Products….

Material:

 Material can be defined as the substance or substances of

which a thing is made or composed.

Materials

Metals Non- metals

Metals:

Metals are solid materials which are typically hard, shiny,

malleable, fusible, and ductile
with good electrical & thermal conductivity and
that are easily shaped by forming.

Metals

Ferrous metals Non- Ferrous metals

 Ferrous Metals:

These are metals which contain iron.

They may have small amounts of other metals or other
elements added, to give the required properties.
All ferrous metals are magnetic and less resistance to
corrosion.

Ferrous Metals

Cast Iron Steel

 Cast iron

Cast iron is basically an alloy of iron and carbon

90-92%-fe , 2-4.5% Carbon, 1-3% silicon, smaller
amount of sulphur, manganese, phosphorous
 Due to high carbon % cast iron are very brittle.
As they are low in ductility they cannot be rolled, drawn
or worked
Good castability, excellent machinability
Fluidity of molten cast iron is very good and therefore
can be cast good and therefore can be cast into
complicated shape.
 Cast Iron

Grey White Malleable Ductile Chilled Alloyed

Cast Iron Cast Iron Cast Iron Cast Iron Cast Iron Cast Iron

Grey cast iron :

3.2-3.5% carbon,1.3-2.3% silicon along with sulphur, phosphorous, manganese in small
amounts
- carbon is present in the form of graphite flakes
-prison rings, cylinder and blocks, machine frames and base of IC engines.
white cast iron (1.8%-3.6% carbon, 0.5-2% silicon)
-Carbon is present in in the form of iron carbides
- pump liners, mill liners, grinding balls and extrusion nozzles
Malleable cast iron:
-By heat treatment of white cast iron about 900 °C in normal atmosphere.
- camshaft, housing steering brackets, pipefittings,flanges, gear parts, hub, brakes and
carriers.
Ductile cast iron:
produced by adding one or more elements of magnesium, calcium, barium, sodium and
lithium –
-used for crankshaft, rolls, punches, dies and sheet metal work
 Cast iron products

Engine base

Crank shaft

Gear
Cam shaft
 Steel
-crystalline alloy of iron and carbon which does not contain
any free graphite.
- Most of the steels have carbon not more than 1.5%;
-steels with carbon less than 0.2% are weak.

Steel

Plain carbon steels Alloy steels Tool steels

 • Plain carbon steels:
Iron-carbon alloys containing 0.03% to 1.2% carbon, 0.25% to 1%
Manganese
Plain carbon steels

Low carbon steels Medium carbon steels High carbon steels

Low carbon steels( mild steels. )

They contain carbon from 0.05% to 0.3%.
Due to excellent formability, -used in refrigerator housing, engine housing, angles,
wheels, levers, boiler plates and beams.
Medium carbon steels:
Medium carbon steels contain carbon in the range of 0.3% to 0.9%.
These steels are used in axles, agricultural tools, springs, locomotive tyres,
hammers, gears, spindles and shear blades.
High carbon steel:
Steels containing more than 0.65% carbon are called high carbon steels.
These steels are used in dies, screw drivers, hammer wrenches, band saws, punches
and rock drills.
Plain carbon steels
* Alloy Steels
The steels which have other elements than carbon.

Alloy Steels

Nickel steels Chromium steels Tungsten steels Stainless steels

Nickel steels:
-Nickel is added in carbon steels -to improve toughness and fatigue strength and increase
resistance to corrosion.
- It also improves elastic limit
-These steels are used in truck gears, cam, crankshaft and manufacturing of measuring
instruments.

Chromium steels:
-chromium with steel.
-Used for ball and roller bearings, crushers and permanent magnets.
-used for food processing equipment, surgical and dental equipment, turbine blades and
acid resistant chambers.
Tungsten steels:
-Tungsten is alloyed with steel
–Tough metals -stable at high temperatures.
-used to make high speed cutting tools and rocket engine nozzles.

Stainless steels:
-Steels which do not easily get stained
-Resitant to rusting and corrosion
-304 grade steel with 8% nickel, 18% chromium, 2% of molybdenum and 0.1
% carbon.
Stainless steel spoons
• Tool steels:
It is suited for forming tools for various mechanical workshop tools.

Carbon 0.7% to 1.5% and will be heat treated to provide desired quality to the tool
steels.
Tool steels are classified based on the alloy content, method of heat treatment
processes and applications.

Tool Steels

Water hardening Shock resisting High speed Hot working

grade steels grade steels steels grade steels
 Non Ferrorus Metals

These are metals which does not contain iron.

Non ferrous metals have good resistance over corrosion, thermal
conductivity & electrical conducticvity.

Non - Ferrous metals

and Alloys

Copper & its Aluminium & its Lead & its Nickel & its alloys
alloys alloys alloys
• Copper & its alloys:
 High electrical and thermal conductivity,
 good corrosion resistance,
 machinability and ease of fabrication.
used for electrical wires, conductors, radiators and heaters.

Copper & its Alloys

Brass Bronze

a)Brass: Brass is an alloy of copper and zinc. They are used in condenser tubes,
radiators cores, plumbing pipes, pipe fittings, storage batteries, etc.
b) Bronze: Bronze is basically an alloy of copper and tin. Commercial bronze may
contain, copper and tin, aluminium, silicon, beryllium, phosphorous, lead, zinc and
nickel.
They are used in bearings, tanks, marine construction, nuts & bolts, surgical
instruments, etc.
Brass

Bronze
* Aluminium & its alloys:
Low density, high electrical and thermal conductivity, resistance to corrosion.
--machinable and rolled to desire thickness. They are used in electrical cables, automobile
components, aircraft construction, etc.

