McGraw-Hill Machining and Metalworking Handbook 3rd ed - R. Walsh_ D. Cormier (McGraw-Hill 2006) WW Part 12 potx

■ High ductility ■ Corrosion resistance 12.4.1 ASTM specifications for selected cast irons and cast steels ASTM A159-83 (R1988), Standard Specification for Automotive Gray Iron Castings. See Fig. 12.14 for mechanical properties. The grades of gray cast iron consist of the following: G1800: ferritic-pearlitic G2500: pearlitic-ferritic G3000: pearlitic G3500: pearlitic Castings, Moldings, Extrusions, and Powder-Metal Technology 769 Figure 12.10 Properties of cast stainless steels. Walsh CH12 8/30/05 10:35 PM Page 769 Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright © 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website. Castings, Moldings, Extrusions, and Powder-Metal Technology G4000: pearlitic Figure 12.15 lists the typical applications for the automotive gray cast irons. ASTM A 148/A 148M-89a, Standard Specification for Steel Cast- ings, High Strength, for Structural Applications. Figure 12.16 lists the tensile strength properties. ASTM A 297/A 297M-89, Standard Specification for Steel Cast- ings, Iron-Chromium, Iron-Chromium-Nickel, Heat Resistant, for General Applications. Figure 12.17 lists the physical properties. 770 Chapter Twelve Figure 12.11 Aluminum casting alloys. Walsh CH12 8/30/05 10:35 PM Page 770 Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright © 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website. Castings, Moldings, Extrusions, and Powder-Metal Technology ASTM A 352/A 352M-89, Standard Specification for Steel Cast- ings, Ferritic and Martensitic, for Pressure Containing Parts, Suitable for Low-Temperature Service. Table 12.1 lists the chem- ical, tensile, and impact properties. ASTM A 436-84, Standard Specification for Austenitic Gray Iron Castings. Figure 12.18 lists the chemical and mechanical require- ments. ASTM A 439-83, Standard Specification for Austenitic Ductile Iron Castings. Figure 12.19 lists the chemical and mechanical properties. ASTM A 487/A 487M-89a, Standard Specification for Steel Cast- ings Suitable for Pressure Service. Tables 12.2 and 12.3 list the heat-treatment and mechanical requirements. ASTM A 743/743M-89, Standard Specification for Castings, Iron- Chromium, Iron-Chromium-Nickel, Corrosion Resistant, for Gen- eral Applications. Tables 12.4 and 12.5 list the heat-treatment and mechanical requirements. Castings, Moldings, Extrusions, and Powder-Metal Technology 771 Figure 12.12 Magnesium casting alloys. Walsh CH12 8/30/05 10:35 PM Page 771 Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright © 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website. Castings, Moldings, Extrusions, and Powder-Metal Technology Brinell hardness measurements for castings and other applications. Calculation of the Brinell hardness number (BHN) can be performed using the equation shown in Sec. 4.8 of this Handbook. Table 12.6 is a table of Brinell hardness numbers as determined by the diameter of the indentation of a 10-mm ball at applied loads of 500, 1500, and 772 Chapter Twelve Figure 12.13 CDA designations and properties of cast copper alloys. Walsh CH12 8/30/05 10:35 PM Page 772 Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright © 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website. Castings, Moldings, Extrusions, and Powder-Metal Technology 3000 kgf (kilogram-force). The table may be used for determining the hardness of most metals and alloys. 12.5 Plastic Moldings There are two classifications of plastics and their moldings: ther- moplastics and thermoset plastics. Thermoplastics are basically the same chemically after molding as they were in the raw form. This means that once molded, they may be reused, in most cases, by chopping the parts into small pieces and remelting. Thermoset Castings, Moldings, Extrusions, and Powder-Metal Technology 773 Figure 12.13 (Continued) Walsh CH12 8/30/05 10:35 PM Page 773 Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright © 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website. Castings, Moldings, Extrusions, and Powder-Metal Technology Figure 12.14 Mechanical properties of gray-iron castings. (Reprinted with permission from the Annual Book of ASTM Standards, copyright 1992, American Society for Testing and Materials.) 