ME 1101 Workshop Engineering 1

Lecture 6: Engineering Materials-

Ferrous and Non Ferrous Metals

R.M.R.C. Udayanandana, B.Sc.Eng. (Hons), P.G.Dip.

Assistant Lecturer

Email: rmrcu@yahoo.com

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 Content
• Materials Classification
• Classification of metals
• Ferrous & non ferrous
• Applications & properties
• Ferrous Metallurgy
• Specific types of steels
• Non-ferrous metals
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 Materials Classification – Metals
Pure metals or combinations of metallic elements
(alloys) – metallic bonding
• Dense
• Good electrical conductors
• Good heat conductors
• Shiny appearance
• Strong 10-10
10 -8 -10-1
• Deformable- malleable
10 -8 -10-4
• Sometimes magnetic
> 10 -6
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 Materials Classification – Ceramics
Compounds between metallic and non-metallic
elements - Ionic or covalently bonded

• Hard
• Brittle
• Electrical insulators
• Poor thermal conduction
• Heat and corrosion resistant
• Can be transparent or opaque

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 Materials Classification – Polymers
Organic compounds based on C, H and other
non-metallic elements – covalent and
secondary bonding

• Huge variety of properties

• Low densities
• Non-conductors
• Low melting points
• Can be very flexible

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 Materials Classification -Composites
-which consist of more than one material type

• Fiberglass, a combination of glass

and a polymer, is an example.
• Concrete and plywood are other
familiar composites.
• Many new combinations include
ceramic fibers in metal or polymer
matrix.

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 Atom Arrangements in Materials
• Atom bond together to form aggregates
• Depending on the manner of atomic grouping,
materials are classified as:
– Molecular structures
– Crystal structures
– Amorphous structures

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Crystal Structures of Metals

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 Crystal Structures of Metals
• Aluminum — FCC • Lead — FCC
• Chromium — BCC • Nickel — FCC
• Copper — FCC • Silver — FCC
• Iron (alpha) — FCC • Titanium — HCP
• Iron (gamma) — BCC • Tungsten — BCC
• Iron (delta) — BCC • Zinc — HCP

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 Crystal Formation
• Crystallization is the transition from the liquid
to the solid state and
• occurs in two stages:
– Nucleus formation
– Crystal growth

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 Crystal Formation

Mechanism of solidification (square grids represent the unit

cells)
(a) Nucleus formation
(b), (c) Growth of the crystallites
(d) Grain boundaries
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 Elastic Deformation
• When a sufficient load is applied to a metal or
other structural material, it will cause the
material to change shape.
• This change in shape is called deformation.
• Elastic deformation describes the effect of a
metal returning to it‘s original shape when a
load (or force) is removed

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Plastic Deformation

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 Metals
• Properties that satisfy a wide variety of
design requirement

High strength & stiffness

Toughness

Good electrical conductivity

Good thermal conductivity

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• Manufacturing Methods which they are
shaped into products
• Cost is low with other Engineering
materials
• But pure metal is very soft and weak

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 Classification of metal alloys
Metal alloys

ferrous non- ferrous

cast iron steels

grey

white 19
 Ferrous Metal
• Ferrous metal include all forms of iron &
steel alloys
• Ferrous metals are magnetic
• Main Iron ores

Magnetite (Fe3O4)

Hematite (Fe2O3)

Limonite (2Fe2O3 + 3H2O)

Siderite (FeCO3)
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• Iron Ores are refined to remove
Impurities (C, O2 , 3H2O)
Fe2O3 + 3CO 2Fe + 3CO2

• Pig iron is obtain from the iron ores by

smelting in a Blast Furnace
• Reducing agents are Coke & Limestone
(Dolomite)

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 Pig Iron

• Contain 93% iron, 3%-5% Carbon &

various other elements
• Weak & brittle due to high carbon
content
• Wrought iron, steel & cast iron produced
using pig iron.

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 Wrought Iron
• Puddling furnace is used to produce
wrought iron
• Carbon is eliminate as the form of carbon
monoxide
• It can be welded, machined & formed
• Used to make rivets, bolts, chains , water
and steam pipes & ornamental iron
works
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Nut & bolt

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 Cast Iron
• Contain 2-4% Carbon & Silicon
• Cupola furnace is used to produce cast
iron
• High compressive strength & wear
resistance
• Alloying with nickel, chromium improve
toughness &tensile strength.
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Cupola furnace 27
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Advantages
• Can be sand cast to complex shapes
using basic technology
• Can be melted easily & Very fluid
• Clean surface
• Range of Strengths & Hardness

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Disadvantage
• Brittle, cannot be used for high stress
• Low impact properties
• Two types

Gray Cast iron

White Cast iron
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 Gray Cast iron
Properties
• Oldest and most common
• Excellent machinability
• Self-lubricating properties
• Weak in tension
• Wear resistance
• Good vibration damping
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 Gray Cast iron
Applications

Crank shaft

Machine parts
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Drain cover Engine Block

