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ENGINEERING MATERIALS SELECTIONN

CHAPTER 5 :
SELECTION OF FERROUS METALS
1. What is ferrous metal?

2. List two examples of non-ferrous metal.

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 What is ferrous metal?

Metal consists of iron (Fe)

CONTENT
5.1 Introduction
5.2 Classification, Designation & Specification for Steel
5.3 Procurement & Specification

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 5.1 Introduction

Metal Alloy

Ferrous Nonferrous

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 Metal Alloy

Ferrous Nonferrous

Steel Cast Iron

High Alloy Grey Iron

Tool Ductile(Nodular) Iron

Stainless White Iron

Low Alloy Malleable Iron

Low Carbon

Plain

High strength, low alloy

Medium Carbon

Plain

Heat treatable

High Carbon

Plain
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Tool
5.1 Introduction

Ferrous metals & alloys irons with carbon added to them :

Alloys < 2% C STEEL (Keluli)

Alloys > 2% C CAST IRON (Besi Tuang)

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 Fe-C Phase Diagram

Steel Cast Iron

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 High carbon low alloy Steel Low carbon low alloy steel

Cutting Tool
Plain low High strength low
carbon alloy (HSLA)
Plain high carbon
Medium carbon low alloy Steel

Heat
treatable

Plain
medium
carbon

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 High-Carbon Steels
Low-Carbon Steels
Medium-Carbon Steels

Cast Irons Stainless Steels

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5.2 Classification, Designation and
Specifications for Steels
Designation:
American Society for Testing and Materials (ASTM) Standard
E 527 The Unified Numbering System (UNS) of Metals and
Alloys

Classification according to:

Composition
Strength
Product Shape, Finish Processing and Quality Descriptors

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 Classification According to Composition
Plain carbon and low alloy steels coded according AISI
SAE* system Chart_1.ppt

* AISI American Iron and Steel Institution

* SAE Society for Automotive Engineering

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 Classification According to
Composition-AISI-SAE.ppt
AISI SAE
Classifications
Number
1XXX Carbon steels
Low carbon steels: 0 to 0.25 % C
Medium carbon steels: 0.25 to 0.55 % C
High carbon steels: Above 0.55 % Carbon

2XXX Nickel steels

5 % Nickel increases the tensile strength without
reducing ductility.
8 to 12 % Nickel increases the resistance to low
temperature impact
15 to 25 % Nickel (along with Al, Cu and Co) develop
high magnetic properties. (Alnicometals)
25 to 35 % Nickel create resistance to corrosion at
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AISI SAE
Classifications
Number
3XXX Nickel-chromium steels
These steels are tough and ductile and exhibit high wear
resistance , hardenability and high resistance to
corrosion.
4XXX Molybdenum steels
Molybdenum is a strong carbide former. It has a strong
effect on hardenability and high temperature hardness.
Molybdenum also increases the tensile strength of low
carbon steels.
5XXX Chromium steels

86XX Triple Alloy steels which include Nickel (Ni), Chromium

87XX (Cr), and Molybdenum (Mo)
93XX
94XX
97XX

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Example: Carbon Steels

1040

Indicates carbon Carbon content

steel (0.40%)

Modification in the
alloys (none)

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Example: Nickel Steels

2515

Indicates nickel Carbon content

steel (0.15%)

Major alloying element

(5% Nickel)

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Example: Chromium Steels

5120

Indicates Carbon content

chromium steel (0.20%)

Major alloying element

(1% Chromium)

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AISI-SAE vs. ASTM vs. ASME Designations

ASTM designation is an arbitrarily chosen number

prefixed by the letter A, which is designated for ferrous
materials AXYZ
ASTM designation are also adopted by ASME* and
prefixed by letter S SAXYZ

* ASME = American Society for Mechanical

Engineers

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 Classification According to Strength

Generally Plain C steels with low yield strength < 40 ksi

-Common materials used for construction buildings, bridges and
ships

High strength : 40 120 ksi

Up to 80 ksi (HSLA-High Strength Low Alloy)

Ultra-high strength : min. 200 ksi

Used as aerospace and defense industry structural materials

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Classification According to Product Shape, Finish
Processing and Quality Descriptors

Product Shape
According to thickness and width

Bars include
Round, square, hexagon and similar cross section 9.52 mm (
in) and greater across
Small angels, channels, tees and other standard shapes less than
76 mm (3 in) across
Concrete-reinforcing bars

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 Product classification of flat-rolled carbon and low-alloy steels
according to size, width and thickness Shapes factor.ppt

Specified Width (in)

