A REFRESHER ON

INDUSTRIAL & FERTILIZER MATERIALS

By Waqas CH

YOUR ASSESSMENT

1 – Iron with temporary magnetic field

2 – Stainless Steel Urea Grade or 25-22-02

5 - a - Austenitic b - Martensitic c - Ferritic d - Duplex

4 - Material which contains by mass more iron than any other material

6 - No

7 – Low Carbon Steel

8 - Copper

9 - Killed Carbon Steel

3 - Yes

MATERIAL CLASSIFICATION

METALS

NON - METALS

NON - FERROUS

FERROUS FERROUS

MATERIALS

FERROUS METALS

ORIGINAL DEFINITION

- IRON CONTENTS GREATER THAN 50%.

REVISED DEFINITION (1993)

- MATERIAL WHICH CONTAINS BY MASS MORE IRON THAN ANY

OTHER SINGLE ELEMENT.

Cr : 26 max.Ni : 22 max.

Mn : 02 max.Si : 1.5 max.

Total : 51.5 max.

SS 310

CLASSIFICATION FERROUS METALS

FERROUS METALS

CARBON STEEL

CAST IRON

ALLOY STEEL

WROUGHT IRON

BASED ON “C” ADDITION

IRON ORE

COKE

LIME STONE

BLAST FURNACE

IRON MAKING STEEL MAKING CONTINUOUS CASTING PRODUCTS

BASIC OXYGEN FURNACE

ELECTRIC ARC FURNACE BILLETS

CASTING

REHEATING FURNACE

PLATES

RODS

PIPEPIG IRON

WROUGHT IRON

CLASSIFICATION FERROUS METALS

FERROUS METALS

CARBON STEEL

CAST IRON

ALLOY STEEL

WROUGHT IRON

BASED ON “C” ADDITION

PROPERTIES OF MATERIALS

ELASTICITY

-The property of a material due to which it comes to its original shape

after the removal of load is called elasticity.

- There is a certain limit of every material upto which it can regain its

original shape. This limit is called Elastic Limit.

PLASTICITY

-The property of a material due to which it is permanently deformed

(re-shaped) on the application of load, without any rupture is called

plasticity.

PROPERTIES OF MATERIALS

HARDNESS

- It is the property of a material due to which it resists wear, abrasion

and indentation.

- Also hardness is the property which enables to cut the other material.

TOUGHNESS

-Ability of material to resist fracture due to sudden shocks

(impact loads) or bending/twisting is called toughness.

PROPERTIES OF MATERIALS

STIFFNESS

- Ability of a material to resist deformation due to the external forces

is called stiffness.

BRITTLENESS

- The property of a material to easily break up into pieces

without deformation is called brittleness.

DUCTILITY

- Ability of a material to be drawn into wires or undergo elongation

without fracture is called ductility.

PROPERTIES OF MATERIALS

STRENGTH

- It is the ability of a material to withstand the external forces of different

types before undergoing the permanent deformation or fracture

- Tensile strength ….. Maximum tension beared per unit area

- Compressive strength ….. Maximum compression beared per unit area

- Shear strength ….. Maximum shearing force beared per unit area

PROPERTIES OF MATERIALS

MALLEABILITY

- If a material can be rolled or hammered to thin sheet, it's

property is called malleability

CONDUCTIVITY

- Ability of a material to allow the passage of heat or electricity

through it, is called its conductivity

WELDABILITY

- Ability of a material to join by welding

EFFECT OF CARBON ON STEEL

Hardness Strength Ductility Weldability

Carbon

WROUGHT IRON

COMPOSITION

MECHANICAL PROPERTIES

- CONTAINS SMALL AMOUNT OF SLAG (SiO2)

- CARBON CONTENTS LESS THAN 0.08 % CARBON

USES

- EASILY WELDABLE

- LOW STRENGTH , MALLEABLE AND DUCTILE

- CURRENTLY WROUGHT IRON IS NOT PRODUCED DUE TO HIGH

MANUFACTURING COST

- MODERN WROUGHT IRON PRODUCTS ARE ACTUALLY MADE

FROM LOW CARBON STEEL

CARBON STEEL

CARBON STEEL IS CLASSIFIED ACCORDING TO:

ITS TREATMENT FOR DEOXIDIZATION

ITS CARBON CONTENTS

TYPE OF STEEL FOR WHICH:

- CARBON CONTENTS ARE < 2%

- NO ALLOYING ELEMENT IS ADDED EXCEPT CARBON

CARBON STEEL CLASSIFICATION ACCORDING TO CARBON CONTENTS

CARBON STEEL

LOW CARBON STEEL

MEDIUM CARBON STEEL

HIGH CARBON STEEL

CARBON CONTENTS < 0.3 %

CARBON CONTENTS BETWEEN 0.3 % AND 0.6%

CARBON CONTENTS BETWEEN 0.6 % AND 2.0%

EFFECT OF CARBON ON MICROSTRUCTURE

Low Carbon Steel Medium Carbon Steel

High Carbon Steel Cast Iron

LOW CARBON STEEL

COMPOSITION

MECHANICAL PROPERTIES

- LESS THAN 0.3 % CARBON

GENERAL USES

- GRADES HAVING CARBON B/W 0.1 % TO 0.3 % ARE HEAT TREATABLE

- EXCELLENT FORMABILITY AND WELDABILITY

- SHEETS MANUFACTURING, PIPING AND PRESSURE VESSEL

COMPONENTS

LOW CARBON STEEL

USED AT FERTILIZER PLANT

- LOW, MEDIUM AND HIGH PRESSURE STEAM/CONDENSATE

- PIPING, VALVES AND VESSELS FOR

- COOLING WATER, INSTRUMENT AIR, FUEL GAS, NATURAL GAS

- LIQUID AMMONIA (HIGH TEMPERATURE)

- LOAD BEARING STRUCTURES AND SHEETS

LOW CARBON STEEL GRADES

API 5L GRADE B

ASTM A - 105

ASTM A - 234

MEDIUM CARBON STEEL

COMPOSITION

MECHANICAL PROPERTIES

- CARBON CONTENTS BETWEEN 0.3% TO 0.6%

GENERAL USES

- HEAT TREATABLE

- GOOD BALANCE BETWEEN STRENGTH AND DUCTILITY

- MANUFACTURING OF GEARS, CRANKSHAFT ETC.

HIGH CARBON STEEL

COMPOSITION

MECHANICAL PROPERTIES

- CARBON CONTENTS BETWEEN 0.6% TO 2.0%

GENERAL USES

- LOW DUCTILITY

- HIGH STRENGTH

- HIGH STRENGTH WIRES AND SPRINGS

- POOR WELDABILITY AND FORMABILITY

CARBON STEEL CLASSIFICATION ACCORDING TO DEOXIDIZATION TREATMENT

CARBON STEEL

CAPPED STEEL

SEMI KILLED STEEL

KILLED STEEL

NO DEOXIDIZER IS ADDED

DEOXIDIZERS ARE ADDED IN SMALL QUANTITY

DEOXIDIZERS ARE ADDED IN SUFFICIENTQUANTITY

RIMMED STEEL

MOLTEN STEEL IS CAPPED TO STOP RIMMING ACTION

KILLED CARBON STEEL

COMPOSITION

MECHANICAL PROPERTIES

- CARBON STEEL WITH INCLUSION OF SILICON OR ALUMINUM

GENERAL USES

- INCREASED STRENGTH DUE TO HOMOGENOUS MICRO STRUCTURE

- PRESSURE VESSEL, PIPING ETC.