Aluminium & its Alloys

Dispersion strengthened and

Wrought aluminium fiber-reinforced aluminium
Aluminium casting
alloy composites

a)Aluminium casting: Aluminium is one of common foundary metals.

Casting process is used to temper the aluminium . Most commonly used casting processes
are sand castings, permanent mould castings and cold chamber pressure die castings.

b)Wrought aluminium alloy: Wrought aluminium alloys has high tensile strength, high
electrical conductivity and good weldability. These are used as rolled plates, sheets, foils, rods,
bars and wires.
c)Dispersion strengthened and fiber-reinforced aluminium composites:
produced by dispersion of fine particles of alumina in the matrix of aluminium
Lead & its alloys:

 High ductile, soft, malleable,

 low electrical conductivity,
 high coefficient of expansion,
 good lubricating properties and
 resistance to corrosion.
They are used in storage batteries, gaskets, joints,
sheathing of cables, bearings and bushing elements, etc.

Nickel & its alloys:

 High density and strength,

 resistance to corrosion and oxidation,
 strong, tough and ductile material.
They are used in measuring tapes, instrument parts,
special springs, etc.
• Composite Materials
Composite material is made by combining two or more
materials –that have very different properties. The two
materials work together to give the composite unique
properties.

A composite material is formed when one or more material

distribute or reinforced in second phase called matrix. The
matrix phase surrounds the other phase which is called
reinforcement.

Reinforced cement concrete is a good example of

composite material, where steel bars are reinforcement and
cement is matrix.
Classification of Composite materials
Composite materials are commonly classified at following two ways:

1) Classification with respect to the matrix constituent:

• Polymer Matrix Composites (PMCs)

• Metal Matrix Composites (MMCs)
• Ceramic Matrix Composites (CMCs)
2) Classification refers to the reinforcement form:

• Particulate composites
• Fibre reinforced composites
• Laminates
• Polymer Matrix Composites (PMCs):
Polymer Matrix Composites are composed of a matrix from thermoset or
thermoplastic and embedded glass, carbon, steel or Kevlar fibers. They are very popular
due to their low cost and simple fabrication methods.
They are characterized by the following properties:
• High tensile strength;
• High stiffness;
• High Fracture Toughness;
• Good abrasion resistance;
• Good puncture resistance;
• Good corrosion resistance;
• Low cost.

They are used for :

 Aerospace structures, boat bodies,
 automotive parts,
 sport goods (golf clubs, tennis rackets, fishing rods),
 bullet-proof vests and other armor parts,
 brake and clutch linings.
•Metal Matrix Composites (MMCs):
Metal Matrix Composites are composed of a metallic matrix and a dispersed
ceramic or metallic phase.

They are characterized by the following properties:

•High strength even at maximum temperatures;
•High stiffness:
•Low density;
•High thermal conductivity;
•Good electrical conductivity;
•Excellent abrasion resistance;
•High wear resistance;
•Good creep resistance;

They are widely classified as follows:

•Aluminium Matrix Composites
•Magnesium Matrix Composites
•Titanium Matrix Composites
•Copper Matrix Composites
• Ceramic Matrix Composites (CMCs):

Ceramic Matrix Composites are composed of a ceramic matrix and embedded

fibers of other ceramic material.

They are characterized by the following properties:

• High mechanical strength even at high temperatures;
• High thermal shock resistance;
• High stiffness;
• High toughness;
• High thermal stability;
• Low density;
• High corrosion resistance even at high temperatures.

They are used for-

 combustion liners of gas turbine engines,
 heat exchangers, rocket propulsion components,
 filters for hot liquids, thermo-photovoltaic burners,
 burner stabilizers, high performance braking systems,
 refractory components, hot-pressed dies,
 heating elements and turbojet engine components.
 Classification refers to the reinforcement form:
Particulate composites:

These composites have discrete particles of one material which is surrounded

by a matrix of another material. These composite structures are normally fabricated by
the powder metallurgy. They are used in grinding wheels, sintered carbides and
ceramics.

Fibre reinforced composites:

Fibre reinforced composites are composed of fibres embedded in matrix

material. Such a composite is considered to be a discontinuous fibre or short fibre
composite if its properties vary with fibre length.
They are used in space shuttles, aerospace turbines, etc.

Laminates:

Laminate is the technique of manufacturing a material in multiple layers, so

that the composite material achieves improved strength, stability, appearance or other
required properties by the application of designed materials.
particulate
laminates
Advantages:
 Composite materials possess an excellent combination of
mechanical, chemical and structural properties;
 Light weight material having higher strength;

 It can be moulded to any shape and size;

 Anti corrosion ;

 Good resistance to heat, cold and rain;

 Ease of production and low cost;

 Aesthetic appearance.
Limitaions:

•If the volume of production is less, then the cost becomes very high;
•It has low flash and fire points;
•Not suitable for very high temperature.

Applications:

•Fibre glass composite is used to make pipes, roofing, storage

containers;
•Carbon reinforced composite are used in aircraft structural
components;
•Boron fibre reinforced composite used in helicopter rotor blades;
•Concrete which contains steel rods in matrix of cement and sand
used in construction of buildings;
•Silicon carbide particles reinforced in titanium-di-oxide matrix has
good wear & corrosion resistance and used in heat exchangers.