McGraw-Hill Machining and Metalworking Handbook 3rd ed - R. Walsh_ D. Cormier (McGraw-Hill 2006) WW Part 4 docx

copper alloy UNS no.Approx- imate relative suitability for being worked* Resistance welding Cold Hot Best temperature for hot working, ⬚C Soldering Brazing Oxyacetylene welding Ca

copper alloy UNS no.

Approx- imate relative suitability for being worked*

Resistance welding

Cold Hot

Best temperature for hot working,

⬚C

Soldering Brazing Oxyacetylene welding Carbon arc welding Gas-shielded arc welding Coated-metal arc welding Spot Seam Butt

hinges, etc.), forged valve bodies.

copper alloy UNS no.

Approx- imate relative

suitability for being worked*

Resistance welding

Cold Hot

Best temperature for hot working,

⬚C

Soldering Brazing Oxyacetylene welding Carbon arc welding Gas-shielded arc welding Coated-metal arc welding Spot Seam Butt

copper alloy UNS no.

Approx- imate relative

suitability for being worked*

Resistance welding

Cold Hot

Best temperature for hot working,

⬚C

Soldering Brazing Oxyacetylene welding Carbon arc welding Gas-shielded arc welding Coated-metal arc welding Spot Seam Butt

forging and pressing, hot heading, and upsetting.

Resistance welding

Cold Hot

Best temperature for hot working,

⬚C

Soldering Brazing Oxyacetylene welding Carbon arc welding Gas-shielded arc welding Coated-metal arc welding Spot Seam Butt

range of nickel contents Higher the nickel, the more silver white the alloy

§ Consumable electrode excellent T

† Suffix symbols may be specified to distinguish between two or more sets of mechanical properties, heat treatment, conditions,

‡ All alloys listed are in the “as cast” condition except those designated as heat treated (HT) and copper alloy UNS No C95800

§ Most commonly used method of casting is shown for each alloy

¶ Mechanical properties shown for die castings are typical, not minimum.

Copper Alloy UNS No C24000

‡ Rockwell hardness values apply as follows: the B scale values apply to metal 0.020 in (0.508 mm) and over in

other tempers shall be agreed upon between the manufacturer and the purchaser at the time of placing the order

§ The thickness of material that may be tested by use of the Rockwell

a The chemical compositions associated with these numbers are listed in the product specifications and in the Standard

b The x in the table indicates commercial availability

c This includes types ETP

d This includes oxygen-free copper to which phosphorus and silver have been added in amounts agreed upon.

e This includes oxygen-free copper to which phosphorus has been added.

f This includes oxygen-free tellurium-bearing copper to which phosphorus has been added in amounts agreed upon.

* Noncurrent specifications.

American Society for Testing and Materials.

a As measured on metal solidified under normal casting conditions.

b Allowance for average castings Shrinkage requirements will vary with intricacy of

c Rating of 1 indicates best of group; 3 indicates poorest of group.

d Ability of liquid alloy to flow readily in mold and fill thin sections.

e Based on radiographic evidence.

f Composite rating based on ease of cutting, chip characteristics, quality of finish, and

h Ability of castings to be cleaned in standard pickle solutions and to be conditioned for

UNS ASTM and SAE

Pattern shrinkage allowance, in/ft (mm/m)

e

Normally heat treated Castability

n Properties applicable for permanent mold castings also.

p Properties applicable for investment castings also.

strength shall be rounded to the nearest 100 psi and each value for elongation shall be rounded to the nearest 0.5%, both in accordance with the rounding method of Recommended Practice E 29.

a Intermediate dimensions shall be rounded off to the third decimal place in accordance with Recommended Practice

242 Chapter Four

tetrachloride with magnesium Titanium is a lustrous, white metalwith low density and good strength The specific gravity of titanium

air and is the only element that burns in nitrogen gas

Titanium is used extensively in modern aircraft and aerospacevehicles, where a lightweight alloy with high strength finds manyapplications Titanium is the ninth most abundant element in theearth’s crust

