CHAPTER 5

SELECTION OF FERROUS MATERIALS (STEEL)

 Ferrous Metal Non-ferrous
Metal
• Contain iron • Do not contain
Metal Classification iron
Generally, metal is • have magnetic • does not have
property magnetic
classified into 2 -
property
Ferrous and Non Ferrous
• Low • More resist to
Metal resistance to corrosion
corrosion
• Most are • Most are light
Nonferrou
Ferrous heavy in in weight
s
weight
• Less • More
expensive expensive
• Higher tensile • Lower tensile
 Fe-C Phase Diagram

Cast Iron

Steel
Steels Classification
American Iron and Steel Institution (AISI) categories steel into 4
groups/grades based on the chemical composition.
1. Carbon Steel
2. Alloy Steel
3. Stainless Steel
4. Tool Steels
Steels Classification
American Iron and Steel Institution (AISI) categories steel into 4 groups/grades based
on the chemical composition.

1. Carbon Steel
2. Alloy Steel
3. Stainless Steel
4. Tool Steels
 Carbon Steels
Low Carbon Steel Medium Carbon Steel High Carbon Steel
• Most widely available • Contain 0.31% - 0.6% C • Contain 0.61% - 1.5% C
• Soft, Cheap, easy to rust • Stronger than low C steel. • Strong, very tough, wear
• Contain 0.05% - 0.3% C • More difficult to form & cut. resistance, more expensive.
• Mild Steel (0.16% - 0.3% C) • Application : shafts, cutting • Difficult to cut, bend & weld.
• Apps: Nuts and bolts, tools, chains, bolts. • Once heat treated it becomes
structural steel, car bodies. extremely hard and brittle.
• Apps: screwdrivers, hammers,
chisels, saws, springs and
garden tools.
Alloy Steels
• Stronger than High Carbon Steels due to alloying.
• Alloying agent such as : Ni, Si, Mn, Cr, Mo,V, Boron (hardness increases in ascending order).
• According to AISI-SAE designation series for alloy steel,

AISI – SAE
Classifications
Number
2XXX Nickel steels
5 % Nickel increases the tensile strength without reducing ductility.
8 to 12 % Nickel increases the resistance to low temperature impact
15 to 25 % Nickel (along with Al, Cu and Co) develop high magnetic properties.
25 to 35 % Nickel create resistance to corrosion at elevated temperatures.

Nickel-Chromium steels
3XXX
These steels are tough, ductile and exhibit high wear resistance, hardenability and high resistance
to corrosion.
Alloy Steels

AISI – SAE
Classifications
Number
4XXX Molybdenum steels
Molybdenum is a strong carbide former. It has a strong effect on hardenability and high
temperature hardness. Molybdenum also increases the tensile strength of low carbon steels.

5XXX Chromium steels - Hard, tough and wear resistance.

6XXX Chromium-Vanadium steels - High tensile strength, easy to bend and cut.
7XXX Tungsten-Chromium steels
Tungsten and Chromium increase hardness, improve grain structure and heat resistance.

8XXX Nikel-Chromium-Molybdenum steels

9XXX Silicone-Manganese steels and other various SAE grade.
Stainless Steels
• Typically contain 10% - 20% Cr.
• Cr is main alloy element makes the SS extremely
corrosion resistance.
• Melting Point :1400°C
• Wide range of application : food processing
equipment, kitchen utensils, medical & surgical
equipment.
• Have a few type based on the microstructure:
• Austenitic – non magnetic, weldable, not heat
treatable.
• Ferritic – magnetic, have good ductility, specialty
alloy
• Martensitic – heat treatable to prevent cracking.
Apps : dental & surgical equipment, knives, cutting
tools.
• Duplex – higher yield strength, greater stress
corrosion cracking to chloride. App: chemical
plant & piping.
Tools Steel
Under AISI and SAE system, tools steel grades are classified by the following letter
codes : W, O, A and D.
1. W – Water hardened. – essentially plain high carbon steel that has been
quenched and added vanadium to increase toughness.
1. O – Cold worked Oil hardened.
2. A – Cold worked Air hardened.
3. D – Cold worked high Carbon and high Chromium.

Others:
HSS – High Speed Steel – Strong, wear resistance. expensive
Classification, Designation and Specifications for Steels
Classification according to:
• Composition
• Strength
• Product Shape, Finish Processing and Quality Descriptors

Designation or common numbering System by:

• American Iron and Steel Institution (AISI)
• Society for Automotive Engineering (SAE)
• The Unified Numbering System (UNS) of Metals and Alloys
• American Society for Testing and Materials (ASTM) Standard E 527
AISI-SAE Steels Designations

 Most commonly used in steel industry.

