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Ma terials science: 4.4 Steels, Finished prod ucts 149
Medium width and w ide I-beams cf. DIN 1025-5 (1994-03)
M edi um w i dt h I - beam s ( I PE) , hot-rolled (selection)
S cross -sectiona l area W axial section modu lus
/ second mo me nt of inertia m' linear mass density
Material: Unalloye d structural steel DIN EN 10025-2, e.g. S235JR
Delivery type: Standard lengths, 8 m to 16 m ± 50 mm with h < 300 mm ,
8 m to 18 m ± 50 mm with h > 300 mm
Desig- For the bending axis Tracing dimen sion
nation accord, to DIN 997
Dimensions in mm x - - X y-- y
IPE
100 hbs t r S m' /x cwmx3 c 'y 4 w, mm mm
120 cm2 kg/m cm 4 m
140 100 55 4.1 5.7 7 cm3 30 8.4
160 10.3 8.1 36 8.4
180 120 64 4.4 6.3 7 13.2 10.4 171 34.2 15.9 5.8
200 318 53.0 27.7 8.7 40 11
240 16.4 12.9 44 13
270 140 73 4.7 6.9 7 20.1 15.8 541 77.3 44.9 12.3 50 13
300 160 82 5.0 7.4 9 23.9 18.8 869 109 68.3 16.7
360 180 91 5.3 8.0 9 1320 146 101 22.2 56 13
400 28.5 22.4 68 17
500 200 100 5.6 8.5 12 39.1 30.7 1940 194 142 28.5
600 240 120 6.2 9.8 15 3890 324 284 47.3 72 21
45.9 36.1 80 23
270 135 6.6 10.2 15 53.8 42.2 5790 429 420 62.2
300 150 7.1 10.7 15 8360 557 604 80.5 90 25
72.7 57.1 96 28
360 170 8.0 12.7 18 84.5 66.3 16270 904 1040 123
400 180 8.6 13.5 21 23130 1160 1320 146 110 28
116 90.7 120 28
500 200 10.2 16.0 21 156 122 48200 1930 2140 214
600 220 12.0 19.0 24 92080 3070 3390 308
I-pro file DIN 1025 - S235JR - IPE 300: Medium width I-beams with parallel flange surfaces,
h = 300 mm, from S235JR
W i d e I - b e a m s l i g h t d u t y (IP El ), hot-rolled (selection) cf. DIN 1025-2 (1994-3)
S cross-s ectiona l area W axial section modulus
I second mo me nt of inertia m' linear mass density
Material: Unalloye d structural steel DIN EN 10025-2, e.g. S235JR
Delivery type: Standard lengths, 8 m to 16 m ± 50 mm with h < 300 mm
3 • s
Desig- For the bending axis Tracing dimension
nation accord, to DIN 997
Dimensions in mm x- X v y
IPBI cWmv3
100 hb st S m' 'x 4 cwmx3 b 4 W-1 w2 w3 d-i
120 cm2 kg/m cm cm 56
140 96 100 58 66 - - 13
114 120 58 21.2 16.7 349 72.8 134 26.8 76 17
160 133 140 5.5 8.5 25.3 19.9 86 - - 21
180 31.4 24.7 606 106 231 38.5 100 -
200 152 160 69 110 - - 23
171 180 6 9.5 38.8 30.4 1030 155 389 55.6 25
240 190 200 6.5 10 45.3 35.5 - 94 — 25
280 53.8 42.3 1670 220 616 76.9 110
320 2510 294 925 103 - 120 - 25
76.8 60.3 3690 389 1340 134 120 25
400 97.3 76.4 - 120 35 28
500 230 240 7.5 12 124.0 97.6 7760 675 2770 231 120 45
600 270 280 8 13 13670 1010 4760 340 — 130 45 28
800 310 300 9 15.5 159.0 125.0 22930 1480 6990 466 45 28
198.0 155.0 - 45 28
390 300 11 19 226.0 178.0 45070 2310 8560 571 45 28
490 300 12 23 286.0 224.0 86970 3550 10370 691 40
25 141200 4790 11270
590 300 13 28 303400 7680 12640 751
790 300 15 843
I-profile DIN 1025 - S235JR - IPBI 320: Wide I-beams light duty from S235JR
Designation according to EURONORM 53-62: HE 320 A
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150 Ma terials science: 4.4 Steels, Finished prod ucts
Wide I-beams
Wid e I-be am s (IPB), hot-rolled (selection) cf. DIN 1025-2(1995-11)
S cross-sectional area W axial selection mo dulus
I second mo me nt of inertia m' linear mass density
Material: unalloyed structural steel DIN EN 10025-2, e.g. S235JR
Delivery ty pe: standard lengths, 8 m to 16 m ± 50 mm at h < 300 mm ,
8 m to 18 m ± 50 mm at h > 300 m m
R, « 2 • S
Desig- For the bending axis Tracing dim ension
nation according to DIN 997
Dimensions in mm x- - X y - y Wi vv2 w3 dy
IPB mm mm mm mm
100 S m' k V wv
hbs cm2 kg/m cm 4 cm3 cm4 cm3 56 - - 13
t 26.0 20.4
100 100 6 10 450 89.9 167 33.5
112400 112400 112400 76.5 1112 4334..00 3236..77 1856140 211464 351508 7582..59 7666 - - 2117
- -
160 160 160 8 13 54.3 42.6 2490 311 889 111 86 - - 23
180 180 180 8.5 14 65.3 51.2 3830 426 1360 151 100 - - 25
200 200 200 9 15 78.1 61.3 5700 570 2000 200 110 - - 25
240 240 240 10 17 106 83.2 11260 938 3920 327 — 96 35 25
- 110 45 25
280 280 280 10.5 18 131 103 19270 1380 6590 471 - 120 45 28
320 320 300 11.5 20.5 161 127 30820 1930 9240 616
400 400 300 13.5 24 198 155 57680 2880 10820 721 - 120 45 28
500 500 300 14.5 28 239 187 107200 4290 12620 842 - 120 45 28
600 600 300 15.5 30 270 212 171000 5700 13530 902 — 120 45 28
800 800 300 17.5 33 334 262 359100 8980 14900 994 - 130 40 28
I-profile DIN 1025 - S235JR - IPB 240: Wide I-beam w ith parallel flange faces, h = 240 mm , m ade of S235JR,
designation according to EURONORM 53-62: HE 240 B cf. DIN 1025-4(1994-03)
Wid e I-beam s, reinforced version (IPBv) hot-rolled (selection)
HEEFT3 S cross-sectional area W axial selection modulus
/ second mo me nt of inertia m' linear mass density
Material: unalloyed structural steel DIN EN 10025-2, e.g. S235JR
— x Delivery typ e: standard lengths, 8 m to 16 m ± 50 m m at h < 300 m m,
i> 8 m to 16 m ± 50 mm at h > 300 m m
tt t i rrr
N W W j
D e s ig - For the bending axis Tracing dim ension
nation
Dimensions in mm x- - X y - y according
IPBv
S m' Ix 4 cwmx3 'y 4 cwmv3 to DIN 997 in mm
100 cm2 kg/m m
120 hbs t cm c Wi w2 w3 di
140 53.2 41.8 13
120 106 12 20 66.4 52.1 1140 190 399 75.3 60 - -
160 140 126 12.5 21 80.5 63.2 2020 283 703 112
180 160 146 13 22 3290 411 1140 157 68 17
200 97.1 76.2
113 88.9 76 - - 21
240 131 103
280 180 166 14 23 5100 568 1760 212 86 — 23
320 200 157 7480 748 2580 277
200 186 14.5 24 240 189 10640 967 3650 354 100 25
400 220 206 15 25 312 245
500 110 - - 25
600 319 250
800 270 248 18 32 344 270 24290 1800 8150 657 - 100 35 25
364 285 2550 13160 914 116 45 25
310 288 18.5 33 404 317 39550 3800 19710 1280
359 309 21 40 68130 - 126 47 28
432 307 21 40 104100 4820 19340 1260 126 47 28
524 306 21 40 161900 6180 19150 1250 - 130 45 28
620 305 21 40 237400 7660 18280 1240 - 130 45 28
814 303 21 40 442600 10870 18630 1230
132 42 28
I-profile DIN 1025 - S235JR - IPBv 400: Wide I-be am , reinforced version, m ade of S235JR, designation
according to EURONORM 53-62: HE 400 M
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Ma terials science: 4.4 Steels, Finished pro duc ts 151
Tubes
Material: Una lloyed structural steel DIN EN 10025
Delivery typ e: DIN EN 10210-2
manufactured lengths 4 m to 16 m, profile
dimen sions a x a = 20 x 20 to 400 x 400
DIN EN 10219-2
dmimaneunfasicotnusread xleang=th2s0 4x 2m0 ttoo 1460m0 ,x p4r0o0file
DIN EN 10210 and DIN EN 10219 also contain circular tubes,
along with square and rectangular tubes.
