COMPOSITION OF METALS

Metal - opaque crystalline solids of high reflectivity having good electrical and thermal
conductivities, a positive chemical valence, and, usually, the important combination of
considerable strength and the ability to flow before fracture
Ferrous Metals
Steel
Carbon Steel
Alloy Steel
Stainless Steel
Tool Steel
Cast Iron
Gray Cast Iron
White Cast Iron
Malleable Cast Iron
Ductile Cast Iron
Cast Steel
Wrought Iron
Carbon Steel - iron alloyed with carbon to form steel
(Since carbon is a present in all steel, carbon steel is not classified as an alloy steel.)
Material properties based on carbon content include:
strength
hardness
ductility
weldability
Low Carbon Steel, LCS (mild steel)
- Carbon content ranges from 0.05-0.30%
- tough, ductile
- easily formed, machined, and welded
- Uses: chain, pipe, nails, screws, bolts, structural shapes
Medium Carbon Steel, MCS
- Carbon content varies from 0.30-0.45%
- harder and stronger than LCS
- more difficult to form, machine, or weld than LCS
- Uses: drive shafts, axles, connecting rods, shovels

High Carbon Steel (HCS)

- Carbon content varies from 0.45-0.75%
and
Very High Carbon Steel (VHCS)
- Carbon content varies from 0.75-1.75%
- very hard, very strong
- very difficult to form, machine, and weld
- Uses: wrenches, screwdrivers, cutting tools, harrow disks, twist drills, files, hammers
Carbon %

USES:

0.05-0.15

pipe, chain, rivets, screws, nails, stampings

0.15-0.30

structural sections, plates, bars, carburized parts

0.30-0.40

axles, connecting rods, shafting

0.40-0.50

crankshafts, gears, crane hooks

0.50-0.60

scraper blades

0.60-0.70

dies for drop hammers, setscrews, locomotive wheels

0.70-0.80

anvil faces, band saws, smithing hammers, rails

0.80-0.90

punches, rock drills, cold chisels, rivet sets

0.90-1.00

springs, axes, knives, shear blades

1.00-1.10

milling cutters, flat drills, taps

1.10-1.20

lathe tools, twist drills, wood chisels

1.20-1.30

files, reamers

1.30-1.40

wire-drawing dies, razors, brass-turning tools

1.40-1.50

saws for cutting steel

An increase in carbon content:

lowers melting point
lowers ductility
lowers weldability
increases hardness
increases tensile strength

Alloy Steels
- Carbon steel alloyed with significant amounts of other chemical compounds that enhance
certain material properties
ALLOY

EFFECTS OF INCREASE

Carbon

hardness, tensile strength; [not considered an alloy steel]

Nickel

strength, toughness, hardness, impact resistance, corrosion

resistance

Chromium

corrosion resistance, hardness, toughness

Molybdenum

toughness, responsiveness to heat treatment, strength, ductility is

retained

Vanadium

impact resistance, fine grain

Tungsten

high-temperature strength, hardness, fine grain (maintains cutting

edges)

Silicon

strength, electrical properties, resilience

Manganese

strength, hardness, impact resistance

Lead

machinability, corrosion resistance

Sulphur

machinability, decrease in weldability

Copper

corrosion resistance, strength

Tool Steel
- higher grade carbon or alloy steel
- provide extreme hot-temperature hardness, toughness, and strength
- Uses: cutting tools
Stainless Steel
- special alloy steel with significant amounts of Chromium (up to 18 percent)
- chemical and corrosion resistance
- Uses: medicinal, chemical, and food-processing industries

Cast Iron
- Carbon content varies from 2 to 5 percent
Gray Cast Iron
- typical tensile strength: 20-60,000 psi
- most common; lowest grade and cheapest of the cast irons
- brittle; poor impact resistance
- difficult to weld
- Uses: blocks, frames, supports, sprockets, stoves
- Note: "Gray" because slow cooling allows free carbon to precipitate out as random flakes of
graphite.
White (Chilled) Cast Iron
- gray cast iron that has been cooled quickly, forcing free carbon to stay in solution
- very hard, very brittle
- high abrasion resistance
- considered unweldable
- Uses: wear plates, dies, molds
- Note: Has a white appearance when broken, because the carbon has no time to precipitate.
Malleable Cast Iron
- typical tensile strength: 50-85,000 psi
- high strength and impact resistance
- bends before breaking
- Uses: gears, tools, housings, mower guards, C-clamps
- Note: obtained by heat treating (annealing=very slow cooling) a white cast iron parent material;
free carbon collects in rounded particles and is evenly distributed.
Ductile (Nodular) Cast Iron
- typical tensile strength: 60-105,000 psi
- high strength and impact resistance
- ductile
- Uses: gears, rollers, valves, propellers
- Note: Magnesium and cerium cause graphite to form as small nodules or spheroids; higher
tensile strength because the iron is not "separated" by planes of weakness.
Cast Steel
- Carbon content up to 1.75 percent
- may include over 8 percent total alloys
- strength, ductility, dynamic loading, impact resistance, fatigue conditions
- Uses: rollers, valves; ship and mining equipment

Wrought Iron
- very low Carbon content (0.004-0.1% C)
- Silicon is added to produce a slag within the metal
- fibrous, soft, malleable, corrosion resistance
- Uses: anchors, temporary magnets, pipes, ornamental ironwork
Nonferrous Metals
Aluminum
- pure and alloy compositions
- good strength, light weight, good electrical conductor
- easy to machine and weld
- some alloys are as strong as steel
Copper Family
Copper
- good conductor of heat and electricity
- Uses: wire, plumbing, building materials
Brass: alloy of Copper and Zinc (up to 40%)
- Uses: medals, marine hardware, fasteners, shell casings
Bronze: alloy of Copper and Tin (up to 20%)
- Uses: fasteners, washers, bearings
Cupronickel: alloy of Copper and Nickel
- Uses: surgical instruments, jewelry
Other:
Zinc - used for coating metal for corrosion resistance
Lead - used for making pipe, containers for corrosive chemicals, X-ray shielding, and batteries
Tin - used for coating steel to prevent corrosion ("tin" cans)
Magnesium - used where weight is to be minimized