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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 Aphroditehttp://www.facts- about.org.uk/science/ Venus in- elementGreek-copper.htm and Roman mythology. There are reports of copper beads dating back to 9000BC found 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
implantable insulin pump
rheumatoid arthritis Chapter 11- FAKE GOLD
HOW? Alloying: All started with Archimedes!
Plating: Thick plating on heavy metal
Mineral:
Fool’s Gold, Pyrite (Iron Chapter 11- Sulfide) 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: Silver French: Argent German: Silber Italian: Argento Latin: Argentum Spanish: Plata
Argentina is named after Silver Chapter 11- Source:http://www.silverinstitute.org 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 Properties Antibacterial properties
The ancient Phoenicians carried wine in silver containers to keep it fresh. A number of food and beverage makers use silver in food preparation to keep equipment free from bacteria
Colloidal soap bar is being sold .
Silver based cleaner are used in swimming pools.
Silver based water filter is used to remove water born disease agents. 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.aspChapter 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 Delhi 7.3 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=9l7JqonyoChapter 11- KA Iron Alloys
Steel (carbon) (category:steels) Iron Stainless steel (chromium, nickel) Anthracite iron (carbon) AL-6XN Cast iron (carbon) Alloy 20 Pig iron (carbon) Celestrium Wrought iron (carbon) Marine grade stainless Fernico (nickel, cobalt) Martensitic stainless steel Surgical stainless steel (chromium, molybdenum, nickel) Elinvar (nickel, chromium) Silicon steel (silicon) Invar (nickel) Tool steel (tungsten or manganese) Kovar (cobalt) Bulat steel Spiegeleisen (manganese, carbon, Chromoly (chromium, molybdenum) silicon) Crucible steel Ferroalloys (category:Ferroalloys) Damascus steel Ferroboron HSLA steel Ferrochrome High speed steel Ferromagnesium Maraging steel Ferromanganese Reynolds 531 Ferromolybdenum Wootz steel Ferronickel Ferrophosphorus Ferrotitanium Ferrovanadium Ferrosilicon
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.) • pewter 1. 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 workChapter of the 11- Devil 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/w atch?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- Applications Medicine
• 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 metabolizedChapter 11- or degraded to ethyl mercury. Although it was widely speculated that Applications Medicine: 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 amountsChapter 11- of mercury vapor," but in such a small amount that it 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- TAXONOMY OF METALS
Adapted from Fig. 11.1, Callister 6e.
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.)
Chapter 11- 2 STEELS
Based on data provided in Tables 11.1(b), 11.2(b), 11.3, and 11.4, Callister 6e. Chapter 11- 3 Ferrous Alloys Iron-based alloys • Steels • Cast Irons
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 76 Chapter 11- NONFERROUS ALLOYS • Cu Alloys • Al Alloys Brass: Zn is subst. impurity -lower : 2.7g/cm3 (costume jewelry, coins, -Cu, Mg, Si, Mn, Zn additions corrosion resistant) -solid sol. or precip. Bronze: Sn, Al, Si, Ni are strengthened (struct. subst. impurity aircraft parts (bushings, landing & packaging) gear) NonFerrous • Mg Alloys Cu-Be: -very low : 1.7g/cm3 precip. hardened Alloys -ignites easily for strength -aircraft, missles • Ti Alloys -lower : 4.5g/cm3 • Refractory metals -high melting T
vs 7.9 for steel • Noble metals -Nb, Mo, W, Ta -reactive at high T -Ag, Au, Pt -space applic. -oxid./corr. resistant
Based on discussion and data provided in Section 11.3, Callister 6e. Chapter 11- 4 Cast Iron:
Past Semester Project
Chapter 11- 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) 79 Chapter 11- – generally a slow process Types of Cast Iron Figs. 11.3(a) & (b), Callister & Gray iron Rethwisch 9e. [Courtesy of C. H. Brady and L. C. Smith, • graphite flakes National Bureau of Standards, Washington, DC (now the National • weak & brittle in tension Institute of Standards and Technology, • stronger in compression Gaithersburg, MD] • excellent vibrational dampening • wear resistant
Ductile iron • add Mg and/or Ce • graphite as nodules not flakes • matrix often pearlite – stronger but less ductile 80 Chapter 11- Types of Cast Iron (cont.)
Figs. 11.3(c) & (d), Corporation Industrial ofAmcast Courtesy Callister & White iron Rethwisch 9e. • < 1 wt% Si • pearlite + cementite
• very hard and brittle Iron Castings Society, Des Plaines, IL Plaines, Des Society, Castings Iron Malleable iron the of permissionwith Reprinted • heat treat white iron at 800-900°C • graphite in rosettes • reasonably strong and ductile
81 Chapter 11- Types of Cast Iron (cont.)
Compacted graphite iron ofSinter Courtesy • relatively high thermal conductivity
• good resistance to thermal shock
- Cast, Ltd. Cast, • lower oxidation at elevated temperatures
Fig. 11.3(e), Callister & Rethwisch 9e.