H o t w o r k e d s q u a r e an d r e c t an g u l a r t u b e s cf. DIN EN 10210-2 (1997-11)
Nominal Linear Area moments and section moduli
dimension mass den-
Wall Cross for the bending axes for torsion
ax a thickness sity /mp 44 c r r r
ax b m' section X-- X y-- y
mm s kg/m S
mm k Wx cm4 W r\
40x40 cm2 cm4 cm3
50x50 crr
60x60 3.0 3.41 4.34 9.78 4.89 9.78 4.89 15.7 7.10
50x30 4.0 4.39 5.59 11.8 5.91 11.8 5.91 19.5 8.54
60x40 3.68 4.68 17.5
2.5 6.99 17.5 6.99 27.5 10.2
80x40
3.0 4.35 5.54 20.2 8.08 20.2 8.08 32.1 11.8
100x50
3.0 5.29 6.74 36.2 12.1 36.2 12.1 56.9 17.7
4.0 6.90 8.79 45.4 15.1 45.4 15.1 72.5 22.0
5.0 8.42 10.7 53.3 17.8 53.3 17.8 86.4 25.7
3.0 3.41 4.34 13.6 5.43 5.94 3.96 13.5 6.51
4.0 4.39 5.59 16.5 6.60 7.08 4.72 16.6 7.77
3.0 4.35 5.54 26.5 8.82 13.9 6.95 29.2 11.2
4.0 5.64 7.19 32.8 10.9 17.0 8.52 36.7 13.7
4.0 6.90 8.79 68.2 17.1 22.2 11.1 55.2 18.9
5.0 8.42 10.7 80.3 20.1 25.7 12.9 65.1 21.9
6.0 9.87 12.6 90.5 22.6 28.5 14.2 73.4 24.2
4.0 8.78 11.2 140 27.9 46.2 18.5 113 31.4
5.0 10.8 13.7 167 33.3 54.3 21.7 135 36.9
Tube DIN EN 10210 - 60 x 60 x 5 - :S355J0: Square tub e, a = 60 mm, s = 5 m m ,
made of S355J0
Cold wo rked , welded , square and rectangular tu bes cf. DIN EN 10219-2 (1997-11)
Nominal Linear Area moments and section moduli
dimension mass den-
Wall Cross for the bending axes for torsion
ax a thickness sity section
ax b m' x-- X y-- y
mm s kg/m S
mm cm2 /x Wx cm4 /mp 44 c r r r
30x 30 1.68 cm4 cm3 crrr
2.0 2 .0 3 2.14
2 .5 2.36 2.59 2.72 1.81 2.72 1.81 4.54 2.75
3.0 3.01
3.16 2.10 3.16 2.10 5.40 3.20
3.50 2.34 3.50 2.34 6.15 3.58
40x40 2.0 2.31 2.94 6.94 3.47 6.94 3.47 11.3 5.23
80x80 2.5 2.82 3.59 8.22 4.11 8.22 4.11 13.6 6.21
40x20 3.0 3.30 4.21 9.32 4.66 9.32 4.66 15.8 7.07
60 x40 4.0 4.20 5.35 11.1 5.54 11.1 5.54 19.4 8.48
3.0 7.07 9.01 87.8 22.0 87.8 22.0 140 33.0
4.0 9.22 11.7 111 27.8 111 27.8 180 41.8
5.0 11.3 14.4 131 32.9 131 32.9 218 49.7
2.0 1.68 2.14 4.05 2.02 1.34 1.34 3.45 2.36
2.5 2.03 2.59 4 . 69 2.35 1.54 1.54 4.06 2.72
3.0 2.36 3.01 5.21 2.60 1.68 1.68 4.57 3.00
3.0 4.25 5.41 25.4 8.46 13.4 6.72 29.3 11.2
4.0 5.45 6.95 31.0 10.3 16.3 8.14 36.7 13.7
5.0 6.56 8.36 35.3 11.8 18.4 9.21 42.8 15.6
3.0 5.19 6.61 52.3 13.1 17.6 8.78 43.9 15.3
80x 40 45..00 86..7131 180..545 7654..18 1168..28 2214..56 1102..73 6555..02 2118..78
100x40
3.0 6.13 7.81 92.3 18.5 21.7 10.8 59.0 19.4
4.0
5.0 7.97 10.1 116 23.1 26.7 13.3 74.5 24.0
9.70 12.4 136 27.1 30.8 15.4 87.9 27.9
Tube DIN EN 10219 - 60 x 40 x 4 - :S355J0: Rectangular tube, a = 60 m m, b = 40 m m,
s = 4 mm, madeofS355J0
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Ma terials science: 4.4 Steels, Finished pro duc ts
Linear mass density and area mass density
L i n ea r m a s s d e n s i t y 1} (Table values for steel with density g =7.85 kg/dm 3)
d diameter m' linear mass density a len gth of side SW wid ths across flats
Steel wir e Round steel bar
d m' d m' d m' d m' d m' d m'
mm kg/1000 m m m kg/1000 m m m kg/1000 m m m kg/m m m kg/m m m kg/m
0.10 0.062 0.55 1.87 1.1 7.46 3 0.055 18 2.00 60 22.2
0.16 0.158 0.60 2.22 1.2 8.88 4 0.099 20 2.47 70 30.2
0.20 0.247 0.65 2.60 1.3 10.4 5 0.154 25 3.85 80 39.5
0.25 0.385 0.70 3.02 1.4 12.1 6 0.222 30 5.55 100 61.7
0.30 0.555 0.75 3.47 1.5 13.9 8 0.395 35 7.55 120 88.8
0.35 0.755 0.80 3.95 1.6 15.8 10 0.617 40 9.86 140 121
0.40 0.986 0.85 4.45 1.7 17.8 12 0.888 45 12.5 150 139
0.45 1.25 0.90 4.99 1.8 20.0 15 1.39 50 15.4 160 158
0.50 1.54 1.0 6.17 2.0 24.7 16 1.58 55 18.7 200 247
Flat steel bar
Hexagonal steel bar
a m ' a m ' a m ' SW m ' SW m' SW m'
mm kg/m mm kg/m mm kg/m mm kg/m mm kg/m mm kg/m
6 0.283 20 3.14 40 12.6 6 0.245 20 2.72 40 10.9
3.29 50 17.0
8 0.502 22 3.80 50 19.6 8 0.435 22 4.25 60 24.5
5.33 70 33.3
10 0.785 25 4.91 60 28.3 10 0.680 25 6.12 80 43.5
6.96 90 55.1
12 1.13 28 6.15 70 38.5 12 0.979 28 8.33 100 68.0
14 1.54 30 7.07 80 50.2 14 1.33 30
16 2.01 32 8.04 90 63.6 16 1.74 32
18 2.54 35 9.62 100 78.5 18 2.20 35
Linear mass den sity of special profiles
Profile Page Profile Page
151
Tee EN 10055 146 Tubes EN 10210-2 151
EN 10219-2 169
Angles, equal legs EN 10056-1 148 Tubes DIN 1798 169
DIN 1796 170
Angles, unequal legs EN 10056-1 147 Al um inu m round bars DIN 1769 1 71
DIN 1795 171
Steel channel DIN1026-1 146 Al um inu m square bars DIN 9713
I-beam s IPE DIN 1025-5 149 Al um inu m flat bars
I-beams IPB DIN 1025-2 149 Al um inu m round tube
I-beams, narrow DIN 1025-1 150 Alu min um channel
A r e a m as s d e n s i t y 1' (Table values for steel with d ensity g = 7.85 kg/dm 3)
Sheet
s sheet thickness m '' area mass density
sm sm sm sm sm sm
mm kg/m2 mm kg/m2 mm kg/m2 mm kg/m2 mm kg/m2 mm kg/m2
0.35 2.75 0.70 5.50 1.2 9.42 3.0 23.6 4.75 37.3 10.0 78.5
0.40 3.14 0.80 6.28 1.5 11.8 3.5 27.5 5.0 39.3 12.0 94.2
0.50 3.93 0.90 7.07 2.0 15.7 4.0 31.4 6.0 47.1 14.0 110
0.60 4.71 1.0 7.85 2.5 19.6 4.5 35.3 8.0 62.8 15.0 118
Table values can be calculated for a different material by taking a ratio of its density to the density of steel
(7,85 kg/dm 3).
Example: Sheet metal wit h s = 4.0 m m of AIMg 3M n (density 2.66 kg/d m3). From the table: m = 31.4 kg /m 2 for steel.
A I M g 3 M n : m = 31.4 kg /m 2 • 2.66 kg/dm3/7.85 kg/dm 3 = 10.64 k g /m2
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1600 M ate ria ls cie nc e: 4. ten
°C |A
Iron-Carbon phase diagram
1536(
1500
liquid (liquid iron with carbon in solution)
1300
liquid + liquid +
austenite crystals cementite
cu austenite ledeburite + cementite
(+ grap hite)1'
3 1100 garuasitnenite + austenite, grain boundary
boundary cementite + ledeburite cementite + ledeburite
ro cementite (+ graphite)1'
CD pearlite + grain (+ graphite )1'
a boundary 5%6
E 1000 cementite 723 °C line carbon content -
0
~ 911 pearlite, grain boundary
cementite + ledeburite—
900 1
(+ graphite)1'
723 aust.%^
700 +ferrite
/ g
ferrite + fe'
ferrite pear ite gl
0 0.5 hyper- 4.3
hypo- eutectoid 2.06
eutectoid 0.8
eutectoid I
steel eutectic mixture
cast iron
1 ) For iron types w ith a C content ove r 2.06% (cast iron) and addition al Si conten t, a portion of the un alloyed pre-
cipitates in the form of graphite.
Heat treatm ent of steel Microstructures of unalloyed steel
Carbon c ontent and c ry s talline s truc ture
Etchant: 3% nitric acid /alcohol solution
Magnification approx. 500 : 1
1100 I h o m o g e n i z in g a n n e al
austenite
°C '
1000 -
900
I 0.1 C 0.45 C
k0_ 800 f e r r it e ferrite + pearlite
00 0.8 C 1.3 C
pearlite pearlite + grain
CD boundary cementite
a 700 temperature range: , k
aE)
temperature stress relief annea l
ranges: recrystallization anneal
ferrite + pearlite pearlitei pearlite + cem entite
0.2 0.4 0.6 0.8 1.0 1.2 % 1.4
carbon content •
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154 M ate ria lsc ie nce : 4. ten
Heat treatm ent of steels - Overview
Illustration Short description Application, inform ation1'
Normalizing To normalize coarse grain structures
^ ^ ^ ^ ^ annealing ^ ^ ^ ^ ^ • Heat and hold at annealing temperature in rolled, cast, welded and forged
products
-»• structural transformation (austenite)
• -C•foinnetr-ogllreadin ecdoonloinrmg taol rsotorumcttuerme perature
Spheroidizing
^ an neali ng ^ ^ ^ ^ ^ • Heat to annealing temperature, hold at tem- To improve c old workability, machin-
perature or cycle anneal ability and hardenability;
-»• spheroidizing of the cementite can be used for all steels
• Cool dow n to room temperature
Stress relief anneal
b • Heat and hold at annealing temperature To reduce internal stresses in welded,
<> (below structure transition) cast and forged parts;
s stress relief by plastic can be used for all steels
s deformation of the workpieces
• Cool dow n to room temperature
e
t
s
T\jT_TjjTa•n=n£e>alinc
Hardening
t f \j• • Heat and hold at hardening temperature For parts sub ject to wear stress, e.g.
<c_b IDfn3 ->• structural transform ation (austenite) tools, springs, guideways, press
OeCro_Ll £/ I5 tempering forms;
• Quench in oil, water, air
£/ i -»• brittle hard, fine struc ture (marte nsite) steels suitable for heat treatment with
C > 0,3%, e.g.
e • Temper ->• transformation of m artensite, C70U, 102Cr6, C45E, HS6-5-2C,
higher toughness, working hardness X38CrMoV5-3
<u time
Quenching and tem pering
t o>// I1 cz • Heat and hold at hardening temperature Usually used for dynamically loaded
Qc3_J s y I S tempering structural transformation (austenite) workpieces with high strength and
<trQCE_oUJL / good toughness, e.g. shafts, gears,
FA • Quench in oil, water, air screws;
hard, brittle, fine-grain structure (marten-
time site), for larger sized parts fine quenched and tempered steels,
core structure (bainite) see page 133,
nitriding steels, see page 134,
• Temper at higher temperatures than for steels for flame and induction
hardening hardening, see page 134,
martensite reduction, fine structure, high steels for heat-treatable springs,
strength with good toughness see page 138
Case hardening
t carburizing hardening • Carburize machined workpieces on the For workpieces with wear-resistant
OJ surface layer surfaces, high fatigue strength and
goo d core strength, e.g. gears, shafts,
POJ ^ ^ | t e m p e r in g • Cool to room temperature bolts;
-»• norm al s tructure (ferrite, pearlite, surface hardening: high wear-resist-
Q. time carbides) ance, low core strength
QJ core hardening: high core strength,
• Harden (for procedure see hardening) hard brittle surface;
surface hardening: heat to surface case hardened steels, see page 133,
hardening tem perature free cutting steels, see page 134
core hardening: heat to hardening
temperature of the core area
Nitriding
t annealing • Anneal usually finish-machined workpieces For workpieces with wear-resistant
in nitrogen-producing atmospheres surfaces, high fatigue strength and
Ja3i \ formation of hard, wear-resistant and good temperature-resistance, e.g.
temperature-resistant nitrides valves, piston rods, spindles;
£na_oj nitriding steels, see page 134
aCE>L • Cool in still air or in
nitrogen stream
1 ) For anntiemaeling an• d temp ering tem peratures, qu enching media and attainable hardness values, see pages 155 to 157.
