Converting Raw Materials to Steel Product Forms

Heat
treatment

Raw Material

Mechanical
treatment

Excess C
3removed
4.5%
(oxidation)
C

William F. Smith. Structure and Properties of Engineering Alloys. McGraw-Hill Publishing Co. 1981`

Blast Furnace
(Iron Making)

William F. Smith. Structure and Properties of Engineering Alloys. McGraw-Hill Publishing Co. 1981`

Steel Making (Oxygen Furnace)

Pig iron: up to 30% scrap

Pure oxygen reacts with liquid

to create iron-oxide
C reacts with iron oxide to
produce CO

45 minutes => 200 tons of steel

Superior to open-hearth:
sulfur contamination avoided (no external fuels)
trace nitrogen in oxygen used for refining, so low N in steel (<0.004%)
residual oxygen in steel less, so few deoxidizing agents required
lower impurities (less scrap)
William F. Smith. Structure and Properties of Engineering Alloys. McGraw-Hill Publishing Co. 1981`

Open Hearth Steelmaking Process

~6-10 hours ==> 200 tons of steel

Shallow bath of steel heated with flame

Slag to remove phosphorous and sulfur

William F. Smith. Structure and Properties of Engineering Alloys. McGraw-Hill Publishing Co. 1981`

Electric Arc Furnace

Electrodes positioned above cold steel scrap and arc is struck
Increased temperature control
60-90 tons per day

William F. Smith. Structure and Properties of Engineering Alloys. McGraw-Hill Publishing Co. 1981`

Continuous Casting

Serope Kalpakjian. Manufacturing Engineering and Technology,

3rd Edition. Addison-Wesley Publishing Co. 1995

Hot Strip Rolling Mill

(Not necessary for continuous casting)

H2O spray to
control temp.

Temperature just slightly above recrystallization temp. (avoid excessive grain growth)
- breaks down coarse grains of ingots - refined grains
- heals porosity
- strength increases in roll direction
William F. Smith. Structure and Properties of Engineering Alloys. McGraw-Hill Publishing Co. 1981`

Intermediate Material Product Forms

24-60

Slabs:
2-9

6x612x12

2x25x5

(processes into plate, sheet)

Blooms:
(processes into shapes and
rails)
Billets:
(processed into bars, rods,
pipe, tubes)

AISI-SAE carbon-steel compositions

Plain carbon steels constitute
~85% of steel used in U.S.
(although very little in
aerospace)
1st two digits denote type
(10 = plain carbon steel)
Last two digits indicate amount
of C in hundredth percent

William F. Smith. Structure and Properties of Engineering Alloys. McGraw-Hill Publishing Co. 1981`

Effect of Trace Elements on Carbon Steel

0-1% manganese: reacts with sulfur, to produce MnS soft inclusions
increased yield strength
0-0.05% sulfur:

if insufficient manganese, sulfur will react with iron at

grain boundaries, cracking during working

0-0.04% phosphorous: forms brittle Fe3 P compound

0-0.03% silicon: forms silicate inclusions (SiO2) but has little effect on
properties

Limitations of Plain Carbon Steels:

William F. Smith. Structure and Properties of Engineering Alloys. McGraw-Hill Publishing Co. 1981`

General Effects of Alloying Elements in Steel

- allows advantage of tempered martensite throughout

- allows slower quench

William F. Smith. Structure and Properties of Engineering Alloys. McGraw-Hill Publishing Co. 1981`

Effects of alloy elements in steel

Generally ~1-4%

Effects of alloy elements in steel

Generally ~1-4%

Effects of alloy elements in steel

Residual Elements in Steel

Alloys Favorably Affecting Properties

--- Element with most influence

Principal Types of Standard Alloy Steels

AISI-SAE System
1st two digits indicate principal
alloy or group of alloys
Last two digits indicate amount
of C in hundredth percent

William F. Smith. Structure and Properties of Engineering Alloys. McGraw-Hill Publishing Co. 1981`

AISI-SAE Designations for Steels and Their Major

Alloying Elements

Serope Kalpakjian. Manufacturing Engineering and Technology, 3rd Edition. Addison-Wesley Publishing Co. 1995

AISI/SAE and UNS Designation Systems and

Composition Ranges for Plain Carbon Steel and
Various Low Alloy Steels

William D. Callister, Jr. Materials Science and Engineering, An Introduction. John Wiley & Sons, Inc. 1985

