Presented by Iwan Susanto, Ph.

Mechanical Engineering Department

Politeknik Negeri Jakarta Created by Dr. Vika Rizkia
 is an element, compound or alloy that is
METAL a good conductor of both electricity and
heat

Metal crystal structure and specific metal properties are determined by metallic
bonding – force, holding together the atoms of a metal

Ability of the valence free electrons to travel throughout the solid explains both the
high electrical conductivity and thermal conductivity of metals

Other specific metal features are: luster or shine of their surface (when polished),
their malleability (ability to be hammered) and ductility (ability to be drawn).

These properties are also associated with the

metallic bonding and presence of free
electrons in the crystal lattice
 Metals are part of the earth’s crust.
Where do metal Economic, chemical and technological
problems have to be solved to obtain
come from? them.

How desirable a metal is often depends on how

scarce it is
Gold diggers dig up tonnes to obtain a few
grams, whereas there is so much iron that
materials technologists are only interested if
they can obtain hundreds of kilograms from
each tonne of ore.
http://www.iit.edu
Metals can be classified into three groups: ferrous metals, non-
ferrous metals and alloys.

Ferrous metals are metals which contain iron. They will corrode if unprotected.
Ferrous metals will be attracted by a magnet

Non-ferrous are metals which do not contain iron. Pure metals such as
aluminium, copper, tin and lead are non-ferrous, and do not rust

Alloys are metals which are a mixture of two or more metals, benefiting from
the properties of both. For example, brass is an alloy of copper and zinc.
 26th element

It is simply a metal or
alloy that contains Iron
(the element ferrous) as
55.85 Atomic Mass
the base (starting) metal

(1) iron-containing compounds exist in abundant

quantities within the earth’s crust;

(2) metallic iron and steel alloys may be produced using

relatively economical extraction, refining, alloying, and
fabrication techniques;

(3) ferrous alloys are extremely versatile, in that they

may be tailored to have a wide range of mechanical and
physical properties
The true equilibrium
iron–carbon phase
diagram with
graphite instead of
cementite as a stable
phase.
 Baja Besi
C < 2% C > 2%
Dipukul nyaring Dipukul tidak nyaring
C terikat/larut membentuk C bebas sebagai GRAFIT
fasa alpha/Fe3C lamel
Temp lebur > 1550oC Temp lebur 1300-1400oC
Ductility tinggi Ductility rendah
Bisa ditempa Tidak bisa ditempa
Geram panjang Geram pendek/putus
Bunga api sedikit Bunga api banyak
 iron–carbon alloys that may contain appreciable concentrations of other alloying
elements

There are thousands of alloys that have

different compositions and/or heat
treatments

The mechanical properties are sensitive to

the content of carbon, which is normally less
than 1.0 wt%.

Different elements are added to steels to

given the steel different properties.

The elements pass on properties such as harden-ability, strength, hardness, toughness,

wear resistance, etc
Boron
Improves hardenability without the loss
of (or even with some improvement in)
machinability and formability.
Carbon
improves hardenability, strength,
hardness, and wear resistance; it reduces
ductility, weldability, and toughness.
Chromium
improves toughness, hardenability, wear
and corrosion resistance, and high-
temperature strength; it increases the
depth of the hardness penetration
resulting from heat treatment by
promoting carburization.
Lead
improves machinability; it causes liquid-
metal embrittlement
Calcium
Deoxidizes steels, improves toughness, and
may improve formability and
machinability
Cerium
controls the shape of inclusions and
improves toughness in high-strength low
alloy steels; it deoxidizes steels
Cobalt
improves strength and hardness at elevated
temperatures .
Copper
improves resistance to atmospheric
corrosion and, to a lesser extent, increases
strength with little loss in ductility; it
adversely affects the hot-working
characteristics and surface quality.
Magnesium
has the same effects as cerium
Manganese
improves hardenability, strength, abrasion
resistance, and machinability; it
deoxidizes the molten steel, reduce shot
shortness, and decreases weldability.
Molybdenum
improves hardenability, wear resistance,
toughness, elevated-temperature strength,
creep resistance, and hardness; it
minimizes temper embrittlement.
Nickel
improves strength, toughness, and
corrosion resistance; it improves
hardenability.
Niobium (columbium)
imparts fineness of grain size and improves
strength and impact toughness; it lowers
transition temperature and may decrease
hardenability.
Phosphorus
improves strength, hardenability, corrosion
resistance, and machinability; it severely
reduces ductility and toughness
Selenium improves machinability
.
Silicon
improves strength, hardness, corrosion
resistance, and electrical conductivity; it
decreases magnetic-hysteresis loss,
machinability, and cold formability
Sulfur
Improves machinability when combined
with manganese; it lowers impact strength
and ductility and impairs surface quality
and weldability
Tantalum
has effects similar to those of niobium
Tellurium
improves machinability, formability, and
toughness
Titanium
improves hardenability; it deoxidizes
steels.
Tungsten has the same effects as cobalt.
Vanadium
improves strength, toughness, abrasion
resistance, and hardness at elevated
temperatures; it inhibits grain growth
during heat treatment.
Zirconium has the same effects as cerium
group by their percentage of carbon content per weight. The higher the carbon content
the greater the hardness, strength and wear resistance after heat treatment. Contains a
1.5% C max, 1.65 % Mn max, 0.60% Si max, 0.60% Cu max, and 0.05 % S and P max.

