Materials Selection Deskbook 2011 Part 1 pdf

MATERIALS SELECTION DESKBOOK by Nicholas P. Cheremisinoff, Ph.D. NOYES PUBLICATIONS Westwood, New Jersey, U.S.A. Copyright 6 19% by Noyes Publications No part of this book may be reproduced a utilized in any form or by any means, electronic 01 mechanical, including photocopying, recording 01 by any informa- tion storage and retrieval system, without permission in writing from the Publisher. Library of Congress Catalog Card Number: 96-10911 Printed in the United States ISBN 0-8155-1400-X Published in the United States of America by Noyes Publications 369 Fairview Avenue Westwood, New Jersey 07675 10 9 8 7 6 5 4 3 2 1 hirary of Congress Cataloging-in-Publication Data Cheremisinoff, Nicholas P. Materials selection deskbook I by Nicholas P. Cheremisinoff. Includes bibliographical references. 1. Materials Handbooks, manuals, etc. I. Title. p. an. ISBN 0-8155-1400-X TA404.8.C48 1996 66Cr.282 &20 96-10911 CIP ABOUT THE AUTHOR Nicholas P. Cheremisinoff is a private consultant to industry, academia, and government. He has nearly twenty years of industry and applied research experience in elastomers, synthetic fuels, petrochemicals manufacturing, and environ- mental control. A chemical engineer by trade, he has authored over 100 engineering textbooks and has contributed extensively to the industrial press, He is currently working for the United States Agency for International Development in Eastern Ukraine, where he is managing the Industrial Waste Manage- ment Project. Dr. Cheremisinoff received his B.S., M.S., and Ph.D. degrees from Clarkson College of Technology. V NOTICE To the best of our knowledge the information in this pub- lication is accurate; however, the Publisher does not assume any responsibility or liability for the accuracy or completeness of, or consequences arising from, such information. This book is intended for informational purposes only. Mention of trade names or commercial products does not constitute endorsement or recommendation for use by the Publisher. Final determ- ination of the suitability of any information or product for use contemplated by any user, and the manner of that use, is the sole responsibility of the user. We recommend that anyone in- tending to rely on any recommendation of materials or pro- cedures mentioned in this publication should satisfy himself as to such suitability, and that he can meet all applicable safety and health standards. viii The chemical and allied industries employ a multitude of unit operations in product manufacturing. Both chemicals and physical mechanisms are employed in these operations, ranging from simple bulk handling and preparation of chemical feedstocks to complex chemical reactions in the presence of heat and or mass transfer. These operations require application of scientific and engineering principles to ensure efficient, safe and economical process operations. To meet these objectives, process equipment must perform intended functions under actual operating conditions and do so in a continuous and reliable manner. Equipment must have the characteristics of mechanical reliability, which includes strength, rigidity, durability and tightness. In addition, it must be designed at an optimized ratio of capital investment to service life. This book is designed as a handy desk reference covering fundamental engineering principles of project planning schemes and layout, corrosion principles and materials properties of engineering importance. It is intended as a general source of typical materials property data, useful for first pass materials selection in process