Thickness (in)
More More More More
More
To 3.5 than 3.5 than 6 to than 8 to than 12
than 48
to 6 8 12 to 28

0.230 and above Bara Bara Bara Platea Platea Platea

0.229 0.204 Bara Bara Strip Strip Sheet Platea
0.203 0.180 Strip Strip Strip Strip Sheet Platea
0.179 and below Strip Strip Strip Strip Sheet Sheetb

aSubject to certain conditions, these dimensions are sold as carbon sheet or strip as well
as bars or plate

bThese products classifications for hot-rolled sheet are based on the median point of the
minimum thickness ordered plus full published thickness tolerances

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 Classification According to Product Shape,
Finish Processing
Finish processing:
and Quality Descriptors
Signify the last processing the steel has undergone hot-rolled,
cold-rolled, annealed, hot-dip galvanizing etc. Hot dip
Galvanising.ppt

Quality descriptors
Indicate product suitability for certain applications or
fabrication processes

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Hot dip galvanizing : immersing iron or steel in a bath
of liquid zinc to produce a corrosion resistant

http://www.galvanizeit.org/aga/inspection-course/galvanizing-process
Selection of Carbon & Low-Alloy
Structural Steel

Low carbon low alloy steel & low plain carbon steel used for civil
engineering structures

Alloy addition in low carbon low alloy steel to increase corrosion

resistance or strength

In various form (eg. bars, plates, strips) construction industries

structural steel (hot-rolled steel)

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Selection of Carbon & Low-Alloy Structural Steel:
Weldability, Formability & Machinability

Weldability :
Measure of ease of forming a strong
weld- does not consist of defects/
imperfections
Normally influenced by composition,
heat input and cooling rate

Joining process : Fusion welding

Edges of base materials are machined
(V-groove) provide filler to fill the V-
groove

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Carbon & Low-Alloy Structural Steel:
Weldability, Formability & Machinability

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 Carbon & Low-Alloy Structural Steel:
Weldability, Formability & Machinability

Formability
Sheet & bulk formability or workability
Sheet formability
Ability of the sheet steel to be stretched or drawn
Bulk formability
Relative ease with which metal can be shaped through the deformation
processes of forging, extrusion or rolling
Require good ductility of materials
Selection via FLD (forming limit diagram)

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 Carbon & Low-Alloy Structural Steel:
Weldability, Formability & Machinability

Machinability
Indicate ease or difficulty with which a material can be
machined to the size, shape and desired surface finish.

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Selection of Heat-treatable Carbon &
Low Alloy Steel

Selected based on their hardenability ?

Hardenability: The ability of steel to form martensite on

quenching

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Heat-treatable Carbon & Low Alloy Steel

What is martensite?
Needle-like crystal
structure

http://www.lassp.cornell.edu/sethna/Tweed/Martensite_History.html

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 Heat-treatable Carbon & Low Alloy
Steel

Major uses:
Up to 0.20% C max toughness (weld)
0.30% C hardness (wear) & toughness)
0.40% C high-strength application
0.50% C high-strength & wear
0.60% C heat-treated springs
> 0.60% C tools & bearing (specialized)

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Heat-treatable Carbon & Low Alloy Steel:
ALLOY STEEL
Increase hardenability in ascending order:
Nickel
Silicon
Manganese
Chromium
Molybdenum
Vanadium
Boron

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Heat-treatable Carbon & Low Alloy Steel:
ALLOY STEEL
How to select steels via hardenability procedure? Jominy
End Quench Test.ppt
Data needed:
Correlation of the Jominy equivalent cooling (Jec) rates in
various section sizes for various quenching media
Minimum hardenability curve of steel

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 Jominy End Quench Test

specimen

water

http://img.youtube.com/vi/qW0aUbTWtVM/0.jpg
http://info.lu.farmingdale.edu/depts/met/met205/jominytest.html
 Jominy End Quench Test
Rockwell
Hardness, HRC

http://pmpaspeakingofprecision.com/2009/07/09/hardness-vs-hardenability-there-is-a-difference/

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 Jominy End Quench Test

surface

R
R

Center
Jominy equivalent cooling rates as a function of bar diameters
quenched in agitated water at different locations of the bar sections

Locations in bar sections

Jominy equivalent cooling rates as a function of bar diameters

quenched in agitated oil at different locations of the bar sections

Conversion
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1 inch = 25.4 mm
Jeq ofBDA 20402
different locations in sections of round bars of varying diameters quenched in different media
(number -1,2,3,..)
Classification of heat-treatable (H) steels according to minimum hardenesses at
various Jominy equivalent (Jeq) cooling distances from quenched end

Classification of heat-treatable (H) steels according to minimum hardenesses at

various Jominy equivalent (Jeq) cooling distances from quenched end

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 EXAMPLE CASE STUDY 1

Ramasamy would likes to design the frame of the bicycle. To

fulfill his target, he needs a 75 mm diameter round bar with
a hardness of 42 HRC at about the 1/2-radius position in its
cross section. The steel will be heat-treated in a reducing
atmosphere (non scaling atmosphere) and will be quenched
in an agitated oil bath at an equivalent velocity of 60 m/min.
Therefore, we need to help Ramasamy in determining
the optimum types steel that can
be used by him.

