materials study, awareness and selection

Material awarness and selection

1. INDUSTRIAL MATERIALS & METALLURGY

2. What is this incident ?

3. Importance of material knowledge for Inspection personnel Type of defect Type of NDT Location of defects Root cause of failure. Repair Procedure

4. Commonly known words. Austenitic Stainless Steel. Sensitization Ferrite contents Maternsitic structure. Grain size. Crystals. etc etc.

5. Today’s Lesson Difference between Crystals and Grains Crystalline structure Material Classification

6. Metallurgy Science deals with physical and chemical behavior of materials.

7. BASIC UNIT OF METAL ?

8. ATOM Electron Proton Neutron

9. MOLECULE

10. MOLECULE Atoms Bonding Neutron

11. CRYSTAL

12. CRYSTAL a crystal structure is a unique arrangement of atoms in a crystal is a solid material whose constituent atoms , molecules , or ions are arranged in an orderly repeating pattern

13. CRYSTAL a crystal structure is a unique arrangement of atoms in a crystal is a solid material whose constituent atoms , molecules , or ions are arranged in an orderly repeating pattern

14. CRYSTAL a crystal structure is a unique arrangement of atoms in a crystal is a solid material whose constituent atoms , molecules , or ions are arranged in an orderly repeating pattern

15. GRAIN

16. GRAIN FORMATION

17. A GRAIN Fast Cooling Grain Boundary Grain

18. A GRAIN Slow Cooling Grain Boundary Grain

19. MATERIAL CLASSIFICATION METALS NON - METALS NON - FERROUS FERROUS FERROUS MATERIALS

20. METALS DEFINITION Good luster Good heat conductivity Good conductors of electricity Mostly solid except mercury Mostly ductile and malleable Higher densities Higher melting and boiling points

21. NON - METALS DEFINITION Dull luster Bad heat conductivity Bad conductors of electricity Mostly Brittle Lower densities Lower melting and boiling points

22. QUESTION ????? GIVE SOME EXAMPLES OF METALS & NON-METALS ?????? Steel Copper Gold Mercury Silver Titanium METALS Wood Glass Paper Plastics Air Rubber NON METALS

23. QUESTION ????? What is this??????

24. QUESTION ????? TRUE OR FALSE ?????? All materials have crystalline structure.

25. QUESTION ????? Identify the material ?

26. QUESTION ????? Identify the material ?

27. QUESTION ????? Identify the material ?

28. QUESTION ????? Identify the material ?

29. DAY # 1 ; Lecture Finished

30. DAY # 1 ; Question of the day Why Steel is most common used metal in the world ?

31. Lecture # 2 : Today’s Lesson Ferrous Metals Carbon Steels Alloy Steel

32. STEEL Among all the metals steels usage is 90 %.

33. FERROUS METALS DEFINITION MATERIAL WHICH CONTAINS BY MASS MORE IRON THAN ANY OTHER SINGLE ELEMENT. IRON OTHERS

34. CLASSIFICATION FERROUS METALS FERROUS METALS CARBON STEEL CAST IRON ALLOY STEEL WROUGHT IRON BASED ON “C” ADDITION

35. EFFECT OF CARBON ON STEEL Hardness Strength Ductility Weldability Carbon

36. WROUGHT IRON COMPOSITION MECHANICAL PROPERTIES - CONTAINS SMALL AMOUNT OF SLAG (SiO 2 ) - CARBON CONTENTS LESS THAN 0.08 % CARBON USES - EASILY WELDABLE - LOW STRENGTH , MALLEABLE AND DUCTILE Mostly used in home furniture's and industrial use is very less.