774 Walsh CH12 8/30/05 10:35 PM Page 774 Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright © 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website. Castings, Moldings, Extrusions, and Powder-Metal Technology plastics, once molded, cannot be remolded or reprocessed because they have a one-way chemistry that alters their “as molded” char- acteristics from their raw constituents. Types of thermoplastics include ■ ABS (acrylonitrile-butadiene-styrene) ■ Acetal (Delrin) ■ Acrylic (Lucite, Plexiglas) ■ Cellulosics (acetates) ■ Fluoroplastics (PTFE, FEP, PFA, CTFE, ETFE, PVDF) ■ Nylon ■ Phenylene oxide ■ Polycarbonate (Lexan) ■ Polyester (Mylar) ■ Polyethylene ■ Polyimide ■ Polyphenylene sulfide ■ Polypropylene ■ Polystyrene Castings, Moldings, Extrusions, and Powder-Metal Technology 775 Figure 12.15 Typical applications of gray iron for automotive castings. (Reprinted with permission from the Annual Book of ASTM Standards, copyright 1992, American Society for Testing and Materials.) Walsh CH12 8/30/05 10:35 PM Page 775 Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright © 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website. Castings, Moldings, Extrusions, and Powder-Metal Technology Figure 12.16 Tensile-strength properties of steel castings. (Reprinted with permission from the Annual Book of ASTM Standards, copyright 1992, American Society for Testing and Materials.) 776 Walsh CH12 8/30/05 10:35 PM Page 776 Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright © 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website. Castings, Moldings, Extrusions, and Powder-Metal Technology ■ Polysulfone ■ Polyurethane ■ Polyvinyl chloride Types of thermoset plastics include ■ Alkyd ■ Allyl (diallyl phthalate) ■ Amino (urea, melamine) ■ Epoxy (including cycloaliphatic) ■ Phenolic ■ Polyester ■ Polyurethane ■ Silicone Polyesters and polyurethanes include thermosets that are also thermoplastics. Thermoset grades usually are filled with reinforcing Castings, Moldings, Extrusions, and Powder-Metal Technology 777 Figure 12.17 Tensile strengths for steel, iron-chromium-nickel, and heat-resisting castings. (Reprinted with permission from the Annual Book of ASTM Standards, copyright 1992, American Soci- ety for Testing and Materials.) (Text continued on page 793.) Walsh CH12 8/30/05 10:35 PM Page 777 Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright © 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website. Castings, Moldings, Extrusions, and Powder-Metal Technology TABLE 12.1 Chemical, Tensile, and Impact Requirements 12 1 ⁄2% Nickel- chromium, Carbon- Carbon- 2 1 ⁄2% chromium- 3 1 ⁄2%4 1 ⁄2% 9% nickel- Carbon Carbon manganese molybdenum nickel molybdenum nickel nickel nickel molybdenum Grade steel steel steel steel steel steel steel steel steel steel Element, % (max, except where range is given) LCA LCB a LCC LC1 LC2 LC2-1 LC3 LC4 LC9 CA6NM Carbon 0.25 a 0.30 0.25 a 0.25 0.25 0.22 0.15 0.15 0.13 0.06 Silicon 0.60 0.60 0.60 0.60 0.60 0.50 0.60 0.60 0.45 1.00 Manganese 0.70 a 1.00 1.20 a 0.50–0.80 0.50–0.80 0.55–0.75 0.50–0.80 0.50–0.80 0.90 1.00 Phosphorus 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 Sulfur 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.03 Nickel 0.50 b 0.50 b 0.50 b — 2.00–3.00 2.50–3.50 3.00–4.00 4.00–5.00 8.50–10.0 3.5–4.5 Chromium 0.50 b 0.50 b 0.50 b — — 1.35–1.85 — — 0.50 11.5–14.0 Molybdenum 0.20 b 0.20 b 0.20 b 0.45–0.65 — 0.30–0.60 — — 0.20 0.4–1.0 Copper 0.30 b 0.30 b 0.30 b —————0.30— Vanadium 0.03 b 0.03 b 0.03 b —————0.03— Tensile Requirements: c Tensile strength, 60.0–85.0 65.0–90.0 70.0–95.0 65.0–90.0 70.0–95.0 105.0–130.0 70.0–95.0 70.0–95.0 85.0 110.0–135.0 ksi (MPa) (415–585) (450–620) (485–655) (450–620) (485–655) (725–895) (485–655) (485–655) (585) (760–930) Yield strength, d 30.0 (205) 35.0 (240) 40.0 (275) 35.0 (240) 40.0 (275) 80.0 (550) 40.0 (275) 40.0 (275) 75.0 (515) 80.0 (550) min, ksi (MPa) Elongation in 2 in 24 24 22 24 24 18 24 24 20 15 or 50 mm, min, % e Reduction of area, 35 35 35 35 35 30 35 35 30 35 min, % 778 Walsh CH12 8/30/05 10:35 PM Page 778 Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright © 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website. Castings, Moldings, Extrusions, and Powder-Metal Technology [...]