A REFRESHER ON

INDUSTRIAL & FERTILIZER MATERIALS

PRESENTED BY
NOOR-UL-HASSAN
 MATERIAL CLASSIFICATION

MATERIALS

NON - FERROUS

METALS

FERROUS

NON - METALS
 FERROUS METALS

ORIGINAL DEFINITION

- IRON CONTENTS GREATER THAN 50%.

Cr : 26 max. Mn : 02 max.
SS 310 Ni : 22 max. Si : 1.5 max.
Total : 51.5 max.

REVISED DEFINITION (1993)

- MATERIAL WHICH CONTAINS BY MASS MORE IRON THAN ANY

OTHER SINGLE ELEMENT.
 CLASSIFICATION FERROUS METALS

FERROUS METALS

WROUGHT IRON

CARBON STEEL BASED ON “C” ADDITION

CAST IRON

ALLOY STEEL
 EFFECT OF CARBON ON STEEL

Carbon

Hardness Strength Ductility Weldability

 WROUGHT IRON

COMPOSITION
- CARBON CONTENTS LESS THAN 0.08 % CARBON
- CONTAINS SMALL AMOUNT OF SLAG (SiO2)

MECHANICAL PROPERTIES
- LOW STRENGTH , MALLEABLE AND DUCTILE

- EASILY WELDABLE

USES
- CURRENTLY WROUGHT IRON IS NOT PRODUCED DUE TO HIGH
MANUFACTURING COST

- MODERN WROUGHT IRON PRODUCTS ARE ACTUALLY MADE

FROM LOW CARBON STEEL
 CARBON STEEL

TYPE OF STEEL FOR WHICH:

- NO ALLOYING ELEMENT IS ADDED EXCEPT CARBON

- CARBON CONTENTS ARE < 2%

CARBON STEEL IS CLASSIFIED ACCORDING TO:

ITS CARBON CONTENTS

ITS TREATMENT FOR DEOXIDIZATION

 CARBON STEEL CLASSIFICATION
ACCORDING TO CARBON CONTENTS

CARBON STEEL

LOW CARBON STEEL CARBON CONTENTS < 0.3 %

MEDIUM CARBON STEEL CARBON CONTENTS BETWEEN 0.3 %

AND 0.6%

HIGH CARBON STEEL CARBON CONTENTS BETWEEN 0.6 %

AND 2.0%
 LOW CARBON STEEL

COMPOSITION
- LESS THAN 0.3 % CARBON

MECHANICAL PROPERTIES
- EXCELLENT FORMABILITY AND WELDABILITY

- GRADES HAVING CARBON B/W 0.1 % TO 0.3 % ARE HEAT TREATABLE

GENERAL USES
- SHEETS MANUFACTURING, PIPING AND PRESSURE VESSEL
COMPONENTS
 LOW CARBON STEEL

USED AT FERTILIZER PLANT

- PIPING, VALVES AND VESSELS FOR

- LOW, MEDIUM AND HIGH PRESSURE STEAM/CONDENSATE

- COOLING WATER, INSTRUMENT AIR, FUEL GAS, NATURAL GAS

- LIQUID AMMONIA (HIGH TEMPERATURE)

- LOAD BEARING STRUCTURES AND SHEETS

LOW CARBON STEEL GRADES

 API 5L GRADE B
 ASTM A - 105
 ASTM A - 234
 MEDIUM CARBON STEEL

COMPOSITION
- CARBON CONTENTS BETWEEN 0.3% TO 0.6%

MECHANICAL PROPERTIES
- GOOD BALANCE BETWEEN STRENGTH AND DUCTILITY

- HEAT TREATABLE

GENERAL USES
- MANUFACTURING OF GEARS, CRANKSHAFT ETC.
 HIGH CARBON STEEL

COMPOSITION
- CARBON CONTENTS BETWEEN 0.6% TO 2.0%

MECHANICAL PROPERTIES
- HIGH STRENGTH

- LOW DUCTILITY

- POOR WELDABILITY AND FORMABILITY

GENERAL USES

- HIGH STRENGTH WIRES AND SPRINGS

 CAST IRON

COMPOSITION
- CARBON CONTENTS BETWEEN 2% AND 5%
- SILICON INCLUSION BETWEEN 1% AND 3%

MECHANICAL PROPERTIES

- MELTING TEMPERATURE BELOW CARBON STEEL

- EXCELLENT FLUIDITY (REQUIRED FOR CASTING PURPOSE)

