Engineering Materials

Engineering Materials
2012 Larsen & Toubro Limited
Metallurgy & Corrosion
15th March, 2012
Technology Advancement - Based on Materials Development

Ti / Al Alloys
Future
Nano materials
Foundry
IRON AGE
Weapons
STONE AGE
Aircrafts
Ceramics Compo Sites
BRONZE AGE
SS/ NICKEL
Space Exploration
CALD Metallurgy & Corrosion, 2012 Larsen & Toubro Limited Metallurgy & Corrosion
Industrial Revolution 01-02. Sept. 2008

15th March, 2012 2
Utensils
Evolution
4000 BC, Iron Tensile strength, magnetic 100 BC, Concrete Compressive strength, mouldability durability 50 BC, Glass Transparency, refractive properties, compressive strength 1840s, Rubber Elasticity, water repellence, electrical resistivity 1850s, Steel Tensile strength, hardness, processability 1880s, Aluminum Strength: weight ratio, corrosion resistance 1930s, Polyethylene Processability, light, thermal and electrical insulation, chemical resistance 1950s, Silicon Semiconductor
2012 Larsen & Toubro Limited Metallurgy & Corrosion 15th March, 2012 3
Catastrophic Failure
Offshore Platform
Airport
Refinery
2012 Larsen & Toubro Limited Metallurgy & Corrosion
Bridge
15th March, 2012 4
Course of Presentation
Engineering Materials
Parameters for engineering materials Engineering Properties Classes of Materials
Advanced Materials
Engineering is the discipline, art, skill, profession and technology of acquiring and applying scientific, mathematical, economic, social and practical knowledge in order to design and build structures, machines, devices, systems, materials and processes.
Temperature
Creep
Cost
Availability
Pressure
Strength
MATERIAL OF CONSTRUCTION
Fabrication
Weldability
Medium
Corrosion Resistance
Function
Such as Conductivity
BASIS
Engineering Properties
Mechanical Strength Thermal stress Ductility/Elongation
Toughness
Fatigue
Creep
Types of Stresses
5 factors effecting strength are tension, compression, torsion, bending & shear
15th March, 2012
Stress during Operation - Pressure For Thin-Walled Vessel Vessel

Stress in Longitudinal direction = P x R 2xt
R = mean radius t =thickness
Stress in Circumferential direction = P x R t

Engineering Materials -Properties

Hardness
Ability to resist abrasion, penetration, cutting or permanent distortion
Brittleness
Property of metal that allows little bending or deformation without shattering
Malleable
A metal that can be hammered, rolled or pressed into various shapes without cracking or breaking
Ductility
Property of metal that allows it to be permanently drawn, bent, or twisted into various shapes without breaking
Elasticity
Property enables metal to return to its original shape when the force which causes the change of shape is removed
Engineering Materials -Properties

Toughness
A material that will withstand tearing or shearing and may be stretched without being deformed or breaking
Density
Weight of a unit volume of material
Fusibility
The ability of a metal to become liquid when heated (can be welded)
Conductivity
Property which enables a metal to carry heat or electricity
Contraction & Expansion

Reaction produced in metals as the result of heating or cooling
15th March, 2012
11
Living quarters MHN
15th March, 2012
12
Worlds largest coke drum

The 630 MT pressure vessel, with an inside diameter of 9.8m, was manufactured at our Hazira Manufacturing Complex for Indian Oil Corporations refinery coming up at Paradip.
15th March, 2012
13
Pressure Vessel Being Loaded Out

1200 MT
16.4 m Diameter, 40 m Long
Largest made in the world

Thermal Stresses
Compressive stress due to fixed support
Expansion due to heat
Thermal Stress = (T) E
= Coefficient of thermal expansion T = Temperature change E = Elastic Modulus

Thermal Properties of Cr containing steels
15th March, 2012
16
Mechanical Strength Elongation / Ductility Toughness Fatigue
Creep
15th March, 2012
19
Elastic Modulus (Stiffness)

As per Hookes Law, In Elastic Region, E = / is a constant
E is the elastic modulus and is a material property Elastic modulus indicates the stiffness of the material to deformation
Creep
Stress-Strain Curve for Mild Steel
15th March, 2012
22
15th March, 2012
23
Measure of Ductility
15th March, 2012
24
Ductile Fracture
normalised 0.3% carbon steel Broken by a high-speed impact at about 20C
15th March, 2012
25
Types of Stresses Mechanical Strength Elongation / Ductility
Toughness / Impact Strength

