Post on 11-Apr-2017
transcript
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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 ApplicationsEquipment for Fluid Storage
FluidWater Grains
Ethanol Sulfuric Acid
ChlorineMilk
ConditionAtmosphere
High PressureVacuum
High TemperatureLow Temperature
EquipmentConcrete PitsRiveted Silos
CS Welded TanksEpoxy Lined TanksSS 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 MaterialsMetal Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High Strength
Medium-CPl
ain
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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Material Selection
Available MaterialsMetal Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High Strength
Medium-CPl
ain
Heat Treatable
High-C
Plain
Tool
High Alloys
Tool
Stainless
Cast Iron
Grey Iron
Ductile
Iron
White
Iron
Malleable
Iron
Non-FerrousSteels : C < 1.0 %wt
Cast Iron : C > 2.14 %wt
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Material Selection
Available MaterialsMetal Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High Strength
Medium-CPl
ain
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 MaterialsMetal Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High Strength
Medium-CPl
ain
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 MaterialsMetal Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High Strength
Medium-CPl
ain
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 MaterialsMetal Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High Strength
Medium-CPl
ain
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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Material Selection
Available MaterialsMetal Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High Strength
Medium-CPl
ain
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 FormationNi – for Toughness, Ductability and ease of Weldability improves, Improves Oxide Film FormationMo – for improving Pitting & Crevice Corrosion Resistance, Elevated Temperature Mechanical Properties ImprovesC, 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 acidMn – partial substitution for NickelSi, Al – improves Oxidation Resistance
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Material Selection
Available MaterialsMetal Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High Strength
Medium-CPl
ain
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 1150-1300oC• Easily melted and amenable to casting
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Material Selection
Available MaterialsMetal Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High Strength
Medium-CPl
ain
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 vibrational energy (base structure of machines & heavy
equipment exposed to vibrations)• Least Cost
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Material Selection
Available MaterialsMetal Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High Strength
Medium-CPl
ain
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
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Material Selection
Available MaterialsMetal Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High Strength
Medium-CPl
ain
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 cementite phase, 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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Material Selection
Fabrication TechniquesMetal Fabrication Techniques
Forming
Forging
Rolling
Extrusion
drawing
Casting
Sand
Die
Investment
Continuous
Misc.
Powder Metallurgy
Welding
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Material Selection
Fabrication TechniquesMetal 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 TechniquesMetal 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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Material Selection
Fabrication TechniquesMetal 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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Selection CriteriaA.) 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 CriteriaB.) Fabrication Requirement
• Cutting • Welding • Molding• Forging• Casting• Grinding (Polishing) • Hardening
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Selection Criteria
C.) Environmental Conditions
• Salty wind in coastal area
• High humidity air
• Hot or cold environment
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Selection Criteria
D.) Scale of Operation
• Small Scale – Glassware
• Big Scale – Metal Equipment
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Selection CriteriaE.) 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 CriteriaCommercial Gas Cylinder
Available Options
• Metal
• Ceramics
• Polymers
• Semi-conductors
• Composites
RequirementsStrength 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 CriteriaCommercial Gas Cylinder
Metal Alloys
Ferrous
Steel
Low Alloys
Low-C
Plain
High Strength
Medium-CPl
ain
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 GIron + 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 CriteriaAero Space Pressure Vessel
Available Options
• Metal
• Ceramics
• Polymers
• Semi-conductors
• Composites
RequirementsStrength Ductility Cost
Despite High Cost, Need of Light Material makes Composite as Suitable Material
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Material Selection
Selection CriteriaLiquid 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 CriteriaReactor• Shell Plates • Undergoes Cutting, Rolling, Welding • Selected MOC Code: ASTM-A240 TP304• Equivalent Steel Grades : BS-1501 Gr 304S15, IS-1570
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Selection CriteriaReactor• Nozzles• Pipe Material Specifications• Selected MOC Code : ASTM- A312 TP304• Equivalent Steel Grade : BS-3605 Gr.304S18
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Selection CriteriaReactor• Flanges• Forged or Cast Ring• Selected MOC Code : ASTM-A182 Gr. F304
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Selection CriteriaReactor• Agitator Shaft• Steel Bar (Martensitic Stainless Steel)• Selected MOC Code : AISI410• Equivalent Steel Grade : BS-410 S21
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Selection CriteriaReactor• Impeller• Casted• Selected MOC Code : A743 CF8
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Selection CriteriaReactor• Fastener• Bolt : ASTM – A193 Gr.B7• Nut : ASTM – A194 Gr. 2H• Washer : ASTM – F436
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Material Selection
Selection CriteriaReactor Part Material Code (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 CriteriaCentrifugal Pump (SS304)
Part Material Code (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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