Materials selection deskbook (1996)

MATERIALS SELECTION DESKBOOK by Nicholas P Cheremisinoff, Ph.D NOYES PUBLICATIONS Westwood, New Jersey, U.S.A Copyright 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 information storage and retrieval system, without permission in writing from the Publisher Library of Congress Catalog Card Number: 96-10911 ISBN 0-8155-1400-X Printed in the United States Published in the United States of America by Noyes Publications 369 Fairview Avenue Westwood, New Jersey 07675 10 hirary of Congress Cataloging-in-Publication Data Cheremisinoff, Nicholas P Materials selection deskbook I by Nicholas P Cheremisinoff an p Includes bibliographical references ISBN 0-8155-1400-X Materials Handbooks, manuals, etc I Title 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 environmental 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 Management 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 publication 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 determination 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 intending to rely on any recommendation of materials or procedures 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 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 CONTENTS AND SUBJECT INDEX OVERALL PROCESS SYSTEM DESIGN 1.1 Introduction 1.2 Planning Projects and Equipment Design 13 Equipment and Instrumentation Codes 1.4 Vessel Codes and Flange Ratings 10 References DESIGN AND CORROSION 2.1 Introduction 2.2 Types of Corrosion 23 Materials Evaluation and Selection 2.4 Design Guidelines 2.5 Glossary of Corrosion Terms References PROPERTIES AND SELECTION OF MATERIALS General Properties and Selection Criteria 3.1 Properties of Cast Irons 3.2 3.2.1 Gray Cast Iron 3.2.2 White Cast Iron 3.2.3 Malleable Cast Irons Nodular Cast Iron 3.2.5 Austenitic Cast Iron Application Requirements of Cast Irons 3.3.1 Abrasion Resistance 3.3.2 Corrosion Resistance 3.3.3 Temperature Resistance 3.2.4 33 ix 12 13 13 13 18 36 46 50 51 51 53 55 56 56 57 57 57 57 57 60 x Contents and Subject Index 3.4 3.5 3.6 3.7 3.8 3.9 3.3.4 Welding Cast Iron 60 Properties of Steels 61 3.4.1 Low Carbon Steels (Mild Steel) 62 63 3.4.2 Corrosion Resistance 63 3.4.3 Heat Resistance 3.4.4 Low Temperatures 63 63 3.4.5 High-Carbon Steels 3.4.6 Low-Carbon Low-Alloy Steels 64 3.4.7 Mechanical Properties 64 3.4.8 Corrosion Resistance 64 3.4.9 Oxidation Resistance and Creep Strength 65 3.4.10 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, 414 416 420 431 440) 68 3.5.3 Medium Carbon Ferritic: 17-30% Chromium (Types 430 and 446) 68 3.5.4 Chromium/Nickel Austenitic Steels (300 Series) 68 3.5.5 Precipitation Hardening Stainless Steels 71 Chromium/NickeliFerrite/Austenite Steels 72 3.5.6 73 3.5.7 Maraging Steels Applications of High-Alloy Steels 73 74 3.6.1 Oxidation Resistance Mechanical Properties at Elevated Temperatures 74 3.6.2 3.6.3 Mechanical Properties at Low Temperatures 74 Corrosion-Resistant Nickel and Nickel Alloys 74 3.7.1 NickeVCopper (Alloy 400) 75 3.7.2 NickeVMolybdenum 75 3.7.3 Nickel/Molybdenum/Chromium 75 Nickel/Chromium/Molybdenum/Iron 75 3.7.4 3.7.5 NickeVChromium/Molybdenum/Copper 76 76 3.7.6 NickeVSilicon 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 Mechanical Properties of Lead and Lead Alloys 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 Resistance 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 98 Metallic Coatings 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 100 3.14.1 Carbon and Graphite 100 101 3.14.2 Glass Cements, Bricks and Tiles 102 3.15.1 Cements 102 3.15.2 Bricks and Tiles 102 Plastic and Thermoplastic Materials 104 3.16.1 Polyolefins 104 3.16.2 Polyvinyl Chloride (€'VC) 114 3.16.3 Rigid PVC (UPVC) 114 3.16.4 High-Impact PVC 114 3.16.5 Chlorinated PVC (CPVC) 114 3.16.6 115 Plastic PVC 3.16.7 Acrylonitrile-Butadiene-Styrene (ABS) 115 3.16.8 115 Fluorinated Plastics 3.16.9 Polyvinyl Fluoride (€'vF) 115 3.16.10 Acrylics 116 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 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 116 116 117 117 118 118 118 118 119 119 120 120 121 123 123 141 141 APPENDIX A: GLOSSARY OF PLASTICS AND ENGINEERING TERMS 145 APPENDIX B: GENERAL PROPERTIES AND DATA ON ELAfXOMERS AND PLASTICS 161 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, process conditions and requirements, equipment design is often unique, or case specific The prime requirement of any piece of equipment is that it performs the function for which it was designed under the intended process operating conditions, and so in a continuous and reliable manner Equipment must have mechanical reliability, which is characterized by strength, rigidness, steadiness, durability and tightness Any one or combination of these characteristics may be needed for a particular piece of equipment The cost of equipment determines the capital investment for a process operation However, there is no direct relationship to profits That is, more expensive equipment may mean better quality, more durability and, hence, longer service and maintenance factors These characteristics can produce higher operating efficiencies, fewer consumption coefficients and operational expenses and, thus, fewer net production costs The net cost of production characterizes the perfection rate of the total technological process and reflects the influences of design indices Therefore, it is possible to compare different pieces of equipment when they are used in the manufacture of these same products The desirable operating characteristics of equipment include simplicity, convenience and low cost of maintenance; simplicity, convenience and low cost of assembly and disassembly; convenience in replacing worn or damaged components; ability to control 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 150 L 150 a0 a d OD v) Appendix B: General Properties and Data on Elastomers and Plastics v) "C h p! V " c- m m (0 Q w a z 181 82 L D 'E: i; W E '00 L W D 182 Materials Selection Deskbook I- o D D m w, E m a e d -0 m -u Appendix B: General Properties and Data on Elastomers and Plastics 183 Table B17 Chemical and Oil Resistance of Silicone Rubber Percent volume change Chemical or medium Acid (7 days, 24°C) 10% Hydrochloric Hydrochloride 10% Sulfuric 10%Nitric Alkali (7 days, 24°C) 10%Sodium hydroxide 50% Sodium hydroxide Solvent (24 hr, 24°C) Acetone Ethyl alcohol Xylene JP4 fuel Butyl acetate Oils ASTM No (7 days, 149°C) Turbo oil 15 (Mil M7808) (1 day, 177°C) Dimethyl siloxane, 500 CS (14 days, 205°C) Fluorosilicone rubber (FVMQ) +I +8 Nil +1 Silicone rubber (VMQ) +2 + 15 +S +8 Nil +1 Nil +9 + 180 + 15 +5 +20 + 10 Over 150 +9 Over 150 Over 150 Over 150 +6 +8 Nil +20 +50 30 Swells, deteriorates 184 Materials Selection Deskbook Appendix B: General Properties and Data on Elastomers and Plastics 185 I I I I I Z I I I I I I ISZIZZI I S Z I Z I I I 186 Materials Selection Deskbook Appendix B: General Properties and Data on Elastomers and Plastics a crl b -A a 187 188 Y er d I88 mmmmm I I I I I I I181 I I I I 8 M Materials Selection Deskbook = 8- &?= =c O c a a -f b Q L e! a u Y C a 5! Appendix B: General Properties and Data on Elastomers and Plastics b 189 190 Materials Selection Deskbook Appendix B: General Properties and Data on Elastomers and Plastics LIST OF FIGURES 1.1 Simplified flow diagram of activities in planning and implementing process and plant design projects 11 1.2 Allowable stress for different materials 2.1 Comparison of corrosion rates of zinc and steel in various parts of the world 37 2.2 Examples of poor and proper connections of dissimilar metals 39 2.3 Example of a corrosion-resistant steel insert used in an aluminum casting 40 2.4 Encapsulation of exposed metal connections 40 2.5 Gasket insertion between pipe flanges for sealing purposes and to minimize galvanic corrosion between dissimilar piping metals 41 2.6 Examples of minimizing galvanic corrosion when piping penetrates partitions and bulkheads 43 2.7 Poor and good designs for heat exchanger inlets 45 2.8 Poor and good designs for vessel drainage 45 3.1 Typical glass sight gauges 53 3.2 Liquid-level gauge for an ammonia tank 54 3.3 Effect of temperature on corrosion rates of steels in crude oil containing sulfur 66 3.4 Operating limits for steels in atmospheres containing hydrogen 66 3.5 Effect of temperature on the tensile strength of copper: (A) effect of annealing on strength and