metal alloys (금속 합금 - manufacturing laboratoryma.gnu.ac.kr/course/ms/09_metals.pdf · ·...
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Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
1
Metal Alloys (금속 합금)
Professor Su-Jin Kim
Mechanical Engineering
Gyeongsang National University
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
OCW
Steel: Iron, Carbon, Stainless, Manganese, Titanium steel
https://youtu.be/omGKUKwJPB8 Stainless: https://youtu.be/gLNltMtBjc8
History: https://youtu.be/7E__zqy6xcw
POSCO: https://youtu.be/YK2pvmVpoVM
Copper, Brass, Bronze: https://youtu.be/ysInnHOoouc
Aluminum: https://youtu.be/yn9qhQSMCRk
Titanium: https://youtu.be/CLLFNmTVmpQ 25min
Aluminum & Titanium: https://youtu.be/R5iK95ZeL-E
Alloys: https://youtu.be/X7b8_9wAREE
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
OCW
Steel C.A.S.T : https://youtu.be/VBzmGyWeNzo
Carbon Steel: https://youtu.be/JTu-Zz5jalc
Alloy Steel: https://youtu.be/dpm_uoXzwXE
Stainless Steel: https://youtu.be/TILs8w6myoU
Tool Steel: https://youtu.be/-fZQ9ElnymI
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
KOCW
철강
http://www.kocw.net/home/cview.do?lid=c2305cd4e3f38472
비철금속
http://www.kocw.net/home/cview.do?lid=e83e3461feb3633f
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Metal Alloys(금속)
Metal Alloy
(금속합금)
Ferrous
(철)
Nonferrous
(비철금속)
Steels
(강)
C<1.4%
Cast Irons
(주철)
3.0~4.5%
Copper
alloy
Aluminum
alloy
…
alloy
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Ferrous Alloys (철)
• Ferrous alloys are useful metals in terms of mechanical, physical and chemical properties.
• Alloys contain iron Fe (density 7.9 g/cm3) as their base metal.
• Carbon steels (700W/kg) are least expensive of all metals while stainless steels (7,000W/kg) is costly.
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Irons
Liquid, L
Austenite, γ
Ferrite, α
Cementite, Fe3C
α+γ
α+Fe3C
γ+Fe3C
γ+L
0 1 2 3 4 5 6 6.7 400
Composition (wt% C)
Tem
pe
ratu
re (
ºC)
600
800
1000
1200
1400
1600
2.14 4.3
0.022
Cast Iron Steel
0.76 727 ºC
1147ºC
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Steels (강)
Composition and processing are controlled in a manner that is suitable for different applications.
Several elements are added to steels for
Strength(강도), Hardness(경도), Toughness(인성)
Hardenability(경화성), Wear resistance(내마모성)
Workability(가공성), Weldability(용접성), Machinability(절삭성)
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Steels Carbon steel
(탄소강)
High alloy steel
(고합급강)
Low carbon
(저탄소강) C < .25 %
Med carbon
(중탄소강) .25-.60%
High carbon
(고탄소강) .60-1.40%
Plain HSLA
(고강도) Plain
Heat
Treatable
(열처리)
Plain Tool
(공구)
Stainless
(스테인리스)
auto struc. sheet
bridges towers press. vessels
crank shafts bolts hammers
pistons gears wear applic.
wear applic.
drills saws dies
high T
turbines furnaces corrosion resistant
strength, hardenability, cost ductility
1010
S10C
4310
SNCM10
1040
S40C 4340
SNCM40 1095 4190
KD11
304, 409
SUS304
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
10
Steels
AISI/SAE JIS/KS Nomenclature(조성) for steels
10xx SxxC Plain Carbon Steels (탄소강)
40xx SMoxx Mo (.2 ~ .3%)
41xx SCMxx Cr (.80~1.1), Mo (.15~.25)
43xx SNCMxx Ni (1.65 ~ 2.0), Cr (.4 ~ .9), Mo (.2~.3)
where xx is % C x 100
Ex) 1045 S45C – Plain Carbon Steel with 0.45 % C
Stainless Steel 304 SUS304 Cr (11%~)
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Carbon steels (탄소강)
Low-carbon steel or mild steel, C< 0.25%, bolts, nuts and sheet plates.
Medium-carbon steel, 0.25% ~ 0.60%, machinery, automotive and agricultural equipment.
High-carbon steel, C > 0.60%, springs, cutlery, cable.
S10C S45C
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Alloy steels (합금강)
• Steels + alloying elements: Cr(hardness, toughness), Co(hot hardness), Mn(hardness, strain), Mo(strength), Ni(strength, corrosion resistance), W(hardness, heat resistance), V(strength). ex) SCM40, SNCM40, SCV50
• Structural-grade alloy steels used for construction industries due to high strength.
• HSLA (High-strength low-alloy steels, 고강도 저합금강) used in automobile bodies and structural plate.
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Tool steels (공구강)
• Designed for high strength, impact toughness, and wear resistance at a range of temperatures.
SKD11 SKD61 Stamping Die
KP4, KP4M, NAK80 Plastic injection Mold
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Stainless steels
A chromium oxide film protects the steel from corrosion. (+ Cr >11% + Ni ...)
Good corrosion resistance and mechanical properties at high temperature (1000°C).
JIS/KS Cr(%) Heat treat
Cor. Res.
Magnetic
Application
SUS304 austenite 19 X OO X Automotive exhaust
SUS409 ferrite 11 X O O Chem. proc. equip.