- POOR WELDABILITY AND DUCTILITY

GENERAL USES
- MANUFACTURING OF PUMPS, TURBINES, COMPRESSORS AND GEAR BOX
CASINGS
 CLASSIFICATION FERROUS METALS

FERROUS METALS

WROUGHT IRON

CARBON STEEL BASED ON “C” ADDITION

CAST IRON

ALLOY STEEL
 ALLOY STEELS

ALLOY STEEL Cr-Mo Alloy

LOW ALLOY STEEL CORROSION RESISTANT

ALLOYING ELEMENT UP TO 8.0%

HEAT RESISTANT

HIGH ALLOY STEEL WEAR RESISTANT

ALLOYING ELEMENT GREATER THAN 8.0%

 Cr – Mo STEELS

COMPOSITION
- Cr UPTO 2.25% AND Mo UP TO 1.25%

ALLOYING EFFECT

- Cr INCREASES CORROSION RESISTANCE

- Mo ADDS ELEVATED TEMPERATURE STRENGTH

MECHANICAL PROPERTIES

- HIGH STRENGTH AT TEMPERATURES UP TO 650 0C

- DIFFICULT WELDING AS HEAT TREATMENT IS INVOLVED

GENERAL USES
- PRESSURE VESSEL, PIPING AT HIGH TEMPERATURE
 Cr – Mo STEELS

USES AT FERTILIZER PLANT

- PIPING, VALVES AND VESSELS FOR VER HIGH PRESSURE STEAM (KS)

Cr - Mo STEEL GRADES

 A-335 GRADE P11 (PLANT-I KS)

 A-335 GRADE P22 (PLANT-I KS)

 STAINLESS STEEL

WHEN Cr CONTENTS ARE GREATER THAN 11.5 %, Cr REACTS WITH ATMOSPHERIC

O2 AND FORM THIN PASSIVE Cr-O2 LAYER ON STEEL SURFACE PREVENTING

OXIDATION OF Fe CONTENTS

Cr–O2 LAYER

STEEL
EFFECT OF CHROMIUM
 STAINLESS STEEL

STAINLESS STEEL

AUSTENITIC

FERRITIC

MARTENSITIC

DUPLEX
SCHAFFLER DIAGRAM
 AUSTENITIC STAINLESS STEEL

COMPOSITION Cr UP TO 30%

Ni UP TO 30%

C 0.3%

MECHANICAL PROPERTIES
- EXCELLENT CORROSION RESISTANT

- GOOD WELDABILITY

- CAN BE USED AT LOW AND HIGH TEMPERATURE (UP TO 900 0C)

- CANNOT BE HARDENED BY HEAT TREATMENT

GENERAL USES

- FOOD PROCESSING, CORROSIVE SERVICES e.g. UREA, ACID etc.

 AUSTENITIC STAINLESS STEEL

USED AT FERTILIZER PLANT

- PIPING, VALVES AND VESSELS FOR

- ALL PRESSURE UREA SERVICE AND UREA FLUSHING CIRCUIT

- MDEA, PROCESS GAS, DEMIN WATER

AUSTENITIC GRADES

 SS- 304
 SS- 316
 SS- 316L Modified
 25 Cr – 22Ni – 02 Mo

 SS- 321
 CONCEPT OF SENSITIZATION IN STAINLESS STEEL

AT HIGH TEMPERATURE (> 750 0C) Cr REACTS WITH C AND FORMS CrC

TO PREVENT SENSITIZATION Ti OR Nb IS ADDED TO FORM TiC OR NbC

GRAIN BOUNDARIES

CHROMIUMCARBIDE
(Cr23 C6)
CHROMIUM
 MARTENSITIC STAINLESS STEEL

COMPOSITION Cr UP TO 17%
Ni 0%

C 1.2%

MECHANICAL PROPERTIES
- MODERATE CORROSION RESISTANT

- POOR WELDABILITY

- CAN BE HARDENED BY HEAT TREATMENT

GENERAL USES

- SHAFTS, SURGICAL INSTRUMENTS, FASTENERS

 MARTENSITIC STAINLESS STEEL

USED AT FERTILIZER PLANT

- PUMP SHAFTS, IMPELLERS FOR CORROSIVE SERVICE

MARTENSITIC GRADES

 SS- 410
 SS- 416
 SS- 420
 SS- 440
 FERRITIC STAINLESS STEEL

COMPOSITION Cr UP TO 30%
Ni 0%
C .3%

MECHANICAL PROPERTIES
- MODERATE TO GOOD CORROSION RESISTANT

- POOR WELDABILITY

- CANNOT BE HARDENED BY HEAT TREATMENT

GENERAL USES

- DOMESTIC EQUIPMENTS
 DUPLEX STAINLESS STEEL

COMPOSITION Cr UP TO 30%

Ni UP TO 8%

C .3%

MECHANICAL PROPERTIES
- GOOD CORROSION RESISTANCE

- GOOD STRENGTH : GREATER THAN AUSTENITIC AND OTHER GRADES

- GOOD WELDABILITY

GENERAL USES

- OFF-SHORE APPLICATIONS, HIGH PRESSURE UREA

 DUPLEX STAINLESS STEEL

USED AT FERTILIZER PLANT

- UREA REACTOR (STAMI CARBON PLANTS)

- STEMS FOR HIGH PRESSURE UREA VALVES

DUPLEX GRADES

 HVD-1
 FERRALIUM ALLOY
 MARTENSITIC
STEEL
SS - 317
INCREASE C
LOWER Cr ADD MORE Mo (4%)
FOR PITTING RESISTANCE
FERRITIC
SS - 317L
STEEL
LOWER C SS - 316L
SS - 316
NO Ni SS - 304L
ADD Mo (2%)
FOR PITTING RESISTANCE
SS - 347

SS – 304
ADD Nb + Ta 18 Cr – 8 Ni
TO REDUCE SENSITIZATION

ADD Ti ADD Cr & Ni SS – 310

SS - 321 STRENGTH & CORROSION RESIST. SS - 309
TO REDUCE SENSITIZATION

DUPLEX REDUCE Ni
STEEL TO REDUCE AUSTENITIC STRUCTURE
 MATERIAL DESIGNATION SYSTEM

ASTM - American Society for Testing Materials

AISI - American Iron and Steel Institute

SAE - Society of Automotive Engineers

UNS - Unified Numbering System

DIN - German Standards

BS - British Standards

JS - Japanese Standards
 AISI/SAE DESIGNATION SYSTEM

CLASSIFY MATERIAL ON THE BASIS OF COMPOSITION

CARBON AND ALLOY STEEL (EXCEPT STAINLESS STEEL)

ADDITION OF ELEMENTS
10 - Carbon Steel

41 - 1% Cr & 0.3% Mo Steel

PREFIX M OR E SUFFIX H
M - Merchant Quality Steel

E - Electric Furnace Steel

X 13 Y 12 Z
B - Boron
L - Lead
CARBON %AGE
H - Hardenability

MATERIAL TYPE
 AISI/SAE DESIGNATION SYSTEM

STAINLESS STEEL

2 - Austenitic Stainless Steel

Element addition
3 - Austenitic Stainless Steel

4 - Martensitic & Ferritic

3 16 Z
L - Low Carbon (<0.03%)

