1. Discovery is dangerous….but so is life. A man unwilling to take risks is doomed never to learn, never to grow, never to live - Pardot Kynes Discovery is dangerous….but so is life. A man unwilling to take risks is doomed never to learn, never to grow, never to live - Pardot Kynes

2. What I learnt in school today: How to pronounce "molybdenum" mo lib den um

3. What I learnt in school today: How to pronounce "molybdenum" mo lib den um

4. What I learnt in school today: How to pronounce "molybdenum" mo lib den um

5. What I learnt in school today: How to pronounce "molybdenum" mo lib den um

6. Is this your design?

7. Looks like a materials problem What kind of steel? Does it matter? What kind of steel? Does it matter? What is the material? Some kind of steel? Steel? Steel = iron + carbon

8. Types of steels 100510061008100910101012101510161017 101810191020102110221023102510261030 103410351038103910401044104410451046 105010601064106510701074108010901095 110811161117111811191132113711411144 1211 12121213121515471548314040121330 13351340134540234027402840324037 40424047411841304140414241454147 41504161441943204340442244274615 46204626471847204815481748205046 5060512051305132. Types of steels 100510061008100910101012101510161017 101810191020102110221023102510261030 103410351038103910401044104410451046 105010601064106510701074108010901095 110811161117111811191132113711411144 1211 12121213121515471548314040121330 13351340134540234027402840324037 40424047411841304140414241454147 41504161441943204340442244274615 46204626471847204815481748205046 5060512051305132.

9. Types of steels 100510061008100910101012101510161017 101810191020102110221023102510261030 103410351038103910401044104410451046 105010601064106510701074108010901095 110811161117111811191132113711411144 1211 12121213121515471548314040121330 13351340134540234027402840324037 40424047411841304140414241454147 41504161441943204340442244274615 46204626471847204815481748205046 5060512051305132 AISI-SAE numbering system for steels XX Types of steels 100510061008100910101012101510161017 101810191020102110221023102510261030 103410351038103910401044104410451046 105010601064106510701074108010901095 110811161117111811191132113711411144 1211 12121213121515471548314040121330 13351340134540234027402840324037 40424047411841304140414241454147 41504161441943204340442244274615 46204626471847204815481748205046 5060512051305132 AISI-SAE numbering system for steels XX wt % carbon x 100 alloy element contents

10. Types of steels 100510061008100910101012101510161017 101810191020102110221023102510261030 103410351038103910401044104410451046 105010601064106510701074108010901095 110811161117111811191132113711411144 1211 12121213121515471548314040121330 13351340134540234027402840324037 40424047411841304140414241454147 41504161441943204340442244274615 46204626471847204815481748205046 5060512051305132 AISI-SAE numbering system for steels XX Types of steels 100510061008100910101012101510161017 101810191020102110221023102510261030 103410351038103910401044104410451046 105010601064106510701074108010901095 110811161117111811191132113711411144 1211 12121213121515471548314040121330 13351340134540234027402840324037 40424047411841304140414241454147 41504161441943204340442244274615 46204626471847204815481748205046 5060512051305132 AISI-SAE numbering system for steels XX alloy element contents wt % carbon x 100

11. So, does it matter? Consider the properties of some steels - all hot-rolled & normalized Consider the properties of some steels - all hot-rolled & normalized Type Tensile strength 1020 64.0 ksi 1030 75.5 ksi 1040 85.5 ksi 1050 108.5 ksi 1060 112.5 ksi 1080 146.5 ksi Type Tensile strength 1020 64.0 ksi 1030 75.5 ksi 1040 85.5 ksi 1050 108.5 ksi 1060 112.5 ksi 1080 146.5 ksi

12. So, does it matter? Consider the properties of some steels - all hot-rolled & normalized Consider the properties of some steels - all hot-rolled & normalized Type Tensile strength 1020 64.0 ksi 1030 75.5 ksi 1040 85.5 ksi 1050 108.5 ksi 1060 112.5 ksi 1080 146.5 ksi Type Tensile strength 1020 64.0 ksi 1030 75.5 ksi 1040 85.5 ksi 1050 108.5 ksi 1060 112.5 ksi 1080 146.5 ksi

13. Apparently, changing carbon content changes mech props significantly Apparently, changing carbon content changes mech props significantly Is changing carbon content only way to change mech props? Is changing carbon content only way to change mech props? SteelTensile strength 1040 hot rolled and normalized 86 ksi 1040 quenched and tempered at 400 F130 ksi 8640 quenched and tempered at 400 F270 ksi (8640: Fe - 0.5%Cr - 0.5%Ni - 0.2%Mo - 0.4%C) SteelTensile strength 1040 hot rolled and normalized 86 ksi 1040 quenched and tempered at 400 F130 ksi 8640 quenched and tempered at 400 F270 ksi (8640: Fe - 0.5%Cr - 0.5%Ni - 0.2%Mo - 0.4%C)

14. Apparently, changing carbon content changes mech props significantly Apparently, changing carbon content changes mech props significantly SteelTensile strength 1040 hot rolled and normalized 86 ksi 1040 quenched and tempered at 400 F130 ksi 8640 quenched and tempered at 400 F270 ksi (8640: Fe - 0.5%Cr - 0.5%Ni - 0.2%Mo - 0.4%C) SteelTensile strength 1040 hot rolled and normalized 86 ksi 1040 quenched and tempered at 400 F130 ksi 8640 quenched and tempered at 400 F270 ksi (8640: Fe - 0.5%Cr - 0.5%Ni - 0.2%Mo - 0.4%C) mechanical work heat treatment add alloying elements

15. What do these things do in steels? change C content mechanical work heat treat alloying elements change C content mechanical work heat treat alloying elements Changing structure changes properties change “structure”

16. What about Al alloys? Lotus Elise 190 hp 1984 lbs 0-60 mph - 4.9 sec top speed - 150 mph 27 mpg hiway $46K Lotus Elise 190 hp 1984 lbs 0-60 mph - 4.9 sec top speed - 150 mph 27 mpg hiway $46K

17. Lotus versatile vehicle architecture system (VVA) Al??? Almost completely "aluminum" - high pressure die-castings, stampings, and extrusions Advanced Materials & Processes, July 2005, p 29

18. 105011452014202422192618 30033004310540324043 5005 505250835154518252625652 601060616262646370057050 707270757175717874757229. 105011452014202422192618 30033004310540324043 5005 505250835154518252625652 601060616262646370057050 707270757175717874757229. OK…..which "aluminum" is it?

19. 105011452014202422192618 30033004310540324043 5005 505250835154518252625652 601060616262646370057050 707270757175717874757229 105011452014202422192618 30033004310540324043 5005 505250835154518252625652 601060616262646370057050 707270757175717874757229 OK…..which "aluminum" is it? Alloy designation NOT same as steels In fact, no carbon at all in ordinary Al alloys Does NOT contain 0.61% carbon

20. 105011452014202422192618 30033004310540324043 5005 505250835154518252625652 601060616262646370057050 707270757175717874757229 105011452014202422192618 30033004310540324043 5005 505250835154518252625652 601060616262646370057050 707270757175717874757229

21. Number Major alloy addition 1xxx - 2xxx Cu 3xxx Mn 4xxx Si 5xxx Mg 6xxx Mg & Si 7xxx Zn 8xxx other Number Major alloy addition 1xxx - 2xxx Cu 3xxx Mn 4xxx Si 5xxx Mg 6xxx Mg & Si 7xxx Zn 8xxx other Here’s the scoop -

22. Al alloy containing 4.4% Cu (say 2024) can be heat treated to strength level much higher than that of pure Al So, does alloying affect the properties? Yield strength Tensile strength Low-strength 30 ksi 60 ksi steel Pure aluminum 5 ksi 13 ksi Al alloy 2024-T4 47 ksi 68 ksi Yield strength Tensile strength Low-strength 30 ksi 60 ksi steel Pure aluminum 5 ksi 13 ksi Al alloy 2024-T4 47 ksi 68 ksi

23. Al alloy containing 4.4% Cu (say 2024) can be heat treated to strength level much higher than that of pure Al So, does alloying affect the properties? Yield strength Tensile strength Low-strength 30 ksi 60 ksi steel Pure aluminum 5 ksi 13 ksi Al alloy 2024-T4 47 ksi 68 ksi Yield strength Tensile strength Low-strength 30 ksi 60 ksi steel Pure aluminum 5 ksi 13 ksi Al alloy 2024-T4 47 ksi 68 ksi What’s this??

24. T4 designates a heat treatment (Al alloys only) "solution heat-treated, quenched, and naturally aged to a substantially stable condition" T4 designates a heat treatment (Al alloys only) "solution heat-treated, quenched, and naturally aged to a substantially stable condition"

25. Assignments for next class: 1. review today's classnotes; know steel and aluminum alloy designation schemes 2. check syllabus materials at: http://www.ems.psu.edu/~ryba/coursework/259/mat se%20259.html 3. Read: sects. 3.12, 4.3, 5.1 pps. 261-262 start chapter 6 Assignments for next class: 1. review today's classnotes; know steel and aluminum alloy designation schemes 2. check syllabus materials at: http://www.ems.psu.edu/~ryba/coursework/259/mat se%20259.html 3. Read: sects. 3.12, 4.3, 5.1 pps. 261-262 start chapter 6