... Moldings, Extrusions, and Powder-Metal Technology 785 Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright © 2004 The McGraw-Hill Companies All rights reserved Any use is subject to the Terms of Use as given at the website CA-15 and CA-15M CE-30 CF-16 and CF-16Fa CH-20 and CH-10 CK-20 CF-8C CF-8M CF-20 CG -1 2 19 Chromium, 9 Nickel 22 Chromium, 12 Nickel 19... 6.62 6.63 6.64 6.65 6.66 6.67 6.68 6.69 6.70 6.71 6.72 6.73 6.74 6.75 6.76 6.77 6.78 6.79 6.80 6.81 6.82 6.83 6.84 6.86 6.86 13.1 13.1 13.0 13.0 12. 9 12. 9 12. 8 12. 8 12. 8 12. 7 12. 7 12. 6 12. 6 12. 5 12. 5 12. 4 12. 4 12. 4 12. 3 12. 3 12. 2 12. 2 12. 1 12. 1 12. 1 12. 0 12. 0 11.9 11.9 11.8 11.8 11.8 11.7 11.7 39.4 39.2 39.1 38.9 38.8 38.7 38.5 38.4 38.3 38.1 38.0 37.9 37.7 37.6 37.5 37.3 37.2 37.1 36.9 36.8 36.7 36.6... 59.8 59.6 59.3 59.1 58.9 58.6 58.4 58.2 57.9 57.7 57.5 57.2 57.0 56.8 56.6 129 129 128 128 127 127 126 126 125 125 124 124 123 123 122 122 121 121 120 120 119 119 118 118 117 117 116 116 115 115 114 114 114 113 5.88 5.89 5.90 5.91 5.92 5.93 5.94 5.95 5.96 5.97 5.98 5.99 6.00 6.01 6.02 6.03 6.04 6.05 6.06 6.07 6.08 6.09 6.10 6.11 6 .12 6.13 6.14 6.15 6.16 6.17 6.18 6.19 6.20 6.21 16.7 16.6 16.5 16.5 16.4... Castings, Moldings, Extrusions, and Powder-Metal Technology Figure 12. 25 Samples of powder-metal parts Figure 12. 26 Close-up view of powder-metal parts Note scale Figure 12. 27 Typical properties of powder-metal parts Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright © 2004 The McGraw-Hill Companies All rights reserved Any use is subject to the Terms... Society of Testing and Materials CA-6NM CD-4MCu CA-6N CA-28MWV‡ CK-3MCuN CN-7MS CN-3M CN-7M CG6MMN CG-8M CF-3MN 690 690 485 585 100 100 70 85 30 — 15 16 15 10 35 35 30 35 30 25 35 30 15 12 35 30 — — 50 24 — 35 — — — — — — — 25 — — — — — 10:35 PM 20 Chromium, 29 Nickel, with copper and molybdenum 19 Chromium, 24 Nickel, with copper and molybdenum 12 Chromium, 4 nickel CA-40 CA-40F CF-3 CF10SMnN 450 380... powder-metal part manufacturer is consulted during the design stages The part manufacturer will advise you if the part can be produced as designed and what remedial Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright © 2004 The McGraw-Hill Companies All rights reserved Any use is subject to the Terms of Use as given at the website Walsh CH12 8/30/05... Reprinted with permission from the Annual Book of ASTM Standards, copyright 1992, American Society of Testing and Materials CK-3MCuN CA-28MWV CF10SMnN CA-6N CD-4MCu CA-6NM CN-7MS CN-7M, CG-6MMN 10:35 PM CN-3M CF-3, CF-3M, CF-3MN CB-30, CC-50 8/30/05 CA-15, CA-15M, CA-40, CA-40F Heat to 1900°F (1040°C) minimum, hold for sufficient time to heat casting to temperature, quench in water or rapid cool by... 400 CA-15, CA-15M CA-40, CA-28MWV Others Minimum preheat temperatures Minimum preheat temperatures Grade Preheat and Tensile Requirements 8/30/05 Grade TABLE 12. 5 Walsh CH12 Page 786 Castings, Moldings, Extrusions, and Powder-Metal Technology 786 Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright © 2004 The McGraw-Hill Companies All rights reserved... Fig 12. 26 is equal to 0.020 in (1/50 inch) One of the parts shown in Fig 12. 26 had secondary machining operations performed on it (threading) All the parts shown in both figures are easy and economical to produce using powder-metal technology Design of powder-metal parts The design and manufacturing of powder-metal parts are not difficult if the basic rules of powder-metal part design are followed and. .. indentation, mm Brinell hardness number 500-kgf load Brinell Hardness Numbers* (Continued ) 1500-kgf load TABLE 12. 6 3000-kgf load Walsh CH12 Page 792 Castings, Moldings, Extrusions, and Powder-Metal Technology 792 Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright © 2004 The McGraw-Hill Companies All rights reserved Any use is subject to the Terms of . Extrusions, and Powder-Metal Technology 773 Figure 12. 13 (Continued) Walsh CH12 8/30/05 10:35 PM Page 773 Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright. Materials.) 774 Walsh CH12 8/30/05 10:35 PM Page 774 Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright © 2004 The McGraw-Hill Companies. All rights reserved. Any. of ASTM Standards, copyright 1992, American Society for Testing and Materials.) Walsh CH12 8/30/05 10:35 PM Page 775 Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright