Manufacturing Processes Prof. T.

zel
Structure and Manufacturing Properties
of Metals
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Turbine Blades for Jet Engines
FIGURE 3.1 Turbine blades for jet engines, manufactured by three different methods: (a)
conventionally cast; (b) directionally solidified, with columnar grains, as can be seen
from the vertical streaks; and (c) single crystal.
Although more expensive, single crystal blades have properties at high temperatures that are
superior to those to those of other blades. Source: Courtesy of United Technologies Pratt and
Whitney.
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The Crystal Structure of Metals
Crystalline material: atoms situated in a repeating 3D periodic array over large
atomic distances
Crystalline structure :The arrangement of atoms in the crystal is called crystalline
structure.
Lattice: 3D array of regularly spaced points
Unit cell: The smallest group of atoms showing characteristic lattice structure of a
particular metal is known as a unit cell.
Three basic patterns of atomic arrangement found in most metals are as
follows:
Body-centered cubic (bcc)
Face centered cubic (FCC)
Hexagonal close packed (hcp)
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atoms pack in periodic, 3D arrays
typical of:
Crystalline materials...
-metals
-many ceramics
-some polymers
atoms have no periodic packing
occurs for:
Noncrystalline materials...
-complex structures
-rapid cooling
Si Oxygen
crystalline SiO2
noncrystalline SiO2
"Amorphous" = Noncrystalline
Adapted from Fig. 3.18(a),
Callister 6e.
AMORPHOUS MATERIALS
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Dense, regular packing
Dense, regular-packed structures tend to have lower energy
Energy
r
typical neighbor
bond length
typical neighbor
bond energy
ENERGY AND PACKING
Non dense, random packing
Energy
r
typical neighbor
bond length
typical neighbor
bond energy
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Body-Centered Cubic Crystal Structure
FIGURE 3.2a The body-centered cubic (bcc) crystal structure: (a) hard-ball model; (b)
unit cell; and (c) single crystal with many unit cells. Source: W.G. Moffatt et al.
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Face-Centered Cubic Crystal Structure
FIGURE 3.2b The face-centered cubic (fcc) crystal structure: (a) hard-ball model; (b) unit
cell; and (c) single crystal with many unit cell. Source: W.G. Moffatt et al.
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Hexagonal Close-Packed Crystal Structure
FIGURE 3.2c The hexagonal close-packed (hcp) crystal structure: (a) unit cell; and (b)
single crystal with many unit cells. Source: W.G. Moffatt et al.
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Plastic Deformation of a Single Crystal
FIGURE 3.3 Permanent deformation,
also called plastic deformation, of a single
crystal subjected to a shear stress: (a)
structure before deformation by slip. The
b/a ratio influences the magnitude of the
shear stress required to cause slip.
FIGURE 3.4 (a) Permanent deformation of a
single crystal under a tensile load. Note that
the slip planes tend to align themselves in the
direction of pulling. This behavior can be
simulated using a deck of cards with a rubber
band around them. (b) Twinning in tension.
When crystals are subjected to an external force, they first undergo
elastic deformation. If the force on the crystal structure is increased
sufficiently, the crystal undergoes plastic (or permanent) deformation.
SLIP
TWINNING
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Shear Stress in Moving Planes of Atoms
FIGURE 3.5 Variation of shear stress in moving a plane of atoms over another plane.
The maximum theoretical shear stress,
max
, to cause permanent deformation in
a perfect crystal is obtained as follows: when there is no stress, the atoms in the
crystal are in equilibrium.
x=0 shear stress is zero. Each atom is attracted to the nearest atom of the lower
row, resulting in non-equilibrium at positions 2 and 4, where shear stress
becomes
max
.
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Slip Lines and Slip
Bands in a Single
Crystal
FIGURE 3.6 Schematic illustration of slip
lines and slip bands in a single crystal
subjected to a shear stress. A slip band
consists of a number of slip planes. The
crystal at the center of the upper drawing is an
individual grain surrounded by other grains.
