31/03/2009 Ferrous alloys 1

The purpose of alloying elements

2

To increase hardenablity

To increase the resistance to corrosion and oxidation

To improve high temperature properties

To increase resistance to abrasion

To enhance the strength

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 Disadvantages of alloying
3

Special handling

Temper brittleness in certain grades

Cost

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 Ferrous Alloys
4

Iron is a prime constituent than any other metal type

It is widely used in the world as a result of :

 Iron containing compounds exist in abundant quantities with in the

earth crust

 Metallic Iron and steel alloys are produced using relatively

economical extraction , refining , alloying and other fabrication
technique

 Physical properties of ferrous alloys are extremly versatile

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 Ferrous Alloys
5

 The properties of all alloys are determined by the kinds and amounts
of phases
 Ferrous alloys contains of two or more phases known as ferrite,
austenite, carbides and graphite.

 The alloying element in ferrous alloying element affect the stability

of this phases

 The alloying element also affect the properties of phases in which

each elements exist
 Thus, alloying elements achieve control of the properties of ferrous
alloys Ferrous alloys 31/03/2009
 Limitation of ferrous alloys
6

1) Relatively high density

2) Relatively low conductivity

3) Poor corrosion resistance

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 Phase diagram of Fe-C
7 Temperature oC

Hard and brittle

Austenite

Cementite
Ferrite

STEEL CAST IRON

Fe Fe C
Weight Percent Carbon
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 Classification of Ferrous Alloys
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Metal
Alloys

Ferrous Non
ferrous

Steel Cast Irons

Low alloy High alloy Ductile Malleable

Gray iron White iron
iron Iron

Low Medium High Tool Stainless

carbon Carbon Carbon steel

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 Steel
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It contains Iron and carbon as main constituent

The mechanical properties of steel is highly dependent on the
composition of carbon

Depending on the composition of alloying element it can be
divided into:
• Low carbon steel
• Medium carbon
• High carbon steel

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 Microstructure of Steel
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Five main constituents:

a) Ferrite
b) Austenite
c) Cementite
d) Pearlite
e) Martensite

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 Ferrite
11

Has a body-centred cubic (BCC) crystal structure.

It is soft and ductile and imparts these properties to the steel.
Very little carbon (less than 0.01% carbon will dissolve in ferrite at
room temperature). Often known as α iron.
T(°C)
1600

1400 L Liquid +
γ +L Graphite
1200 γ 1153°C
Austenite 4.2 wt% C
1000
α+γ γ + Graphite
800
740°C
0.65

600
α + Graphite
400
0 1 2 3 4 90 100
(Fe) Co , wt% C alloys
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 Austenite
12

This is the structure of iron at high temperatures

(over 912 oC).

Has a face-centre cubic (FCC) crystal structure.

This material is important in that it is the structure
from which other structures are formed when the
material cools from elevated temperatures.

Often known as γ iron.

Not present at room temperatures.

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 Cementite
13

 A compound of iron and

carbon, iron carbide (Fe3C)
 It is hard and brittle
 its presence in steels causes
an increase in hardness and
a reduction in ductility and
toughness.

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 Pearlite
14

 A laminated structure formed of

alternate layers of ferrite and
cementite.
 It combines the hardness and
strength of cementite with the
ductility of ferrite and is the key to
the wide range of the properties of
steels.
 The laminar structure also acts as a
barrier to crack movement as in
composites, this gives it toughness.

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 Martensite
15

 A very hard needle-like structure

of iron and carbon.
 Only formed by very rapid
cooling from the austenitic
structure (i.e. above upper
critical temperature).

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 Low carbon steel
16

It contains less than about 0.25wt% of C

Un responsive to heat treatments intended to form martensite
It can be strengthened by cold working
Main microstructures are ferrite and pearlite
It is soft and weak
It has an outstanding ductility and toughness , in addition to that they
are machinable ,weldable etc.
They are the least expensive
Mainly employed in car body.
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 Medium Carbon Steel
17

 Carbon concentration is 0.25wt% to 0.6wt%

 It is heat treatable

 Plain medium carbon steel have low hardenablity

 The addition of chromium, nickel, and molybdenum improves the

capacity of these alloys.

