HISTORICAL DEVELOPMENT AND CHARACTERISTICS OF STRUCTURAL STEELS CORROSION, FIRE PROTECTION AND FATIGUE CONSIDERATIONS
Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
2 Layout of the Lecture Historical Development of Steel Metallurgy of steel Production Process Mechanical properties Special steels Corrosion aspects Fire Engineering of steel structures Fatigue considerations
Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
3 Early constructions in Steel Indus Valley, Greeks and Egyptians (1000 BC) Wrought Iron as tie bars in Haghia Sophia (6th Century) Galleries for house of Commons and railings for St.Pauls cathedral (17th Century) 18th Century refractory furnace - Coalbrookadale bridge 1855 Henry Bessemer invented the modern steel making Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
4 Iron & Steel Tradition of India Our Great Epics Iron Pillar of Mehrauli Dwaja Stamba - a rustless wonder for 1.5 millennia ! Rabindra Sethu! Numerous Steel monuments of colonial past Second Hooghly and Jogighopa Bridges- Steel intensive constructions Visionaries like Tata, Pandit Nehru and Visweswaraya have sown the seed for development in Steel Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
5 Into the Lecture ... Historical Development of Steel Metallurgy of steel Production Process Mechanical properties Special steels Corrosion aspects Fire Engineering of steel structures Fatigue considerations
Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
6 What do we do in these situations? And Why should we teach the students a little bit of metallurgy? Bhai Sahib, I saw some pipes lying in your back door, can I use them as purlins for your shop floor extension shed? A failure investigation report say ..the bolts have matensitic structure in microstructure analysis. After exposure to fire the steel member a hard ness value of 345 PHN.
Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
7 The world has become cramped ? ! ! So do Engineering disciplines No Single conventional Eng. discipline can exist on its own Structural Steel Construction, Metallurgy and Mechanical Engineering disciplines crisscross each other ! Air Crossing ! Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
8 (b) Face centred cube (fcc) (a) Body centred cube (bcc) Crystal structure of Iron Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
9 Allotropy of Iron 200 400 600 800 1000 1200 1400 1600 Magnetic Non-Magnetic Heating Cooling 768 0 C 910 0 C 1400 0 C 1539 0 C bcc fcc bcc 0 | o
o Temp 0 C Time Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
10 Interstitial solid solution of Carbon in Iron Steel is alloy of Iron and Carbon ! (Point to ponder) --Carbon -Ferrite More Carbon more strength? - Yes But what happens to ductility? Adding Carbon - Is it the only way to get strength? Is there a limit for carbon content in structural steel? Carbon content in Structural steel- 0.12-.25% Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
11 Iron Iron-Carbon phase diagram Peritectic point 1.0 2.0 3.0 4.0 6.0 5.0 6.67 910 0 C 1147 0 C 723 0 C 1493 0 C 0.02% o ferrite phase Austenite + Liquid Liquid Fe 3 C+ Liquid + Fe 3 C Austenite + Cementite o + Fe 3 C Ferrite + Cementite Cementite
Eutectoid point o + 0.0 0.0 200 400 600 800 1000 1200 1400 1534 0 C 0.1% o ferrite 0.8% 4.3% Eutectic point % Carbon
Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
12 The Eutectoid section of the Iron Iron Carbon phase diagram Weight % of Carbon Temp 0 C 0.0 200 400 600 800 1000 1200 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 723 0 C Austenite 1147 0 C Ferrite Ferrite +Pearlite Ferrite +Austenite Austenite +Cementite Hypo-Eutectoid steel Eutectoid Point Cementite +Pearlite Hyper-Eutectoid steel b a c d i j k l Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
13 Different stages of formation of Pearlite Austenite Ferrite nuclei Ferrite Austenite Ferrite Pearlite C (a) (b) (c) Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
14 Microstructures of steels (a)100% Ferrite in extra low carbon steel (b)Ferrite+Pearlite (c) 100% Pearlite in Eutectoid steel (d)Pearlite+Cementite in hyper-Eutectoid steel SOURCE: Thelning K.E., Steel and its heat treatment, Butterworths, (1984). Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
15 d k 0 f y f + = Are there any their any parameters which increases strength of steel? Yes, Grain size Using temperature control we can achieve small grain size Using Mechanical pressure during rolling we can get smaller grain size Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
16 0. 0 200 400 600 800 Temp 0
C Variation of microstructure as a function of cooling Time in Seconds 1 10 100 100 0 10 4
10 5
Eutectoid temperature Mantensite Mantensite+ Pearlite Fine Pearlite Course Pearlite Full annealing Normalise Oil quench Water quench Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
17 Substitution solid solution of Manganese in Iron -Manganese - Ferrite Are there any their any parameters which increases strength of steel? Yes, Additive metals How much can we add? It Should not exceed C eq (0.45) C eq =%C + % Mn/6 + (% Cr + % Mo + % V)/5+(% Ni + % Cu)/15
What happens then (C eq >0.45)? Welding becomes a problem !! Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
18 Points to Ponder about steel! More carbon : more strength; but negatively affect the important property of ductility! Smaller the grain size greater the strength (Production control) Smaller additive metals also increases the strength of steel - HSLA steels Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
19 Into the Lecture ... Historical Development of Steel Metallurgy of steel Production Process Mechanical properties Special steels Corrosion aspects Fire Engineering of steel structures Fatigue considerations
Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
20 Iron ore, Limestone and coal is fed into the BF Liquid pig iron collects at the bottom of BF(C- 4.0%;Mn-.5%;P-0.12%;S- 0.05%) Hot metal is charged into Steel making vessel. Oxygen is blown in a controlled manner to reduce carbon and impurities like silicon, manganese, phosphorous and sulphur . Final steel is produced. (C-0.1-.25%;Mn- .4-1.2%;P-0.05%;S-0.05%). Oxygen less than 30 ppm - fully killed steel; 150 ppm semi-killed steel.