Each "grain" is a single crystal.
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Cohesive Stress As a Function of Distance
FIGURE 3.7 Variation of cohesive stress as a
function of distance between a row of atoms.
Ideal tensile strength
Work done per unit area in breaking
The bond between the two atomic planes
Involving surface energy of the material
Approximately
10
2
max
max
max
max
E
a
E
Work
a
E

=
=
=

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Defects In a Crystal
FIGURE 3.8 Various defects in a single-crystal lattice.
Imperfections
1. Point defects
2. Linear (1-D) defects, dislocations
3. Planar (2-D) defects, grain boundaries
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Edge and Screw Dislocations
FIGURE 3.9
(a) Edge dislocation, a linear defect at the edge of an extra plane of atoms.
(b) Screw dislocation, a helical defect in a three-dimensional lattice of atoms.
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Movement of An Edge Dislocation
FIGURE 3.10 Movement of an edge dislocation across the crystal lattice under a shear
stress. Dislocations help explain why the actual strength of metals is much lower than
that predicted by theory.
Strain hardening (work hardening)
Dislocations can become entangled and interfere with each other,
and be impeded by barriers, such as grain boundaries and impurities in the material.
This causes increase in shear stress required and hence increase in overall strength,
which is known as strain hardening, or work hardening.
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Polycrystalline Materials
FIGURE 3.11 Schematic illustration of the various stages during solidification of molten
metal. Each small square represents a unit cell. (a) Nucleation of crystals at random sites in
the molten metal. Note that the crystallographic orientation of each site is different. (b) and
(c) Growth of crystals as solidification continues. (d) solidified metal, showing individual
grains and grain boundaries. Note the different angles at which neighboring grains meet each
other. Source: W. Rosenhain.
Formation of grains and random grain boundaries
Nuclei form during solidification, each of which grows into
crystals
Each
"grain" is a
single
crystal.
Manufacturing Processes Prof. T. zel
Tensile Stress
Across a Plane
FIGURE 3.12 Variation of tensile stress across a plane of polycrystalline metal specimen
subjected to tension. Note that the strength exhibited by each grain depends on its orientation.
Relation between grain size
and yield strength
Hall-Petch Equation
Y=Y
i
+ k d
-1/2
Y
i
basic yield stress
k constant indicating level of dislocations
d average grain diameter
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Embrittlement of Copper
FIGURE 3.13 Embrittlement of copper by
lead and bismuth at 350 C (660 F).
Embrittlement has important effects on the
strength, ductility, and toughness of
materials. Source: After W. Rostoker.
Influence of grain boundaries
on:
-strength
-ductility
When brought into close atomic
contact with certain low-melting-
point metals,
a normally ductile and strong metal
can crack under very low stresses,
A phenomenon referred to as grain
boundary embrittlement.
Manufacturing Processes Prof. T. zel
Plastic Deformation in Compression
FIGURE 3.14 Plastic deformation of idealized (equiaxed) grains in a specimen subjected to
compression, such as is done metals: (a) before deformation; and (b) after deformation. Note
the horizontal alignment of grain boundaries.
Anisotropy
(Texture)
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Result of Bulging Using a Steel Ball
FIGURE 3.15 (a) Illustration of a crack in sheet metal subjected to bulging, such as by pushing
a steel ball against the sheet. Note the orientation of the crack with respect to the rolling
direction of the sheet. This material is anisotropic. (b) Aluminum sheet with a crack (vertical
dark line at center) developed in a bulge test. Source: Courtesy of J. S. Kallend, Illinois Institute
of Technology.
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Recovery,
Recrystallization and
Grain Growth
FIGURE 3.16 Schematic illustration of
the effects of recovery, recrystallization,
and grain growth on mechanical
properties and shape and size of grains.
Note the formation of small new grains
during recrystallization. Source: G.
Sachs.
Recovery: It occurs at a certain
temperature range below
the recrystallization temperature.
Recrystallization: The process in
which, at a certain temperature range,
new equiaxed and strain-free grains are
formed.
Grain growth: When temperature is
continuously increased, the grains begin
to grow, and their size eventually
exceed the original grain size.
Manufacturing Processes Prof. T. zel
Variation of Strength and Hardness
FIGURE 3.17 Variation of strength and hardness with recrystallization temperature, time, and
prior cold work. Note that the more a metal is cold worked, the less time it takes to
recrystallize, because of the higher stored energy from cold working due to increased
dislocation density.
Manufacturing Processes Prof. T. zel
Effects of Prior
Cold Work
FIGURE 3.18 The effect of prior cold
work on the recrystallized grain size of
alpha brass. Below a critical elongation
(strain), typically 5%, no recrystallization
occurs.
FIGURE 3.19 Surface roughness on the
cylindrical surface of an aluminum specimen
subjected to compression. Source: A. Mulc and
S. Kalpakjian.
Surface
Roughening
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Cold, Warm and Hot Working
Table 3.1 Homologous temperature ranges for various processes
PROCESS T/T
m
Cold working
Warm working
Hot working
< 0.3
0.3 to 0.5
> 0.6
Hot working - above recrystallization temperature
recrystallization, grain growth occurs
Cold working - below recrystallization temperature
no recrystallization or grain growth, significant grain elongation and work hardening
results
Warm working - intermediate temperature.
Rcrystallization occurs, but little or no grain growth. Grains are equiaxed but smaller
than hot working.
Manufacturing Processes Prof. T. zel
Fracture in Metals
Ductile fracture is characterized by
plastic deformation
Brittle fracture occurs with little or no
plastic deformation
Buckling
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Types of Failure in Materials
FIGURE 3.20 Schematic illustration of types of
failure in materials:
(a) necking and fracture of ductile materials;
(b) buckling of ductile materials under a
compressive load;
(c) fracture of brittle materials in compression;
(d) cracking on the barreled surface of ductile
materials in compression.
FIGURE 3.21 Schematic illustration of the types
of fracture in tension:
(a) brittle fracture in polycrystalline metals;
(b) shear fracture in ductile single crystals;
(c) ductile cup-and-cone fracture in
polycrystalline metals
(d) complete ductile fracture in polycrystalline
metals, with 100% reduction of area.
Fracture Buckling
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Surface of Low-Carbon
Steel
FIGURE 3.22 Surface of ductile fracture
in low-carbon steel, showing dimples.
Fracture is usually initiated at impurities,
inclusions, or preexisting voids in the
metal. Source: K.-H. Habig and D.
Klaffke. Photo by BAM, Berlin,
Germany.
Upon close examination of a
ductile fracture, we see fibrous
pattern with dimples, as if a
number of very small tension
tests have been carried out over
fracture surface.
Failure is initiated with the
formation of tiny voids, usually
around small inclusions or
preexisting voids, which then
grow and coalesce, developing
cracks that grow in size and lead
fracture.
Manufacturing Processes Prof. T. zel
Sequence of Necking And Fracture
FIGURE 3.23 Sequence of events on necking and fracture
of a tensile-test specimen:
(a) early stage of necking;
(b) small voids begin to form within the necked region;
(c) voids coalesce, producing an internal crack;
(d) rest of cross-section begins to fail at the periphery by
shearing;
(e) final fracture surfaces, known as cup-(top fracture
surface) and-cone (bottom surface) fracture.
Voids and porosities
developed during
processing of the
metal, such as from
casting, reduce the
ductility of a material.
Manufacturing Processes Prof. T. zel
Effect of Second Phase Particles on True Strain
at Fracture
FIGURE 3.24 The effect of volume fraction
of various second-phase particles on the true
strain at fracture in a tensile test for copper.
Source: After B. I. Edelson and W. M.