Fatigue
Creep
Toughness
Resistance of a material to fracture under load.
Indicated by the work done to plastically deform the material. Energy absorbed in the process before fracture. Describes the way a material reacts under sudden impact.
2012 Larsen & Toubro Limited Metallurgy & Corrosion 15th March, 2012 27 27
Toughness
Describes the way a material reacts under sudden impacts. It is defined as the work required to deform one cubic inch of metal until it fractures. Toughness is measured by the Charpy test or the Izod test as the energy absorbed at a given temperature.
For example for some plate steels to be used in bridges 27 J (equivalent to 20 ft.lb.) at -40 C is required.
For high performance steels, e.g. aircraft undercarriages, a KIc value may be used to quantify the toughness.
2012 Larsen & Toubro Limited CALD Metallurgy & Metallurgy & CorrosionCorrosion, 01-02. Sept. 2008 15th March, 2012 30 30
Toughness Impact Test
Maximum energy developed by the hammer is 120 ft-lb in the Izod test and 240 ft-lb in the Charpy test Greater the amount of energy absorbed by the specimen, the smaller the upward swing of the pendulum will be and the tougher the material is.
Ductile to Brittle Transition Temperature
Joules
C, Nb, V, Ti, Si, Mn
C, Nb, V, Ti, Si, Mn

Ni Ni
15th March, 2012
32
Carbon Content on CS Impact Strength
CALD Metallurgy & Metallurgy & CorrosionCorrosion,
01-02. Sept. 2008 15th March, 2012
33 33
Titanic Ship (1912)
Wreckage of Titanic Ship
The Titanic under construction
Photo courtesy of the Titanic Historical Society.

Composition of Steel from Titanic

C Titanic Hull Plate ASTM A36 0.21 0.20 Mn 0.47 0.55 P 0.045 0.012 S 0.069 0.037 Si 0.017 0.007 Cu 0.024 0.01 O 0.013 0.079 N 0.0035 0.0032 MnS: Ratio 6.8:1 14.9:1
Titanic hull steel showing banding & MnS inclusions in microstructure

Impact Strength of Materials

Low Carbon Steel Carbon Steel
Aluminium
Aus. Stainless Steel
01-02. Sept. 2008 15th March, 2012
36 36
Brittle Fracture
normalised 0.3% carbon steel, broken by high-speed impact at about 190C.
01-02. Sept. 2008 15th March, 2012
37 37
Types of Stresses Mechanical Strength Elongation / Ductility
Toughness
Fatigue Strength
Creep
Fatigue
Alternating stresses arise during operation due to
Vibration Rotation and Thermal cycling
Fails by progressive brittle cracking Failure is influenced by

Peak Stress Number of Cycles Duration
39
15th March, 2012
Fatigue
15th March, 2012
40
Fatigue Fracture
01-02. Sept. 2008 15th March, 2012
41 41
A fractured pipe/flange weldment from a crane frame assembly
15th March, 2012
42
Cement plant kiln
15th March, 2012
43
Fatigue Curve (S-N Curve)

The amplitude (or range) of cyclic stress that can be applied to the material without causing fatigue failure.
Fatigue Endurance Limit
15th March, 2012
44
Fatigue Endurance limit

Steel Sn = 0.5 x Su Titanium Sn = 0.450.6 x Su Cast Iron Sn = 0.45 x Su
@ N=106
Aluminum Sn = 0.4 x Su Magnesium Sn = 0.35 x Su Nickel alloys Sn = 0.350.5 x Su Copper alloys Sn = 0.250.5 x Su
@ N=108
Do not have a distinct limit and will eventually fail even from small stress amplitudes
Most steels have an endurance limit about half the tensile strength.
Steel 0.4% Carbon 0.4% Carbon Carbon, manganese Carbon, manganese 3% Chrome molybdenum Spring steel
BS
Threatment
Tensile Styrength - u (N/mm2) 540 700 540 700
Endurance Limit - e (N/mm2) 270 340 250 325
e/u 0.5 0.49 0.46 0.53
BS970 080M40 Normalized BS970 080M40 Hardened and tempered
BS970 150M19 Normilized BS970 150M19 Hardened and tempered Hardened and tempered Hardened and tempered
BS970 709M40
BS970 735A50
1000
1500
480
650
0.48
0.43
18.8 Stainless
Cold rolled
1200
490
0.41
15th March, 2012
46
Thermal Fatigue
Thermal fatigue arises from thermal stresses produced by cyclic changes in temperature. This type of fatigue is at most concern in turbine engines, steam piping and many rotating machinery.
15th March, 2012
48
Thermal fatigue cracks
15th March, 2012
49
Creep
Creep
Slow and progressive deformation of a material with time under a constant stress at temperatures approximately above 0.4 Tm (M.P. in Kelvin) Thermally activated process. More severe at elevated temperatures Low melting point materials (Pb, Sn) show creep at R.T. Magnitude of the applied stress and its duration Creep is a "time-dependent" deformation.
Creep Curve
In the initial stage, or primary creep, the strain rate is relatively high, but slows with increasing time-work hardening Strain rate eventually reaches a minimum and becomes near constant. This is due to the balance between work hardening and annealing (thermal softening). This stage is known as secondary or steady-state creep The strain rate exponentially increases with stress because of necking phenomena
Creep Limit
Stress required to cause fracture in a creep test within a specified time. Alternate term is stress rupture strength.
The stress to which a material can be subjected without the creep exceeding a specified amount after a given time at the operating temperature. (for example, a creep rate of 0.01% in 100,000 hours at operating temperature).
Screen Boiler Tube Rupture By Short Term Creep
Fish mouth opening
Creep cavity
01-02. Sept. 2008 15th March, 2012
54 54
Rupture Stress : Nickel Alloys