Source:Adams P.F., Krentz H.A. and Kulak G.L., Limit state design in structural design SI Units, Canadian Institute of Steel Construction (1979). Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
21 Ingot slab bloom Billet Basic shapes and their relative proportions Primary rolls for plates Primary rolls for structural shapes Molten steel Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
22 Into the Lecture ... Historical Development of Steel Metallurgy of steel Production Process Mechanical properties Special steels Corrosion aspects Fire Engineering of steel structures Fatigue considerations
Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
23 F Standard tensile test specimen F r t d L c
Area=S 0-
L Tensile strength of steel F Deformed regions Moving edges of Luders band Luders bands in tensile test specimen Tensile test specimen before rupture F Area=S -
L F F Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
24 f c y y
c sh ~ 10c y
f y
Elastic range Plastic range Strain hardenin g range E sh
Stress strain curve for sharp yielding structural steels Variation due to Luders bands c Stress strain curve for continuously yielding structural steels f c c y
f y
0.2% strain Uniform plastic Non-uniform plastic Elastic 0.2% proof stress Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
25 Hardness
Hardness is regarded as the resistance of a material to indentations and scratching. This is generally determined by forcing an indentor on to the surface. (a) Brinell hardness Square based diamond pyramids of 135 O included angle (b) Vickers Hardness Diamond core with 120 O included angle Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
26 h 1
h 2
c Experimental set up for notch toughness test Test specimen for notch toughness test Temperature Strain rate Energy absorbed Region of Cleavage(brit tle) failure Region of Shear (Ductile) failure Transition Temperature Effect of temperature on notch toughness of steel Ductile to brittle transition curve Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
27 1.2 1.1 10 -5
1.0 10 -4 10 -3 10 -2 10 -1
Strain rate in seconds -1
) 4 10 x 2 @( y f y f
33 . 0 . 45 . 0 973 . 0 ) 4 10 x 2 @( y f y f c + =
Effect of strain rate on the yield strength of
steel Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
28 Yield strength (Mpa) Thickness (mm) Type of steel Design- ation UTS (MP a) <20 20- 40 >40 Elongat ion Gauge Charpy V - notch values Joules (min) Fe 410A 410 250 24 0 230 23 27 Fe 410B 410 250 24 0 230 23 27 Standard structura l steel Fe 410C 410 250 24 0 230 23 27 St58HT 580 360 0.0 5 1.00 20 - High tensile structura l steel ST55- HTW 550 360 .05 1.00 20 - Some Mechanical properties of structural Steel Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
29 Into the Lecture ... Historical Development of Steel Metallurgy of steel Production Process Mechanical properties Special steels Corrosion aspects Fire Engineering of steel structures Fatigue considerations
Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
30 Special steels Stainless steels Stainless Steel grades and their usage Grade of stainless steel Usage 316 (18% Cr) Profiled roofing, cladding, gutters, facades and hand railingsin highly polluted environments 304 (18% Cr- (% Ni) Decorative elements in areas near coast line. Also for kitchen and sanitary warescoastal and less polluted areas 430 (17% Cr) Roofing, gutters, decorative wall tiles, hallow structural sections non-polluted environments 409 (11% Cr) Painted roofing-- non-polluted environments Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
31 Cold rolled steel and cold forming of steel Unheated slabs are rolled at ambient temperature into thin sheets (.3mm-8mm) Results in smooth surface and improved mechanical properties Cold forming of hold /cold rolled sheets CF sheets are basically low carbon steels which are reheated to 650 0 C to recrystalise ferrite to get finer grain size Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
32 TMCP steels and HSLA steels Thermo-Mechanically Controlled Process (TMCP) steels are becoming popular in obtaining high strength steels of yield strength of 800 MPa and thickness even beyond 40 mm.