Baldwin.
Inclusions have an
important influence on
ductile fracture and thus on
the formability of the
materials.
Inclusions may consist of
impurities of various kinds
and second-phase particles
such as oxides, carbides,
and sulfides.
Fatigue fracture is
basically of
a brittle nature.
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Deformation of Soft and Hard Inclusions
FIGURE 3.25 Schematic illustration of the deformation of soft and hard inclusions and
their effect on void formation in plastic deformation. Note that hard inclusions, because they
do not comply with the overall deformation of the ductile matrix, can cause voids.
There are two factors affecting void formation:
(1) strength of the bond at the interface of an inclusion and the matrix.
(2) The hardness of the inclusion. If the inclusion is soft, such as manganese
sulfide, it will conform to the overall change in shape of the specimen or
workpiece during plastic deformation.
If it is hard, such as a carbide or oxide, it could lead to void formation.
Hard inclusions may also break up into smaller particles during deformation.
Manufacturing Processes Prof. T. zel
Transition
Temperature
FIGURE 3.26 Schematic illustration of
transition temperature. Note the narrow
temperature range across which the
behavior of the metal undergoes a major
transition.
FIGURE 3.27 Strain aging and its effect on
the shape of the true-stress-true-strain curve
for 0.03% C rimmed steel at 60 C (140 F).
Source: A. S. Keh and W. C. Leslie.
Strain Aging
Many metals go undergo a sharp change
in ductility and toughness across a narrow
temperature arnge called the transition
temperature.
Strain aging is a phenomenon in which
carbon atoms in steels segregate to
dislocations, thereby pinning them and thus
increasing the steels resistance to
dislocation movement.
Manufacturing Processes Prof. T. zel
Fracture Surface of Steel
FIGURE 3.28 Typical fracture surface of steel that has failed in a brittle manner.
The fracture path is transgranular (through the grains).
Magnification: 200X. Source: Courtesy of B. J. Schulze, S. L. Meiley, and Packer
Engineering Associates, Inc.
Brittle fracture occurs with little or no gross plastic deformation preceeding the
separation of the material into two or more pieces.
In tension fracture takes place along a crystallographic plane, called a cleavage
plane, on which the normal tensile stress is a maximum.
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Intergranular Fracture
FIGURE 3.29 Intergranular fracture, at two different magnifications. Grains and grain
boundaries are clearly visible in this micrograph. The fracture path is along the grain
boundaries. Magnification: left, 100X; right, 500X. Source: Courtesy of B. J. Schulze,
S. L. Meiley, and Packer Engineering Associates, Inc.
Where the fracture path is along the grain boundaries, generally
occurs when grain boundaries are soft, contain a brittle phase, or
have been weakened by liquid-or solid metal embrittlement.
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Modes of Fracture
FIGURE 3.30 Three modes of fracture.
Mode I has been studied extensively, because it is the most commonly observed in
engineering structures and components.
Mode II is rare.
Mode III is the tearing process; examples include opening a pop-top can, tearing a
piece of paper, and cutting materials with a pair of scissors.
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Typical Fatigue Fracture Surface
FIGURE 3.31 Typical fatigue fracture surface on metals, showing beach
marks. Most components in machines and engines fail by fatigue and not
by excessive static loading. Magnification; left, 500X; right, 1000X.
Source: Courtesy of B. J. Schulze, S. L. Meiley, and Packer Engineering
Associates, Inc.
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Surface Finish
and Fatigue
Strength
FIGURE 3.32 Reduction in
fatigue strength of cast steels
subjected to various surface-
finishing operations. Note
that the reduction is greater
as the surface roughness and
strength of the steel
increase. Source: M. R.
Mitchell.
Manufacturing Processes Prof. T. zel
Properties of Materials
Table 3.2 Physical properties of various materials at room temperature.