design problems. This book is based upon seminars given by the author during the 1980s. With the recent addition of material relating to elastomers and plastics, this book has been brought up-to-date. Nicholas P. Cheremisinoff vii LIST OF FIGURES 1.1 1.2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3.1 3.2 3.3 3.4 3.5 3.6 3.7 Simplified flow diagram of activities in planning and 4 Allowable stress for different materials 11 Comparison of corrosion rates of zinc and steel in various parts of the world 37 Examples of poor and proper connections of dissimilar metals 39 Example of a corrosion-resistant steel insert used in an aluminum casting 40 Encapsulation of exposed metal connections 40 Gasket insertion between pipe flanges for sealing purposes and to minimize galvanic corrosion between dissimilar piping metals 41 Examples of minimizing galvanic corrosion when piping penetrates partitions and bulkheads 43 Poor and good designs for heat exchanger inlets 45 Poor and good designs for vessel drainage 45 Liquid-level gauge for an ammonia tank 54 Effect of temperature on corrosion rates of steels in crude oil containing sulfur 66 Operating limits for steels in atmospheres containing hydrogen 66 Effect of temperature on the tensile strength of copper: (A) effect of annealing on strength and ductility; (B) hardened high conductivity copper 80 Effect of sulfuric acid on aluminum 92 Effect of nitric acid on stainless steel and aluminum 92 implementing process and plant design projects Typical glass sight gauges 53 Xlll LIST OF TABLES 1.1 1.2 1.3 1.4 1.5 2.1 2.2 2.3 2.4 2.5 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 Major items in operating guidelines planning 5 Common equipment symbols and letter codes 7 Typical instrument codes and examples 9 mange ratings for different materials 10 Typical flange pressure-temperature data 11 Parameters to analyze in materials selection 22 Fabrication parameters to analyze in materials selection 24 General properties of the corrosion resistance of metals to various chemicals 27 General properties of the corrosion resistance of nonmetals to various chemicals 31 Corrosion rates of steel and zinc panels exposed for two years 35 Typical mechanical properties of various types of cast iron 55 Typical data showing the effect of strength on gray iron castings 563 Properties of white iron 56 58 Properties of flake graphite-grade cast irons 58 Maximum working stresses for various grades of cast iron up to 600OC 61 Properties of spheroidal graphite-grade cast irons Rods and electrodes for fusion-welding cast iron 61 Applications of low-carbon, low-alloy steels 64 Comparison of mild and low-alloy quenched and tempered steels 65 Alloying effects that improve creep properties 67 AISI classifications of wrought stainless and heat-resisting steels (based on AISI type numbers) 69 xiv List of Tables xv 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23 3.24 3.25 3.26 3.27 3.28 3.29 3.30 3.31 3.32 3.33 3.34 3.35 3.36 3.37 3.39 3.40 3.41 3.42 3.43 3.44 3.45 3.46 3.47 3.48 3.49 3.50 B.l Examples of precipitation hardening stainless steels 72 Various grades of copper 78 Mechanical properties vs temperature for copper 79 Mechanical properties vs low temperature for copper 79 Compositions of ferrite/austenite stainless steels 72 Classification used for copper alloys in the U.S. 77 Properties of common brasses 82 Properties of tin bronzes and gunmetals 82 Mechanical properties of annealed cupro-nickel alloys 83 Standard U.S. leads 84 Mechanical properties of sheet lead 84 Mechanical properties of annealed lead vs temperature 84 Maximum stresses in