82 Chapter 11- 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.)
83 Chapter 11- Limitations of Ferrous Alloys
1) Relatively high densities 2) Relatively low electrical conductivities 3) Generally poor corrosion resistance
84 Chapter 11- More comprehensive information at: http://en.wikipedia.org/wiki/Cast_iron
Chapter 11- Part III Manufacturing Techniques
Chapter 11- Metal Fabrication
• How do we fabricate metals? – Blacksmith - hammer (forged) – Cast molten metal into mold
• Forming Operations – Rough stock formed to final shape • Deformation temperature • Deformation below highHot enoughworking for vs. Coldrecrystallization working recrystallization temperature • Large deformations • Strain hardening occurs • Small deformations
87 Chapter 11- METAL FABRICATION METHODS-I
FORMING • Forging • Rolling (wrenches, crankshafts) (I-beams, rails) force die often at Ao blank Ad elev. T
Adapted from force Fig. 11.7, • Drawing • Extrusion Callister 6e. (rods, wire, tubing) (rods, tubing)
die Ad A tensile o force die
Chapter 11- 6 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- METAL FABRICATION METHODS-II
CASTING • Sand Casting • Die Casting (large parts, e.g., (high volume, low T alloys) auto engine blocks)
• Continuous Casting • Investment Casting (simple slab shapes) (low volume, complex shapes e.g., jewelry, turbine blades) plaster die formed around wax prototype Chapter 11- 8 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- METAL FABRICATION METHODS-III
FORMING CASTING JOINING • Powder Processing • Welding (materials w/low ductility) (when one large part is impractical) filler metal (melted) base metal (melted) fused base metal heat affected zone unaffected unaffected Adapted from Fig. piece 1 piece 2 11.8, Callister 6e. (Fig. 11.8 from Iron Castings • Heat affected zone: Handbook, C.F. Walton and T.J. (region in which the Opar (Ed.), 1981.) microstructure has been changed). Chapter 11- 9 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- THERMAL PROCESSING OF METALS Annealing: Heat to Tanneal, then cool slowly.
Based on discussion in Section 11.7, Callister 6e. Chapter 11- 10 FROM: http://www.materialsengineer.com/E-Steel%20Properties%20Overview.htm
Chapter 11- Chapter 11- Hardenability -- Steels • Hardenability – measure of the ability to form martensite • Jominy end quench test used to measure hardenability.
Fig. 11.12, Callister & flat ground Rethwisch 9e. specimen (Adapted from A.G. Guy, Essentials of Materials Science, (heated to γ McGraw-Hill Book Company, New York, 1978.) phase field) Rockwell C 24°C water hardness tests
• Plot hardness versus distance from the quenched end.
Fig. 11.13, Callister &
Rethwisch 9e. Hardness, HRC Hardness,
Distance from quenched end 107 Chapter 11- Video
• https://www.youtube.com/watch?v=qjsZVi vfzcg • https://www.youtube.com/watch?v=nEV6R qDr9CA
Chapter 11- Hardenability vs Alloy Composition • Hardenability curves for 100 10 3 2 Cooling rate (°C/s) 60 five alloys each with, 100 C = 0.4 wt% C 4340 80 %M 50 40 4140
Fig. 11.15, Callister & Rethwisch 9e. 8640 Hardness, HRC Hardness, (Adapted from figure furnished courtesy 5140 Republic Steel Corporation.) 20 0 10 20 30 40 50 Distance from quenched end (mm) • "Alloy Steels" 800 T (4140, 4340, 5140, 8640) T(°C) E -- contain Ni, Cr, Mo 600 A B (0.2 to 2 wt%) 400 -- these elements shift M the "nose" to longer times 200 (start) (from A to B) M(90%) -- martensite is easier 0 -1 3 5 Time (s) 10 10 10 10 109 to form Chapter 11- Influences of Quenching Medium & Specimen Geometry • Effect of quenching medium:
Medium Severity of Quench Hardness air low low oil moderate moderate water high high • Effect of specimen geometry: When surface area-to-volume ratio increases: -- cooling rate throughout interior increases -- hardness throughout interior increases Position Cooling rate Hardness center low low surface high high
110 Chapter 11- Precipitation Hardening • Particles impede dislocation motion. • Ex: Al-Cu system 700 T(ºC) L CuAl • Procedure: 600 2 α +L θ+L -- Pt A: solution heat treat A (get α solid solution) 500 θ -- Pt B: quench to room temp. α + θ 400 C (retain α solid solution) -- Pt C: reheat to nucleate 300 0 B 10 20 30 40 50 small θ particles within (Al) wt% Cu α phase. composition range • Other alloys that precipitation available for precipitation hardening Fig. 11.25, Callister & Rethwisch 9e. harden: Temp. (Adapted from J.L. Murray, International Pt A (sol’n heat treat) Metals Review 30, p.5, 1985. Reprinted by • Cu-Be permission of ASM International.) • Cu-Sn • Mg-Al Pt C (precipitate )
Adapted from Fig. 11.23, Callister & Time Pt B Rethwisch 9e. 111 Chapter 11- Influence of Precipitation Heat Treatment on TS, %EL • 2014 Al Alloy: • Maxima on TS curves. • Minima on %EL curves. • Increasing T accelerates process.
30 400 20
300 in in sample)
2 2 10
149ºC ( 200 149ºC
204ºC 204ºC EL
100 % 0
tensile strength (MPa) strength tensile 1min 1h 1day 1mo 1yr 1min 1h 1day 1mo 1yr precipitation heat treat time precipitation heat treat time
Callister & Rethwisch 9e [Adapted from Metals Handbook: Properties and Selection: Nonferrous Alloys Fig. 11.28, . 112 and Pure Metals, Vol. 2, 9th ed., H. Baker (Managing Ed.), 1979. Reproduced by permission of ASM International, Chapter 11- Materials Park, OH.]