METAL
DENSITY
(kg/m
3
)
MELTING POINT
(C)
SPECIFIC HEAT
(J/kgK)
THERMAL
CONDUCTIVITY
(W/m K)
COEFFICIENT
OF THERMAL
EXPANSION
(m/mC)
Aluminum
Aluminum alloys
Berylium
Columbium (niobium)
Copper
Copper alloys
Gold
Iron
Steels
Lead
Lead alloys
Magnesium
Magnesium alloys
Molybdenum alloys
Nickel
Nickel alloys
Silicon
Silver
Tantalum alloys
Titanium
Titanium alloys
Tungsten
2700
2630-2820
1854
8580
8970
7470-8940
19300
7860
6920-9130
11350
8850-11350
1745
1770-1780
10210
8910
7750-8850
2330
10500
16600
4510
4430-4700
19290
660
476-654
1278
2468
1082
885-1260
1063
1537
1371-1532
327
182-326
650
610-621
2610
1453
1110-1454
1423
961
2996
1668
1549-1649
3410
900
880-920
1884
272
385
337-435
129
460
448-502
130
126-188
1025
1046
276
440
381-544
712
235
142
519
502-544
138
222
121-239
146
52
393
29-234
317
74
15-52
35
24-46
154
75-138
142
92
12-63
148
429
54
17
8-12
166
23.6
23.0-23.6
8.5
7.1
16.5
16.5-20
19.3
11.5
11.7-17.3
29.4
27.1-31.1
26.0
26.0
5.1
13.3
12.7-18.4
7.63
19.3
6.5
8.35
8.1-9.5
4.5
NONMETALLIC
Ceramics
Glasses
Graphite
Plastics
Wood
2300-5500
2400-2700
1900-2200
900-2000
400-700
-
580-1540
-
110-330
-
750-950
500-850
840
1000-2000
2400-2800
10-17
0.6-1.7
5-10
0.1-0.4
0.1-0.4
5.5-13.5
4.6-70
7.86
72-200
2-60
Manufacturing Processes Prof. T. zel
Steels
Manufacturing Processes Prof. T. zel
Properties of Stainless Steels
Table 3.3 Room-temperature mechanical properties and typical applications of
annealed stainless steels.
AISI
(UNS)
ULTIMATE
TENSILE
STRENGTH
(MPa)
YIELD
STRENGTH
(MPa)
ELONGATION
(%)
CHARACTERISTICS AND TYPICAL
APPLICATIONS
303
(S30300)
550-620 240-260 50-53 Screw-machine products, shafts, valves, bolts,
bushings, and nuts; aircraft fittings; bolt; nuts;
rivets; screws; studs.
304
(S30400)
565-620 240-290 55-60 Chemical and food processing equipment,
brewing equipment, cryogenic vessels, gutters,
downspouts, and flashings.
(316
(S31600)
550-590 210-290 55-60 High corrosion resistance and high creep strength.
Chemical and pulp handling equipment,
photographic equipment, brandy vats, fertilizer
parts, ketchup cooking kettles, and yeast tubs.
410
(S41000)
480-520 240-310 25-35 Machine parts, pump shafts, bolts, bushings, coal
chutes, cutlery, fishing tackle, hardware, jet
engine parts, mining machinery, rifle barrels,
screws, and valves.
416
(S41600)
480-520 275 20-30 Aircraft fittings, bolts, nuts, fire extinguisher
inserts, rivets and screws.
Manufacturing Processes Prof. T. zel
Types of Tool and Die Steels
Table 3.4 Basic types of tool and die steels.
TYPE AISI
High speed M (molybdenum base)
T (tungsten base)
Hot work H1 to H19 (chromium base)
H20 to H39 (tungsten base)
H40 to H59 (molybdenum base)
Cold work D (high carbon, high chromium)
A (medium alloy, air hardening)
O (oil hardening)
Shock resisting S
Mold steels P1 to P19 (low carbon)
P20 to P39 (others)
Special purpose L (low alloy)
F (carbon-tungsten)
Water hardening W
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Applications of Tool and Die Steels
Table 3.5 Typical tool and die materials for various processes.
PROCESS MATERIAL
Die casting
Powder metallurgy
Punches
Dies
Molds for plastic and rubber
Hot forging
Hot extrusion
Cold heading
Cold extrusion
Punches
Dies
Coining
Drawing
Wire
Shapes
Bar and tubing
Rolls
Rolling
Thread rolling
Shear spinning
Sheet metals
Shearing
Cold
Hot
Pressworking
Deep drawing
Machining
H13, P20
A2, S7, D2, D3, M2
WC, D2, M2
S1, O1, A2, D2, 6F5, 6F6, P6, P20, P21, H13
6F2, 6G, H11, H12
H11, H12, H13
W1, W2, M1, M2, D2, WC
A2, D2, M2, M4
O1, W1, A2, D2
52100, W1, O1, A2, D2, D3, D4, H11, H12, H13
WC, diamond
WC, D2, M2
WC, W1, D2
Cast iron, cast steel, forged steel, WC
A2, D2, M2
A2, D2, D3
D2, A2, A9, S2, S5, S7
H11, H12, H13
Zinc alloys, 4140 steel, cast iron, epoxy composites, A2, D2, O1
W1, O1, cast iron, A2, D2
Carbides, high-speed steels, ceramics, diamond, cubic boron nitride
Manufacturing Processes Prof. T. zel
Non-ferrous Alloys in a Jet Engine
FIGURE 3.33 Cross-section of a jet engine (PW2037) showing various components and the
alloys used in making them. Source: Courtesy of United Aircraft Pratt & Whitney.
Manufacturing Processes Prof. T. zel
Properties of Aluminum Alloys
Table 3.6 Properties of various aluminum alloys at room temperature.
ALLOY (UNS) TEMPER
ULTIMATE TENSILE
STRENGTH (MPa)
YIELD STRENGTH
(MPa)
ELONGATION
In 50 mm (%)
1100 (A91100)
1100
2024 (A92024)
2024
3003 (A93003)
3003
5052 (A95052)
5052
6061 (A96061)
6061
7075 (A97075)
7075
O
H14
O
T4
O
H14
O
H34
O
T6
O
T6
90
125
190
470
110
150
190
260
125
310
230
570
35
120
75
325
40
145
90
215
55
275
105
500
35-45
9-20
20-22
19-20
30-40
8-16
25-30
10-14
25-30
12-17
16-17
11
Manufacturing Processes Prof. T. zel
Properties of Wrought Aluminum
Table 3.7 Manufacturing properties and typical applications of wrought aluminum alloys.
CHARACTERISTICS
*
ALLOY
CORROSION
RESISTANCE MACHINABILITY WELDABILITY TYPICAL APPLI CATIONS
1100 A D-C A Sheet-metal work, spun hollow wear, tin stock
2014 C C-B C-B heavy-duty forgings, plate and extrusions for
aircraft structural components, wheels.
3003 A D-C A Cooking utensils, chemical equipment, pressure
vessels, sheet metal work, buildershardware,
storage tanks
5054 A D-C A Welded structures, pressure vessels, tube for
marine uses.
6061 B D-C A Trucks, canoes, furniture, structural applications
7005 D B-D B Extruded structural members, large heat
exchangers, tennis racquets and softball bats.
* From A (excellent) to D (poor)
Manufacturing Processes Prof. T. zel
Properties of Wrought Magnesium Alloys
Table 3.8 Properties and typical forms of various wrought magnesium alloys.
COMPOSITION (%)
ALLOY Al Zn Mn Zr
CONDI-
TION
ULTIMATE
TENSILE
STRENGTH
(MPa)
YIELD
STRENGTH
(MPa)
ELONGA-
TION
IN 50 mm
(%) TYPI CAL FORMS
AZ31B
AZ80A
HK31A
*
ZK60A
3.0
8.5
1.0
0.5
5.7
0.2
0.2
0.7
0.55
F
H24
T5
H24
T5
260
290
380
255
365
200
220
380
255
365
15
15
7
8
11
Extrusions
Sheet and plates
Extrusions and forgings
Sheet and plates
Extrusions and forgings
* HK31A also contains 3% Th.
Manufacturing Processes Prof. T. zel
Properties of Wrought Copper and Brasses
Table 3.9 Properties and typical applications of various wrought copper and brasses.
TYPE
AND UNS
NUMBER
NOMINAL
COMPOSI-
TION (%)
ULTIMATE
TENSILE
STRENGTH
(MPa)
YIELD
STRENGTH
(MPa)
ELONG-
ATION IN
50 mm (%)
TYPI CAL APPLI CATIONS
Oxygen-free
electronic
(C10100)
99.99 Cu 220-450 70-365 55-4 Busbars, waveguides, hollow conductors,
lead in wir es, coaxial cables and tubes,
microwave tubes, rectifiers.
Red brass,
85%
(C23000)
85.0 Cu
15.0 Zn
270-72 70-435 55-3 Weather-stripping, conduit, sockets,
fasteners, fire extinguishers, condenser and
heat exchanger tubing
Low Brass,
80%
(C24000)
80.0 Cu
20.0 Zn
300-850 80-450 55-3 Battery caps, bellows, musical instruments,
clock dials, flexible hose.
Free-cutting
brass
(C36000)
61.5 Cu,
3.0 Pb,
35.5 Zn
340-470 125-310 53-18 Gears, pinions, automatic high-speed
screw machine parts
Naval brass
(C46400 to
C46700)
60.0 Cu,
39.25 Zn,
0.75 Sn
380-610 170-455 50-17 Aircraft turnbuckle barrels, balls, bolts,
marine hardware, valve stems, condensor
plates
Brass= copper + zinc
Bronze= copper + tin or copper + aluminum
Manufacturing Processes Prof. T. zel
Properties of Wrought Bronzes
Table 3.10 Properties and typical applications of various wrought bronzes.
TYPE
AND UNS
NUMBER
NOMINAL
COMPOSI-
TION (%)
ULTIMATE
TENSILE
STRENGTH
(MPa)
YIELD
STRENGTH
(MPa)
ELONG-
ATION IN
50 mm (%)
TYPI CAL APPLI CATIONS
Architectural
bronze
(C38500)
57.0 Cu,
3.0 Pb,
40.0 Zn
415 140
(As
extruded)
30 Architectural extrusions, store fronts,
thresholds, trim, butts, hinges
Phosphor
bronze, 5%
A (C51000)
95.0 Cu,
5.0 Sn,
trace P
325-960 130-550 64-2 Bellows, clutch disks, cotter pins,
diaphragms, fasteners, wire brushes,
chemical hardware, textile machinery
Free-cutting
phosphor
bronze
(C54400)
88.0 Cu,
4.0 Pb,
4.0 Zn,
4.0 Sn
300-520 130-435 50-15 Bearings, bushings, gears, pinions, shafts,
thrust washers, valve parts
Low silicon
bronze, B
(C65100)
98.5 Cu,
1.5 Si
275-655 100-475 55-11 Hydraulic pressure lines, bolts, marine
hardware, electrical conduits, heat
exchanger tubing
Nickel-
silver, 65-18
(C74500)
65.0 Cu,
17.0 Zn,
18.0 Ni
390-710 170-620 45-3 Rivets, screws, zippers, camera parts, base
for silver plate, nameplates, etching stock.
Manufacturing Processes Prof. T. zel
Properties of Nickel Alloys
Table 3.11 Properties and typical applications of various nickel alloys (all alloy names are
trade names).