pipe wall of lead alloys 85 Fatigue-strength data of lead alloys 85 Mechanical properties of aluminum 87 Mechanical properties of aluminum annealed at 37OOC 87 Tensile and compression allowable stresses for mild aluminum (annealed) vs metal operating temperature 87 Effect of purity on the properties of aluminum 88 Typical properties of fully annealed nonheat-treatable aluminum alloys 89 Effect of heat treatment on heat-treatable aluminum alloys 89 Various aluminum casting alloys 91 Aluminum alloys recommended for cryogenic applications 91 Properties of titanium. tantalum and zirconium 93 Mechanical properties of titanium and alloys 94 Effect of elevated temperatures on strength of titanium and alloys 95 Comparative corrosion resistance of tantalum and platinum 97 Properties of carbon and graphite 101 Chemical resistance of bedding and jointing cements 103 General properties and uses of thermoplastic materials 105 Mechanical properties of thermoplastics 111 Hydrostatic design pressures for thermoplastic pipe for temperatures up to 130°C 112 Effect of density on polyethylene polymers 112 Effects of degree of crystallinity and molecular weight 113 Properties of different nylons 116 Properties of different engineering plastics 117 Various properties of fiberglass resins 119 Various filler materials and their property contributions to plastics 121 Chemical resistance of epoxy resin coatings 124 Properties of important plastics and elastomers 162 mi List of Tables B.2 B.3 B.4 B.5 B.6 B.7 B.8 B.9 B.10 B.ll B.12 B.13 B.14 B.15 B.16 B.17 B.18 Terminology and properties of important elastomers 166 Synthesis and features of hydrogenated diene-diene copolymers 168 Synthesis and features of hydrogenated aromatic-diene Hydrogenation of functional diene polymers 170 Properties of liquid polysulfide polymers 171 Properties of arc0 ply bd R-45 HT urethane composition 172 Properties of Cll3N-expoxy resin compositions 173 Properties of unfilled thermoplastic compositions 174 True stress at break of selected melt-mixed rubber- Properties of various types of elastomer compositions 175 Nonextended polymers with unsaturated center block 176 Some commercial macroglycols that have been used to make TPU elastomers 177 TPU product comparison chart 178 Physical properties of 1. 2-polybutadiene 180 Chemical and oil resistance of silicone rubber 183 Summary of solid EP and EPDM worldwide products 184 copolymers 169 plastic blends 175 Applications and features of 1, 2-polybutadiene 181 CONTENTS AND SUBJECT INDEX 1 . OVERALL PROCESS SYSTEM DESIGN 1 1.1 Introduction 1 1.2 Planning Projects and Equipment Design 2 Equipment and Instrumentation Codes 6 1.4 Vessel Codes and Flange Ratings 10 References 12 13 2 . DESIGN AND CORROSION 13 2.1 Introduction 13 Types of Corrosion 13 23 Materials Evaluation and Selection 18 2.4 Design Guidelines 36 2.5 Glossary of Corrosion Terms 46 References 50 2.2 3 . PROPERTIES AND SELECTION OF MATERIALS 51 General Properties and Selection Criteria 51 Properties of Cast Irons 53 3.2.1 Gray Cast Iron 55 3.2.2 White Cast Iron 56 3.2.3 Malleable Cast Irons 56 3.2.4 Nodular Cast Iron 57 3.2.5 Austenitic Cast Iron 57 Application Requirements of Cast Irons 57 3.3.1 Abrasion Resistance 57 3.3.2 Corrosion Resistance 57 3.3.3 Temperature Resistance 60 3.1 3.2 33 ix [...]