ductility; 80 (B) hardened high conductivity copper 3.6 Effect of sulfuric acid on aluminum 92 3.7 Effect of nitric acid on stainless steel and aluminum 92 Xlll LIST OF TABLES Major items in operating guidelines planning Common equipment symbols and letter codes Typical instrument codes and examples 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 2.4 General properties of the corrosion resistance of nonmetals to 31 various chemicals 2.5 Corrosion rates of steel and zinc panels exposed for two years 35 3.1 Typical mechanical properties of various types of cast iron 55 3.2 Typical data showing the effect of strength on gray iron castings 563 3.3 Properties of white iron 56 3.4 Properties of spheroidal graphite-grade cast irons 58 3.5 Properties of flake graphite-grade cast irons 58 3.6 Maximum working stresses for various grades of cast iron up to 600OC 61 Rods and electrodes for fusion-welding cast iron 61 3.7 3.8 Applications of low-carbon, low-alloy steels 64 Comparison of mild and low-alloy quenched and tempered 3.9 steels 65 3.10 Alloying effects that improve creep properties 67 3.11 AISI classifications of wrought stainless and heat-resisting steels (based on AISI type numbers) 69 1.1 1.2 1.3 1.4 1.5 2.1 2.2 2.3 xiv List of Tables xv Examples of precipitation hardening stainless steels 72 Compositions of ferrite/austenite stainless steels 72 Classification used for copper alloys in the U.S 77 Various grades of copper 78 Mechanical properties vs temperature for copper 79 Mechanical properties vs low temperature for copper 79 82 Properties of common brasses Properties of tin bronzes and gunmetals 82 Mechanical properties of annealed cupro-nickel alloys 83 84 Standard U.S leads 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 3.29 Effect of purity on the properties of aluminum 88 3.30 Typical properties of fully annealed nonheat-treatable 89 aluminum alloys 3.31 Effect of heat treatment on heat-treatable aluminum alloys 89 91 3.32 Various aluminum casting alloys 3.33 Aluminum alloys recommended for cryogenic applications 91 3.34 Properties of titanium tantalum and zirconium 93 3.35 Mechanical properties of titanium and alloys 94 3.36 Effect of elevated temperatures on strength of titanium and alloys 95 3.37 Comparative corrosion resistance of tantalum and platinum 97 101 3.39 Properties of carbon and graphite 3.40 Chemical resistance of bedding and jointing cements 103 3.41 General properties and uses of thermoplastic materials 105 3.42 Mechanical properties of thermoplastics 111 3.43 Hydrostatic design pressures for thermoplastic pipe for 112 temperatures up to 130°C 3.44 Effect of density on polyethylene polymers 112 3.45 Effects of degree of crystallinity and molecular weight 113 3.46 Properties of different nylons 116 3.47 Properties of different engineering plastics 117 3.48 Various properties of fiberglass resins 119 3.49 Various filler materials and their property contributions to plastics 121 3.50 Chemical resistance of epoxy resin coatings 124 B.l Properties of important plastics and elastomers 162 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 mi List of Tables B.2 B.3 Terminology and properties of important elastomers 166 Synthesis and features of hydrogenated diene-diene copolymers 168 Synthesis and features of hydrogenated aromatic-diene copolymers 169 Hydrogenation of functional diene polymers 170 Properties of liquid polysulfide polymers 171 Properties of arc0 p l y 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 rubberplastic blends 175 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 Applications and features of 1,2-polybutadiene 181 Chemical and oil resistance of silicone rubber 183 Summary of solid EP and EPDM worldwide products 184 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 ... liniitations and tolerances [3] More specifically, these include: 22 Materials Selection Deskbook Table 2.1 Parameters to Analyze in Materials Selection Metals Nonmetals General Physical Characteristics... 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... Corrosion 23 Materials Evaluation and Selection 2.4 Design Guidelines 2.5 Glossary of Corrosion Terms References PROPERTIES AND SELECTION OF MATERIALS