CHAPTER V

Selection of Metallic Materials

Dr. Nur Azam bin Badarulzaman

FKMP
Chapter V: Selection of Metallic Materials

TABLE OF CONTENT…
1. Processing & Designation
2. Selection of Ferrous Metals
& Case Study
3. Selection of Non-ferrous
Metals & Case Study.

Notes for Chapter 5 can be downloaded from

www.pemilihanbahan.blogspot.com
Chapter V: Selection of Metallic Materials
5.1 PROCESSING & DESIGNATION…

• PROCESS
– A method of shaping, finishing or
joining a material

• DESIGNATION
– Names, codes or standards given
according to a material composition,
process or attributes
Chapter V: Selection of Metallic Materials

5.1 PROCESSING & DESIGNATION…

5.1 Processing & Designation

CLASSES OF PROCESSING…

POWDER
CASTING METHODS
DEFORMATION

MACHINING
PRESSURE SURFACE
MOULDING FINISH

SPECIAL
HEAT
JOINING METHODS
TREATMENT
5.1 Processing & Designation

PROCESS – MATERIALS…
5.1 Processing & Designation

PROCESS – SHAPE…
5.1 Processing & Designation

PROCESS – MASS-RANGE…
5.1 Processing & Designation

PROCESS – SECTION THICKNESS…

5.1 Processing & Designation

PROCESS – TOLERANCE…
5.1 Processing & Designation

PROCESS – SURFACE ROUGHNESS…

5.1 Processing & Designation

PROCESS – ECONOMIC BATCH SIZE…

5.1 Processing & Designation

DESIGNATION…
• American Society for Testing and
Materials (ASTM)
– ASTM E 527 – The Unified Numbering System
(UNS) of Metals and Alloys

• Classification according to:

– Composition
– Strength
– Product Shape, Finish Processing and Quality
Descriptors
 5.1 Processing & Designation

DESIGNATION…

• UNS Designation for non-ferrous metals & alloys:

o A00001 - A99999 : Al & Al alloys: alloys
o C00001 - C99999 : Cu & Cu alloys: alloys
o E00001 - E99999 : rare earth & rare earthlike metals & alloys:
o L00001 - L99999 : low melting metals & alloys: alloys
o M00001 - M99999: misc. nonferrous metals & alloys: alloys
o N00001- N99999 : Ni & Ni alloys: alloys
o P00001- P99999 : precious metals & alloys: alloys
o R00001 - R99999 : reactive & refractory metals & alloys: alloys
o Z00001 - Z99999 : Zn & Zn alloys: alloy
5.1 Processing & Designation

DESIGNATION…
• UNS of Ferrous Metals & Alloys
o D00001 - D99999 : specified mechanical properties steels: steels
o F00001 - F99999 : cast irons and cast steels: steels
o G00001 - G99999 : AISI and SAE carbon & alloy steels: steels
o H00001 - H99999 : AISI H-steels
o J00001 - J99999 : cast steels (except tool steels): steels)
o K00001 - K99999 : misc. steels & ferrous alloys: alloys
o S00001 - S99999 : heat & : corrosion resistant (stainless) steels
o T00001 - T99999: tool steels: steels

• UNS of Specialized Metals & Alloys

o W00001 - W99999 : welding filler metals, covered & tubular
electrodes, classified by weld deposit composition
5.1 Processing & Designation

DESIGNATION BY COMPOSITION…
• Plain carbon and low alloy steels coded according to
A I S I - SA E system
o A I S I – American Iron and Steel Institution
o S A E – Society for Automotive Engineering

o Classification of steel by composition:

Carbon Content Alloy Content
• Low : < 0.25% • Plain Carbon:
• Med. : 0.25 – 0.55% o no alloying element except Mn up to 1.65%
• High : > 0.55% • Low Alloy
o total alloy content < 5%
• High Alloy
o total alloy content > 5%
5.1 Processing & Designation

DESIGNATION BY STRENGTH…
• Example: Plain Carbon Steels

o Low strength : < 40 ksi

o High strength : 40 – 120 ksi

• Up to 80 ksi
• Excess 80 ksi

o Ultra-high strength : min. 200 ksi

5.1 Processing & Designation

DESIGNATION BY SHAPE, FINISHING AND

QUALITY DESCRIPTORS
• Product Shape
– According to thickness and width
– Example: “Bars””include
• Round, square, hexagon and similar cross section
• 9.52 mm ( (⅜⅜in) and greater across small angels, channels, tees and other
standard shapes less than 76 mm (3 in) across
• Concrete reinforcing bars

• Finish processing:
– Signify the last processing the steel has undergone – hot hot-rolled,
cold cold-rolled, annealed, hot hot-dip galvanizing etc. Hot dip
Galvanising.ppt

• Quality descriptors
– Indicate product suitability for certain applications or fabrication
processesapplications processes
Chapter V: Selection of Metallic Materials

5.2 SELECTION OF FERROUS METALS…

FERROUS

STEEL CAST IRON

CARBON ALLOY WHITE

LOW MEDIUM HIGH TOOL GREY

PLAIN PLAIN PLAIN STAINLESS MALLEABLE

HEAT DUCTILE
HSLA TOOL
TREATABLE (NODULAR)
5.2 Selection of Ferrous Metals

STEEL…
• 10XX or 10XXX
o First two digits (10) – type of alloy
addition
o X X / X X X  indicates % carbon when
divided by 100
o Eg: 1010  0.1% C; 10100  1%C
o Exceptional for 9 X X (SAE grades  X X
indicates minimum yield strength in
ksi).
5.2 Selection of Ferrous Metals

STEEL…
5.2 Selection of Ferrous Metals

STEEL…
5.2 Selection of Ferrous Metals

STEEL…
5.2 Selection of Ferrous Metals

CAST IRON…
5.2 Selection of Ferrous Metals

CAST IRON…

GRAY WHITE NODULAR (DUCTILE)

α-Fe and graphite Cementite & pearlite α-Fe and graphite
flakes spheres

MALLEABLE COMPACTED
α-Fe and tempered GRAPHITE (TYPE IV)
graphite flakes
5.2 Selection of Ferrous Metals

CAST IRON…
5.2 Selection of Ferrous Metals

CAST IRON…
• Consideration for design of iron castings:
o Technical / functional requirements / constraints of
casting / components  Forces/stresses the casting
must withstand
o Shape and section size of casting
o Materials to be used
o Manufacturing processes that may include casting or
forming process, machining and some welding.