SUS410 martensitic 12.5 O O O Knifes
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Posco
• Hot rolled steel, Steel plate, Wire rod, Cold rolled steel, Electric steel, Stainless steel, Galvanized steel, Titanium
Posco http://www.posco.co.kr
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Cast Irons (주철)
• Ferrous alloys with 3.0 ~4.5% C, 1~3% Si
• Cementite decomposes to ferrite + graphite
Fe3C 3 Fe () + C (graphite) : slow process
• Low melting point relatively easy to cast
• Generally brittle
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Cast Irons
Gray cast iron(회주철)
• graphite flakes brittle
• weak in tension, stronger in compression
• excellent vibrational dampening
• most commonly used cast iron: engine cylinder blocks, flywheels, gearbox cases, machine-tool bases
Ductile cast iron(구상흑연주철,연주철)
• add Mg and/or Ce
• graphite as nodules not flakes
• strong and ductile
• gears, camshafts, crankshafts
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Cast Irons
White cast iron(백주철)
• fast cooling(급랭) and lower Si content
• pearlite + cementite Fe3C
• high hardness but brittle
• Bearing surfaces
Malleable cast iron(가단주철)
• heat treat(가열) white iron at 900°C
• graphite in rosettes
• reasonably strong and ductile
• Axle bearings, track wheels, crankshafts
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Cast irons
• 대한주조공업 http://daesp.co.kr
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Nonferrous Alloys (비철금속)
More expensive than ferrous metals.
Applications:
• aluminium for aircraft bodies
• copper wire
• titanium for jet-engine turbine blades
• tantalum for rocket engines
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
21
Nonferrous Alloys(비철금속)
NonFerrous Alloys
• Al Alloys -low r: 2.7 g/cm3
-Cu, Mg, Si, Mn, Zn additions -solid sol. or precip. strengthened (struct.
aircraft parts & packaging)
• Mg Alloys -very low r : 1.7g/cm3
-ignites easily - smartphone
• Refractory metals -high melting T’s -Nb, Mo, W, Ta • Noble metals
-Ag, Au, Pt - oxid./corr. resistant
• Ti Alloys -relatively low r: 4.5 g/cm3
vs 7.9 for steel -reactive at high T’s - space applic.
• Cu Alloys Brass: Zn is subst. impurity (costume jewelry, coins, corrosion resistant) Bronze : Sn, Al, Si, Ni are subst. impurities (bushings, landing gear) Cu-Be : precip. hardened for strength
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Copper alloys
• Copper alloys(구리합금) have electrical and mechanical properties, corrosion resistance, thermal conductivity and wear resistance.
• Applications are electronic components, springs and heat exchangers.
Brass(황동) is an alloy of copper and zinc (Zn 30%). Applications are costume jewelry, coins, corrosion resistant.
Bronze(청동) is an alloy of copper and tin (Sn 10% , Al, Si, Ni). Applications are bushings, landing gear.
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Aluminium alloys
• High strength to weight ratio ( 2.7 g/cm3)
• Resistance to corrosion Al2O3 surface layer, Anodising
• High thermal and electrical conductivity
• Ease of machinability, Non-magnetic, Light reflection
• Age hardening
Ex) A7075 A6061 A5052
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Magnesium alloys
• Magnesium (Mg) is the lightest metal (1.7g/cm3).
• It ignites easily. Combustible.
• Typical uses of magnesium alloys are the frame of electric device like as smart phone.
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Titanium alloys
• Titanium (Ti) is expensive, has high strength-to-weight ratio and corrosion resistance. Relatively low density 4.5 g/cm3.
• Used as components for aircrafts, jet-engines, racing-cars and medical equipment.
• Ex) Ti-6AI-4V
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Nickel alloys
• Nickel (Ni) has strength, toughness, and corrosion resistance to metals.
• Used in stainless steels and nickel-base alloys at chemical and food processing industry (Nikel200).
• Inconel 600 (Ni 72% Cr 15% Fr8%) alloys are used for high temperature applications, such as jet-engine components and rockets.
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Superalloys
• Superalloys (초합금) are high-temperature alloys use in jet engines and gas turbines.
Ex) IN-100 -102, Inconel 625 718, MAR-M 200 432 …
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Refractory metals
• Refractory metals (고용융점 금속) have a high melting point and retain their strength at elevated temperatures.
• Applications are electronics, nuclear power and chemical industries.
• Molybdenum, columbium, tungsten, and tantalum (Nb, Mo, W, Ta) are referred to as refractory metal.
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Other nonferrous metals
1. Beryllium (Be)
2. Zirconium (Zr)
3. Low-melting-point (저 용융점) metals: - Lead (Pb, 납) - Zinc (Zn, 아연) - Tin (Sn, 주석)
4. Precious metals (귀금속): - Gold (Ag, 금) - Silver (Au, 은) - Platinum (Pt, 백금)
Metal Alloys
Manufacturing Processes
© Su-Jin Kim, GNU
Korea Zink (고려아연)
• Zinc (Zn) : Galvanized steel plate(pipe, wire), color steel plate, automobile part, machine/electronic part, anti-corrosion paint
• Lead (Pb) : Automobile and industrial battery, electric wire coating, radiation shielder
• Copper, God, Silver, Indium, nickel, bismuth, antimony trioxide, palladium, platinum, cadmium, gallium, germanium, tellurium, cobalt