37. CARBON STEEL CARBON STEEL IS CLASSIFIED ACCORDING TO: ITS TREATMENT FOR DEOXIDIZATION ITS CARBON CONTENTS TYPE OF STEEL FOR WHICH: - CARBON CONTENTS ARE < 2% NO ALLOYING ELEMENT IS ADDED EXCEPT CARBON

38. CARBON STEEL CLASSIFICATION ACCORDING TO CARBON CONTENTS CARBON STEEL LOW CARBON STEEL MEDIUM CARBON STEEL HIGH CARBON STEEL CARBON CONTENTS < 0.3 % CARBON CONTENTS BETWEEN 0.3 % AND 0.6% CARBON CONTENTS BETWEEN 0.6 % AND 2.0%

39. LOW CARBON STEEL COMPOSITION MECHANICAL PROPERTIES - LESS THAN 0.3 % CARBON GENERAL USES - GRADES HAVING CARBON B/W 0.1 % TO 0.3 % ARE HEAT TREATABLE - EXCELLENT FORMABILITY AND WELDABILITY SHEETS MANUFACTURING, PIPING AND PRESSURE VESSEL COMPONENTS

40. LOW CARBON STEEL USES IN INDUSTRY - LOW, MEDIUM AND HIGH PRESSURE STEAM/CONDENSATE - PIPING, VALVES AND VESSELS FOR - COOLING WATER, INSTRUMENT AIR, GASEOUS SERVICE - LOAD BEARING STRUCTURES AND SHEETS LOW CARBON STEEL GRADES API 5L GRADE B ASTM A - 105 ASTM A - 234

41. MEDIUM CARBON STEEL COMPOSITION MECHANICAL PROPERTIES CARBON CONTENTS BETWEEN 0.3% TO 0.6% GENERAL USES - HEAT TREATABLE - GOOD BALANCE BETWEEN STRENGTH AND DUCTILITY MANUFACTURING OF GEARS, CRANKSHAFT ETC.

42. HIGH CARBON STEEL COMPOSITION MECHANICAL PROPERTIES CARBON CONTENTS BETWEEN 0.6% TO 2.0% GENERAL USES - LOW DUCTILITY - HIGH STRENGTH HIGH STRENGTH WIRES AND SPRINGS - POOR WELDABILITY AND FORMABILITY

43. CAST IRON COMPOSITION MECHANICAL PROPERTIES - CARBON CONTENTS BETWEEN 2% AND 5% GENERAL USES - MELTING TEMPERATURE BELOW CARBON STEEL POOR WELDABILITY AND DUCTILITY - EXCELLENT FLUIDITY (REQUIRED FOR CASTING PURPOSE) - SILICON INCLUSION BETWEEN 1% AND 3% MANUFACTURING OF PUMPS, TURBINES, COMPRESSORS AND GEAR BOX CASINGS

44. CLASSIFICATION FERROUS METALS FERROUS METALS CARBON STEEL CAST IRON ALLOY STEEL WROUGHT IRON BASED ON “C” ADDITION

45. ALLOY STEELS ALLOY STEEL LOW ALLOY STEEL HIGH ALLOY STEEL ALLOYING ELEMENT UP TO 8.0% ALLOYING ELEMENT GREATER THAN 8.0% CORROSION RESISTANT HEAT RESISTANT WEAR RESISTANT Cr-Mo Alloy

46. Cr – Mo STEELS GENERAL USES PRESSURE VESSEL, PIPING AT HIGH TEMPERATURE COMPOSITION - Cr UPTO 2.25% AND Mo UP TO 1.25% MECHANICAL PROPERTIES - HIGH STRENGTH AT TEMPERATURES UP TO 650 C - DIFFICULT WELDING AS HEAT TREATMENT IS INVOLVED ALLOYING EFFECT - Cr INCREASES CORROSION RESISTANCE - Mo ADDS ELEVATED TEMPERATURE STRENGTH

47. Cr - Mo STEEL GRADES A-335 GRADE P11 Cr – Mo STEELS A-335 GRADE P22 USES IN INDUSTRY PIPING, VALVES AND VESSELS FOR VER HIGH PRESSURE STEAM

