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Its fluidity is not good and is not suitable for general casting
purpose.
c) Malleable cast Iron : It has fairly good amount of
malleability. It is produced in two steps. First cast iron
castings are produced by melting white cast iron in
cupola furnace. These castings are packed in Iron
boxes containing material rich in O2. These boxes are
kept for four days in annealing furnaces at a
temperature of 815oC to 1010oC and then allowed to
cool slowly along with the furnace. This allows
Cementite to decompose into iron and carbon.
d)Nodular Cast Iron : This is also known as Spheroidal
Graphite ( or simply SG) Cast Iron, Ductile Cast
Iron or High Strength Cast Iron. For its production
the shape of graphite present in cast iron is changed
from flakes to spheroids or nodules.
This is achieved by adding magnesium metal to the
molten cast iron just after tapping. This magnesium
treated metal when cast into moulds gives SG cast iron.
This changed shape of graphite prevents formation and
propagation of cracks and enhances ductility of Cast
Iron. It has chemistry similar to gray cast iron
Alloy Steels :
All steels in addition to Iron and Carbon contain
other elements like silicon, manganese, sulphur and
phosphorous. In some steels special elements like
Nickel, Chromium, Molybdenum, Vanadium and
Tungsten etc. are added to enhance their mechanical
properties. These steels are called alloy steels.
They have their properties as per the alloying elements
in them. These steels are named normally on the basis
of their principal alloying element.
These are various types-
Stainless steel
Tool steel
Spring steel
Stainless steels : They are corrosion resistant steels.
Their principal alloying element is chromium, while
other elements like nickel, manganese can also be
present in small amounts.
To impart high corrosion resistance to steels
Chromium up to 12% is added.
The chromium present in steels reacts with O2 in air to
form a strong layer of chromium oxide on the surface
of the metal. This layer protects the metal from
corrosion. Stainless steels carrying more than 12%
chromium are known as true stainless steels.
These alloy steels have special application in
manufacture of cutting tools for those applications
where tools made of carbon steel will either fail to
perform or will have a very short life. They are put into
two categories namely :
High Speed Steel : It is a high alloy tool steel used for
making cutting tools suitable for high temperature
applications.
Main Constituents in HSS are Carbon, tungsten,
chromium, vanadium and molybdenum. High Speed
Steel has high wear resistance, high abrasion resistance and
high red hardness. They retain their hardness up to 620oC.
The most commonly used high speed steel is 18-4-1
which carries 18% Tungsten, 4% Chromium, 1%
Vanadium, 0.7% Carbon and rest Iron.
It has good red hardness, wear resistance shock
resistance and widely used for making cutting tools for
lathe, shapers, slotters, milling machines, drill etc
Non ferrous Metals are those
which do not contain Iron. Most
commonly used nonferrous
metals are Aluminium, Copper,
Magnesium, Lead, Tin, Nickel,
Zinc etc. Also they form useful
alloys among themselves.
Non ferrous metals have following advantages
over ferrous metals
Very good electrical and thermal conductivity
Good castabilty
Good formability
Good cold working property
High corrosion resistance
Attractive appearance
Lower density and high strength to weight
ratio.
High
cost, High shrinkage,
Lower strength at elevated
temperature
Properties and usage of copper :
High electrical conductivity : Used for making
cables and contactors.
High heat conductivity : Used in heat exchangers,
heating vessels and appliances.
Good corrosion resistance : Used to provide base
coating on steel prior to nickel and chromium
plating.
High ductility : Can be easily cold worked, rolled,
drawn and spun. Looses ductility in cold working
requires annealing between the process.
Properties and usage of Zinc :
High corrosion resistance : It is widely used
for providing protective coating on iron and
steel. It may be coated either by dip
galvanizing, Electroplating, Sheradising* or
just by painting.
Low melting point and high fluidity: Makes it
most suitable for pressure die casting.
Properties and usage of Tin
Good resistance to acid corrosion and used
as coating on steel container for food.
It is soft, has good plasticity and can be easily
worked.
It can be easily rolled into thin foils but can
not be drawn into wires due to low strength.
It is used as alloying element in soft solders,
bronzes and bearing metals.
Properties and usage of
magnesium:
It the lightest metal, weighing two third of
aluminum.
It can be easily cast into fine shapes.
Is has good ductility so it can be easily cold
worked.
When in powder form, it is likely to catch fire,
requiring adequate fire protection measures
for its storage.
Properties and usage of lead :
Good corrosion resistance : Used for water pipes
and roof protection.
Good resistance to chemical action: Used for acid
baths and containers in chemical industry.
Its soft heavy and malleable and can be easily
worked and shaped.
Used as alloying element in making solders.
It is alloyed with Brass and Steel to impart them
free cutting properties.
Properties and usages of Aluminium:
High Electrical conductivity: Used for heavy
conductors and bus bars.
High heat conductivity: Used in domestic utensils
and other heat conducting appliances.
Good resistance to corrosion: Used for
manufacture of containers for chemical industry
and window frames etc. The corrosion resistance
can be further enhanced by anodizing*. (*Process
of increasing the thickness of natural oxide layer
on the metal surface. It is done through
electrolysis. Metal forms anode of electrical
circuit)
Properties and usage of Nickel
Good resistance to both acid and alkali
corrosion. Widely used for food processing
equipment.
Has high tensile strength and can be easily
hot or cold worked.
It is plated on steel to provide corrosion
resistance surface.
-Brass – These are the
alloy of copper and zinc
-Bronze-They are alloys
of copper and Tin.
Composite materials are combinations of
two or more materials which differ in
chemical composition and physical
properties and are insoluble in each other.
They are manmade or naturally occurring.
Examples: Natural Wood, Fiber glass used
for making bath tubs etc., imitation granite,
cultured marble, plywood etc. .
There are two major components of composite materials:
a) Reinforcements i.e materials that provide
strength to the composite.
b) Matrix i.e the material that holds the
reinforcement in place
Natural Composites such as
wood , human body etc
Synthetic composite all man
made composites such as fiber
glass, clad metal, plywood,
reinforced plastics et.
Low density, high strength, high hardness and
stiffness.
Corrosion resistant, weather resistant and
tailored surface finish
Low thermal conductivity, low coefficient of
thermal expansion
High dielectric strength, nonmagnetic, Radar
transparency
Can withstand high temperature in corrosive
environment
Good formability, good durability and good
damping properties
High cost of raw material and manufacturing
Matrix is weak giving rise to low toughness
Environmental degradation takes place in
matrix.
Composites ingredient can not be reused.
Joining is difficult
Difficult to analyze
Used as a replacement material in various
engineering applications such as cylinder block
liners, vehicle drive shafts, automotive pistons,
bicycle frames etc
Hockey sticks, vaulting poles, golf carts etc
Fuel and chemical storage tanks
Aerospace applications : helicopter blades, engine
couplings, ducts etc
Marine : Boats , ships , hulls etc
Electronic and recreational industries
high voltage power transmission lines and heat sinks
for electronic components
As bio compatible materials