Table 4.52 lists the tensile and bend requirements of titaniumalloys for annealed titanium plate, sheet, and strip, which are clas-sified as follows:

Grades 1 through 4: Unalloyed titanium

Grade 5: Titanium alloy (6 percent aluminum, 4 percent

Grade 11: Unalloyed titanium plus palladium

Grade 12: Titanium alloy (0.3 percent molybdenum, 0.8 percent

nickel)

Table 4.53 lists the mechanical properties of wrought titanium alloys

4.6 The Unified Numbering System (UNS) for

Metals and Alloys

The Unified Numbering System (UNS) provides a means of nating many nationally used numbering systems currently admin-istered by societies, trade associations, and the producers of metalsand alloys, thereby avoiding confusion caused by use of more thanone identification number for the same material or by having thesame number assigned to two or more entirely different materials.Table 4.54 shows the primary series of numbers, and Table 4.55lists the secondary division of some series of numbers When youknow the UNS number for a metal or alloy, you may use these

coordi-(Text continued on page 248.)

‡For grades 5 and 6 the elongation on materials under 0.025 in (0.635 mm) in thickness may be

§For grade 5, the elongation will be 8% minimum for thicknesses between 0.025 and 0.063 in

¶Elongation for continuous rolled and annealed (strip product from coil) for grade 9 shall be 12%

TABLE 4.53 Mechanical Properties of Wrought Titanium Alloys

Room temperature

Near Alpha Alloys

4 Zr

aAlso contains 0.2 Pd.

bAlso contains 0.8 Ni and 0.3 Mo.

TABLE 4.54 Primary Series of Numbers

Nonferrous Metals and AlloysA00001–A99999 Aluminum and aluminum alloys

C00001–C99999 Copper and copper alloys

E00001–E99999 Rare earth and rare earth-like metals and alloys

L00001–L99999 Low-melting metals and alloys

M00001–M99999 Miscellaneous nonferrous metals and alloys

N00001–N99999 Nickel and nickel alloys

P00001–P99999 Precious metals and alloys

R00001–R99999 Reactive and refractory metals and alloys

Z00001–Z99999 Zinc and zinc alloys

Ferrous Metals and AlloysD00001–D99999 Specified mechanical properties steels

F00001–F99999 Cast irons and cast steels

G00001–G99999 AISI and SAE carbon and alloy steels

H00001–H99999 AISI H-steels

J00001–J99999 Cast steels (except tool steels)

K00001–K99999 Miscellaneous steels and ferrous alloys

S00001–S99999 Heat and corrosion resistant (stainless) steels

T00001–T99999 Tool steels

Specialized Metals and AlloysW00001–W99999 Welding filler metals, covered and tubular electrodes,

classified by weld deposit composition

Stan-dards, copyright 1992, American Society for Testing and Materials.

246 Chapter Four

TABLE 4.55 Secondary Division of Some Series of Numbers

E00001–E99999 Rare Earth and Rare Earth–Like Metals and Alloys

Materials: Physical Properties, Characteristics, and Uses 247

W00001–W99999 Welding Filler Metals Classified

by Weld Deposit CompositionW00001–W09999 Carbon steel with no significant alloying elementsW10000–W19999 Manganese-molybdenum low-alloy steels

W20000–W29999 Nickel low-alloy steels

W30000–W39999 Austenitic stainless steels

W40000–W49999 Ferritic stainless steels

W50000–W59999 Chromium low-alloy steels

W60000–W69999 Copper-base alloys

W70000–W79999 Surfacing alloys

W80000–W89999 Nickel-base alloys

Z00001–Z99999 Zinc and Zinc Alloys

* Alloys in which the rare earths are used in the ratio of their natural rence (that is, unseparated rare earths) In this mixture, cerium is the mostabundant of the rare earth elements

Stan-dards, copyright 1992, American Society for Testing and Materials.

tables to determine the prime material (metal) or classification ofalloy represented by the UNS number.

4.7 Hardness Tests and Hardness Number

Conversions

The Brinell hardness system is one of the most widely used systemsfor indicating the hardness of metals and alloys The Brinell hardnessnumber of a material may be calculated from the following equation:

the material, mmThe standard ball is 10 mm in diameter, and standard loads are

500, 1500, and 3000 kg The test is not valid when the hardness of thetest material is above the anticipated Brinell hardness number of 630

The Vickers hardness is determined by forcing a square-base mond pyramid having an apex angle of 136° into the test specimenunder a load ranging from 3 to 50 kg and then measuring the diag-onals of the indentation created The Vickers hardness is defined

dia-as the load per unit area of surface contact in kilograms per squaremillimeter and may be calculated from the average diagonal usingthe following equation:

␣ ⫽ apex angle, 136°

L d

P D

π2

4.8 Plastics (Thermoplastics and

Thermoset Plastics)

Plastic materials are derived mainly from petroleum products Thetypes, trade names, and compositions of the various modern plas-tics form a long list, with more being developed as required to meetspecific design and application needs in industry

A thermoplastic is a plastic in which the finished molded part may be remelted for remolding A thermoset plastic is a plastic in

which the chemical reaction cannot be reversed, thus allowing thepart to be cast only once Thermoplastics are extruded, injection-molded, and cast in dies Thermoset plastics usually are compression-molded Some of the thermoplastics are also formulated for thermosetapplications, such as the urethanes Table 4.56 lists the commontrade names, suppliers, SAE symbols, and plastic “family” namesfor most plastics

more prevalent plastics and compositions

Epoxy, epoxy glass

Diallyl phthalate, Melamine

Mylar (polyester film)

(Text continued on page 263.)

Materials: Physical Properties, Characteristics, and Uses 263

(poly-Teflon (PTFE, polytetrafluoroethylene), urea-formaldehyde

Common plastics and typical uses

Acetal (Delrin, Celcon). Properties: High modulus of elasticity, low

coefficient of friction, excellent abrasion and impact resistance, low

moisture absorption, excellent machinability, ablative Typical uses:

Bearings, gears, antifriction parts, electrical components, washers,seals, insulators, and cams

Acetate (Cellulose). Properties: Odorless, tasteless, nontoxic, grease resistant, high impact strength Typical uses: Badges, blister packag-

ing, displays, optical covers, and book covers

Acrylic (Plexiglas, Lucite). Properties: Unusual optical clarity, high

tensile strength, weatherability, good electrical properties, ablative

Typical uses: Displays, signs, models, lenses, and electrical and

elec-tronic parts

Benelex (Laminate). Properties: High compressive strength,

machin-able, resists corrosion (alkalis or acids), good electrical insulation,

high flexural, shear, and tensile strength Typical uses: Work

sur-faces, electrical panels and switch gear, bus braces (low voltageonly), and neutron shielding

Diallyl phthalate, Melamine. Properties: High strength, chemical tant, low water absorption, medium-high temperature use Typical uses: Terminal blocks and strips, dishware, automotive applications,

resis-and aerospace applications

Epoxy glass. Properties: High strength, high-temperature

applica-tions, flame retardant, low coefficient of thermal expansion, low

water absorption Typical uses: High-quality printed circuit boards,

microwave stripline applications, VHF and UHF applications, trical insulation, and service in temperature range –400 to 500°F

elec-264 Chapter Four

Mylar (polyester film, polyethylene terephthalate). Properties: High dielectric

strength, chemical resistance, high mechanical strength, moistureresistant, temperature range 70 to 105°C, does not embrittle with age

Typical uses: Electrical and industrial applications and graphic arts

applications

Nylon Properties: Wear resistant, low friction, high tensilestrength, excellent impact resistance, high fatigue resistance, easy

machining, corrosion resistant, lightweight Typical uses: Bearings,

bushings, valve seats, washers, seals, cams, gears, guides, wheels,insulators, and wear parts