 The heat treated alloys are stronger than the low carbon steel , but
they are less ductile and tough

 They are applied in : railway wheels and tracks , gears , crank shaft
and other machine parts and high strength structural components
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 High carbon steel
18

 Carbon content 0.6wt%-1.4wt%

 It the hardest and strongest

 Least ductile and toughness

 It is used in the hardened and tempered condition

 They are wear resistant and capable of holding sharp cutting edges

 The alloying elements like ;Chromium, vanadium, tungsten and

molybdenum are employed to enhance the strength

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 Application of high carbon steel
19

 As a tool of: drill , lathe and planner

 Punches
 Shear blades
 Pipe cutters
 Concrete drills

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 Stainless steel
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• High corrosion resistant

• Chromium is a major constituent (11wt%)
• Nickel and molybdenum can also be added to enhance
corrosion resistant.
• The are used at elevated temperature up to 10000C
• Oxidation resistant's
• There are three classes
a) Martensitic
b) Ferretic
c) Austentic

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 Stainless steel cont.
21

• Marrensitic stainless steels

are heat treatable
• Austentic and ferritic stainless
steels are hadened and
strengthen by cold working
• Austenitic stainless steels are
high corrosion resistant
• Feritic and Martrensitic
stainless steels are more
magnetic

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 Applications of stainless steel
22

 Automotive exhaust components , tanks

 Aircrafts , missiles ,high temperature steam boilers

 Valves for combustion chamber

 Chemical food processing equipments

 Jet engine parts, rifle barrels

 Surgical tools , bearings

 Springs

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 Cast Iron
23

 Ferrous alloys with C contents

above 2.14wt%
 At a temperature higher than
11500C ,it starts to melt , so they
are easily melted and casted
 Brittle
 Cementite is a metastable
compound ,under some conditions
it can be decomposed to form
ferrite and graphite

Fe 3 C → 3 Fe (α ) + C ( grahite )
Equilibrium of iron
Ferrous –carbon
alloys phase diagram
31/03/2009
 Gray iron
24

 Carbon content : 2.5-4wt%

 Silicon content :1-3wt% Ferrite
matrix
 Graphite exist in the form of flakes(similar
to corn flakes surround by ferrite Graphite
 Due to this flakes fracture surface takes
place on a gray appearance
 It is weak and brittle
 The sharp tips of graphite flakes are responsible for point of
stress concentration when external tensile load is applied

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 Gray iron cont.
25

 Strength and ductility is high under compressive load

 capable of damping vibration

Steel

Gray iron

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 Ductile (nodular) iron
26

 It is an alloy of gray iron and small

amount on of Magnesium and /or cerium Ferrite
matrix
 Graphite is appeared in the form of
nodules or spheres instead of flakes
 Spherical graphite are surrounded by Graphite
ferrite or pearlier depending on heat
treatment
 It is more ductile than gray iron
 It is applied in: valves pump bodies, crank
shafts and gears.

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 White iron
27

 It is produced by cooling cast iron of

silicon content less than 1wt% rapidly
Ferrite
 Carbon exist as cementite Cementite

 The name white iron is given ,because

of the appearance of fractured
surface is white
 Due to the presence of cementite ,
white iron is extremely hard and
brittle
 it is applied in very hard and wear
resistance materials
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 Malleable iron
28

• Heating white iron at a temperature 800-

9000C for a prolonged time in a neutral
atmosphere(to prevent oxidation) Graphite
• The decomposition of cementite , forming
graphite which forms in the form of clusters
or rosettes surrounded by a ferrite or Ferrite
pearlite matrix matrix
• Micro structure is similar to the nodular iron
• It contains high strength and appreciable
ductility and malleability
• Application; automotive industry , flanges,
pipe fittings and valves Ferrous alloys 31/03/2009
 Compacted graphite iron (CGI)
29

Silicon content : 1.7-3wt%

Carbon content: 3.1-4wt% Graphite

The microstructure is in the
intermediate between gray iron and
ductile iron Ferrite

Sharp edges of the graphite flakes matrix

is avoided, which results in reduction

of fracture and fatigue resistance of
a material
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 Important properties of CGI
30

High thermal conductivity

Better resistance to thermal shock

Low oxidation at elevated temperature

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 Production of Cast Iron
31
Gf Graphite flakes
Gr Graphite rosettes
Gn Graphite nodules
P Pearlite

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