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M ate ria lsc ie nc e: 4. ten
Tool s teels, Case hardened steels
H e at t r e a t m e n t o f u n a l lo y e d c o l d w o r k s t ee ls cf. DIN EN ISO 4957 (2001-02)
Steel typ< Sphero idizing Hardenii n g Surlface hlardni3SS
in HF
Designation Material Hot Tempe- Hardness Tempera- Cooling Case Full after after
number working rature HB ture medium harden. harden, hard- te m jDerincj2> at
temperature depth1) up to 0 ening 100 200 300
°C
°C max. °C mm mm °C °C °C
C45U 1.1730 1000-800 680-710 207 800-820 water 3.5 15 58 58 54 48
C70U 1.1520 183 790-810 3.0 10 64 63 60 53
C80U 1.1525 1050-800 192 780-800 64 64 60 54
C90U 10 64 64 61 54
C105U 1.1535 1050-800 680-710 207 770-790 water 3.0
65 64 62 56
1.1545 1000-800 212 770-790
1 ) For diameters of 30 mm.
2 ) The tem perin g temp erature is set according to the application and the desired workin g hardness. The steels are
normally delivered spheroidized.
H e at t r e a t m e n t o f al l o y c o l d w o r k s t e el s , cf. DIN EN ISO 4957 (2001 02)
h o t w o r k s t e el s a n d h i g h -s p e ed s t e el s
Steel type Hot Sph eroidizing Hardening Surface hardness in HRC «
t em p e- H ard n. t em p e- c o ol in g a fte r t e m p er in g2 ' at
M ate ria l w o rk in g rature HB rature1 > m e d i u m a fte r
Designation number temperature °C max. °C h ar de n - 2 00 30 0 4 00 5 00 55 0
°C ing °C °C °C °C °C
105V 1.2834 i n c n OC A 710-750 212 780-800 water 68 64 56 48 40 36
X153CrMoV12 63 61 59 58 58 56
1.2379 800-850 255 1010-1030 air
X210CrW12 1.2436 1050-850 800-8 40 255 96-980 oil 64 62 60 58 56 52
90MnCrV8 1.2842 680-720 229 780-800 65 62 56 50 42 40
102Cr6 1 .2 06 7 710 -750 2 23 830-8 50 65 62 57 50 43 40
X603W7CCrrMVo8V5-1 11..22354530 11100500--980500 775100--870500 222299 101900-01-093200 On iill 6523 5620 5528 5533 4584 4562
HS6-5-2C 1.3343 1100-900 770-840 269 1200-1220 oil, 64 62 62 62 65 65
HS10-4-3-10 1.3207 302 1220-1240 hot 66 61 61 62 66 67
HS2-9-1-8 1.3247 277 1180 -1200 bath, air 66 62 62 61 68 69
1 ) The austenitizing tim e is the holdin g time at hardening temp erature, wh ich is approx. 25 min for cold work steels
and approx. 3 min. for high-speed steels. Heating is performed in stages.
2 ) High-speed steels are tem pered at least twice at 540-5 70°C . Holding tim e at this temperature is at least 60 min.
Heat treatm ent of case hardened steels cf. DIN EN 10084 (2008-06)
Steel type|1) Hard<3ning Quench- En d q<uench test
Material Carburizing Core harden, Surf, harden, Temper- Hardn( HRCat distanee of:
Designation number temperature temperature temperature ing ing Temp.
me d iu m °C max.2* 3 mm 5 mm 7 mm
°C °C °C °C
C10E 1.1121 880-920 water
C15E 1.1141
17Cr3 1.7016 880-980 860-900 780-820 150-200 880 47 44 40 33
16MnCr5 1.7131 830-870 870 47 46 44 41
oil
20MnCr5 1.7147 870 49 49 48 46
20MoCr4 1.7321 910 49 47 44 41
17CrNi6-6 1.5918 870 47 47 46 45
15NiCr13 1.5752 840-880 880 48 48 48 47
20NiCrMo2-2 1.6523 860-900 920 49 45 42
18CrNiMo7-6 1.6587 830-870
860 48 48 48
1 ) The same values apply to steels with con trolled sulfur conten t, e.g. C10R, 20MnCrS5.
2 ) For steels with norm al ha rdenability (+H) at a distance of 1.5 mm fro m the end face.
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156 M ate ria lsc ie nc e: 4. ten
Quenched and temp ered steels
H e at t r e a t m e n t o f u n a l lo y e d q u e n c h e d a n d t e m p e r e d s t e el s cf. DIN EN 10083-2 (2006-10 )1'
Steel typ es2) End quench test Q ijenching and temperi ng
Normaliz- Hardness HR C at
hardeni ng depth in mm 3 ) Hardening4' Quenching medium Tempering5'
Designation Material ing
number °C °C 1 3 5 °C °C
C22E 1.1151 880-940 - - - - 860-900 water 550-660
water or oil 550-660
C 3 5 E 1) 1.1181 860-920 870 48-58 33-55 22-49 840-880
C40E 1.1186 850-910 870 51-60 35-59 25-53 830-870 oil or water 550-66 0
C45E1' 1.1191 840-900 850 55-62 37-61 28-57 820-860
C 5 0 E 1) 1.1206 830-890 850 56-63 44-61 31-58 810-850
C55E1' 1.1203 825-885 830 58-65 47-63 33-60 810-850
C60E 1.1221 820-880 830 60-67 50-65 35-62 810-850
28M n6 1.1170 85 0-8 90 850 4 5 - 5 4 4 2 - 5 3 3 7 - 5 1 8 4 0 - 8 8 0 water or oil 540-680
H e at t r e a t m e n t o f q u e n c h e d a n d t e m p e r e d a l lo y s t e el s (s el e c ti on ) cf. DIN EN 10083-3 (2007-01
Steel typie s2' End queinch test Q ijenching and temperi ng
Designation Material h aSrudrnfaecses6' hardHenairndngedssepHthR Ci n amt m 3 ' Hardening 4' Q u e n ch i n g m e d i u m Tempering5'
number HRC
°C 1.5 5 15 °C °C
850
38Cr2 1.7003 51-59 37-54 -35 830-870 oil or water 540-680
4 6 C r 2 1) 1.7006 54-63 40-59 22-39 820-860 oil or water
54
34Cr4 1.7033 51 49-57 45-56 27-44 830-870 water or oil 540-680
3 7 C r 4 1) 1.7034 53 850 51-59 48-58 31-48 825-865 oil or water
4 1 C r 4 1) 1.7035 oil or water
53-61 50-60 32-52 820-860
25CrMo4 1.7218 53 44-52 40-51 27-41 840-900 water or oil 540-680
34CrMo4 1.7220 58 850 49-57 48-57 34-52 830-890 oil or water 540-680
42CrMo41> 1.7225 oil or water
53-61 52-61 37-58 820-880
50CrMo41> 1.7228 oil
51CrV4 1.8159 58-65 57-64 48-62 820-870 oil
39NiCrMo3 1.6510 850 57-65 56-64 48-62 820-870 oil or water
52-60 50-59 43-56 820-850
34CrNiMo6 1.6582 — 50-58 50-58 48-57 830-860 oil or water 540-660
30CrNiMo8 1.6580 850 48-56 48-56 46-55 830-860 oil or water 540-660
36NiCrMo16 1.6773 550-650
50-57 48-56 47-55 865-885 air or oil
38MnB5 1.5532 850 52-60 50-59 3 1 - 4 7 840-880 water/oil 400-600
33MnCrB5-2 1.7185 880 48-57 47-57 41 -54 860-90 0 oil 400-6 00
1 ) DIN 17212 Steels for flame and induction hardening was withdrawn witho ut replacement. More information about
steels for flame and induction hardening on page 133 and 134 in the section Quenched and tempere d steels .
2 ) Identical values apply to the high-grade steels C35 to C60 and steels wit h con trolled s ulph ur con tent, such as C35R.
3)
4 > THhaerdleonwaebriltietymrpeeqruaitruermeernatnsg: e+Hapnpoliremsatlo hqaurednecnhaibniglitiyn water, the higher range to quenc hing in oil.
5 ) The tempe ring time is 60 minutes m inim um .
6 ) M inim um surface hardness of the steel after flame or induction h ardening.
Hardenability and hardening depth of quenched and tempered steels (scatter bands)
C35E 37Cr4 HH 51CrV4+HH
37Cr4 HL 51CrV4 HL
0 5 10 15 20 25 30 35
hardening depth •
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M ate ria lscie nc e: 4. ten
Nitriding steels, Free cu tting steels, Aluminum alloys
Heat treatmen t of nitriding steels cf. DIN EN 10085 (2001-01)
Steeltyp >e He<3t treatment f>cefore nitridiing Nitri ding treatm<ant1>
Quenchling and tem pering
Material Spheroid, H a r d ie n i n g Tempering Gas Nitrocar-
number nitriding burizing Hardness5'
Designation temperature Tempera- Quenching tempera-
2 34
°C tu°rCe ' medium t u r°eC ' ' °C °C HV1
24CrMo13-6 1 .8 5 16 650 -700 870-970 -
31CrMo12 1 .8 5 15 650 -700 870-930 800
32CrAIMo7-10 1.8505 650-75 0 870-930 -
31CrMoV9 1.8519 680-720 870-930 oil or 580-700 500-600 570-650 800
33CrMoV12-9 1 .8 52 2 680-72 0 870-970 water
3 4 C r A I N i7 - 1 0 1 .8 5 50 650 -700 870 -930 -
950
41CrAIMo7-10 1.8509 650 -750 8 7 0 - 9 3 0 950
40CrMoV13-9 1.8523 680 -72 0 8 7 0 - 9 7 0 -
34CrAIMo5-10 1.8507 650-750 870-930 950
1 ) The nitriding tim e is a function of the desired nitriding hardness depth.