48. QUIZ TIME: MADE OF ? MEDIUM CARBON STEEL

49. QUIZ TIME: MADE OF ? LOW CARBON STEEL

50. QUIZ TIME: MADE OF ? CAST IRON

51. QUIZ TIME: MADE OF ? MEDIUM CARBON STEEL

52. Why Cast Iron is used for making steel casings and foundations of heavy machines? DAY # 2 ; Question of the day

53. DAY # 2 ; Lecture Finished

54. Lecture # 3 : Today’s Lesson Ferrite Austenite Martensite Stainless Steels

55. Ferrites Body Centered Cubic Structure Metallurgy Of Carbon Steel

56. Ferrites Body Centered Cubic Structure Metallurgy Of Carbon Steel

57. Austenites Face Centered Cubic Structure Metallurgy Of Carbon Steel

58. Martensites body centered tetragonal crystal structure Metallurgy Of Carbon Steel The martensite is formed by rapid cooling (quenching) of austenite which traps carbon atoms that do not have time to diffuse out of the crystal structure

59. What is the material ?

60. STAINLESS STEEL Stainless Steel: Stands for something that has no stains.

61. STAINLESS STEEL WHEN Cr CONTENTS ARE GREATER THAN 11.5 % , Cr REACTS WITH ATMOSPHERIC O 2 AND FORM THIN PASSIVE Cr-O2 LAYER ON STEEL SURFACE PREVENTING OXIDATION OF Fe CONTENTS Cr–O 2 LAYER STEEL

62. EFFECT OF CHROMIUM

63. STAINLESS STEEL FERRITIC MARTENSITIC DUPLEX AUSTENITIC STAINLESS STEEL

64. COMPOSITION MECHANICAL PROPERTIES GENERAL USES - GOOD WELDABILITY - EXCELLENT CORROSION RESISTANT Piping and vessels in high corrosive service. - CAN BE USED AT LOW AND HIGH TEMPERATURE (UP TO 900 C) Ni UP TO 30% Cr UP TO 30% C 0.3% AUSTENITIC STAINLESS STEEL - CANNOT BE HARDENED BY HEAT TREATMENT

65. USED IN INDUSTRY - CORROSIVE SERVICE - PIPING, VALVES AND VESSELS FOR - DEMIN WATER AUSTENITIC STAINLESS STEEL AUSTENITIC GRADES SS- 304 SS- 316 SS- 316L SS- 321

66. CONCEPT OF SENSITIZATION IN STAINLESS STEEL CHROMIUMCARBIDE (Cr 23 C 6) GRAIN BOUNDARIES CHROMIUM AT HIGH TEMPERATURE (> 750 C) Cr REACTS WITH C AND FORMS CrC TO PREVENT SENSITIZATION Ti OR Nb IS ADDED TO FORM TiC OR NbC

67. COMPOSITION MECHANICAL PROPERTIES GENERAL USES - POOR WELDABILITY - MODERATE CORROSION RESISTANT SHAFTS, SURGICAL INSTRUMENTS, FASTENERS - CAN BE HARDENED BY HEAT TREATMENT MARTENSITIC STAINLESS STEEL C 1.2% Cr UP TO 17% Ni 0%

68. USED AT FERTILIZER PLANT - PUMP SHAFTS, IMPELLERS FOR CORROSIVE SERVICE MARTENSITIC GRADES SS- 416 SS- 420 MARTENSITIC STAINLESS STEEL SS- 440 SS- 410

69. COMPOSITION MECHANICAL PROPERTIES GENERAL USES - POOR WELDABILITY - MODERATE TO GOOD CORROSION RESISTANT DOMESTIC EQUIPMENTS FERRITIC STAINLESS STEEL - CANNOT BE HARDENED BY HEAT TREATMENT C .3% Cr UP TO 30% Ni 0%

70. COMPOSITION MECHANICAL PROPERTIES GENERAL USES - GOOD STRENGTH : GREATER THAN AUSTENITIC AND OTHER GRADES - GOOD CORROSION RESISTANCE Internal lining of vessels in high corrosion service. Valves in high corrosive environment. DUPLEX STAINLESS STEEL - GOOD WELDABILITY C .3% Cr UP TO 30% Ni UP TO 8%

71. USED In INDUSTRY - Internal Linings DUPLEX STAINLESS STEEL - Valves DUPLEX GRADES HVD-1 FERRALIUM ALLOY

72. SS – 304 18 Cr – 8 Ni SS - 316 SS - 317 ADD Mo (2%) FOR PITTING RESISTANCE ADD MORE Mo (4%) FOR PITTING RESISTANCE ADD Nb + Ta TO REDUCE SENSITIZATION SS - 347 ADD Ti TO REDUCE SENSITIZATION SS - 321 LOWER C SS - 317L SS - 316L SS - 304L ADD Cr & Ni STRENGTH & CORROSION RESIST. SS – 310 SS - 309 REDUCE Ni TO REDUCE AUSTENITIC STRUCTURE DUPLEX STEEL NO Ni FERRITIC STEEL INCREASE C LOWER Cr MARTENSITIC STEEL

73. Austenite or Ferrite ? QUIZ ?

74. Why Stainless Steel is corrosion resistant ? What makes it resist corrosion ? QUIZ ? Good Shining lustre Chromium oxide layer Austenite structure Martensitic structure Ferritic structure Nickel addition Hardness Additional Carbon inside Grain size

75. QUIZ ? Which structure?

76. QUIZ ? What is this ? 50 m m

77. DAY # 3 ; Lecture Finished

78. Question of today ? A steel sensitized is better in corrosion resistance than carbon Steel ?

79. Lecture # 4 : Today’s Lesson AISI ASTM UNS Discussion

80. MATERIAL DESIGNATION SYSTEM WHY ?

81. MATERIAL DESIGNATION SYSTEM - American Society for Testing Materials ASTM - American Iron and Steel Institute AISI - Society of Automotive Engineers SAE - Unified Numbering System UNS - German Standards DIN - British Standards BS - Japanese Standards JIS

82. SAE DESIGNATION SYSTEM CLASSIFY MATERIAL ON THE BASIS OF COMPOSITION CARBON AND ALLOY STEEL (EXCEPT STAINLESS STEEL) X X X CARBON %AGE MATERIAL TYPE X ADDITION OF ELEMENTS SUFFIX H

83. SAE DESIGNATION SYSTEM CLASSIFY MATERIAL ON THE BASIS OF COMPOSITION CARBON AND ALLOY STEEL (EXCEPT STAINLESS STEEL) Carbon steels and alloy steels are designated by a four digit number, where the first digit indicates the main alloying element(s), the second digit indicates the secondary alloying element(s), and the last two digits indicate the amount of carbon, in hundredths of a percent by weight. For example, a 1060 steel is a plain-carbon steel containing 0.60 wt% C. An "H" suffix can be added to any designation to denote hardenability is a major requirement

84. SAE Major classifications of steel SAE designation Type 1xxx Carbon steels 2xxx Nickel steels 3xxx Nickel-chromium steels 4xxx Molybdenum steels 5xxx Chromium steels 6xxx Chromium-vanadium steels 7xxx Tungsten steels 8xxx Nickel-chromium-vanadium steels 9xxx Silicon-manganese steels

85. SAE Carbon steels 10xx Plain carbon (Mn 1.00% max) 11xx Resulfurized 12xx Resulfurized and rephosphorized 15xx Plain carbon ( Mn 1.00% to 1.65%) Manganese steels 13xx Mn 1.75% Nickel steels 23xx Ni 3.50% 25xx Ni 5.00%

86. AISI The American Iron and Steel Institute (AISI) originally started a very similar system. Over time they used the same numbers to refer to the same alloy, but the AISI system used a letter prefix to denote the steelmaking process. The prefix "C" denoted open-hearth furnace, electric arc furnace or basic oxygen furnace, while "E" denotes electric arc furnace steel.

87. Decode it ? E 1240H

88. AISI/SAE DESIGNATION SYSTEM STAINLESS STEEL 3 16 No Specific Interpretation MATERIAL TYPE Z Element addition - Austenitic Stainless Steel (Mn) 2 - Austenitic Stainless Steel (Ni) 3 - Low Carbon (<0.03%) L - High Carbon Contents H - Added Nitrogen N - Added Copper Cu - Martensitic & Ferritic 4

