Klc material selection-2017

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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



Material Selection

Man & Materials

Stone Age to Space Age•Meeting Needs•Incomplete Knowledge

•Curiosity to Know More



Material Selection

Importance of Material Selection

•Columbia Space Shuttle Failure

•Safety Aspects



Material Selection


•Erosion of Pump Impeller

•Plant Life Aspects



Material Selection


•Iron Pick Up by DM Water

•Product Contamination



Material Selection


•Bacterial Contamination in Food Industry

•Process Contamination



Material Selection


•Reactor Explosion due to Temperature Rise

•Equipment Failure



Material Selection

Industrial Applications• Fluid Storage• Fluid Transportation• Fluid Heating/Cooling• Fluid Conversion• Fluid Separation

In Chemical Plant • Equipment• Piping• Instrument• Electrical• Civil/ Structure



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



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



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



Material Selection

Available Materials•Metallic

• Pure - CS, Cu, Ni, Ti….

• Alloys – SS304, SS304L, SS316, SS316L…



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



Material Selection


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



Material Selection


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)



Material Selection


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



Material Selection


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



Material Selection


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



Material Selection


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



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%



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



Material Selection


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



Material Selection


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



Material Selection


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



Material Selection


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



Material Selection

Fabrication TechniquesMetal Fabrication Techniques

Forming

Forging

Rolling

Extrusion

drawing

Casting

Sand

Die

Investment

Continuous

Misc.

Powder Metallurgy

Welding



Material Selection


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



Material Selection


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



Material Selection


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.



Material Selection

Selection Criteria

Basic Considerations

• Fluid should not get contaminated

• Material should not be affected



Material Selection

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



Material Selection

Selection CriteriaB.) Fabrication Requirement

• Cutting • Welding • Molding• Forging• Casting• Grinding (Polishing) • Hardening



Material Selection

Selection Criteria

C.) Environmental Conditions

• Salty wind in coastal area

• High humidity air

• Hot or cold environment



Material Selection

Selection Criteria

D.) Scale of Operation

• Small Scale – Glassware

• Big Scale – Metal Equipment



Material Selection

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



Material Selection

Selection Criteria

Matching What is Required

and What is Available

Keeping in mind Economics & Safety



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)



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)



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



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



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



Material Selection

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



Material Selection

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



Material Selection

Selection CriteriaReactor• Agitator Shaft• Steel Bar (Martensitic Stainless Steel)• Selected MOC Code : AISI410• Equivalent Steel Grade : BS-410 S21



Material Selection

Selection CriteriaReactor• Impeller• Casted• Selected MOC Code : A743 CF8



Material Selection

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



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



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



Material Selection

Selection Methodology

• From Literature

• By Lab Testing

• Pilot Plant Trials

• Past Experience



Material Selection

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Date post:	11-Apr-2017
Category:	Education
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Klc material selection-2017

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