Phenol formaldehyde (Bakelite). Properties: Wear resistant, rigid,

mold-able to precise dimensions, strong, excellent electrical properties,

economical, will not support combustion Typical uses: Electrical and

electronic parts, handles, housings, insulator parts, mechanismparts, and parts that are to resist temperatures to 250°C

Phenolic laminates. Properties: Immune to common solvents, weight, strong, easily machined Typical uses: Bearings, machined

light-parts, insulation, gears, cams, sleeves, and electrical and electronicparts

Polycarbonate (Lexan). Properties: Virtually unbreakable, weather

resistant, optically clear, lightweight, self-extinguishing,

thermo-formable, machinable, solvent cementable Typical uses: High-voltage

insulation, impact resistant injection moldings, glazing, bulletproof,glazing, and plumbing fittings The strongest thermoplastic

Polyester glass. Properties: Extremely tough, high dielectric

strength, heat resistant, low water absorption, antitracking

electri-cally, self-extinguishing, machinable Typical uses: Insulators and

bus braces, switch phase barriers, general electrical insulation,mechanical insulated push rods for switches and breakers, contactblocks, and terminal blocks

Polyethylene. Properties: Transparent in thin sheets, water resistant Typical uses: Bags for food storage, vapor barriers in construction,

trays, rollers, gaskets, seals, and radiation shielding

Polypropylene. Properties: Good tensile strength, low water

absorp-tion, excellent chemical resistance, stress-crack resistant, electrical

properties Typical uses: Tanks, ducts, exhaust systems, gaskets,

laboratory and hospital ware, wire coating, and sporting goods

Materials: Physical Properties, Characteristics, and Uses 265

Polystyrene. Properties: Outstanding electrical properties, excellent

machinability, ease of fabrication, excellent chemical resistance, oil

resistant, clarity, rigidity, hardness, dimensional stability Typical uses: Lighting panels, tote boxes, electronic components, door panels

(refrigerators), drip pans, displays, and furniture components

Polysulfone. Properties: Tough, rigid, high-strength,

high-tem-perature thermoplastic, temhigh-tem-perature range –150 to +300°F, excellentelectrical characteristics, good chemical resistance, low creep and

cold-flow properties, capable of being autoclaved repeatedly Typical uses: Food-processing and medical industries, electrical and electron-

ics, appliance, automotive, aircraft, and aerospace uses

Polyurethane. Properties: Elastomeric to rock-hard forms available,

high physical characteristics, toughness, durability, broad hardnessrange, withstands severe use, abrasion resistant, weather resistant,radiation resistant, temperature range –80 to 250°F, resistant

to common solvents, available also in foam types Typical uses:

Replaces a host of materials that are not performing well; extremelybroad range of usage; replaces rubber parts, plastic parts, and somemetallic parts

Polyvinyl chloride (PVC). Properties: Corrosion resistant, formable,

lightweight, excellent electrical properties, impact resistant, low

water absorption, cementable, machinable, weldable Typical uses:

Machined parts, nuts, bolts, PVC pipe and fittings, valves, andstrainers

RTV silicone rubber. Properties: Resistant to temperature extremes

(–75 to 400°F), excellent electrical characteristics, weather tant, good chemical resistance; FDA, USDA, and UL approved

resis-Typical uses: General-purpose high-quality sealant, gasket cement,

food contact surfaces, electrical insulation, bonding agent, tank construction, and countless other applications

glass-Styrofoam. Properties: Low water absorption, floats, thermal insulator, extremely lightweight Typical uses: Insulation board for

homes and buildings, cups, containers, thermos containers, absorbing packaging, plates (food), and flotation logs

shock-Teflon (PTFE) Properties: Unexcelled chemical resistance, cryogenic

service, electrical insulation, very low friction, high dielectricstrength, very low dissipation factor, very high resistivity, machin-

ability Typical uses: Valve components, gaskets (with caution, due