quench

low

moderate

high

Hardness

low

moderate

high

• Effect of specimen geometry:

When surface area-to-volume ratio increases:

-- cooling rate throughout interior increases

-- hardness throughout interior increases

Position

center

surface

Cooling rate

low

high

Hardness

low

high

Influences of Quenching Medium & Specimen

Geometry

Chapter 11-

• Particles impede dislocation motion.

• Ex: Al-Cu system

• Procedure:

111

0 10 20 30 40 50wt% Cu

L+Lα

α+θθ

θ+L

300

400

500

600

700

(Al)

T(ºC)

composition range available for precipitation hardening

CuAl2

A

Fig. 11.25, Callister & Rethwisch 9e. (Adapted from J.L. Murray, International

Metals Review 30, p.5, 1985. Reprinted by

permission of ASM International.)

Precipitation Hardening

Adapted from Fig.

11.23, Callister &

Rethwisch 9e.

-- Pt B: quench to room temp.

(retain α solid solution)

-- Pt C: reheat to nucleate

small θ particles within

α phase.• Other alloys that precipitation

harden:• Cu-Be

• Cu-Sn

• Mg-Al

Temp.

Time

-- Pt A: solution heat treat

(get α solid solution)

Pt A (sol’n heat treat)

B

Pt B

C

Pt C (precipitate )

Chapter 11-112

• 2014 Al Alloy:

• Maxima on TS curves.

• Increasing T accelerates

process.

Fig. 11.28, Callister & Rethwisch 9e. [Adapted from Metals Handbook: Properties and Selection: Nonferrous Alloys

and Pure Metals, Vol. 2, 9th ed., H. Baker (Managing Ed.), 1979. Reproduced by permission of ASM International,

Materials Park, OH.]

Influence of Precipitation Heat Treatment on

TS, %EL

precipitation heat treat time

tensile

str

ength

(M

Pa

)

200

300

400

1001min 1h 1day 1mo 1yr

204ºC149ºC

• Minima on %EL curves.

%E

L(2

in s

am

ple

)10

20

30

01min 1h 1day 1mo 1yr

204ºC 149ºC

precipitation heat treat time