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Solution: Step 1
determine as-quenched hardness (AQ) from the
required/desired hardness
In this case 42 HRC (required hardness)

50 HRC ~ AQ
hardness

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 Solution: Step 2
Requires 75 mm diameter round bar at about the 1/2-radius
quenched in an agitated oil bath at an equivalent velocity of 60m/min

~14 Jeq

Jominy equivalent cooling rates as a function of bar diameters quenched

in agitated oil at different locations of the bar section.
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Solution: Step 3 Match the results of AQ
hardness and Jeq to the Table 1
Table 1
to find the suitable steel for the
Classification of heat-treatable (H) steels according to minimum hardenesses at
various Jominy equivalent (Jeq) cooling distances from quenched end frame of the bicycle

Classification of heat-treatable (H) steels according to minimum hardenesses at

various Jominy equivalent (Jeq) cooling distances from quenched end

Jeq = 14 at 50 HRC
gives steel of 4150
http://www.ileach.co.uk/post/jef_mallett/jef.html

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EXERCISE :

Mr Ong needs to determine the optimum steel to be used for his design of
a mini bridge. The design requires a 75 mm round with a minimum
hardness of 1500 MPa tensile strength at about a -radius position in the
cross section. The steel will be heat treated in non-scaling atmosphere and
will be quenched in an agitated water bath at velocity of 200ft/min.
Determine the suitable steel that can be use by Mr Ong (using Fig.1a 1d
and Table 1).

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 Figure 1a
Figure 1b

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Figure 1c Figure 1d
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Table 1

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 EXAMPLE CASE STUDY 2

A design requires a 50 mm (2 in) diameter round bar with

a minimum hardness equivalent to 1250 MPa
tensile strength at about the 3/4-radius position in its cross
section. The steel will be heat-treated in a reducing
atmosphere (nonscaling atmosphere) and will be quenched
in an agitated oil bath at an equivalent velocity of 200
ft/min. We need to determine the optimum steel that can
be used.

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SOLUTION :
Convert the tensile strength requirement to hardness (use Fig. 1)
The minimum 1250 MPa tensile strength = 390 HB

Figure 1 : Tensile strength as a

function of Brinell hardness
number for steels, in the as-rolled,
normalized, or quenched and
tempered condition.

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 Convert the hardness in HB to HRC (Fig 2).
390 HB = 42 HRC

Figure 2 : Relationship between BHN and HRC for steels

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 Convert the hardness in HRC to the as-quenched (AQ) hardness (use
Fig 3).
42 HRC = 50 HRC as-quenched hardness
Figure 3 : As-quenched
hardness of steel as a function
of the desired hardness
(HRC) after tempering.

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 Use Fig 4 or Fig 5 (a) to get the Jominy equivalent cooling (Jec) at the
-radius of a 50 mm diameter bar.
Jec = 7.5 units from the quenched end.

Figure 4 : Jominy equivalent cooling rates as a function of bar

diameters quenched in agitated oil at different locations of the bar
section.
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 OR by using Fig 5 (a)
Jec = 7.5 units from the quenched end.

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 Refer to Table 1, using the 50 HRC at 7.5 J, we obtain
three possible steels 5160, 9262 and 50B50.
To increase the number of steels from which to select, we
can also use the steels that will give 50 HRC at the 8J
position we get 3 steels, 4142, 81B45 and 8650.

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 Table 1 :

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EXERCISE :

Mr Ong needs to determine the optimum steel to be used for his design of
a mini bridge. The design requires a 75 mm round with a minimum
hardness of 1500 MPa tensile strength at about a -radius position in the
cross section. The steel will be heat treated in non-scaling atmosphere and
will be quenched in an agitated water bath at velocity of 200ft/min.
Determine the suitable steel that can be use by Mr Ong (using Fig.1a 1d
and Table 1).

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 Figure 1a
Figure 1b

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Figure 1c Figure 1d
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Table 1

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