2 ) Aus tenitizing time at least 0.5 hours.
3 ) Tem pering tim e at least 1 hour.
4 ) The tem pering tem perature s hould not be less than 50°C above the nitriding te mpe rature.
5 ) Hardness of the nitrided surface.
H e at t r e a t m e n t o f fr ee c u t t i n g s t e el s cf. DIN EN 10087 (1999-01)
Free cutting case hardened steels
Steel typ>e Carburizing Core hardening Surface harden, Quenching Tempering
temperature temperature medium1' temperature2'
Material temperature °C °C
°C °C
Designation number
10S20 1.0721 880-980 880-920 780-820 water, oil, 150-200
10SPb20 1.0722 emulsion
15SMn13 1.0725
| Free cutt ing quenched and temp ered steels
S t e e l t y p >e Hardness Quenching Quench, and Quenclned and te m p e r e d3 '
temperature medium1' tem p, temperat.
Material A
°C °C %
Designation number N/mm2 Am
N/mm2
35S20 1.0726 860-890 water 430 630 -780 15
35SPb20 1.0756 460 14
460 700-850 15
36SMn14 1.0764 850-880 or oil 540-680
36SMnPb14 1.0765 850-880 oil or
38SMn28 1.0760
38SMnPb28 1.0761
44SMn28 1.0762
44SMnPb28 1.0763 884400--8 7 0 water 480 16
490 12
46S20 1.0757 2 ) Tem pering tim e at least 1 hour.
1 ) The choice of quenching m edium depends on the shape of the workpiece.
3 ) Values apply to diameters 10 < d < 16.
Hardening of aluminum alloys
Alloy EN /\W - Solution Artificic Jl aging Natural Age ha rdened
aging time
Material Type of age annealing temperature holding Am A
number hardening2' temperature time days N/mm2 %
Designation °C °C h
Al Cu4MgSi 2017 T4 500 5-8 390 12
Al Cu4SiMg 2014 T6 420 8
- 130 15
280 6
Al MgSi 6060 T4 5-8 210 12
545 8
Al MgSilMgMn 6082 T6 525 100-300 8-24 - 250 1
Al Zn4,5Mg1 7020 T6 470 -
T6 525
Al Zn5,5MgCu 7075 T6 -
Al Si7Mg1) 420001'
4
1 ) Al um inu m cas ting alloy EN AC-AI Si7M g or EN AC 42000.
2 ) T4 solutio n annealed and naturally aged; T6 solution an nealed and artificially aged.
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158 Ma terial science 4.6 Cast iron
Designation system for cast iron m aterials
Designations and m aterial nu mbers cf. DIN EN 1560 (1997-08)
Cast iron materials are referenced either with a designation or a material number.
Example:
Cast iron w ith flake graphite, tensile strength Rm = 300 N/ mm 2
D e s i g n a ti o n Material number
EN-GJL-300 EN-JL1050
Material designations
Material designations have up to six characters without spaces,
beginning with EN (European standard) and GJ (cast iron; I iron)
Designation example: B 350 Cast iron with flake graphite
W H B 1 55 Cast iron with flake graphite
EN GJ L A 350-22U Cast iron with spheroidal graphite (ductile Iron)
EN GJ L
EN GJ S 4 5 0 -6 Malleable cast iron - blackheart
3 6 0 -1 2 W Malleable cast iron - whitehead:
EN GJ M HV600(XCr14)
EN GJ M XNiCuCr 15-6-2 Wear-resistant cast iron
EN GJ M Austenitic cast iron
EN G J L
Material numbers
Material numbers have seven characters without spaces,
beginning with EN (European standard) and J (iron; Iiron)
Designation examples:
EN - J L 2 0 4 7 Cast iron wit h flake graphite and hardness as characteristic spheroidal
EN - J S 1 0 2 2 graphite casting with cast-on test specimen, characteristic /?m
EN - J M 1 1 3 0 Malleable cast iron with out special requiremen ts, characteristic Rm
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M ate rial science 4.6 Cast iron 159
Classification of Cast Iron Materials
Type Standard Examples/ Tensile Properties Application examples
material number strength
N/mm2
I Cast iron
with flake DIN EN EN-GJL-150 100 Very good castability, For complex workpieces
graphite (gray 1561 (GG-15)1> to good compression strength, with many contours;
EN-JL1020 450 damping capacity, very ve rsatile in its applica-
iron) emergency running tions.
350 properties, and good
corrosion resistance Machine frames,
to gear housings
with spheroidal DIN EN EN-GJS-400 900 Very good castability, Wear stressed
( G G G - 4 0 )1' high strength even with workpieces;
graphite 1563 EN-JS1030 300 dynamic loading, clutch parts, fittings,
surface hardenable engine/motor construction
to
with vermicular ISO ISO Very good castability, high Automotive parts,
16112/JV/300 500 strength without expensive engine/motor construction,
graphite 16112 800 alloying additions gear housings
bainitic DIN EN EN-GJS-800-8 to Heat treatment and con- Highly stressed parts, e.g.
cast iron trolled cooling produce bai- wheel hubs, gear rings, ADI
1564 EN-JS1100 1400 nite and austenite for high castings2'
strength and good tough-
> 1000 ness
wear-resistant DIN EN EN-GJN-HV350 Wear-resistant due to Wear-resistant cast iron,
castings, 12513 EN-JN2019 martensite and carbides, e.g. dressing rolls,
white cast iron also alloyed with Cr and Ni dredging shovels,
impellers for pumps
Malleable cast iron
decarburized DIN EN EN-GJMW-350 270 Decarburization of the sur- True to shape, thin-walled,
(whiteheart) 1562
1 5to70 fsatcreenbgythteamndpetoriunggh. nHeisgsh, il emvpearcst,- lboraadkeedd rpuamr tss ;
ductile
E(GNT-WJM-3150)1>0
not DIN EN EN-GJMB-450 300 Cluster graphite in entire True to shape, thick w alled,
decarburized 1562 (GTS-45)1' to cross-section due to mal- impact stressed parts;
(blackheart) EN-JM1140 800 leablizing. High strength levers, universal joint yokes
and toughness in larger
wall thickness
I Cast steel
for general DIN EN GE240 380 Unalloyed and low alloy Minimum mechanical values
use 102933* 1.0446 to cast steel for general use f r o m - 1 0 °C to 300 °C
600
with improved DIN EN G20Mn5 430 Lower carbon content w ith Welded assembly construction,
102934' 1.6220 to manganese and m icroalloy fine-grain structural steels wit h
weldability 650 larger wa ll thickness
quenched and DIN EN G30CrMoV6-4 500 Fine quenched and tem- Chains,
tempered 102935> 1.7725 to pered structure with high plating
cast steel 1250 toughness
DIN EN GP280GH Pressure vessels for hot or
for pressure 10213 1.0625 420 Types with high strength cold media, high tempera-
vessels to and toughness at low and ture resistant and tough at
960 high temperatures low temperatures; rustproof
stainless DIN EN GX6CrNi26-7 450 Resistant to chemical attack Pump impellers in acids,
heat-resistant 10283 1.4347 to and corrosion duplex steel
1100
DIN EN GX25CrNiSi18-9 Resistant to scaling gases Turbine parts,
10295 1.4825 400 to furnace grates
550
1 ) previous designa tion 2 ) ADI -»•Austempered Ductile Iron
3> Replaces DIN 1681 4 ) Replaces DIN 17182 5 ) Replaces DIN 17205
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160 Material science: 4. to
Cast iron w ith flake graphite, Cast iron w ith spheroidal graphite
C as t i r o n w i t h f l ak e g r a p h i t e (g r ay i r o n ) cf. DIN EN 1561 (1997-08)
Tens ile s tr ength R m as identify ing c har ac ter is tic Hardness HB as identifying characteristic
TyiDe Wall Tensile strength Type Material Wall Brinell
thickness Designation number thickness hardness
Designation Material Rm
number mm mm HB30
2
max. 155
N/mm 100-175
EN-GJL-100 EN-JL1010 5-40 100-200 EN-GJL-HB155 EN-JL2010 40-80 120-195
EN-GJL-150 EN-JL1020 2.5-300 150-250 EN-GJL-HB175 EN-J L2020 40-80 145-215
EN-GJL-200 EN-JL1030 2.5-300 200-300 EN-GJL-HB195 EN-JL2030 40-80 165-235
EN-GJL-250 EN-JL1040 5-300 250-350 EN-GJL-HB215 EN-JL2040 40-80 185-255
EN-GJL-300 EN-JL1050 10-300 300-400 EN-GJL-HB235 EN-JL2050 40-80
EN-GJL-350 EN-JL1060 10-300 350-450 EN-GJL-HB255 EN-JL2060 40-80
EN-GJL-100: Cast iron w ith flake graph ite (gray EN-GJL-HB215: Cast iron wi th flake graphite (gray
iron), minim um tensile strength /? m = 100 N/mm2 iron), maximum Brinell hardness = 215 HB
Properties
Good castability and machinability, vibration damping, corrosion resistance, high compression strength,
good sliding properties.
Application examples
Machine frames, bearing housings, plain bearings, pressure-resistant parts, turbine housings.
Hardness as characteristic property provides information on the machinability.
C as t i r o n w i t h s p h e r o i d a l ( n o d u l ar ) g r a p h i t e cf. DIN EN 1563 (2005-10)
Tens ile s tr ength R m as identify ing c har ac teris tic
Type Material Tensile Yield Elongation Properties,
Designation number strength strength EL application examples
Rm ftp 0.2 %
N/mm2 N/mm2
EN-GJS-350-22-LT1' EN-JS1015 350 220 22
EN-GJS-350-22-RT2' EN-JS1014 350 220 22
EN-GJS-350-22 EN-JS1010 350 220 22 Good machinability,
EN-GJS-400-18-LT1) EN-JS1025 400 250 18 low wear resistance;
EN-GJS-400-18-RT2' EN-JS1024 18 housings
400 250
EN-GJS-400-18 EN-JS1020 400 250 18
EN-GJS-400-15 EN-JS1030 400 250 15
EN-GJS-450-10 EN-JS1040 450 310 10 Good machinability,
EN-GJS-500-7 EN-JS1050 500 320 7 average wear resistance;
EN-GJS-600-3 EN-JS1060 600 370 3 fittings, press frames
EN-GJS-700-2 EN-JS1070 700 420 2 Good surface hardness;
EN-GJS-800-2 EN-JS1080 800 480 2 gears, steering and clutch parts,
EN-GJS-900-2 EN-JS1090 900 600 2 chains
1 ) LT for low temperatures 2 ) RT for room temperature
EN-GJS-400-18: Cast iron wit h spheroidal (nodular) graphite, m inim um tensile strength R m = 400 N/m m2 ;
elonga tion at fracture EL = 18%
Hardness HB as identifying characteristic
Type Material Tensile Yield Brinell Properties,
Designation number strength hardness application examples
strength
R p 0.2 HB
Rm
N/mm2
N/mm2
EN-GJS-HB130 EN-JS2010 350 220 < 160
EN-GJS-HB150 EN-JS2020 400
EN-GJS-HB155 EN-JS2030 400 250 130-175
EN-GJS-HB185 EN-JS2040 450 250 135-180
EN-GJS-HB200 EN-JS2050 500
EN-GJS-HB230 EN-JS2060 600 310 160-210 By specifying hardness values the pur-
320 170-230 chaser can better adapt process para-
EN-GJS-HB265 EN-JS2070 700
EN-GJS-HB300 EN-JS2080 800 370 190-270 Ampeptelircsattioonmsaacshianbinogveo.f the cast parts.
EN-GJS-HB330 EN-JS2090 900
420 22 5-3 05
480 24 5-3 35
600 27 0-3 60
EN-GJS-HB130: Cast iron with spheroidal (nodular) graphite, Brinell hardness HB 130, maximum hardness 162/431
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M ate rial science : 4.6 Cast iron 161
Mall eabl e cast iron, Cast steel
Malleable cast iro n 1) cf. DIN EN 1562 (2006-08)
Type Material Tensile Yield Elongation Brinell Properties,
Designation number strength strength at fracture hardness application examples
ftm ftp 0.2 EL HB
N/mm2 N/mm2
%
Decarburizing annealed malleable cast iron (whiteheart malleable cast iron)
EN-GJMW-350-4 EN-JM1010 350 4 230 All types have good castability and
EN-GJMW-400-5 EN-JM1030 400 220 5 220 good machinability.
EN-GJMW-450-7 EN-JM1040 450 260 7 250 Workpieces with low wall thickness,
EN-GJMW-550-4 EN-JM1050 550 340 4 250 e.g. levers, chain links
EN-GJMW-360-12 EN-JM1020 360 190 12 200 Especially we ll suited for w elding.
=> EN-GJMW-350-4 :Whiteheart malleable cast iron, Rm = 350 N/ mm 2 , EL = 4
Non-decarburizing annealed malleable iron (blackheart malleable cast iron)
EN-GJMB-300-6 EN-JM1110 300 6 -1 50 High pressure tightness
EN-GJMB-350-10 EN-JM1130 350 200 10 - 1 5 0
EN-GJMB-450-6 EN-JM1140 450 270 6 150-200
EN-GJMB-500-5 EN-JM1150 500 300 5 165-215 All types have good castability and
EN-GJMB-550-4 EN-JM1160 550 340 4 180-230 good machinability.
EN-GJMB-600-3 EN-JM1170 600 390 Workpieces with high wall thickness,
EN-GJMB-650-2 EN-JM1180 650 430 3 195-245 e.g. housings, universal joint yokes
EN-GJMB-700-2 EN-JM1190 700 530 2 210-260 pistons
EN-GJMB-800-1 EN-JM1200 800 600 2 240-290
1 270-320
=s> EN-GJMB-350-10 :Non-decarburizing annealed malleable cast iron, Rm = 350 N/m m 2 , EL = 10%
1 ) Previous designations : page 159
Cast steel for general app lications (selection) cf. DIN EN 10293 (2005-06 )1'
Type Tensile Yield Elongation Notch Properties,
strength strength impact application examples
energy
Designation Material ftm ftp 0.2 EL For workpieces w ith average
number N/mm2 N/MM2 Kv dynamic loading;
G E2 0 02) % J wheel spiders, levers
GE2402' 1.0420 380-530 200
GE3002' 1.0445 450-600 240 25 27 Improved weldability;
G 1 7 M n 5 3) 1,0558 600-750 300 22 31 composite welded structures
G 2 0 M n 5 2> 15 27
G X 4 C r N i M o 1 6 - 5 - 13) 1.1131 450-600 240 For workpieces with high dynamic
G 2 8 M n 6 2) 1.6220 480-620 300 24 70 loading;
G 1 0 M n M o V 6 - 33) 1.4405 760-960 540 20 60 shafts
G 3 4 C r M o 43) 15 60 For corrosion-protected workpieces
G32NiCrMo8-5-4 3) 1.1165 520-670 260 with high dynamic loading
G X 2 3 C r M o V 1 2 - 1 3) 1.5410 600-750 500 18 27
1.7230 620-770 480 18 60
10 35
1.6570 850-1000 700
1.4931 740-880 540 16 50
15 27
1 1 DIN 17182 Steel cast types with im proved weldability and toughness was withd rawn w ithout replacement.
2 ) normalized 3 ) quenched and tempered
Cast steel for pressure vessels (selection) cf. DIN EN 10213 (2004-03)
Type Tensile Yield Elongation Notch Properties,
strength1' strength1' at fracture impact application examples
Designation energy Kv
Material ftm ftp 0m.22 EL
GP240GH number N/mm2 N/m % J
G17CrMo5-5
1.0619 420 240 22 27
X8CrNi12 1.7357 490 315 20 27 For high and low tempe ratures, e.g.
GX4CrNiMo16-5-1
1.4107 540 355 18 steam turbines, super heated steam
1.4405 760 540 15 45 armatures, also corrosion resistant
60
1 ) Values for a wall thickness up to 40 m m
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162 Ma terial science: 4.7 Foun dry techn olog y
Patterns, Pattern equipment and core boxe s c f D I N ^ooo oe
Materials and grades
Characteristics Wood Materials Metal
Type of material Plastic
Plywood, particle board or
Application sandwich board, hard and Epoxy resins or Cu, Sn, Zn alloys
soft wood polyurethane with Al alloys
fillers Cast iron or steel
Recurring individual pieces
and smaller lots, low preci- Jobbing work and volume Moderate to large vo lumes
sion requirements; production with higher preci- with high precision
normally hand molding sion requirements; requirements;
hand and machine molding machine molding
Max. production run approx. 750 approx. 10000 approx. 150000
for molding W 12), W2, H3 P1 2), P2 M 12), M2
Quality classes1'
Surface quality Sand paper Ra = 12.5 pm Ra = 3.2-6.3 pm
60-80 grit
1 1 Classification system for the manufacture a nd use of patterns, pattern equipm ent and core boxes, according to
their application, quality and service life: W wo od; P plastic; M metal
2 > best grade
Mo ld draft for sand casting
Mold draft Tin mm
Small draft surfaces Large draft surfaces
Height h Hand nl o l d i n g Machine Hand nl o l d i n g Machine
mm Molding sand Molding sand molding Molding sand Molding sand molding
clay bonded chem. bonded clay bonded chem. bonded
-30 1.0 1.0 1.0 1.5 1.0 1.0
> 30 -8 0 2.0 2.0 2.0 2.5 2.0 2.0
>80-180 3.0 2.5 2.5 3.0 3.0 3.0
>180-250 3.5 3.0 3.0 4.0
>250-1 000 4.0 4.0
>10 00-40 00 + 1.0 mm each 250 m m
+ 2.0 mm each 1 000 mm
Paint and color codes on patterns
Surface or partial surface Cast steel Nodular Gray Malleable Heavy Light
blue cast cast iron metal alloy
Basic color for areas that iron iron castings castings
should remain unmachined gray
on the casting purple red yello w green
Areas to be machined on the yellow stripes yellow stripes yellow stripes yellow stripes red stripes yellow stripes
casting
Locations of loose parts framed in black
and their attachments red red blue red blue blue
Locations of black
chill plates yellow stripes
Core marks
Risers
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M a t e r i a l s c ie n c e : 4 .7 F o u n d r y t e c h n o l o g y 163
Shrinkage allowances, Dimensional tolerances, Molding and casting methods
Shrinkage allowances cf. DIN EN 12890 (2000-06)
Cast iron Shrinkage Other c as ting m aterials Shrinkage
allowance in allowance in
with flake graphite 1.0 Cast steel 2.0
with spheroidal graphite, annealed 0.5 Auste nitic mangane se cast steel 2.3
with spheroidal graphite, not annealed 1.2 Al, Mg, CuZn alloys 1.2
austenitic 2.5 CuSnZn, Zn alloys 1.3
malleable cast iron, decarburizing anneal 1.6 CuSn alloys 1.5
malleable cast iron, no decarburizing anneal 0.5 Cu 1.9
Dimensional tolerances and m achining allowances, RMA cf. DIN ISO 8062 (1998-08)
Ex amples of toleranc e s pec ific ations in a drawing: R rough casting - nominal dimension
F dimension after finishing
1. ISO 8062-CT12-RMA6 (H) CT casting tolerance grade
Tolerance grade 12, material allowance 6 mm T total casting tolerance
RMA material allowance for machining
2. Individual tolerances and machining allowances are given
directly after a dimension.
/? = F 2 • RM A + 772
Casting tolerances
Nominal Tot,al cast ing tol erancei T in mi m
dimensions for castirig tole ranee grade CT
in mm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
-10 0.09 0.13 0.18 0.26 0.36 0.52 0.74 1.0 1.5 2.0 2.8 4.2 - - - -
> 10-16
> 16-25 0.10 0.14 0.20 0.28 0.38 0.54 0.78 1.1 1.6 2.2 3.0 4.4 - - - -
> 25-40
>40-63 0.11 0.15 0.22 0.30 0.42 0.58 0.82 1.2 1.7 2.4 3.2 4.6 6 8 10 12
>63-100
>100-160 0.12 0.17 0.24 0.32 0.46 0.64 0.9 1.3 1.8 2.6 3.6 5 7 9 11 14
>160-250
> 250-400 0.13 0.18 0.26 0.36 0.50 0.70 1.0 1.4 2.0 2.8 4.0 5.6 8 10 12 16
> 400-630
>630-1000 0.14 0.20 0.28 0.40 0.56 0.78 1.1 1.6 2.2 3.2 4.4 6 9 11 14 18
0.15 0.22 0.30 0.44 0.62 0.88 1.2 1.8 2.5 3.6 5 7 10 12 16 20
- 0.24 0.34 0.50 0.70 1.0 1.4 2.0 2.8 4.0 5.6 8 11 14 18 22
- - 0.40 0.56 0.78 1.1 1.6 2.2 3.2 4.4 6.2 9 12 16 20 25
- - 0.64 0.90 1.2 1.8 2.6 3.6 5 7 10 14 18 22 28
- - - - 1.0 1.4 2.0 2.8 4 6 8 11 16 20 25 32
M o l d i n g a n d c as t in g m e t h o d s
Method Application Advantages and Relative dim en- Achievable
disadvantages C as ting mater ial s ional ac c ur ac y 1' r oughnes s a
in m m / m m in pm
Hand large castings, all sizes, expensive, GJL, GJS, GS, 0.00-0.10 40-320
molding small lots low dimensional GJM, Al and
accuracy Cu alloys
Machine small to medium dimensionally accurate, GJL, GJS, GS, 0.00 0.06 20-160
molding
sized parts, volume good surface GJM, Al alloys
Vacuum medium to large dimensionally accurate, GJL, GJS, GS,
molding parts, volum es
good surface, GJM, Al and 0.00-0.08 40-160
high investment costs Cu alloys
Shell small parts, dimensionally accurate, GJL, GS, 0.00-0.06 20-160
molding large volum es
high mold costs Al and Cu alloys
Investment small parts, complex parts, GS, Al alloys 0.00-0.04 10-80
casting 0.00-0.04
Die casting large volum es high mold costs hot chamber: 10-40
small to medium dimensionally accurate Zn, Pb, Sn, Mg
sized parts, even with thin walls, cold chamber:
large volum es fine-grain structure, Cu, Al
high investment costs
1 ) The ratio of largest relative deviation to the nom inal dime nsion is called the relative dime nsion al accuracy.
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164 Material science: 4. h a l s
Aluminum , Aluminum alloys - Overview
Alloy Material Main characteristics Main areas of application Product shapes1'
group number S|B|T
eCqounitpamineenrst,focor nthdeuiftosoadndand
Pure aluminum chemical industry, electrical page 166
conductors, reflectors, trims,
A(Al l content AW-to1000 •• wveerldyagboleodancdoldbrwazoarkbalebility license plates in automotive
>99.00%) AW-1990 • difficult for cutting ma chining manufacturing
• corrosion resistant
(Series1000) • anodized for decorative
purposes
A l u m i n u m , w r o u g h t a lu m i n u m a ll o ys , non-heat treatable (selection) page 166
AIMn AW-3000 • cold workable Roofing, siding, and supporting
to • weldable and solderable structures in the construction
industry, parts for radiators and air
AW-3990 • good machinability in conditioning units in automotive
(Series 3000) work-hardened condition manufacturing,
Com pared to Series 1000: drink and food cans
• higher strength in the packaging industry
• improved lye resistivity
AIMg AW-5000 • good cold workability with high Lightweight material for super-
AIM gM n to work hardening structures of com mercial vehicles,
tank and silo trucks,
AW-5990 • limited weldability metal signs, traffic sign,
(Series 5000) • good machinability in work-hard- rolling shutters and doors,
windows, doors, hardware in the
ened condition and with higher construction industry, machine
alloy contents frames, parts in the construction of
• weather and saltwater resistant jigs and fixtures and m old making
• good cold workability with high
• wgooorkd hwaerlddeanbiinligty
• good cutting machinability
• saltwater resistant
A l u m i n u m , w r o u g h t a l u m i n u m a l lo y s , heat treatable (selection) page 167
• 2) • 2) • 2)
AIMgSi AW-6000 • good cold and hot workability Load-bearing structures in the
to • corrosion resistant construction industry,
windows, doors,
AW-6990 • good weldability machine beds,
(Series 6000) • good cutting machinability in hydraulic and pneumatic parts;
with Pb, Sn or Bi additions:
heat treated condition very good cutting machinable free
cutting alloys
AlCuMg AW-2000 • high-strength values Lightweight material in automotive
to • good high-temperature strength and aircraft construction;
with Pb, Sn or Bi additions: • 2) • 2) • 2)
AW-2990 • limited corrosion resistance very good cutting machinable free
(Series 2000) • limited weldability cutting alloys
• good cutting machinability in
heat treated condition
AlZnMgCu AW-7000 • highest strength of all Al alloys High-strength lightweight material
to • best corrosion resistance in aircraft industry, machine con-
struction, tools and molds for plas-
AW-7990 in artificially aged condition tic molding, screws, extruded parts
(Series 7000) • limited weldability
• good cutting machinability in
heat treated condition
1 ) Product forms: S sheet; B bars; T tubes 166/431
2 ) Free mach ining alloys are only delivered as bars or tubes.
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Material science: 4. h a l s 165
Aluminum wrought aluminum alloys: Designations and material numbers
D es i g n at io n s f or a l u m i n u m a n d w r o u g h t a l u m i n u m a ll o y s cf. DIN EN 573-2 (1994-12)
The designations apply to wrought products, e.g. sheet, bars, tubes, wires and for wrought parts.
Designatio n examples: EN AW - Al 99,98
EN AW -AI MqISiCu - H111
EN European standard Chemical composition, purity
AW Alum inum w rought products
Al 99.98 pure aluminu m, degree of purity 99,98% Al
MglSiCu 1 % Mg, low percentage of Si and Cu
Material condition (excerpt) cf. DIN EN 515 (1993-12)
Condition Symbol Meaning of the symbol Meaning of the
material conditions
manufac- F Wrought products are manufactured without specifying mechanical
tured Wrought products
condition 0 limits, e.g. tensile strength, yield strength, elongation at fracture without secondary
01 operations
spher- 02 Spheroidizing can be replaced by hot working
oidized Solution annealed, cooled slowly to room temperature To restore w orka
H12 Thermomechanically formed, highest workability bility after cold
Work to working
hardened H18 Work hardened with the fo llowing hardness grades:
H111 To assure guaran-
H112 H12 H14 H16 H18 teed mechanical
1 4 hard 1 2 hard 3 / 4 hard 4 / 4 hard values,
e.g. tensile strength,
Annealed with subsequent slight work hardening yield strength
Slight work hardening
Heat T1 Solution annealed, stress relieved and naturally age hardened, not redressed To increase in ten-
treated
T2 Quenched like T1, cold wo rked and naturally aged sile strength, yield
T3 Solution heat treated, cold worked and naturally age hardened snter sesn,grtehdauncdt i ohna rodf-
T3510 Solution annealed, stress relieved and naturally aged the cold workability
T3511 Like T3510, redressed to hold the lim it deviation s
T4 Solution annealed, naturally age hardened
T4510 Solution annealed, stress relieved and naturally age hardened, not redressed
T6 Solution annealed, artificially aged
T6510 Solution annealed, stress relieved and artificially aged, not redressed
T8 Solution annealed, cold worked, artificially aged
T9 Solution annealed, artificially aged, cold worked
M a t er i a l n u m b e r s f or a l u m i n u m a n d w r o u g h t a l u m i n u m a ll o y s cf. DIN EN 573-1 (1994-12)
Material numbers apply to wrought products, e.g. sheet, bars, tubes, wires and for wrought parts.
Designation examples: EN AW - 1050A
EN AW-5154
EN European standard Indicates that country-specific limits deviate
AW Alum inum wrought products from the original alloy.
Alloy groups Alloy modifications Type number
Number Group Number Group 01-9 OAlrliogyinsal athllaoty deviate Within an alloy group, e.g.
from the original alloy AIMgSi, each type is assigned
1 pure Al 5 AIMg its own number.
2 AlCu 6 AIMgS i
3 AIMn 7 AlZn
4 AISi 8 other
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166 Material science: 4. h a l s
Aluminum wrought aluminum alloys
A l u m i n u m a nd w r o u g h t a lu m i n u m a ll oy s , cf. DIN EN 485-2 (2004-09),
non-heat treatable (selection) DIN EN 754-2,7 55-2 (2008-06)
Designation Delivery DC3> Mater ial 4 Thickness/ Tensile Yield Elong. at
(material- forr ns 2> onditi on diameter strength strength fracture Applications,
1) c ' firm EL Examples
N/mm2
number) RS mm N/mm2 %
Al 99.5 P F, H112 < 200 > 60 > 20 25 Equipment manufacturing,
(1050A) - z O, H111 <80 60-95 25 pressure vessels,
<40 100-135 >70
z H14 6 signs,
0,5-1,4 65-95 >20 packaging,
- w O, H111 1,5-2,9 65-95 >20
3,0-5,9 65-95 >20 22 trim
26
29
Al Mn1 — p F, H112 <200 >95 >35 25 Equipment manufacturing,
(3103) z O, H111 <60 95-130 >35 25 extruded parts,
z H14 < 10 130-165 > 110
6 vehicle superstructures,
0.5-1.4 90-130 >35 heat exchangers
- w O, H111 19
31..05 -- 52 .. 99 99 00 -- 11 33 00 >> 33 55 2214
Al MnlCu — p F, H112 <200 >95 >35 25 Roofing,
(3003) z O, H ill <80 95-130 >35 25 facades,
z H14 <40 130-165 > 110
6 load-bearing structures
- w O, H111 0.5-1.4 95-135 >35 in metal working
1.5-2.9 95-135 >35
3.0-5.9 95-135 >35 17
20
23
Al Mg1 — p F, H112 <200 > 100 >40 18 Roofing,
(5005) z O, H111 <80 100-145 >40 18 facades,
z H14 <40 > 110 6 windows, doors,
> 140
- w O, H111 0.5-1.49 >35 hardware
1.5-2.9 100-145 19
3.0-5.9 100-145
100-145 > 3 5 20
> 3 5 22
Al Mg2Mn0.3 p F, H112 < 200 > 160 >60 16 Equipment and devices for
(5251) - z O, H111 <80 150-200 >60 17 the food industry
<30 200-240 > 160
z H14 5
- w O, H111 0.5-1.4 160-200 >60 14
1.5-2.9 160-200 >60 16
3.0-5.9 160-200 >60 18
— p F, H112 < 150 > 180 >80 14 Equipment manufacturing,
O z 0, H il l <80 180-250 >80 16 aircraft industry,
z H14 <25 240-290 > 180 4 body parts,
H
c - w 0, H111 mold making
01..55--12..94 11 99 00 -- 22 44 00 >> 88 00 1164
3.0-5.9 190-240 >80 18
Al Mg5 — p F, H112 <200 > 250 > 110 14 Optical equipment,
(5019) z 0, H111 <80 250-320 > 110 16 packaging
z H14 <40 270-350 > 180
Al Mg3Mn 8
(5454) - p F, H112
0, H111 <200 >200 >85 10 Container construction,
200-275 >85 18 including pressure vessels,
- w 0, H111 0.5-1.4
1.5-2.9 215-275 >85 conduits,
3.0-5.9 215-275 >85 13 tank and silo trucks
215-275 >85 15
17
Al Mg4.5Mn0.7 — F, H111 <200 >270 > 110 12 Mold making and
(5083) pz 0, H111 <80 270-350 > 110 16 construction of jigs and fix-
z H12 <30 >200 6 tures, machine frames
>280
1 ) For simplification all designations and material numbers are written withou t the addition EN AW - .
2 ) Delivery forms: R round bar; S sheet, strip
3 ) DC Delivery con dition: p extrud ed; z draw n; w cold-rolled
4 ) Material con dition, see page 165
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Material science: 4. h als 167
Wrought aluminum alloys
Wrought aluminum alloys, cf. DIN EN 485-2 (2004-09),
heat treatable (selection) DIN EN 754-2,7 55-2 (2008-06)
Designation Deli very Thickness/ Tensile Yield Elong. at
(material- forr ns2> diameter strength
D C 3 ' Material 4 strength fracture Application,
1 ondition Am
c ' N/mm2 ftp 0.2 EL Examples
number) '
RS mm N/mm2 %
Al Cu4PbMgMn P T4, T4510 <80 > 370 > 250 8 Free cutting alloys,
(2007) - z T3 <30 >370 >240 7 also good mac hinability
30-80 >340 >220 6 at high machining
l Cu4PbMg z T3
(2030) P T4, T4510 <80 >370 > 250 outputs, e.g. for
- z T3 <30 >370 > 240 8 turned parts, milled parts
Al MgSiPb z T3 30-80 >340 > 220 7
(6012) p T5, T6510
- z T3 < 150 >310 >260 6
Al Cu4SiMg z T6 <80 >200 > 100
(2014) — p O, H il l <80 >310 >260 8
z T3 10
z T4 <200 <250 < 135 8
<80 >380 >290
wO <80 >380 >220 12 Parts in hydraulic,
p O, H111 0.5-1.4 <220 < 140 8 apunteoummoatitvice, and aircraft
- z T3 1.5-2.9 <220 < 140 12
3.0-5.9 <220 < 140 manufacturing,
z T6 12 load-bearing structures in
<200 < 250 < 150 13 metal m anufacturing
- wO 10-80 >425 >290
<80 >425 >315
16
0.5-1.4 <220 < 140
Al Cu4Mg1 1.5-2.9 <220 < 140 12 Parts in automotive and
(2024) 3.0-5.9 <220 < 140 9 aircraft manufacturing,
5 load-bearing structures in
- <> 113200 <> 66 50
>215 > 160 metal working
12
< 160 < 110
> 205 > 110 13
>310 >255
13
< 150 <85
Al MgSi — pz TT44 << 81050 < 150 <85 Windows, doors, vehicle
(6060) z T6 <80 < 150 <85 1156 superstructures, machine
12 beds, optical equipment
Al SilMgMn — p O, H111 <200 >350 > 290
(6082) z T4 <80 >350 >280 14 Hardware, parts in mold
z T6 <80 14 making and m anufacturing
- <220 < 140 10 of jigs and fixtures,
wO 0.5-1.4 < 220 < 140
1.5-2.9 < 220 < 140 machine beds, equipment
3.0-5.9 14 in the food industry
>490 >420 16
Al Zn4.5Mg1 - pz T6 <50 >460 >380 18
(7020) T6 <80
>450 >370 10 Parts in automotive and air-
- wO 0.5-1.4 >450 >370 10 craft manufacturing,
1.5-2.9 >450 >370
3.0-5.9 machine beds,
<275 < 165 12 superstructures of rail cars
> 540 >485 13
>455 >385 15
Al Zn5Mg3Cu - pz T6, T6510 <80 > 275 > 145 7 Parts in hydraulic,
(7022) T6 <80 8 pneumatic and aircraft
>>22 77 55 >> 114455
- w T6 3.0-12 manufacturing,
12.5-24 8 screws
Al Zn5.5MgCu 8
(7075) 25-50
7
— p O, H111 <200 10 Parts in automotive
z T6 <80 7 and aircraft manufacturing,
z T73 <80 10 mold making and
0.4-0.75 manufacturing of jigs and
10 fixtures, screws
wO 01..85--12..495
-
1100
1 ) For simplification all designations and material numbers are written withou t the addition EN AW - .
2 ) Delivery forms: R round bar; S sheet, strip
3 ) DC Delivery cond ition: p extruded ; z draw n; w cold-rolled
4 ) Material cond ition, see page 165
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168 Material science: 4. h als
Aluminum casting alloys
Designation of aluminum castings cf. DIN EN 1780-1 ...3 (2003-01), DIN EN 1706 (1998-06)
Alu min um castings are identified by designations or material numbers.
Designation Designation Material number
examples: EN AC - Al Mg5KF EN AC - 51300KF
EN European standard T.
AC Alu min um casting
K casting method K casting method
F material cond ition F material condition
(table below) (table below)
Chemical com position Alloy groups Type number
No. Group
Example Alloy percentage 21 AlCu No. Group Within one alloy group each
41 AISiMgTi 46 AISi9Cu type has its own number.
AIMg5 5% Mg 47 AlSi(Cu)
AISi6Cu 6% Si, additions of Cu 4424 AAIISSii7Mg
7511 AAlIZMngM g
AICu4M gTi 4M%g Caun,dadTdi itions of
Cas ting m ethod Material condition
Letter Casting me thod Letter Mean ing
S Sand casting F Casting condition, without subsequent processing
K Permanent mold O Spheroidized
casting I
D Die casting
L Investment casting Controlled cooling after pouring, naturally aged
I Solution annealed and naturally aged
IL Controlled cooling after pouring, artificially aged
O
IO Solution annealed and artificially aged
Alum inum casting alloys cf. DIN EN 1706(1998-06)
Strength values in casting condition (F)
Designation Hardn. Tensile Yield Elongation Properties 4'
(material- C2> M 3 ) strength strength at fracture
number)1'
HB ftm ftp 0m,22 EL
N/mm2 N/m C p M Application
AC-AIMg3 S F 50 140 70 3 Corrosion resistant,
(AC-51000) K F 50 150 70 5 - polishable,
AC-AIMg5 S F 55 160 90 anodized for decorative
3 - purposes; fittings,
(AC-51300) K F 60 180 100
AC-AIMg5(Si) S F 60 160 100 4 shhoiupsebhuoillddinagp, pliances,
(AC-51400) K F 65 180 110 3 chemical industry
3 -
AC-AISi12 S F 50 150 70 4 Resistant to we ather
(AC-44100) K F 55 170 80 5 influences, for comp lex,
L F 60 160 80 1 thin-walled and pressure-
AC-AISi7Mg tight parts;
(AC-42000) I 220 180 2
260 220 1 pump and motor housings,
75S O 240 190 1 cylinder heads, parts in air-
craft manufacturing
90I
KO
75L I O
AC-AISi12(Cu) S F 50 150 80 1 -
(AC-47000) K F 55 170 90 2
AC-AICu4Ti S T6 95 300 200 3 Highest strength values,
(AC-21100) K T6 95 330 220 7 - - vibration and high temp,
resistance; simple castings
1 ) For simplification all designations and material numbers are written withou t EN ,
e.g. AC-AIM g3 instead of EN AC-AIMg3 or AC-51000 instead of EN AC-51000.
2 ) C casting meth od (table above) 3 ) M material con dition (table above)
4 > C castability, P pressure tightness , M ma china bility; • very good , o goo d, - c ond itionally goo d
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Material science: 4. h als 169
Aluminum profiles - Overview, Round bars, Flat bars
Alum inum sections, Overview
Illustration Fabrication, Standard Illustration Fabrication, Standard
dimensions Round tubes dimensions
DIN EN Square tubes DIN EN
Round bars 755-3 Flat tub es seamless extruded 755-7
DIN EN d= 20-250 mm DIN EN
extruded 754-3 L profiles cold-drawn seamless 754-7
d = 3 - 1 0 0 m m d= 3 - 2 7 0 m m
DIN EN DIN EN
drawn 755-4 extruded 754-4
d= 8-320 mm DIN EN a = 15-100 mm
754-4 DIN EN
Square bars extruded seamless 755-7
DIN EN a = 15-250 mm DIN EN
extruded 755-4 b= 1 0 - 1 0 0 m m 754-7
s = 10-220 m m cold-drawn seamless
DIN EN a = 15-250 m m DIN
drawn 754-4 b= 1 0 - 1 0 0 m m 17711>
s =3 - 1 0 0 m m
Flat bars
extruded
w =1 0 -6 0 0 m m
s= 2 - 2 4 0 m m
w drawn
w= 5-200 mm
s= 2-60 mm
Sheet and strip
rolled DIN EN sharp corners or
s = 0.4-15 mm 485 round corners
h = 10-200 m m
Channels Tees
sharp corners or DIN sharp corners or DIN
round corners 97131' round corners 97141'
h = 10-160 mm h = 15-100 mm
1 ) Standards were withdra wn withou t replacement.
Round b ars, Flat bars, draw n cf. DIN EN 754-3, 754-4 (1996-01), DIN 179 81> , DIN 1796 1)
S cross-sectional area S m Wx = /x J=y
m' linear mass cm2 kg/m cm3 cm4
d, a
density mm • • • •O O O O0.79 1.00 0.21 0.27 0.10 0.17 0.05 0.08
W axial section mo dulus
0
/ axial moment 12
of inertia 16
20 1.13 1.44 0.31 0.39 0.17 0.29 0.10 0.17
25
30 2.01 2.56 0.54 0.69 0.40 0.68 0.32 0.55
35 3.14 4.00 0.85 1.08 0.79 1.33 0.79 1.33
40 4.91 6.25 1.33 1.69 1.53 2.60 1.77 3.26
45 7.07 9.00 1.91 2.43 2.65 4.50 3.98 6.75
9.62 12.25 2.60 3.31 4.21 7.15 7.37 12.51
12.57 16.00 3.40 4.32 6.28 10.68 12.57 21.33
15.90 20.25 4.30 5.47 8.95 15.19 20.13 34.17
50 19.64 25.00 5.30 6.75 12.28 20.83 30.69 52.08
55 23.76 30.25 6.42 8.17 16.33 27.73 44.98 76.26
28.27 36.00 9.72 21.21 36.00 63.62 108.00
60 7.63
Materials
<444' Wrought aluminum alloys, see pages 166 and 167.
1 ) DIN 1796 und DIN 1798 were replaced by DIN EN 754-3 or DIN EN 754-4. The 171/431
v DIN EN standards con tain no dime nsions . However, dealers continue to offer DIN
1798 and DIN 1796 round and square bars.