USES AT FERTILIZER PLANT

- PIPING, VALVES AND VESSELS FOR LOW TEMPERATURE LIQUID

AMMONIA

- DIFFICULT WELDING AS HEAT TREATMENT IS INVOLVED

CAST IRON

COMPOSITION

MECHANICAL PROPERTIES

- CARBON CONTENTS BETWEEN 2% AND 5%

GENERAL USES

- MELTING TEMPERATURE BELOW CARBON STEEL

- POOR WELDABILITY AND DUCTILITY

- EXCELLENT FLUIDITY (REQUIRED FOR CASTING PURPOSE)

- SILICON INCLUSION BETWEEN 1% AND 3%

- MANUFACTURING OF PUMPS, TURBINES, COMPRESSORS AND GEAR BOX

CASINGS

CLASSIFICATION FERROUS METALS

FERROUS METALS

CARBON STEEL

CAST IRON

ALLOY STEEL

WROUGHT IRON

BASED ON “C” ADDITION

ALLOY STEELS

ALLOY STEEL

LOW ALLOY STEEL

HIGH ALLOY STEEL

ALLOYING ELEMENT UP TO 8.0%

ALLOYING ELEMENT GREATER THAN 8.0%

CORROSION RESISTANT

HEAT RESISTANT

WEAR RESISTANT

Cr-Mo Alloy

Cr – Mo STEELS

GENERAL USES

- PRESSURE VESSEL, PIPING AT HIGH TEMPERATURE

COMPOSITION

- Cr UPTO 2.25% AND Mo UP TO 1.25%

MECHANICAL PROPERTIES

- HIGH STRENGTH AT TEMPERATURES UP TO 650 0C

- DIFFICULT WELDING AS HEAT TREATMENT IS INVOLVED

ALLOYING EFFECT

- Cr INCREASES CORROSION RESISTANCE

- Mo ADDS ELEVATED TEMPERATURE STRENGTH

Cr - Mo STEEL GRADES

A-335 GRADE P11 (PLANT-I KS)

Cr – Mo STEELS

A-335 GRADE P22 (PLANT-I KS)

USES AT FERTILIZER PLANT

- PIPING, VALVES AND VESSELS FOR VER HIGH PRESSURE STEAM (KS)

STAINLESS STEEL

WHEN Cr CONTENTS ARE GREATER THAN 11.5 %, Cr REACTS WITH

ATMOSPHERIC O2 AND FORM THIN PASSIVE Cr-O2 LAYER ON STEEL

SURFACE PREVENTING OXIDATION OF Fe CONTENTSCr–O2 LAYER

STEEL

EFFECT OF CHROMIUM

STAINLESS STEEL

FERRITIC

MARTENSITIC

DUPLEX

AUSTENITIC

STAINLESS STEEL

SCHAFFLER DIAGRAM

COMPOSITION

MECHANICAL PROPERTIES

GENERAL USES

- GOOD WELDABILITY

- EXCELLENT CORROSION RESISTANT

- FOOD PROCESSING, CORROSIVE SERVICES e.g. UREA, ACID etc.

- CAN BE USED AT LOW AND HIGH TEMPERATURE (UP TO 900 0C)

Ni UP TO 30%

Cr UP TO 30%

C 0.3%

AUSTENITIC STAINLESS STEEL

- CANNOT BE HARDENED BY HEAT TREATMENT

USED AT FERTILIZER PLANT

- ALL PRESSURE UREA SERVICE AND UREA FLUSHING CIRCUIT

- PIPING, VALVES AND VESSELS FOR

- MDEA, PROCESS GAS, DEMIN WATER

AUSTENITIC STAINLESS STEEL

AUSTENITIC GRADES

SS- 304

SS- 316

SS- 316L Modified

25 Cr – 22Ni – 02 Mo

SS- 321

CONCEPT OF SENSITIZATION IN STAINLESS STEEL

CHROMIUMCARBIDE(Cr23 C6)

GRAIN BOUNDARIES

CHROMIUM

AT HIGH TEMPERATURE (> 750 0C) Cr REACTS WITH C AND FORMS CrCTO PREVENT SENSITIZATION Ti OR Nb IS ADDED TO FORM TiC OR NbC

COMPOSITION

MECHANICAL PROPERTIES

GENERAL USES

- POOR WELDABILITY

- MODERATE CORROSION RESISTANT

- SHAFTS, SURGICAL INSTRUMENTS, FASTENERS

- CAN BE HARDENED BY HEAT TREATMENT

MARTENSITIC STAINLESS STEEL

C 1.2%

Cr UP TO 17%Ni 0%

USED AT FERTILIZER PLANT

- PUMP SHAFTS, IMPELLERS FOR CORROSIVE SERVICE

MARTENSITIC GRADES

SS- 416

SS- 420

MARTENSITIC STAINLESS STEEL

SS- 440

SS- 410

COMPOSITION

MECHANICAL PROPERTIES

GENERAL USES

- POOR WELDABILITY

- MODERATE TO GOOD CORROSION RESISTANT

- DOMESTIC EQUIPMENTS

FERRITIC STAINLESS STEEL

- CANNOT BE HARDENED BY HEAT TREATMENT

C .3%

Cr UP TO 30%

Ni 0%

COMPOSITION

MECHANICAL PROPERTIES

GENERAL USES

- GOOD STRENGTH : GREATER THAN AUSTENITIC AND OTHER GRADES

- GOOD CORROSION RESISTANCE

- OFF-SHORE APPLICATIONS, HIGH PRESSURE UREA

DUPLEX STAINLESS STEEL

- GOOD WELDABILITY

C .3%

Cr UP TO 30%

Ni UP TO 8%

USED AT FERTILIZER PLANT

- UREA REACTOR (STAMI CARBON PLANTS)

DUPLEX STAINLESS STEEL

- STEMS FOR HIGH PRESSURE UREA VALVES

DUPLEX GRADES

HVD-1

FERRALIUM ALLOY

SS – 30418 Cr – 8 Ni

SS - 316

SS - 317

ADD Mo (2%)FOR PITTING RESISTANCE

ADD MORE Mo (4%)FOR PITTING RESISTANCE

ADD Nb + TaTO REDUCE SENSITIZATION

SS - 347

ADD TiTO REDUCE SENSITIZATION

SS - 321

LOWER C

SS - 317L

SS - 316L

SS - 304L

ADD Cr & NiSTRENGTH & CORROSION RESIST.

SS – 310SS - 309

REDUCE NiTO REDUCE AUSTENITIC STRUCTURE

DUPLEX STEEL

NO Ni

FERRITIC STEEL

INCREASE CLOWER Cr

MARTENSITIC STEEL

MATERIAL DESIGNATION SYSTEM

- American Society for Testing MaterialsASTM

- American Iron and Steel InstituteAISI

- Society of Automotive EngineersSAE

- Unified Numbering SystemUNS

- German StandardsDIN

- British StandardsBS

- Japanese StandardsJS

AISI/SAE DESIGNATION SYSTEM

CLASSIFY MATERIAL ON THE BASIS OF COMPOSITION

CARBON AND ALLOY STEEL (EXCEPT STAINLESS STEEL)

13 Y 12X

CARBON %AGE

MATERIAL TYPE

PREFIX M OR E

Z

ADDITION OF ELEMENTS

SUFFIX H

- Carbon Steel10

- 1% Cr & 0.3% Mo Steel

41 - Merchant Quality

SteelM

- Electric Furnace Steel

E

- BoronB

- LeadL

- HardenabilityH

AISI/SAE DESIGNATION SYSTEM

STAINLESS STEEL

3 16

No Specific Interpretation

MATERIAL TYPE

Z

Element addition- Austenitic Stainless Steel

2

- Austenitic Stainless Steel

3

- Low Carbon (<0.03%)

L

- High Carbon Contents

H

- Added NitrogenN

- Added CopperCu

- Martensitic & Ferritic

4

ASTM STANDARDS

Ferrous Metals

DESIGNATION SYSTEM

ASTM A182 / 182M - 93bF 304LASTM A182 / 182M - 93bF 304L

Arbitrary Number

Metric System

Year of Revision

AISI NO

CLASSIFY PRODUCTS ON THE BASIS OF MANUFACTURING METHOD

MOST WIDELY USED SYSTEM – COVERS ALL DETAILS REQUIRED FOR MATERIAL PROCUREMENT

Grade

ASTM STANDARDSDESIGNATION SYSTEM

- Corrosion ResistantC

- Heat ResistantH

- Addition of MolybdenumM

- Carbon PercentageDigital No.

