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EMM2512
Ferrous Alloys
Dr. N S Mahesh
Session Objectives
At the end of the session delegates should have understood
– Classification of materials
– Ferrous alloys and its classification
• Iron-Iron Carbide diagram
• AISI/SAE and UNS Designation Systems
• Manufacture of steel coil and sheet for the automobile
industry
• Steel
– High strength steel types
– Ultra high strength steel
• Cast iron and types
Metal Alloys
• Ferrous Alloys
and
• Non-ferrous Alloys
Ferrous Alloys
Polymorphism of Fe:
At 1394 C: d g At 912 C: g a
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Fe-Fe3C system EMM2512
Fe-Fe3C system
Five basic solid phases
• d-phase: solid solution of C in bcc Fe at high T.
• Austenite (A, g): solid solution of C in fcc Fe.
Maximum solubility of C in fcc Fe: 2.11wt% at
1148°C.
• Ferrite (F, a): solid solution of C in bcc Fe.
Maximum solubility of C in bcc Fe: 0.022wt% at
727°C.
• Cementite (Fe3C): Fe-C intermetallic compound of
complex structure; metastable.
• Graphite (G): pure C; stable.
γ-Fe
(Austenite):
solid solution of
C in FCC iron,
formed by
solidification
from liquid, large
grains and
straight grain
boundaries,
stable at high
temperatures,
high solubility
for C, high
ductility and
formability
α-Fe (ferrite): A
solid solution of C in
BCC iron, formed
from austenite
through solid phase
transformation,
small grains and
irregular grain
boundaries, stable at
room temperature,
very low solubility
for carbon, ductile
and soft, not so
strong
Pearlite (P): A
composite
structure of
laminar ferrite and
cementite, formed
as a product of
eutectoid
transformation
from Austenite,
good combined
strength and
toughness, ideal
for structural
applications
Hypoeutectoid steels:
Steel of <0.77%C. These
account for low and medium
carbon steels. Microstructure
consists of pearlite and pro-
eutectoid ferrite. The
proportion of pearlite
increases with increasing C%
towards 0.77wt%. Higher
portion of P makes the steel
stronger but less ductile.
Pearlite matrix
Cementite
Composition of HSLA
Stainless Steels
Stainless Steels: Addition of Cr and Nickel to Fe-C will significantly increase
corrosion resistance
Alloys designation
AISI UNS
2xx S2xx00
3xx S3xx00 304, 316, 316L (Austenitic)
4xx S4xx00 410 (Martensitic), 446 (Ferritic)
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Stainless Steels EMM2512
Steel
• Low cost
• Ease of forming
• Consistency of supply
• Corrosion resistance with zinc coating
• Ease of joining
• Recyclable
• Good crash energy absorption
• Heavier than alternative materials
• Corrosion if uncoated
Heat Treatments
• A – Furnace Annealed – Slow cooled
• N - Normalized - Air cooled.
• O - Oil Quenched
• WQ – Water quenched.
• WT(370)– Water quenched, tempered at 370°C for 1 hour.
• WT(705)– Water quenched, tempered at 705°C for 1 hour.
It comprises of :
• Heating the material to specified temperature
• Holding at heat treatment temperature so that desired
transformation is complete
• Cooling in a specified rate to room temperature
– Fine Pearlite
TTT Diagrams
Bainite
• Upper (550-350°C)
– Rods of Fe3C
• Lower (350-250°C)
– Fe3C Precipitates in Plates of
Ferrite
• It is still Ferrite and Cementite!
It’s just acicular.
Martensite
• Diffusionless transformation
of FCC to BCT (more
volume!)
• Lenticular structure
• Very hard & very brittle.
Slow Cooling
Medium Cooling
Cooling Rate, R, is
Change in Temp / Time
°C/s
Fast Cooling
What is Tempering?
• Martensite needs to be tempered to get better ductility. This
happens when Fe3C is allowed to precipitate from the
supercooled Martensite.
Spheroidite
• If tempered for a long
time, Fe3C forms
“spheres” and grows
inside Ferrite.
• Very soft, easy to
machine
Austenite
Austenite + Ferrite
723 o C
Water or oil Furnace cooling
cooling Air cooling
Cast Iron
• Carbon content ranging from 2-4.3%
• Castable, hard & strong
• Wide range of types depending on:
Ductile (Nodular/spherulitic) CI
• C precipitates in black nodules
• High fluidity/castability
Good machineability
Wear resistance
Pearlitic matrix
Spherulites
White CI
Malleable CI
Malleable iron:
Nodular iron: graphite clusters
graphite nodules in converted from
ferrite matrix, decomposing
significantly cementite in white
improving toughness iron, significantly
and ductility of the improving toughness
metal and ductility of the
metal
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EMM2512
Summary
• Ferrous alloys and its classification, Iron-Iron
Carbide diagram
• Steels - AISI/SAE and UNS designation
• Heat treatment of Steels
• Cast iron and its types