Nominal Compositions and Typical Applications of

Select Standard Alloy Steels

William F. Smith. Structure and Properties of Engineering Alloys. McGraw-Hill Publishing Co. 1981`

Typical Applications and Mechanical properties for

Oil-Quenched and Tempered Steels

William D. Callister, Jr. Materials Science and Engineering, An Introduction. John Wiley & Sons, Inc. 1985

Common Applications for Common Steels

Serope Kalpakjian. Manufacturing Engineering and Technology, 3rd Edition. Addison-Wesley Publishing Co. 1995

Chemical Compositions and Typical Applications of

Low-Alloy Chromium-Molybdenum Steels

Chromium: improves hardenability, strength and wear resistance

Combination allows slower oil quench to produce martensite,
which reduces thermal gradients and internal stresses
William F. Smith. Structure and Properties of Engineering Alloys. McGraw-Hill Publishing Co. 1981`

Continuous Cooling Diagram, AISI 4140 Alloy Steel

Ferrite to
pearlite
transformation
is delayed

William F. Smith. Structure and Properties of Engineering Alloys. McGraw-Hill Publishing Co. 1981`

Material
Properties for
ChromiumMolybdenum
Steels

William F. Smith. Structure and Properties of Engineering Alloys. McGraw-Hill Publishing Co. 1981`

Chemical Compositions and Typical Applications of

Low-Alloy Nickel-Chromium-Molybdenum Steels

Nickel with Chromium: improved elastic limit, hardenability, impact resistance

and fatigue resistance
Molybdenum: further improvements to hardenability and reduced embrittlement

William F. Smith. Structure and Properties of Engineering Alloys. McGraw-Hill Publishing Co. 1981`

Continuous Cooling Diagram, AISI 4340 Alloy Steel

Ferrite to pearlite
transformation is
significantly delayed

William F. Smith. Structure and Properties of Engineering Alloys. McGraw-Hill Publishing Co. 1981`

Material Properties for Normalized and Annealed

Nickel-Chromium-Molybdenum Alloy Steels

William F. Smith. Structure and Properties of Engineering Alloys. McGraw-Hill Publishing Co. 1981`

Material Properties
for Quenched and
Tempered NickelChromiumMolybdenum Alloy
Steels

William F. Smith. Structure and Properties of Engineering Alloys. McGraw-Hill Publishing Co. 1981`

Stainless Steel
High Chromium content (>10%)
Corrosion resistant, hight strength and ductility
Stainless ==> chromium oxide resists corrosion

Stainless Steel
*

* Corrosion resistance decreases with carbon content, due to chromium

carbide formation
Thus, stainless steel utensils generally low in carbon content (what
does this imply?)

Mechanical Properties and Applications of Select

Annealed Stainless Steels

Serope Kalpakjian. Manufacturing Engineering and Technology, 3rd Edition. Addison-Wesley Publishing Co. 1995

Tool and Die Steels

High strength, impact toughness, wear resistance

Elevated operating temperature

M more common

Impact toughness
(dies, punches, chisels)

Serope Kalpakjian. Manufacturing Engineering and Technology, 3rd Edition. Addison-Wesley Publishing Co. 1995

Tool and Die

Materials for
Metalworking

Serope Kalpakjian. Manufacturing Engineering and Technology, 3rd Edition. Addison-Wesley Publishing Co. 1995

Approximate Cost of Raw Materials for

Various Product Forms

Serope Kalpakjian. Manufacturing Engineering and Technology, 3rd Edition. Addison-Wesley Publishing Co. 1995

Materials Properties For Steels

MIL-HDBK-5E, Chapter 2

Hardness and Hardenability

Richard A. Flinn and Paul K. Trojan. Engineering Materials and Their Applications, 4th Edition. Houghton Mifflin Co. 1990.

Representative Hardenability Curves

Richard A. Flinn and Paul K. Trojan. Engineering Materials and Their Applications, 4th Edition. Houghton Mifflin Co. 1990.

Hardenability Example

Richard A. Flinn and Paul K. Trojan. Engineering Materials and Their Applications, 4th Edition. Houghton Mifflin Co. 1990.

Hardenability Example

Richard A. Flinn and Paul K. Trojan. Engineering Materials and Their Applications, 4th Edition. Houghton Mifflin Co. 1990.