 Specified by a 4-digits number system which identify the base Carbon and
alloy steel.
 Often expressed as AISI XXXX or SAE XXXX.
 For example: for 1020 steel is expressed as AISI 1020.
 Other e.g : AISI 1030, AISI 1524, AISI 4130
Steels Designations
Steels Designations
Example: Carbon Steels

1040

Indicates carbon Carbon content

steel (0.40%)

Modification in the
alloys (none or
plain carbon)
Example: Nickel Steels

2515

Indicates nickel Carbon content

steel (0.15%)

Major alloying element

(5% Nickel)
Example: Chromium Steels

5120

Indicates Carbon content

chromium steel (0.20%)

Major alloying element

(1% Chromium)
ASTM and ASME Designations
• ASTM* designation is an arbitrarily chosen number prefixed by the letter “A”,
which is designated for ferrous materials : AXXX
• ASTM designation are also adopted by ASME** and prefixed by letter “S” :
SAXXX

* ASTM = American Society for Testing and Materials

** ASME = American Society for Mechanical Engineers
Steels Designations
Unified Numbering System (UNS)
• The Unified Numbering System - UNS - was developed by ASTM and SAE to
correlate different numbering systems for commercial metals and alloys.
• In the 1960’s in the USA, the traditional system was found to have some problems.
The problems included use of same number for different alloys, use of different
numbers for the same alloy and use of trade names for many alloys. This gave rise
to the need for a new metals designation system.
• Therefore, the UNS was developed by a large group comprising trade associations
(Aluminum Association (AA), the American Iron and Steel Institute (AISI), and the
Copper Development Association (CDA)), metal producers, professional societies
(ASTM International, the American Welding Society (AWS), and the Society of
Automotive Engineers (SAE)), and the U.S. government.
• The designations were listed in a UNS Handbook published in 1975.
Unified Numbering System (UNS)

• The UNS number is not a specification for a metal or alloy .

• The numbers are to be used only to identify metals and alloys that are regularly
produced and used.
• It will not be issued for a material that has just been conceptualized or that is still
in experimental stage.
• The numbers assigned integrated numbers from existing numbering systems
whenever possible so as to enable easy recognition.
• The numbering system is designed to adapt current metals and alloys, and to
anticipate the need to furnish numbers for new alloys for the future.
Unified Numbering System (UNS)

UNS numbering consist of SINGLE-LETTER prefix follow by FIVE digits. In

most cases the letter is suggestive for the family of metal identified.

For example : for aluminum 6061 (AA6061) into UNS A96061

Other e.g: A92024, G41300, N06007, S30452, T30138
Designation UNS of Nonferrous Metals & Alloys
AXXXXX : Al & Al alloys
CXXXXX : Cu & Cu alloys
EXXXXX : rare earth & rare earth like metals & alloys
LXXXXX : low melting metals & alloys
MXXXXX : miscellaneous nonferrous metals & alloys
NXXXXX : Ni & Ni alloys
PXXXXX : precious metals & alloys
RXXXXX : reactive & refractory metals & alloys
ZXXXXX : Zn & Zn alloys
UNS of Ferrous Metals & Alloys

 DXXXXX : specified mechanical properties steels

 FXXXXX : cast irons and cast steels
 GXXXXX : AISI and SAE carbon & alloy steels
 HXXXXX : AISI H-steels
 JXXXXX : cast steels (except tool steels)
 KXXXXX : misc. steels & ferrous alloys
 SXXXXX : heat & corr. Resistant (stainless) steels
 TXXXXX : tool steels

26
Classification According to Strength
 Generally Plain C steels with low yield strength < 40 ksi
-Common materials used for construction → buildings, bridges and
ships

 High strength : 40 – 120 ksi

 Up to 80 ksi → (HSLA-High Strength Low Alloy)

 Ultra-high strength : min. 200 ksi

 Used as aerospace and defense industry structural materials
Classification According to Product Shape,
Finish Processing and Quality Descriptors
 Product Shape
 According to thickness and width

 “Bars” include
 Round, square, hexagon and similar cross section 9.52 mm (⅜ in) and
greater across
 Small angels, channels, tees and other standard shapes less than 76 mm (3
in) across
 Concrete-reinforcing bars