Nominal Composition Rupture Stress, Kg/cm2 (for 10,000 hours) Grade
HK40 HP- 45Nb HP- 45NbMA
C
0.4 0.45 0.45
Cr
25 25 25
Ni
20 35 35
Other
Nb-1.5 Nb1.5, Ti, Zr
8710C
190 302 330
9820C 10930C
84 123 130 32 32 32
HP- 45NbW
HP- 45W HP- 45Mo 45Ni-35Cr.MA Hp-15Nb
0.45
0.45 0.45 0.45 0.15
25
25 25 35 25
35
35 35 45 35
Nb-1.5, W 1.5
W4 Mo 1.5 Nb1.5, Ti, Zr Nb 1.5
309
295 239 316 246
130
102 123 120 105
15th March, 2012
35
30 35 42 21
55
Thickness for different alloy steels
15th March, 2012
56
Summary
Engineering Materials are those used for the construction of the equipment /component for intended service. They should possess good combination of properties to meet the mechanical integrity of the component. Depending on the design and operating conditions they should have appropriate
Ductility Toughness Fatigue strength Creep strength Corrosion resistance etc.
Classes of Engineering Materials
15th March, 2012
58
Engineering Metals & Alloys

Ferrous-widely used

Mild Steels Carbon Steels Low Alloy Steels Stainless Steels

Aluminium Alloys Copper Alloys Nickel Alloys Titanium Alloys
Metallurgy & Corrosion 15th March, 2012 59 59
Non-Ferrous
CARBON STEEL
15th March, 2012
60
LOW ALLOY STEEL Low Alloy (2-5%) Med. Alloy (5-10%)
Used for high temperatures. Oxidation resistance & creep strength increases with alloy content
LOW ALLOY STEELS
0C
552 552 566 566 566 566 566 566 593 602 602 566 602 602 566
15th March, 2012
62
SS 300 series Normal, L grades and H grades
15th March, 2012
63
Compositional modification of 18:8 Austenitc stainless steel

Ni-Cr-Fe alloys
347
Ni
309, 310, 314, 330
303, 303Se
Ni, Cr
321
Duplex stainless steel
Ti
304
Mo
Precipitation hardened stainless steel
304L Carbon Lower
316L
316
317L
More Mo
317
Austenitic FeNi-Mn-N SS
15th March, 2012
64
Alloy 803 Alloy 601
Alloy 800 H
Alloy 825 Alloy 600
NICKEL ALLOYS FOR SEVERE APPLICATIONS Alloy 617 Alloy 625

Hastelloys
15th March, 2012
65
Titanium and its Alloys
15th March, 2012
66
15th March, 2012
67
Ti - Corrosion Resistance
Thin (100A), transparent

Very stable, chemically resistant Adherent, Tenacious Resilient Instant healing
15th March, 2012
68
Aluminium Alloys
15th March, 2012
69
15th March, 2012
70
Copper Alloys
15th March, 2012
71
Copper Alloys
Alloy Admiralty Gunmetal Leaded Gunmetal Leaded Gunmetal + nickel Nickel aluminium bronze Aluminium brass Cu 88 85 86 Sn Zn 10 5 2 5 Al 5 Other 2.5% Lead 2% Nickel 5% Iron 5% Nickel 0.02% Arsenic
7 2.5
85
10
76
22
15th March, 2012
72
First cost comparisons Material Glass (clear) Mild steel Hot dip galvanised steel 304 stainless Aluminium alloy (extruded) 316 stainless Copper Brass Bronze
Approximate Price ($/kg) 0.2 1.0-1.5 1.5-2.5 4.0-5.0 4.0-5.5 5.0-6.0 8.0 8.5 10.0
Metallurgy & Corrosion 15th March, 2012 73
Strength - Max. service temperature - Ceramics

Strength Toughness of engineering materials

Strength - Max. service temperature . Metals


Engineering Materials

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Engineering Materials

Caricato da

Copyright:

Formati disponibili

Engineering Materials

2012 Larsen & Toubro Limited

Metallurgy & Corrosion

15th March, 2012

Technology Advancement - Based on Materials Development

Industrial Revolution 01-02. Sept. 2008

2012 Larsen & Toubro Limited

Metallurgy & Corrosion

15th March, 2012

Stress during Operation - Pressure For Thin-Walled Vessel Vessel

Stress in Circumferential direction = P x R t