Material Selection

This program develops the concepts for selecting suitable material of construction (MOC) for the industrial applications.

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Material Selection
Contents
•Introduction
•Importance of Material Selection
•Industrial Applications
•Material Properties Required
•Available Materials
•Fabrication Techniques
•Selection Criteria
•Selection Methodology

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Material Selection
Man & Materials
Stone Age to Space Age
•Meeting Needs
•Incomplete Knowledge
•Curiosity to Know More

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Material Selection
Importance of Material Selection
•Columbia Space Shuttle Failure
•Safety Aspects

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Material Selection
Importance of Material Selection
•Erosion of Pump Impeller
•Plant Life Aspects

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Material Selection
Importance of Material Selection
•Iron Pick Up by DM Water
•Product Contamination

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Material Selection
Importance of Material Selection
•Bacterial Contamination in Food Industry
•Process Contamination

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Material Selection
Importance of Material Selection
•Reactor Explosion due to Temperature Rise
•Equipment Failure

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Material Selection
Industrial Applications
•Fluid Storage
•Fluid Transportation
•Fluid Heating/Cooling
•Fluid Conversion
•Fluid Separation
In Chemical Plant
•Equipment
•Piping
•Instrument
•Electrical
•Civil/ Structure

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Material Selection
Industrial Applications
Equipment for Fluid Storage
Fluid
Water
Grains
Ethanol
Sulfuric Acid
Chlorine
Milk
Condition
Atmosphere
High Pressure
Vacuum
High Temperature
Low Temperature
Equipment
Concrete Pits
Riveted Silos
CS Welded Tanks
Epoxy Lined Tanks
SS Welded Tanks
Smooth Surface Finish Tanks

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Material Selection
Material Properties Required
•Mechanical –Strength, Elastic Modulus
•Electrical –Conductivity, Dielectric Constant
•Thermal –Heat Capacity, Thermal Conductivity
•Magnetic –Response of Material in Magnetic Field
•Optical –High Radiation, Index of Reflection/ Refraction
•Deteriorative –Chemical Reactivity of Materials

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Material Selection
Available Materials
•Metals–Strong, Heat Transfer, Deformable
•Ceramics –Hard but Brittle, Insulation
•Polymers –Light, Flexible, Compressible
•Composites –Strength of Fiber & Flexibility of Polymer

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Material Selection
Available Materials
•Metallic
•Pure-CS, Cu, Ni, Ti….
•Alloys–SS304, SS304L, SS316, SS316L…

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Material Selection
Available Materials
Metal
Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
High
Alloys
Tool Stainless
Cast Iron
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Non-
Ferrous

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Sharing Experiences
Material Selection
Available Materials
Metal
Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
High
Alloys
Tool Stainless
Cast Iron
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Non-
Ferrous
Steels : C < 1.0 %wt
Cast Iron : C > 2.14 %wt

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Material Selection
Available Materials
Metal
Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
High
Alloys
Tool Stainless
Cast Iron
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Non-
Ferrous
Low Carbon Steels (C < 0.25 %wt)
•These alloys relatively soft and weak but have outstanding Ductility & Toughness.
•They are Machinable, Weldable, Least Expensive
•Applications: Automobile Body Parts, Structural Shapes (I-Beam, Channels)

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Material Selection
Available Materials
Metal
Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
High
Alloys
Tool Stainless
Cast Iron
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Non-
Ferrous
High Strength, Low Alloy
•Contain alloying elements such as copper, vanadium, nickel and molybdenum
•Higher strength than Plain Carbon Steel
•Strengthen by heat treatment
•Ductile, Formable and Machinable
•More resistant to corrosion than plain Carbon Steel

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Material Selection
Available Materials
Metal
Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
High
Alloys
Tool Stainless
Cast Iron
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Non-
Ferrous
Medium Carbon Steel (C: 0.25 –0.60 %wt)
•May be heat treated by austenitizing, quenching and then tempering to improve
mechanical properties
•Plain medium carbon steels –Low harden abilities, can be heat treated only in thin
sections and with very rapid quenching rates
•Heat treated alloys are stronger than low carbon steels but at sacrifice of ductility
and toughness

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Material Selection
Available Materials
Metal
Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
High
Alloys
Tool Stainless
Cast Iron
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Non-
Ferrous
High Carbon Steel (C: 0.60 –1.40 %wt)
•Hardest, Strongest, yet least ductile of carbon steel
•Used in a hardened and tempered conditions especially wear resistant and capable
of holding sharp cutting edge
•Tools & Die steels
•Knives, Razors, Hacksaw Blades

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Sharing Experiences
Material Selection
Available Materials
Metal
Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
High
Alloys
Tool Stainless
Cast Iron
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Non-
Ferrous
Stainless Steel
•Highly resistant to Corrosion
•3-Classes
•Martensitic(AISI-410) –Used for Cutlery, Riffle Barrel, Jet Engine Parts
•Ferritic(AISI-409) –Used for Automatic Exhaust Components
•Austenitic
•AISI-304 –Used for Chemical & Food Processing Equipment
•AISI-316L –Used for Welding Construction

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Material Selection
Available Materials
•Typical Composition of SS
SS304 SS304L SS316 SS316L
C (Max) 0.08% 0.03% 0.08% 0.03%
N 0.10% 0.10% 0.10% 0.10%
Cr 18-20% 18-20% 16-18% 16-18%
Ni 8-10.5% 8-12% 10-14% 10-14%
Mo - - 2-3% 2-3%
Si (Max) 0.75% 0.75% 0.75% 0.75%
P 0.045% 0.045% 0.045% 0.045%
S 0.03% 0.03% 0.03% 0.03%

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Material Selection
Available Materials
•Typical Composition of SS
SS304 SS304L SS316 SS316L
C (Max) 0.08% 0.03% 0.08% 0.03%
N 0.10% 0.10% 0.10% 0.10%
Cr 18-20% 18-20% 16-18% 16-18%
Ni 8-10.5% 8-12% 10-14% 10-14%
Mo - - 2-3% 2-3%
Si (Max) 0.75% 0.75% 0.75% 0.75%
P 0.045% 0.045% 0.045% 0.045%
S 0.03% 0.03% 0.03% 0.03%
Influence of Components on Material Properties
Cr–for Oxide Film Formation
Ni –for Toughness, Ductabilityand ease of Weldabilityimproves, Improves Oxide Film Formation
Mo –for improving Pitting & Crevice Corrosion Resistance, Elevated Temperature Mechanical Properties Improves
C, N –to Increase Strength & Hardness
S, Se, Pb–to Improve Machinability, Prolong Tool Life and Reduces Machining Power Requirement.
Ti, Co, Ta –to prevent Sensitization and thereby eliminate susceptibility to inter-granular corrosion.
Columbium –improves high temperature creep strength.
Cu –improves resistance to sulfuric acid
Mn–partial substitution for Nickel
Si, Al –improves Oxidation Resistance

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Sharing Experiences
Material Selection
Available Materials
Metal
Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
High
Alloys
Tool Stainless
Cast Iron
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Non-
Ferrous
Cast Iron (C > 2.14 %wt)
•Alloys within this composition remain liquid at temperature 1150-1300
o
C
•Easily melted and amenable to casting

23. [email protected] Learning Center
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Material Selection
Available Materials
Metal
Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
High
Alloys
Tool Stainless
Cast Iron
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Non-
Ferrous
Grey Iron (C : 2.5-4 %wt, Si : 1-3 %wt)
•Mechanically –comparatively weak & brittle in tension
•Strength & Ductility –much higher under compressive loads
•Effective in dampening vibrationalenergy (base structure of machines & heavy
equipment exposed to vibrations)
•Least Cost

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Material Selection
Available Materials
Metal
Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
High
Alloys
Tool Stainless
Cast Iron
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Non-
Ferrous
Ductile Iron
•Adding small amount of Mg & Cerium to Gray Iron before casting produces a
distinctly different microstructure and set of mechanical properties
•Graphite forms as nodules or sphere like particles instead of flakes
•Casting are much more stronger and ductile than Gray Iron
•Mechanical characteristics approaching those of steel
•Application: Valves, Pump Bodies, Crank Shafts, Gears

25. [email protected] Learning Center
Sharing Experiences
Material Selection
Available Materials
Metal
Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
High
Alloys
Tool Stainless
Cast Iron
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Non-
Ferrous
White Iron & Malleable Iron
•White iron –extremely hard due to cementitephase, but also brittle
(unmachinable)
•Used for very hard and wear resistant surface and without a high degree of ductility
e.g. rollers in rolling mills
•Connecting rods, transmission gears, flanges, pipe fittings

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Sharing Experiences
Material Selection
Fabrication Techniques
Metal Fabrication Techniques
Forming
Forging
Rolling
Extrusion
drawing
Casting
Sand
Die
Investment
Continuous
Misc.
Powder Metallurgy
Welding

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Sharing Experiences
Material Selection
Fabrication Techniques
Metal Fabrication Techniques
Forming
Forging
Rolling
Extrusion
drawing
Casting
Sand
Die
Investment
Continuous
Misc.
Powder Metallurgy
Welding
Forming: Shape of metal piece is
changed by plastic deformation
•Forging–Hot metal put in Die
•Rolling–Metal passed through rollers
•Extrusion–Hot metal passed through Die
•Drawing –Metal pulled like wire making

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Material Selection
Fabrication Techniques
Metal Fabrication Techniques
Forming
Forging
Rolling
Extrusion
drawing
Casting
Sand
Die
Investment
Continuous
Misc.
Powder Metallurgy
Welding
Casting: Molten metal is
poured into a mould cavity
having desired shape
•Sand –Liquid metal in
sand mold
•Die–Liquid metal under
pressure in mold
•Investment–Wax casting
•Continuous –Casting with
Forming

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Sharing Experiences
Material Selection
Fabrication Techniques
Metal Fabrication Techniques
Forming
Forging
Rolling
Extrusion
drawing
Casting
Sand
Die
Investment
Continuous
Misc.
Powder Metallurgy
Welding
Welding: High temperature fusion.
•Alteration of properties/ microstructures
•If work piece material was previously cold worked, heat
affected zone may have experienced re-crystallization and
grain growth , thus diminishment of strength, hardness and
toughness
•Upon cooling, residual stresses may form in this region,
which weakens the joint
•For steels, material heated to form Austenite
•Some stainless steels may be “sensitized” during welding
which renders them susceptible to inter-granular corrosion.

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Material Selection
Selection Criteria
Basic Considerations
•Fluid should not get contaminated
•Material should not be affected

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Material Selection
Selection Criteria
A.) Operating Conditions
•Pressure –Plastic/ rubber will not be suitable for high
pressure applications
•Temperature–For high temperature applications like
furnaces, even metals will not be suitable
•Fluid Concentration–Low alloy materials may not be
suitable for high concentration acids/ alkalies

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Material Selection
Selection Criteria
B.) Fabrication Requirement
•Cutting
•Welding
•Molding
•Forging
•Casting
•Grinding (Polishing)
•Hardening

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Material Selection
Selection Criteria
C.) Environmental Conditions
•Salty wind in coastal area
•High humidity air
•Hot or cold environment

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Material Selection
Selection Criteria
D.) Scale of Operation
•Small Scale –Glassware
•Big Scale –Metal Equipment

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Material Selection
Selection Criteria
E.) Other Requirements
•Thermal Conductivity –Insulation, Heat Exchanger Tubes
•Electrical Conductivity –Earthing
•Compressibility –For sealing of fluids
•Flexibility –hoses
•Economics –Cheaper is better
•Ease of Operation –Light material like rubber hose
•Safe in Operation –Glass wool with Al cladding

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Material Selection
Selection Criteria
Matching
What is Required
and
What is Available
Keeping in mind Economics & Safety

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Material Selection
Selection Criteria
Commercial Gas Cylinder
Available Options
•Metal
•Ceramics
•Polymers
•Semi-conductors
•Composites
Requirements
Strength Ductility Cost
High Strength but poor ductility
High Strength & Ductility but High Cost
High Strength & Ductility with Low Cost (Selected)

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Material Selection
Selection Criteria
Commercial Gas Cylinder
Metal
Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High
Strength
Medium-C
Plain
Heat
Treatable
High-C
Plain Tool
High
Alloys
Tool Stainless
Cast Iron
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Non-
Ferrous
ASTM A414-Grade G
Iron
+ 0.31 wt% C (max)
+ 1.35 wt% Mn(max)
+ 0.035 wt% P (max)
+ 0.04 wt% S (max)

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Material Selection
Selection Criteria
Aero Space Pressure Vessel
Available Options
•Metal
•Ceramics
•Polymers
•Semi-conductors
•Composites
Requirements
Strength Ductility Cost
Despite High Cost, Need of Light Material
makes Composite as Suitable Material

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Material Selection
Selection Criteria
Liquid Bulk Storage Tank
•Non-Corrosive Liquid : Carbon Steel Plates (IS2061)
•Salt Solution (Brine): Carbon Steel Rubber Lined (CSRL)
•Corrosive Liquid : SS-304 Plates
•Hygienic Liquids (Milk) : SS-316 Plates with high surface finish

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Material Selection
Selection Criteria
Reactor
•Shell Plates
•Undergoes Cutting, Rolling, Welding
•Selected MOC Code: ASTM-A240 TP304
•Equivalent Steel Grades : BS-1501 Gr304S15, IS-1570

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Material Selection
Selection Criteria
Reactor
•Nozzles
•Pipe Material Specifications
•Selected MOC Code : ASTM-A312 TP304
•Equivalent Steel Grade : BS-3605 Gr.304S18

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Material Selection
Selection Criteria
Reactor
•Flanges
•Forged or Cast Ring
•Selected MOC Code : ASTM-A182 Gr. F304

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Material Selection
Selection Criteria
Reactor
•Agitator Shaft
•Steel Bar (MartensiticStainless Steel)
•Selected MOC Code : AISI410
•Equivalent Steel Grade : BS-410 S21

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Material Selection
Selection Criteria
Reactor
•Impeller
•Casted
•Selected MOC Code : A743 CF8

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Material Selection
Selection Criteria
Reactor
•Fastener
•Bolt : ASTM –A193 Gr.B7
•Nut : ASTM –A194 Gr. 2H
•Washer : ASTM –F436

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Material Selection
Selection Criteria
Reactor
Part MaterialCode (ASTM)
Plate A240 TP304
Nozzle A312 TP304
Flange A182 Gr.F304
Shaft AISI 410
Impeller A743 CF8
Bolt A193 Gr.B7
Nut A194 Gr2H
Washer F436

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Material Selection
Selection Criteria
Centrifugal Pump (SS304)
Part MaterialCode
(ASTM)
Casing A743 CF8
Impeller A743 CF8
Stuffing Box A743 CF8
Shaft AISI 410
Shaft Sleeve AISI 304
Casing Wear Ring AISI 304
Impeller Wear Ring AISI 304
Base Plate MS Fabricated

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Material Selection
Selection Methodology
•From Literature
•By Lab Testing
•Pilot Plant Trials
•Past Experience

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Material Selection
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