ALLOY
(CONDITION)
PRINCIPAL
ALLOYING
ELEMENTS
(%)
ULTIMATE
TENSILE
STRENGTH
(MPa)
YIELD
STRENGTH
(MPa)
ELONGATION
in 50 mm
(%) TYPI CAL APPLI CATIONS
Nickel 200
(annealed)
None 380-550 100-275 60-40 Chemical and food processing
industry, aerospace equipment,
electronic parts
Duranickel 301
(age
hardened)
4.4 Al,
0.6 Ti
1300 900 28 Springs, plastics extrusion equipment,
molds for glass, diaphragms
Monel R-405
(hot rolled)
30 Cu 525 230 35 Screw-machine products, water meter
parts.
Monel K-500
(age
hardened)
29 Cu,
3Al
1050 750 20 Pump shafts, valve stems, springs
Inconel 600
(annealed)
15 Cr,
8 Fe
640 210 48 Gas turbine parts, heat-treating
equipment, electronic parts, nuclear
reactors
Hastelloy C-4
(solution-
treated and
quenched)
16 Cr,
15 Mo
785 400 54 High temperature stability, resistance
to stress corrosion cracking
Manufacturing Processes Prof. T. zel
Properties of Nickel-Base Superalloys
Table 3.12 Properties and typical applications of various nickel-base superalloys at 870C
(1600 F). All alloy names are trade names.
ALLOY CONDITION ULTIMATE
TENSILE
STRENGTH
(MPa)
YIELD
STRENGTH
(MPa)
ELONGATION
IN 50 mm
(%)
TYPI CAL APPLI CATIONS
Astroloy Wrought 770 690 25 Forgings for high temperature
Hastelloy X Wrought 255 180 50 Jet engine sheet parts
IN-100 Cast 885 695 6 Jet engine blades and wheels
IN-102 Wrought 215 200 110 Superheater and jet engine parts
Inconel 625 Wrought 285 275 125 Aircraft engines and structures,
chemical processing equipment
Inconel 718 Wrought 340 330 88 Jet engine and rocket parts
MAR-M 200 Cast 840 760 4 Jet engine blades
MAR-M 432 Cast 730 605 8 Integrally cast turbine wheels
Ren 4 1 Wrought 620 550 19 Jet engine parts
Udimet 700 Wrought 690 635 27 Jet engine parts
Waspaloy Wrought 525 515 35 Jet engine parts
Manufacturing Processes Prof. T. zel
Properties of Wrought Titanium Alloys
Table 3.13 Properties and typical applications of wrought titanium alloys.
ROOM TEMPERATURE VARIOUS TEMPERATURES
NOMINAL
COMPOSI-
TION (%) UNS
COND-
ITION
ULTIMATE
TENSILE
STRENGTH
(MPa)
YIELD
STRENGTH
(MPa)
ELON-
GATION
IN 50
mm (%)
REDUC-
TION
OF AREA
(%)
TEMP
( C)
ULTIMATE
TENSILE
STRENGTH
(MPa)
YIELD
STRENGT
H (MPa)
ELON-
GATION
IN 50
mm (%)
REDUC-
TION
OF AREA
(%) TYPI CAL APPLI CATIONS
99.5 Ti R5025
0
Annealed 330 240 30 55 300 150 95 32 80 Airframes; chemical, desalination,
and marine parts; plate type heat
exchangers
5 Al, 2.5
Sn
R5452
0
Annealed 860 810 16 40 300 565 450 18 45 Aircraft engine compressor
blades and ducting; steam turbine
blades
6 Al, 4 V R5640
0
Annealed 1000 925 14 30 300
425
550
725
670
530
650
570
430
14
18
35
35
40
50
Rocket motor cases; blades and
disks for aircraft turbines and
compressors; orthopedic implants
Solution
+ age
1175 1100 10 20 300 980 900 10 28 structural forgings and fasteners
13 V
11 Cr
3 Al
R5801
0
Solution
+ age
1275 1210 8 - 425 1100 830 12 - High strength fasteners;
aerospace components;
honeycomb panels.