Phase diagrams

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Metals Phase diagram Property high stiffness, better toughness, good electrical conductivity, good thermal conductivity Why metals have these nice properties

- structures at atomic level

Fig.1.1

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Metals Phase diagram Ways to change the structure temperature, alloying, chemistry, mechanical Pure metals and their Alloys

- Gold, silver, and copper may exist in applications as their pure form, but most of metals are alloyed.
- An alloy is a metal comprised of two or more elements, at least one of which is metallic. Two main categories of alloys are: (1) solid solutions and (2) intermediate phase.
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Metals Phase diagram Solid solutions: one element dissolved in another to form single-phase solution Phase-Any homogeneous mass, i.e. metal with grains having same lattice structure Types: Substitutional and Interstitial Fig.1.2

- Solid solution alloy structure stronger and harder Handouts than either of the component 1elements.

Metals Phase diagram Conditions for substitutional solid solutions possible: (1) The atomic radii of the two elements similar (2) Their lattice types must be the same (3) The lower valency metal becomes the solvent

(4) Their chemical affinity is small Example: BRASS (ZINC in COPPER)

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Metals Phase diagram Interstitial solid solution:

Atoms of dissolving element fit into vacant spaces between base metal atoms in lattice structure
- Solute atoms small compared to Solvent atoms Example: Carbon dissolved in Iron to form STEEL

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Metals Phase diagram Intermediate phases: Every element has a limit for its solubility of another element When element A completely dissolved into another element B, the whole system is one phase of that solid solution.

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Metals Phase diagram Intermediate phases: When the amount of the dissolving element in the alloy exceeds the solid solubility limit of the base metal, a second phase forms in the alloy. Intermediate phase I II Its properties are between two pure elements

Here, the system has two elements (A,B) and two phases: solid solution (I) and intermediate phase (II)
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Metals Phase diagram Phase diagram A means to represent the phase or status of a metal alloy system with respect to (1) composition and (2) temperature

P = f (T, C)
(a) Amount of dissolving element A and amount of solvent element B ? (b) Amount of phase 1 and amount of phase 2 ?
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Metals Phase diagram Fig. 1.3 is a copper-nickel alloy system

Fig.1.3
1221 C

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Metals Phase diagram The following things are known from Fig.1.3

(1) Pure copper melts at 1981 F

(2) Pure nickel melts at 2651 F (3) Below solidus line solid

(4) Above liquidus line liquid

(5) The system is a solid solution throughout (below solidus line) (6) Between, two phases: solid and liquid
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Metals Phase diagram - The overall composition of the alloy (i.e., amount of copper and amount of nickel) is given by its position along the horizontal axis. -The compositions of the liquid and solid phases are not the same for a temperature (Cu-Ni ratio in Solid phase NOT EQUAL to Cu-Ni ratio in Liquid phase) - Ex 1. 50 % copper-nickel and at 1260 deg C, see Fig.1.3. Find the compositions of the solid and liquid. Solution: draw a horizontal line, which intersects the liquidus and solidus lines, respectively, see Fig.1.3.
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Metals Phase diagram Ex. 1, cont.: Obtain: 62 % Ni in solid, 36 % Ni in liquid When reduce temperature at 50-50 point to the solidus line, we obtain: 50% Ni in solid and 26% Ni in liquid. This is the result of the assumption made in the phase diagram that the equilibrium state has been achieved: There is sufficient time given for diffusion to occur and for the whole system gradually change composition to that which is indicated by the intersection point along the liquidus.

In practice, there is a situation called segregation when the liquid alloy freezes (i.e. a casting) because not enough time occurs for equilibrium to be achieved.
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Metals Phase diagram Segregation: The first liquid to solidify has a composition that is rich in the metal element with the higher melting point. Then, as additional metal solidifies, its composition is different from that of the first metal to freeze.

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Metals Phase diagram Inverse lever rule (determine amounts of phases 1&2):

L phase proportion = CS/(CS+CL)

S phase proportion = CL/(CS+CL)

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Metals Phase diagram Remark 1.1: The method of determining the chemical composition of phases and the amounts of each phase are applicable to the solid region of the phase diagram as well as to the liquidus-solidus region.

When only one phase is present (in Fig.1.3), this is in the entire solid region), the composition of the phase is its aggregate composition under equilibrium conditions, and the inverse lever rule does not apply since there is only one phase.
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Metals Phase diagram Tin-lead system a more complicated phase diagram, see Fig. 1.4. Fig.1.4

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Metals Phase diagram New features (Fig.1.4): (1) Presence of two new solids: and (2) Eutectic point, which has the lowest melting point (3) Pure tin and lead have the highest melting point; any of their alloys melt at lower temperature. Ex 2: determine the compositions in two corresponding phases for the aggregate composition, 25 %, at temperature 500 F.
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Metals Phase Diagram for Iron and Carbon 1. Ferrous Metals, based on Iron (Fe) BCC and FCC structures

Iron + Carbon = Alloys: Steel and Cast iron

2. Iron Carbon phase diagram (Fig.2.1) Pure iron, melting point 1539 C (2802 F) From room temp. to melting, transforms through several solid phases: (BCC) -> (FCC) -> (BCC)
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Metals Phase diagram for Iron and Carbon

Steel FCC BCC Region Eutectic

Fe3C

2.1% 0.022% Eutectoid Handouts 1 20

Metals Phase diagram for Iron and Carbon Iron: - pure iron (99.99 %), - ingot iron (some carbon, 0.1 % impurities), - wrought iron (3% slag with low carbon). Solubility of carbon in iron will depend on solid phases of iron: Ferrite 0.02%; Austenite 2.1 %; Steel: 0.02 2.1 %; Cast iron: 2.1-4 % Cementite, Fe3C: hard and brittle Carbon: an element increasing strength; Fe is soft.
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Metals Phase diagram for Iron and Carbon 3. Steel - Steel is an alloy of iron that contains carbon ranging by weight between 0.02% and 2.11% -It often includes other alloying ingredients as well: manganese, chromium, nickel, molybdenum - classification of steels: plain carbon, low-alloy, stainless, tool

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Metals Phase diagram for Iron and Carbon 3. Steel Plain carbon steel: low-carbon (<0.2%), mediumcarbon (0.2%< and <0.5%), high-carbon (>0.5%).

Low-alloy steel: Cr, Mn, Mo, Ni, V; alloying elements <5%

Stainless steels: highly alloyed steels; Cr >15%, Ni Tool steel: highly alloyed steels designed for use as industrial cutting tools, dies, and molds.
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Metals Nonferrous metals 1. Metals Ferrous and nonferrous 2. Nonferrous Aluminum, copper, magnesium, nickel, titanium, and zinc and their alloys.

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General features of non-ferrous metals: (1) Strength is not as good as steel (2) Corrosion resistance and/or strength-to-weight ratios for certain non-ferrous alloys are higher than steels (3) Lower electrical resistance copper

(4) Higher thermal conductivity aluminum

(5) Lower melting point Zinc (die casting)

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 Superalloys - Substantial amount of 3 or more metals rather than one base metal + alloying elements - 3 groups: iron, nickel, or cobalt (based on the main element) - Used in high strength and wear applications at high temperatures (>1100 C)

Processing of metals - Shaping (i.e. casting, forming, material removal) - Assembly (i.e. welding, mechanical fastening) - Finishing process (i.e. electroplating, painting) - Property Enhancement (Alloying, Cold working, and Heat treatments)
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