High Strength Low Alloy(HSLA) also are very popular which requires very good process control. Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
33 Chemical composition of fire resistant steel C Mn Si S P Mo+Cr FRS s 0.20 % s 1.50 % s 0.50 % s 0.04 0% s 0.04 0% s 1.00 % Mild Steel s 0.23 % s 1.50 % s 0.40 % s 0.05 0% s 0.05 0% - Fire resistant steels Very cost effective compared to structural steel FRS are available in India Very popular and cost effective - Japanese experience Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
34 Into the Lecture ... Historical Development of Steel Metallurgy of steel Production Process Mechanical properties Special steels Corrosion aspects Fire Engineering of steel structures Fatigue considerations
Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
35 Electrolyte C Metal Connection Mechanism of corrosion as a miniature battery A Anode Drop of water Metal bar C A Cathode Mechanism of Corrosion in steel Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
36 Drop of Water
A
C Mechanism of crevice corrosion F C A F Mechanism of stress corrosion The mechanism of fretting corrosion A C Galvanic corrosion Hydrogen embritlement Bacterial corrosion Types of corrosion Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
37
Simple orientation of members Methods of prevention corrosion - Simple procedures
Detailing to enhance air movement between joints
Simple rule: Eliminate the electrolyte Avoid simultaneous presence of water and oxygen Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
38 Is Corrosion a real Problem? Indian designers feel that steel corrodes most in India. Is it true? Steel corrodes all over the world! But they are better managed in the western countries! Excellent protective coatings which retain their life even up to 20 years are available! Corrosion-where does it matter? Normal inland there is no problem! Exposed conditions ofcourse do need attention. Corrosion is no more a disincentive for not using steel in housing sector! Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
39 Into the Lecture ... Historical Development of Steel Metallurgy of steel Production Process Mechanical properties Special steels Corrosion aspects Fire Engineering of steel structures Fatigue considerations
Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
40 Positive points of steel as a construction material under fire Damage to strength of steel due to fire is reversible in most of the cases Using the principle if the member is straight after the fire - the steel is O.K many of the members could be salvaged. Up to about 215 0 C steel retains its strength In the case of concrete, at 235 0 C turns pink; 590 0 C turns red and irreversible damage after 600 0 C Steel exposed to 600 0 C could be strengthened and reused. Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
41 Examples of fire load in various structures Type of steel structure Kg wood / m 2 School 15 Hospital 20 Hotel 25 Office 35 Departmental store 35 Textile mill show room >200 Typical fire loads and behaviour of steel under fire Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
42 Typical fire loads and behaviour of steel under fire Time (Minutes) 1000 500 0 0 C 30 60 90 Furnace temperature Unprotected steel Fire protected steel temperature Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
43 Mechanical properties of steel at elevated temperatures 0.5 1.0 1.5 200 400 600 800 1000 Youngs modulus ratio Coeff. of thermal expansion (x 10 5 ) Yield stress ratio Temperature 0 C Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
44 High H p / A Value Low H p / A Value The section factor concept Some typical values of H P of fire protected steel sections B D t H p
=2D+3B-2t H p =2D+B H p =2D+2B H p
=2D+4B-2t Fire Engineering of steel structures- very well developed in the literature Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
45 Methods of fire protection Spray protection
Board protection
Intumescent coatings
Concrete encasement?
Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
46 Into the Lecture ... Historical Development of Steel Metallurgy of steel Production Process Mechanical properties Special steels Corrosion aspects Fire Engineering of steel structures Fatigue considerations
Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
47 d m n o o Stress concentrations in the presence of notches and holes Hole m n o o Notch >o Stress concentration Crack growth and fatigue failure under cyclic load Number of cycles Crack length 1 2 3 4 o o Crack length Fatigue crack +o -o Applied cyclic stress Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
Cycles of stress for failure (N) Stress range in MPa (S) 10 6
Endurance Limit S-N Curve Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
49 Modified Goodman diagram for fatigue resistant design of steel structures Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG
50 Schematic stress diagram Point of stress concentration Stress concentration at the weld toe Fillet Weld F F F >F Class F detailing according to IS:1024 (1968) Weldement Direction of applied stress Teaching Resource in Design of Steel Structures IIT Madras, SERC Madras, Anna Univ., INSDAG