Production%20Technology%20(IND%20006)

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Production Technology(IND 006)
Lecture No. 3

• Preparatory Year,
• Faculty of Engineering,
• Fayoum University

Dr. Ahmed Salah Abou Taleb Lecturer, Industrial
Engineering Dept., Faculty of Engineering, Fayoum
University
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Introduction
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Introduction

• What are the common characteristics of
  engineering materials such as physical, chemical,
  mechanical, thermal, optical, and electrical?
• How they can be processed economically to get the
  desired product?

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Materials
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Materials Integration
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Metals
Why metals are considered as the most important
materials?

• They have properties that satisfy a wide variety
  of design requirements.
• The metal manufacturing processes have been
  developed and refined over many years.
• Engineers understand metals.
• High stiffness and strength - can be alloyed for
  high rigidity, strength and hardness.
• Toughness - capacity to absorb energy.
• Good electricity and thermal conductivity.
• Cost.

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Metals
Metals
Pure elements
Alloying
Gold Silver Copper
is a mixture of two or more elements, at least
one of which is metallic
through alloying, it is possible to increase
strength, hardness, and other properties compared
to pure metals.
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Phase Diagram
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Phase Diagram
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Ferrous Metals
Ferrous metals and alloys are defined as the
materials that contain a large amount of iron.
They are used in the majority of metallic
applications in current eng. design,
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Ferrous Metals
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1. FERROUS MATERIALS AND ALLOYS
Ferrous Materials
Steel
Cast Iron

• Steel is an alloy of iron and carbon up to 2.11
  in addition to various elements (or Alloying
  Elements) in order to improve properties .

Cast Iron (C.I.) is an alloys of iron, carbon
(1.7 - 6.67), and silicon (3.5).
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FERROUS MATERIALS AND ALLOYS
I- Cast Iron (CI)

• Low cost,
• Good casting characteristics,
• High compressive strength,
• High wear resistance and
• Excellent machinability,
• Tensile strength from 100 to 200 MPa,
• Compressive strength from 400 to 1000 MPa and,
• Shear strength is 120 MPa.

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FERROUS MATERIALS AND ALLOYS
I- Cast Iron (CI)
Gray Cast Iron
Ductile (Nodular)Cast Iron
Cast Iron Categories
White Cast Iron
Malleable Cast Iron
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A- Gray Cast Iron
FERROUS MATERIALS AND ALLOYS
I- Cast Iron

• Carbon is free in the form of graphite, which
  exists in the form of flakes.
• Good compressive tensile strength,
  machinability, and vibration-damping ability
• Uses machine bases, crankshafts, furnace doors,
  Engine Blocks

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B- Ductile (Nodular) Cast Iron
FERROUS MATERIALS AND ALLOYS
I- Cast Iron

• Carbon is free in the form of graphite but it
  takes nodular or spheroid form.
• High fluidity, excellent castability, strength,
  high toughness, excellent wear resistance,
  pressure tightness, weldability and higher
  machinability
• Use in gears, cam shaft, crank shaft.

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C- White Cast Iron
FERROUS MATERIALS AND ALLOYS
I- Cast Iron

• Carbon exists in the combined form (Cementite).
• Very hard wear resistant, brittle , very
  difficult to machine, high tensile strength and
  low compressive strength.
• Use in bearing surface, rim of car, and Railway
  brake blocks.

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D- Malleable Cast Iron
FERROUS MATERIALS AND ALLOYS
I- Cast Iron

• It has structure similar to nodular C.I.
• It has ductility, strength and shock resistance.
• Use in axle bearing, tracks wheels

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FERROUS MATERIALS AND ALLOYS
II- Steel
Plain Carbon Steel
Low Alloy Steel
Steel Categories
Stainless Steel
Tool Die Steels
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A- Plain Carbon Steels
FERROUS MATERIALS AND ALLOYS
II- Steel

• So-called plain-carbon steel contains up to 0.5
  manganese,
• Strength increase and ductility reduced with
  carbon increase.

Alloy Composition Application
Low Carbon Steel (Mild Steel) has 0.05 up to 0.20 carbon Automobile sheet metal railroad rails
Medium Carbon Steel has 0.20 up to 0.50 carbon M/C component engine parts
High Carbon Steel Greater than 0.50 carbon Springs, cutting tool blades
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B- Low Alloy Steels (Constructional Steel)
FERROUS MATERIALS AND ALLOYS
II- Steel

• Contains additional alloying elements in amount
  less than 5 by weight,
• Mechanical properties superior than plain carbon
  steel.
• Higher strength, hardness, wear resistance, and
  toughness.
• Used for machine parts highly stressed in tension
  or compression.

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C- Stainless Steels (Special Steel) (SS)
FERROUS MATERIALS AND ALLOYS
II- Steel

• High alloyed steel design for corrosion
  resistant.
• Principle alloying element is chromium (gt 15).
• Nickel is used to improve corrosion protection.
• Is more strength and ductile steel.
• Austenitic stainless - typical composition 18 Cr
  and 8 Ni
• Ferritic stainless - about 15 to 20 Cr, low C,
  and no Ni
• Martensitic stainless - as much as 18 Cr but no
  Ni, higher C content than ferritic stainless

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FERROUS MATERIALS AND ALLOYS
II- Steel
D- Tool Die Steels

• High alloy steel.
• have great strength, hardness and wear
  resistance.
• High strength, hardness, wear resistance, and
  toughness under impact
• Used to fabricate cutting tool, moulds and dies.

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Effect of carbon content on mechanical properties