89. AISI/SAE DESIGNATION SYSTEM ? 440 ?

90. ASTM STANDARDS DESIGNATION SYSTEM

91. ASTM STANDARDS Ferrous Metals DESIGNATION SYSTEM ASTM A 182 / 182 M - 93b F 304L ASTM A 182 / 182 M - 93b F 304L Arbitrary Number Metric System Year of Revision AISI NO CLASSIFY PRODUCTS ON THE BASIS OF MANUFACTURING METHOD MOST WIDELY USED SYSTEM – COVERS ALL DETAILS REQUIRED FOR MATERIAL PROCUREMENT Grade

92. ASTM STANDARDS DESIGNATION SYSTEM - Corrosion Resistant C - Heat Resistant H - Addition of Molybdenum M - Carbon Percentage Digital No. - Pipe P - Tube T - Tube and Pipe TP - Forging F EXAMPLES A 403/A 403M -93 P304L A 336/A 336M-89 Class F22 - Wrought W

93. UNIFIED NUMBERING SYSTEM (UNS) JOINT VENTURE AS ASTM AND SAE TO GENERATE UNIFIED COMPUTER FRIENDLY SYSTEM The unified numbering system ( UNS ) is an alloy designation system consists of a prefix letter and five digits designating a material composition. A prefix of S indicates stainless steel alloys, C for copper, brass, or bronze alloys, T for tool steels, etc. The first three digits often match older three-digit numbering systems, while the last two digits indicate more modern variations. For example, Copper Alloy No. 377 (forging brass) in the original three-digit system became C37700 in the UNS System.

94. UNIFIED NUMBERING SYSTEM (UNS) JOINT VENTURE AS ASTM AND SAE TO GENERATE UNIFIED COMPUTER FRIENDLY SYSTEM 1040 1 X ELEMENT ADDITION TYPE OF STEEL AISI/SAE NUMBER - Carbon and Alloy steels G - Cast Irons F Heat and Corrosion Resistant Steels H - Boron 1 - Lead 4 - Electric Furnace Steel 6

95. Some Questions ? Is martensite friendly or not ?

96. Why Cast Iron is used for making steel casings and foundations of heavy machines? DAY # 2 ; Question of the day

97. Why Steel is most common used metal in the world ?

98. Some Questions ? A steel sensitized is better in corrosion resistance than carbon Steel ?

99. THE END

100. Cr – Mo STEELS

101. C .3% Cr UP TO 30% Ni UP TO 8% C 0.3% Cr UP TO 30% Ni 0% Ni UP TO 30% Cr UP TO 30% C 0.3% C 1.2% Cr UP TO 17% Ni 0%

102. STAINLESS STEEL CONCEPT OF SENSITIZATION CHROMIUM CARBIDE (Cr 23 C 6) CHROMIUM DEPLETED LAYER

103. MATERIAL CLASSIFICATION FERROUS METALS CAST IRON LOW ALLOY STEEL HIGH ALLOY STEEL CARBON STEEL LOW CARBON HIGH CARBON MEDIUM CARBON

104. STAINLESS STEEL Ni UP TO 30% Cr UP TO 30% C .3% AUSTENITIC STAINLESS STEEL C 1.2% MARTENSITIC STAINLESS STEEL Cr UP TO 17% Ni 0% C .3% DUPLEX STAINLESS STEEL Cr UP TO 30% Ni UP TO 8% C .3% FERRITIC STAINLESS STEEL Cr UP TO 30% Ni 0%

105. AUSTENITIC STAINLESS STEEL UN-STABILIZED GRADE - SS 304 - SS 316 - 25 Cr – 22 Ni – 2 Mo - 316L + G510 STABILIZED GRADE - SS 321 - SS 347 Cannot Be Used for High Temperature Can Be Used for High Temperature

106. SS – 304 18 Cr – 8 Ni SS - 316 SS - 317 ADD Mo (2%) FOR PITTING RESISTANCE ADD MORE Mo (4%) FOR PITTING RESISTANCE ADD Nb TO REDUCE SENSITIZATION SS - 347 ADD Ti TO REDUCE SENSITIZATION SS - 321 LOWER C SS - 317L SS - 316L SS - 304L ADD Cr & Ni STRENGTH & CORROSION RESIST. SS – 310 SS - 309 AUSTENITIC STAINLESS STEEL