The first two digits designate the type

of steel, 10 for plain carbon steels.

The second two digits show the carbon

content in hundredths
of percent.

For example, designation AISI 1045

indicates a plain carbon steel with a
nominal carbon content of 0.45 percent.
 Contains a maximum of 0.25 percent
carbon
These are arguably produced in the greatest
quantities than other alloys.
It is easily machined, formed, and welded
Carbon present in these alloys is limited, and
is not enough to strengthen these materials
by heat treatment; hence these alloys are
strengthened by cold work

Their microstructure consists of ferrite and

pearlite, and these alloys are thus relatively
soft, ductile combined with high toughness
Applications : structural shapes, tin cans,
automobile body components, buildings,
nails, screws, pipes, panels, sheets, wires
Carbon content between 0.25 % -
0.65%
These are stronger than low carbon
steels
Less ductile than low carbon steels
These alloys can be heat treated to
improve their strength

Medium-carbon steels are the most

versatile of all plain carbon steels and
used for a wide range of applications

Application : railway tracks & wheels,

gears, crankshafts, planet pinion
shafts, struts, and tie rod ends, mining
equipment, cranes, garden tools,
structural steel
Contains between 0.60% - 1.0% C

These are strongest and hardest of

carbon steels, and of course their
ductility is very limited, brittle

These are heat treatable, and mostly

used in hardened and tempered
conditions

They possess very high wear

resistance, and capable of holding
sharp edges

High-carbon steels are more costly to

make and have poor formability and
weldability
Dipasaran dalam bentuk : Symbol Keterangan
• Plain Sheet SPCC For General use
• Coil SPCD For Deep Drawing Use
SPCE For Extra Deep Drawing Use

ε
Symbol ASTM Class C Si Mn P S UTS
0.2%
ASTM 0.50 0.040 0.045 270
SPCC Class 1 0.12 max - 32 min
A366-72 max max max min

ASTM 0.45 0.035 0.035 270

SPCD Class 2 0.10 max - 34 min
A619-82 max max max min

ASTM 0.40 0.030 0.030 270

SPCE Class 3 0.08 max - 36 min
A620-82 max max max min
The name comes from their high resistance to corrosion i.e. they are rust-less (stain-less)
Steels are made highly corrosion resistant by addition of special alloying elements,
especially a minimum of 12% Cr along with Ni and Mo

Chromium forms a surface oxide film that protects the underlying metal from further
corrosion
The addition of nickel to stainless steel improves its corrosion resistance in neutral or
weakly oxidizing media
Nickel in sufficient amounts also improves the ductility and formability by retaining an
austenitic structure at room temperature

Molybdenum improves corrosion resistance of stainless steel in the presence of chlorine

ions
These stainless steels are called ferritic
because their microstructure remains
mostly as ferrite at normal heat
treatment conditions
Ferritic stainless steels are essentially
iron-chromium alloys containing 12 -
30% chromium and a limited amount
of carbon

ferritic stainless steels have low

ductility, are sensitive to surface
damage, and have poor weldability
When a regular steel is cooled
fast enough, such as quenched in
water, it has a martensitic
structure at room temperature

iron-chromium alloys containing

12-17% Cr

Compared with ferritic stainless steels, martensitic stainless steels contain larger amounts
of carbon. This is necessary so that a martensitic structure can be formed after quenching
from high temperature.