... Polyphenylene Oxide 3 .16 .17 Polysulfone Thermosetting Plastics 3 .17 .1 Phenolic Resins 3 .17 .2 Polyester Resins 3 .17 .3 Epoxy Resins 3 .17 .4 Furane Resins 3 .17 .5 Rubber Linings Organic Coatings and Paints Glossary of Fabrication and Plastics Terms Nomenclature References 11 6 11 6 11 7 11 7 11 8 11 8 11 8 11 8 11 9 11 9 12 0 12 0 12 1 12 3 12 3 14 1 14 1 APPENDIX A: GLOSSARY OF... 11 5 3 .16 .8 11 5 Fluorinated Plastics 3 .16 .9 Polyvinyl Fluoride (€'vF) 11 5 3 .16 .10 Acrylics 11 6 xii Contents and Subject Index 3 .17 3 .18 3 .19 3 .16 .11 Chlorinated Polyether 3 .16 .12 Nylon (Polyamide) 3 .16 .13 Miscellaneous Engineering Plastics 3 .16 .14 Acetal Resin 3 .16 .15 Polycarbonate 3 .16 .16 Polyphenylene... 3 .15 .2 Bricks and Tiles 10 2 Plastic and Thermoplastic Materials 10 4 3 .16 .1 Polyolefins 10 4 3 .16 .2 Polyvinyl Chloride (€'VC) 11 4 3 .16 .3 Rigid PVC (UPVC) 11 4 3 .16 .4 High-Impact PVC 11 4 3 .16 .5 Chlorinated PVC (CPVC) 11 4 3 .16 .6 11 5 Plastic PVC 3 .16 .7 Acrylonitrile-Butadiene-Styrene... 98 3 .13 .1 Electrodeposition 98 99 3 .13 .2 Dip Coating 3 .13 .3 Sprayed Coatings 99 3 .13 .4 Diffusion Coatings 99 Carbon, Graphite and Glass 10 0 3 .14 .1 Carbon and Graphite 10 0 10 1 3 .14 .2 Glass Cements, Bricks and Tls ie 10 2 3 .15 .1 Cements 10 2 3 .15 .2 Bricks... 83 86 3 .10 .1 Corrosion Resistance Aluminum and Aluminum Alloys 86 3 .11 .1 Aluminum Alloy Compositions 88 3 .11 .2 Aluminum of Commercial 99% Minimum Aluminum Purity 88 3 .11 .3 Nonheat-Treatable Magnesium and 88 Manganese Alloys 3 .11 .4 Heat-Treatable Alloys 89 3 .11 .5 Casting Alloys 90 90 3 .11 .6 Temperature Effects 3 .11 .7 Corrosion... Heat-Resistant Nickel Alloys 76 3.8 .1 NickeVChromium 76 3.8.2 Nickel/Chromium/Iron 76 Copper and Copper Alloys 77 3.9 .1 Brasses 79 3.9.2 Tin Bronzes 81 Aluminum and Manganese Bronzes 81 3.9.3 3.9.4 Silicon Bronzes 81 3.9.5 Cupro-Nickels 83 Contents and Subject Index 3 .10 3 .11 3 .12 3 .13 3 .14 3 .15 3 .16 xi 83 3.9.6 Corrosion Resistance... Low-Temperature Ductility 67 3.4 .11 High-Carbon Low-Alloy Steels 67 Properties of High-Alloy Steels 67 3.5 .1 Chromium Steels (400 Series), Low-Carbon Ferritic (Type 405): 12 -13 % Chromium 68 3.5.2 Medium Carbon Martensitic: 13 -17 % Chromium (Types 403 410 , 414 416 420 4 31 440) 68 3.5.3 Medium Carbon Ferritic: 17 -30% Chromium (Types 430 and 446) 68 3.5.4... 90 3 .11 .8 OrganicAcids 91 Miscellaneous Precious Metals 93 3 .12 .1 Titanium 94 3 .12 .2 Tantalum 95 3 .12 .3 Zirconium 96 3 .12 .4 Precious Metals 97 3 .12 .5 Silver 97 3 .12 .6 Gold 98 3 .12 .7 Platinum ... 14 1 APPENDIX A: GLOSSARY OF PLASTICS AND ENGINEERING TERMS 14 5 APPENDIX B: GENERAL PROPERTIES AND DATA ON ELAfXOMERS AND PLASTICS 16 1 1 OVERALL PROCESS SYSTEM DESIGN 1. 1 INTRODUCTION The chemical process industries (CPI), petroleum and allied industries apply physical as well as chemical methods to the conversion of raw feedstock materials into salable products Because of the diversity of products,... during operation and test before permanent installation; continuous operation and steady-state processing of materials without excessive noise, vibration or upset conditions; a minimum of personnel for its operation; and, finally, safe operation Low maintenance often 1 2 Materials Selection Deskbook is associated with more complex designs as well as cost Automation of production is the most complete . 11 7 3 .16 .14 Acetal Resin 11 7 3 .16 .15 Polycarbonate 11 8 3 .16 .16 Polyphenylene Oxide 11 8 3 .16 .17 Polysulfone 11 8 3 .17 Thermosetting Plastics 11 8 3 .17 .1 Phenolic Resins 11 9. 11 5 3 .16 .9 Polyvinyl Fluoride (€'vF) 11 5 3 .16 .10 Acrylics 11 6 xii Contents and Subject Index 3 .16 .11 Chlorinated Polyether 11 6 3 .16 .12 Nylon (Polyamide) 11 6 3 .16 .13 Miscellaneous. 10 0 3 .16 .3 Rigid PVC (UPVC) 11 4 3 .16 .4 High-Impact PVC 11 4 3 .16 .6 Plastic PVC 11 5 3 .16 .7 Acrylonitrile-Butadiene-Styrene (ABS) 11 5 3 .16 .8 Fluorinated Plastics 11 5