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Auto parts, machine parts, pump parts, gear box
castings, motorcycle parts, couplings, flanges, fittings,
pulleys, engine exhaust manifolds, burners, grates,
grills, plates 34
 White Cast iron
• Iron carbide (Fe3C)
• Very hard & High wear resistance
• Un- machinebility
• Very brittle
Adding Chromium, increase hardness and
improve abrasion resistance.
Cr 10% used for railway-car wheels,
crushing rolls, stamp shoes and dies &
many heavy-duty machinery parts
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 Steel
• Iron – carbon alloy ( ≤ 1.7 wt % carbon)
• Plain Carbon Steels (Fe +C +Mn )
• Alloy Steels (Fe +C +Mn +other additions )
• Steel is obtaining refining pig iron
• The Bessemer converter, open hearth
furnace, electric arc furnace can be used to
produce steel
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• Steel can be cast
technically difficult (due to high melting
temperature & high cost)

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 Steel
Advantages Disadvantages
• Low cost • Heavy (high density)
• High strength • Poor Corrosion
• Relatively high resistance
Toughness
• Can be Weld

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 Steel bridges & structures

• Ironbridge, made of
cast iron

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furniture

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 Stainless steel
• Fe with >11 wt% Cr = stainless steel
• Combination of high strength & ductility
• Adding Cr, Cr+ O2 → Cr2O3 formation
oxide protects the primary alloy
• Adding Ni increase corrosion protection

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 Applications
• Resistance to corrosion
• Low maintenance
• Relatively low cost
• Coils , sheets, plates, bars, wire available
• Tubing to be used in cookware, cutlery,
surgical instruments, industrial
equipment, and automotive and
aerospace
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• Storage tanks & tankers used to transport
orange juice & other food (corrosion
resistance and antibacterial properties)
• Commercial kitchens & food processing
plants (steam cleaned, sterilized, no need
of painting)

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 applications
Kitchen equipments , Soaking tub, die baths
food container,

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New York's Chrysler Building is
clad with stainless steel Architectural work

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 Non-ferrous alloys
• Aluminium and Aluminium alloys
• Magnesium and Magnesium alloys
• Titanium and Titanium alloys
• Copper and Copper alloys
• Nickel and Nickel alloys
• Super alloys

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 Properties
• Light weight
• Stiffness –strength to weight ratio
• High temperature properties
• Corrosion resistance
• Biocompatibility
• Oxidation resistance
• High cost
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Materials Density(g.cm-3)
• Iron 7.87
• Steel 7.80
• Aluminium 2.70
• Magnesium 1.74
• Titanium 4.54
• Copper 8.96
• Zinc 7.13
• Nickel 8.89
• Lead 11.36
• Silver 10.49
• Gold 19.32

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 Aluminium and its alloys
Properties Applications
• Light weight • Building/construction
• High corrosion resistance • Container
• High electrical and • Packaging
thermal conductivities
• Transportation
• High ductility
• Electrical conductors
• Easily deformable
• Machinery/equipment
• Low melting point (600˚C)

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 Applications

Automobile body Light-weight bike

Equipments

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 Magnesium and its alloys

Advantages: Disadvantages:
• Very low density • Expensive
(1.74 g/cm3) • Difficulty in
• High machinability melting process
• Low wear
resistance
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 Applications
• Used as alloying element for
Aluminium, steel & ductile cast iron.
• Die casting for aerospace
• Transport industry

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Magnesium side Mobile phone
panels bodies

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The missile fuselage
was constructed
with magnesium
frames and
aluminium alloy

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 Titanium and its alloys
Advantages:
Disadvantages:
• Medium density
(4.54 g/cm3) • High cost

• High melting • Difficulty in

point (1700˚C) extraction
• Good Corrosion • Expensive in
resistance production
• Biocompatibility
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 Applications
• Structure of high speed aircrafts
• 75% in aerospace
• Medical Applications

Turbine blades Hip-joint

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Turbine blades Aeroengine Fan
Blades

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 Copper and its alloys
Properties

• High electrical conductivity

• High thermal conductivity
• High corrosion resistance
• Good ductility and malleability
• Reasonable tensile strength.

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 Applications

• Electrical conductance
• Plating on components
• Different copper alloys; brasses and
bronzes

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 Applications
Electronic
Copper wires
products Copper plating

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Forged Rings Bullet jackets

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 Nickel and its alloys
Properties
• Tough and ductile
• Good high and low temperature strength
• High oxidation resistance
• Good corrosion resistance
• High cost
• Not normally mixed with cheaper alloying
metals

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 Applications

• Applications required necessary

corrosion or heat- resisting properties
• Special engineering applications
• Turbine blades in combustion section

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 Applications
Pipes, tubes, bar, wire, sheet,
Machine parts plate, forgings, pipe fittings
and flanges.

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Titanium alloys have superior specific strength
than steels or aluminium good for high strength
where high temperature applications such as
aircrafts.

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