Because of the strengthening effect, martensitic stainless steels are used primarily in
applications that require high hardness
They are essentially Fe-Cr-Ni alloys
containing 16-25% Cr and 7-20%Ni
The most common austenitic
stainless steel is type 304. It
contains 18% Cr and 8% Ni and is
referred to as 18-8 stainless steel.

These stainless steels are called

austenitic because their structure
remains austenitic at all normal
heat treatment temperatures
Some of the nickel can be replaced
by manganese and maintain their
austenitic structure

Austenitic stainless steels are popular mainly because of their high corrosion resistance
and formability
 Material Fe yang mengandung C > 2,14 % dengan struktur terdiri
dari:
• Partikel karbon bebas (grafit)
• dan matriks perlit dan ferit austenitic, martensitic, bainitic
(austempered).

• Sangat keras dan getas

• Kuat dalam beban tekan
• Cocok untuk aplikasi pengecoran [dapat
dituang pada temperatur relatif rendah]

Engine block, machine

parts
Lebih Murah dari Baja (Biaya Produksi lebih rendah dan peralatan lebih sederhana)

Temperatur Lebur Rendah (1140-12000C)

Kemampuan Cor Tinggi (Casting ability)

Mudah Permesinan

Tahan Aus (wear resistance)

“Damping Capacity” Tinggi

Sangat cocok untuk applikasi yang membutuhkan “rigidity and resistance to wear”
1. kelas dari ferrous alloys dengan
kandungan C > 2.14%
2. Terdapat grafit dalam
mikrostrukturnya
3. Jenisnya antara lain : Besi Cor
Kelabu, Besi Cor Putih, Besi
Cor Nodular, Besi Cor Malleable
1. Kandungan Karbon antara 2.5 - 4.0 wt%
2. Kandungan Silikon antara 1.0 - 3.0 wt%,
3. Umumnya karbon berlebih membentuk
grafit yang berbentuk flakes (mirip corn
flakes), dikelilingi matrix ferrite atau
pearlite
4. Karena grafitnya berbentuk flakes maka
patahannya berwarna abu-abu Grafit

Grey iron has a high damping capacity,

excellent sliding properties and thermal
conductivity
Machine bases, damping plates for pianos, engine
blocks, flywheels, piston rings, brake discs dan drums
1. Didapat dengan cara menambahkan
magnesium dan atau cerium sebelum
dicor untuk mendapatkan kekuatan yang
lebih besar
2. Umumnya karbon berlebih membentuk
grafit yang berbentuk bulat, dikelilingi
matrix ferrite atau pearlite

Ductile iron has greater strength and Grafit

ductility than grey iron, good machining
qualities

Heavy duty gears, pistons, rolls for rolling

mills, gear cases, valves, tubes and door
hinges
 1. Kandungan Karbon antara 2.5 - 4.0 wt%
2. Kandungan Silikon < 1.0 wt%,
3. Umumnya karbon berlebih berbentuk
cementit
4. Patahannya berwarna putih
Cementit
White cast iron has a high compressive
strength and alloyed versions have a good
retention of strength and hardness Pearlite
at elevated temperatures
shot-blasting nozzles, rolling mill
rolls, crushers, pulve rizers and ball mill liners
1. Didapat dengan cara memanaskan besi
cor putih pada temperature antara 800 -
900oC dalam waktu yang lama dan
atmosfer yang netral (mencegah korosi)
2. Terjadi dekomposisi cementite
membentuk grafit yang berbentuk
rossete, dikelilingi matrix ferrite atau
pearlite
Grafit
Malleable iron is replaced by nodular iron
for economical reasons, especially since
the fields of application are very similar
Ferrite
 Semua Jenis Baja yang dipergunakan sebagai perkakas (tool)

Biasanya dipergunakan untuk

• CUTTING
• SHAPING
• FORMING

Kondisi selama pemakaian:

• Beban yang Tinggi dan Tiba-tiba
(Very high & rapidly loads)
• Temperatur Operasi yang Tinggi
(Very high temperature)
 Tool Steel merupakan paduan kompleks
yang mengandung sejumlah besar unsur:
 Carbon (C)
 Tungsten (W)  Tahan terhadap “softening”
 Molybden (Mo) (pelunakan) material pada
 Vanadium (V) Temperatur tinggi (Kemampuan
 Mangan (Mn) mempertahankan “high red
 Chrom (Cr) hardness” atau “hot hardness”)
 Tahan terhadap wear (keausan),
 Kebanyakan Tool Steel dibuat: deformation (perubahan bentuk) &
 Wrought Product (Rolling)
perpatahan
 Precision Casting (Cor Khusus)  Tangguh (toughness) untuk
 Powder Metallurgy (Serbuk)
menyerap beban yang besar dan
tiba-tiba
 Memiliki sifat mampu mesin
(Machinability)
 Baja yang dapat menjaga kekerasan yang tinggi saat digunakan

Penggunaannya untuk High Speed Cutting

 Aplikasi :
 Cutting Tools
 Bor
 Bubut

 Jenis :
 Group M (Alloy Molybdenum)
 Group T (Alloy Tungsten = W)
Dipergunakan untuk kombinasi:

Panas
Temperatur
Tekanan
Tinggi
Abrasi

Cocok Untuk:
- Dies untuk Ekstrusi
- Hot Forging
- Die Casting
- Hot Shears
. .

Application Area Specific Application Application Area Specific Application

Hot Forging Tool  Dies for presses and Shearing Tools :  For shearing knives :
and Dies : Dies hammer: H20, H21 Dies for H11, H12
and Insert;  For severe condition pierching,  For severe hot
Forging machine over extended punching, and shearing application:
service period : H22- triming; Shear H21, H25
H26 blade
Hot Extrusion  Extrusion dies Dies Casting and  For Aluminum and
and Dies : dummy block; : H21 - Molding Dies : lead; : H11, H13
Extrusion dies H26  For brass : H21
and , mandrel;  Tool exposed to less
Dummy block; heat: H10 - H14, H16
Valve extrusion
tool
Cold Forming  Cold-heading die Structural Part  For air craft
Dies : Bending; casings : H13 for Sever Service components (Landing
Forming; Condition gear, arrester hook,
Drawing; Deep rocket cases) : H11
Drawing Dies and
Punches
Features 1. Finely distributed spherical carbides
2. Excellent quenching nature
3. Excellent softening resistance under high temperature
4. Excellent heat impact and fatigue resistance
5. Excellent erosion resistance to molten
Applications - Al, Zn, die caster mold
- Mold's accessories (Plunger sleeve, chip etc.)

Equivalent JIS DIN AISI ASSAB BOHLER HITACHI NIPPON KOSHUHA

SKD61 1.2344 H13 8407 W302 DAC KDA-1

Composition (%) C Si Mn Cr Mo V

0.32-0.42 0.80-1.20 max 0.50 4.50 - 5.50 1.00 - 1.50 0.80 - 1.20

Heat treatment (oC) Forging Annealing Hardening Tempering

820 - 870 1,000 - 1,050 550 - 650

1,100 - 900
(Slow cooling) (Air cooling) (Air cooling)

Hardness Annealed Tempered

229 HB (20.5 HRC) max. 53 HRC max.

Thermal conductivity 25 oC 100 oC 200 oC 300 oC 400 oC 500 oC 600 oC 700 oC

(cal/cm.sec.oC) 0.0569 0.0605 0.0702 0.0707 0.0687 0.0624 0.0712 0.0721

Coefficient of thermal ~100 oC ~200 oC ~300 oC ~400 oC ~500 oC ~600 oC ~700 oC

expansion
(x10-6/oC) 10.5 11.4 12.1 12.8 13.3 13.7 13.6
Tidak Tahan Terhadap
KELOMPOK A KELOMPOK D KELOMPOK O (Oil
“Softening” pada Temp.
(Air Hardening) (High C, High Cr) Hardening)
Tinggi
Cr: 4.75 – 5.5 % Cr : 11 – 13.5 % Cr : < 0.85 %
C: 0.5 – 1.5 % C : 1.4 – 2.5 % C : 0.85 – 1.5%
Temp Operasi < 260 oC
Aplikasi : shear knives, Aplikasi : dies for High Wear Resitant at T rendah
punches, blanking, blanking, forming, deep Poor Resistant to Softening pada
Temp Operasi < 260 oC trimming dies drawing, shear & Slitter T tinggi
knives Aplikasi: Dies, punches for
blanking, trimming, drawing &
forming
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