H - High Carbon Contents

No Specific Interpretation
N - Added Nitrogen

MATERIAL TYPE Cu - Added Copper

 ASTM STANDARDS
DESIGNATION SYSTEM

CLASSIFY PRODUCTS ON THE BASIS OF MANUFACTURING METHOD

MOST WIDELY USED SYSTEM – COVERS ALL DETAILS REQUIRED FOR MATERIAL
PROCUREMENT

Grade

ASTM A 182 / 182 M - 93b F 304L

Ferrous Metals AISI NO

Arbitrary Number Year of Revision

Metric System
 ASTM STANDARDS
DESIGNATION SYSTEM

C - Corrosion Resistant
H - Heat Resistant EXAMPLES
M - Addition of Molybdenum
A 403/A 403M -93 WP304L
Digital No. - Carbon Percentage
A 351 Grade HK40
P - Pipe
T - Tube A 336/A 336M-89 Class F22

TP - Tube and Pipe

A 351 Grade CF8M
F - Forging
W - Wrought
 UNIFIED NUMBERING SYSTEM (UNS)

JOINT VENTURE AS ASTM AND SAE TO GENERATE UNIFIED COMPUTER FRIENDLY

SYSTEM

AISI/SAE NUMBER
1 - Boron
4 - Lead
TYPE OF STEEL
6 - Electric Furnace Steel
G - Carbon and Alloy steels
X 1040 1
F - Cast Irons
H - Heat and Corrosion
ELEMENT ADDITION Resistant Steels
 MATERIAL COMPOSITION

WHERE TO FIND

BLACK BOOK BY CASTII PUBLISHING (PDF FORMAT)

KEY TO STEEL (SOFTWARE)

ASTM STANDARDS
THE END
Cr – Mo STEELS
 Cr UP TO 30% Cr UP TO 30%

Ni UP TO 30% Ni UP TO 8%

C 0.3%
C .3%

Cr UP TO 30% Cr UP TO 17%
Ni 0% Ni 0%

C 0.3% C 1.2%
 STAINLESS STEEL
CONCEPT OF SENSITIZATION

CHROMIUM CARBIDE (Cr23 C6)

CHROMIUM DEPLETED LAYER

 MATERIAL CLASSIFICATION

FERROUS METALS LOW CARBON

CARBON STEEL HIGH CARBON

MEDIUM CARBON

CAST IRON

LOW ALLOY STEEL

HIGH ALLOY STEEL

 STAINLESS STEEL

Ni UP TO 30%
Cr
UP TO 30%
Cr UP TO 30% Cr UP TO 30%

Cr UP TO 17%

Ni 0% Ni 0%
Ni UP TO 8%

C 1.2%
C .3% C .3% C .3%

AUSTENITIC DUPLEX FERRITIC MARTENSITIC

STAINLESS STEEL STAINLESS STEEL STAINLESS STEEL STAINLESS STEEL
 AUSTENITIC STAINLESS STEEL

UN-STABILIZED GRADE STABILIZED GRADE

Cannot Be Used for High Can Be Used for High

Temperature Temperature

- SS 304 - SS 321

- SS 316 - SS 347
- 316L + G510
- 25 Cr – 22 Ni – 2 Mo
 AUSTENITIC STAINLESS STEEL
SS - 317

ADD MORE Mo (4%)

FOR PITTING RESISTANCE
SS - 317L

LOWER C SS - 316L
SS - 316
SS - 304L
ADD Mo (2%)
FOR PITTING RESISTANCE
SS - 347

SS – 304
ADD Nb 18 Cr – 8 Ni
TO REDUCE SENSITIZATION

ADD Ti ADD Cr & Ni SS – 310

SS - 321 STRENGTH & CORROSION RESIST. SS - 309
TO REDUCE SENSITIZATION
 CARBON STEEL

CARBON STEEL

LOW CARBON STEEL CARBON CONTENTS < 0.3 %

MEDIUM CARBON STEEL

CARBON CONTENTS BETWEEN
0.3 % AND 0.6%

HIGH CARBON STEEL

CARBON CONTENTS BETWEEN
0.6 % AND 2.0%
OBJECTIVE
 CARBON STEEL CLASSIFICATION
ACCORDING TO CARBON CONTENTS
SHAEFFLER DIAGRAM