- PipeP

- TubeT

- Tube and PipeTP

- ForgingF

EXAMPLES

A 403/A 403M -93 WP304L

A 351 Grade HK40

A 336/A 336M-89 Class F22

A 351 Grade CF8M

- WroughtW

UNIFIED NUMBERING SYSTEM (UNS)

JOINT VENTURE AS ASTM AND SAE TO GENERATE UNIFIED COMPUTER FRIENDLY SYSTEM

1040 1X

ELEMENT ADDITION

TYPE OF STEEL

AISI/SAE NUMBER

- Carbon and Alloy steels

G

- Cast IronsF

- Heat and Corrosion Resistant Steels

H

- Boron1

- Lead4

- Electric Furnace Steel

6

MATERIAL COMPOSITION

WHERE TO FIND

BLACK BOOK BY CASTII PUBLISHING (PDF FORMAT)

KEY TO STEEL (SOFTWARE)

ASTM STANDARDS

THE END

Cr – Mo STEELS

C .3%

Cr UP TO 30%

Ni UP TO 8%

C 0.3%

Cr UP TO 30%

Ni 0%

Ni UP TO 30%

Cr UP TO 30%

C 0.3%

C 1.2%

Cr UP TO 17%Ni 0%

STAINLESS STEEL

CONCEPT OF SENSITIZATION

CHROMIUM CARBIDE

(Cr23 C6)

CHROMIUM DEPLETED LAYER

MATERIAL CLASSIFICATION

FERROUS METALS

CAST IRON

LOW ALLOY STEEL

HIGH ALLOY STEEL

CARBON STEEL

LOW CARBON

HIGH CARBON

MEDIUM CARBON

STAINLESS STEEL

Ni UP TO 30%

Cr UP TO 30%

C .3%

AUSTENITIC STAINLESS STEEL

C 1.2%

MARTENSITIC STAINLESS STEEL

Cr UP TO 17%

Ni 0%

C .3%

DUPLEXSTAINLESS STEEL

Cr UP TO 30%

Ni UP TO 8%

C .3%

FERRITIC STAINLESS STEEL

Cr UP TO 30%

Ni 0%

AUSTENITIC STAINLESS STEEL

UN-STABILIZED GRADE

- SS 304

- SS 316

- 25 Cr – 22 Ni – 2 Mo

- 316L + G510

STABILIZED GRADE

- SS 321

- SS 347

Cannot Be Used for High Temperature

Can Be Used for High Temperature

SS – 30418 Cr – 8 Ni

SS - 316

SS - 317

ADD Mo (2%)FOR PITTING RESISTANCE

ADD MORE Mo (4%)FOR PITTING RESISTANCE

ADD NbTO REDUCE SENSITIZATION

SS - 347

ADD TiTO REDUCE SENSITIZATION

SS - 321

LOWER C

SS - 317L

SS - 316L

SS - 304L

ADD Cr & NiSTRENGTH & CORROSION RESIST.

SS – 310SS - 309

AUSTENITIC STAINLESS STEEL

CARBON STEEL

CARBON STEEL

MEDIUM CARBON STEEL

HIGH CARBON STEEL

LOW CARBON STEEL

CARBON CONTENTS < 0.3 %

CARBON CONTENTS BETWEEN 0.3 % AND 0.6%

CARBON CONTENTS BETWEEN 0.6 % AND 2.0%

OBJECTIVE

CARBON STEEL CLASSIFICATION ACCORDING TO CARBON CONTENTS

SHAEFFLER DIAGRAM