O round bars; • square bars
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170 Material science: 4. h als
Flat bars from aluminum alloys
Flat bars drawn (selection) cf. DIN EN 754-5 (1996-01), replace sDIN 17619)
S cross-sectional area w* h S m ©X ey Wx /x Wy 'y
m ' linear mass mm cm 2 kg /m cm cm cm 3 cm4 cm3 cm4
density 10x3 0 .3 0 0 .0 8 0.15 0.5 0.015 0.0007 0.033 0.016
e distanc et o edge 10 x 6 0.60 0.16 0.3 0.5 0.060 0.018 0.100 0.050
10 x 8 0.80 0.22 0.4 0.5 0.106 0.042 0.133 0.066
IW aaxxiiaall smeocmtioenntmodulus
o f inertia 15x3 0 .4 5 0 .1 2 0.15 0.75 0.022 0.003 0.112 0.084
15 x 5 0.75 0.24 0.25 0.75 0.090 0.027 0.225 0.168
15x8 1 .2 0 0 .3 2 0.4 0.75 0.230 0.064 0.300 0.225
20 x 5 1.00 0.27 0.25 1.0 0.083 0.020 0.333 0.333
20x8 1.60 0.43 0.4 1.0 0.213 0.085 0.533 0.533
20 x 10 2.00 0.54 0.5 1.0 0.333 0.166 0.666 0.666
20 x 15 3.00 0.81 0.75 1.0 0.750 0.562 1.000 1.000
25 x 5 1.25 0.34 0.25 1.25 0.104 0.026 0.520 0.651
25x8 2.00 0.54 0.4 1.25 0.266 0.106 0.833 1.041
25 x 10 2.50 0.67 0.5 1.25 0.416 0.208 1.041 1.302
3.75 1.01 0.75 1.25 0.937 0.703 1.562 1.953
25 x 15 5.00 1.35 1.0 1.25 1.666 1.666 2.083 2.604
25 x 20
3.00 0.81 0.5 1.5 0.500 0.250 1.500 2.250
Xr 30 x 10 4.50 1.22 0.75 1.5 1.125 0.843 2.250 3.375
<ux 30 x 15 6.00 1.62 1.0 1.5 2.000 2.000 3.000 4.500
30 x 20
4.00 1.08 0.5 2.0 0.666 0.333 2.666 5.333
40 x 10 6.00 1.62 0.75 2.0 1.500 1.125 4.000 8.000
40 x 15 8.00 2.16 1.0 2.0 2.666 2.666 5.333 10.666
40 x 20
10.00 2.70 1.25 2.0 4.166 5.208 6.666 13.333
40 x 25 12.00 3.24 1.5 2.0 6.000 9.000 8.000 16.000
40 x 30 14.00 3.78 1.75 2.0 8.166 14.291 9.333 18.666
40x35
5.00 1.35 0.5
50 x 10 7.50 2.03 0.75 2.5 0.833 0.416 4.166 10.416
50 x 15 10.00 2.70 1.0
50 x 20 2.5 1.875 1.406 6.250 15.625
12.50 3.37 1.25
50 x 25 15.00 4.05 1.5 2.5 3.333 3.333 8.333 20.833
50 x 30 17.50 4.73 1.75
50x35 2.5 5.208 6.510 10.416 26.041
20.00 5.40 2.0 2.5 7.500 11.250 12.500 31.250
50 x 40 6.00 1.62 0.5 2.5 10.208 17.864 14.583 36.458
60 x 10 9.00 2.43 0.75
60 x 15 2.5 13.333 26.666 16.666 41.668
12.00 3.24 1.0
60 x 20 15.00 4.05 1.25 3.0 1.000 0.500 6.000 18.000
60 x 25
3.0 2.250 1.687 9.000 27.000
3.0 4.000 4.000 12.000 36.000
3.0 6.250 7.812 15.000 45.000
60 x 30 18.00 4.86 1.5 3.0 9.000 13.500 18.000 54.000
60 x 35 21.00 5.67 1.75 3.0 12.250 21.437 21.000 63.000
24.00 6.48 2.0 3.0 16.000 32.000 24.000 72.000
60 x 40 2.16 0.5 4.0 10.666 42.666
80 x 10 8.00 1.333 0.666
80 x 15 12.00 3.24 0.75 4.0 3.000 2.250 16.000 64.000
16.00 4.52 1.0 4.0 5.433 5.333 21.333 85.333
80x20 20.00 5.40 1.25 4.0 8.333 10.416 26.666 106.66
80 x 25
80x30 24.00 6.48 1.5 4.0 12.000 18.000 32.000 128.00
80x35 28.00 7.56 1.75 4.0 16.333 28.583 37.333 149.33
80 x 40 32.00 8.64 2.0 4.0 21.333 42.666 42.666 170.66
100 x 20 20.00 5.40 1.0 5.0 6.666 3.666 33.333 166.66
Edge radii r 100 x 30 30.00 8.10 1.5 5.0 15.000 22.500 50.000 250.00
h 100 x 40 40.00 10.8 2.0 5.0 26.666 53.333 66.666 333.33
mm
'max
< 10
m m Material Wrought aluminum alloys, s ee page s166 and 167.
> 10-30
>30-60 0.6
1 0 1 ) DIN EN 754-5 contain sn o dimen sions. Specialized dealers still offer flat bar sin dimen-
sions according to DIN 1769.
20
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M a t e ri al s cie n ce : 4 . h als 171
Round tu bes. Channels from aluminum alloys
Round tubes, cold-drawn seamless (selection) cf. DIN EN 754-7 (1998-10), replaces DIN 1795 1)
d outside diameter dx s S m Wx /x dx s S m Wx /x
s wall thickness mm cm2 kg/m cm3 cm4 mm cm2 kg/m cm3 cm4
S cross-sectional
10 x 1 0.281 0.076 0.058 0.029 35 x 3 3.016 0.814 2.225 3.894
area
10 x 1.5 0.401 0.108 0.075 0.037 35 x 5 4.712 1.272 3.114 5.449
m dliennesairtymass 10 x 2 0.503 0.136 0.085 0.043 35 x 10 7.854 2.121 4.067 7.118
W axial section
12 x 1 0.346 0.093 0.088 0.053 40 x 3 3.487 0.942 3.003 6.007
modulus 12 x 1.5 0.495 0.134 0.116 0.070 40 x 5 5.498 1.484 4.295 8.590
I axial moment 12 x 2 0.628 0.170 0.136 0.082 40 x 10 9.425 2.545 5.890 11.781
of inertia 16 x 1 0.471 0.127 0.133 0.133 50 x 3 4.430 1.196 4.912 12.281
16 x 2 0.880 0.238 0.220 0.220 50 x 5 7.069 1.909 7.245 18.113
16 x 3 1.225 0.331 0.273 0.273 50 x 10 12.566 3.393 10.681 26.704
20 x 1.5 0.872 0.235 0.375 0.375 55x3 4.901 1.323 6.044 16.201
20 x 3 1.602 0.433 0.597 0.597 55 x 5 7.854 2.110 9.014 24.789
20 x 5 2.356 0.636 0.736 0.736 55 x 10 14.137 3.817 13.655 37.552
2255 xx32 21..047435 00..356900 01..707202 01..926738 6600 xx 510 185..673098 42..323431 1107..901797 3521..903581
25 x 5 3.142 0.848 1.335 1.669 60 x 16 22.117 4.890 20.200 60.600
30 x 2 1.759 0.475 1.155 1.733 70 x 5 10.210 2.757 15.498 54.242
30 x 4 3.267 0.882 1.884 2.826 70 x 10 18.850 5.089 24.908 87.179
30 x 6 4.524 1.220 2.307 3.461 70 x 16 27.143 7.331 30.750 107.62
Material e.g. alum inum alloys, non-heat treatable, see page 166
aluminum alloys, heat-treatable, see page 167
1 ) DIN EN 754-7 contains no dimens ions. Specialized dealers still offer round tubes in dimen-
sions according to DIN 1795.
Extruded channel sections (selection) cf. DIN 9713 (1981-09)1)
w width hx w * s x f cm m ex cm Wx cm W cm
h height mm kg/m cm cm; cm
1 62 0.780 0.945 0 628
S cross-sectional 20 x 20 x 3 x 3 0.437 1 00 0.945 3.64 0.805
area 30x30 x 3 x 3 2.52 0.687 1 10 2.43 2.29
35 x 35 x 3 x 3 2.97 1.50 1 28 3.44 6 02 2.06 3.73
m linear mass 0 802 1.75
density 40 x 15 x 3 x 3 1.92 0.431 2.04 4.07 2.91 0.349
40 x 20 x 3 x 3 2.25 0.518 2.0 0.610 2.59 5.17 0.795
W axial section 40 x 30 x 3 x 3 2.85 3.62 7.24 2.49 0 810 2.52
modulus 0.608 2.0
2.0 1.30
I axial moment 0.770 2.49
of inertia
40 x 30 x 4 x 4 3.71 1.00 2.0 1.05 4.49 8.97 3.03 3.17
40 x 40 x 4 x 4 20
40 x 40 x 5 x 5 4.51 1 22 2.0 1.49 5.80 11.6 4.80 7.12
5.57 1.50 1.52 6.80 13.6 5.64 8.59
50 x 30 x 3 x 3 3.15 0.851 2.5 0.929 4.88 12 2 2.91 2.70
50 x 30 x 4 x 4 5.65 7.80
50 x 40 x 5 x 5 4.91 1.33 2.5 1.38 7.83 19.6 6.54 9.26
6.07 1.64 2.5 1.42 9.32 23.3
60 x 30 x 4 x 4 4.51 1 22 3.0 0.896 7.90 23.7 4.12 3.69
60 x 40 x 4 x 4 5.31 1.43 3.0 1.29 10.1 30.3 6.35 8.20
60 x40 x 5 x 5 6.57 1.77 3.0 1.33 12 0 36.0 7.47 9.94
80 x 40 x 6 x 6 8.95 2.42 4.0 1 22 20 6 82.4 10.6 20 6
80 x 45 x 6 x 8 3.02 4.0
100 x 40 x 6 x 6 11 2 2.74 5.0 1.57 27.1 108 13.9 21 8
10 1
1 11 28.3 142 12.5 13.8
Rounded edges r< \ and 2r100 x 50 x 6 x 9 14.1 3.80 5.0 1.72 43.4 217 19.9 34.3
t 120 x 55 x 7 x 9 17.2 4.64 6.0 1.74 61.9 295 28 2 49.1
mm 12.35 3.35 1.83 56.4 350
mm '2 140 x 60 x 4 x 6 7.0 24.7 45.2
mm
3,4 2.5 0.4 Materials AIMgSi0.5; AIMgSil; AIZn4.5Mg1
5,6 0 6 1 ) DIN 9713 was withdrawn without replacement. Specialized dealers still offer channels
8,9 0.6 according to this standard.
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172 M a t er ia l scie nce: 4. h a l s
Magnesium alloys , Titanium , Titanium alloys
W r o u g h t m a g n e s iu m a l lo y s (selection) cf. DIN 9715 (1982-08)
Designation Material- Dcilive ry M 2) Bar dia- Tensile Yield Elong. at
number meter strength strength fracture Properties,
MgMn2 f(D r m 1) mm
MgAI3Zn Am N/mm2 EL application
BTD N/mm2
3.3520 F20 V 0o 200 145 Corrosion resistant,
3.5312 F24 I 0 240 155 15 weldable, cold workable;
10 cladding, containers
V 0 o
I 0
MgAI6Z n 3.5612 F27 < 8 0 270 195 10 Higher strength, limited weld-
ability; lightweight material
F29 0o 290 205
F31 0 310 215 10 in automotive, m achine and
gAI8Zn 3.5812 6 aircraft manufacturing
V 0 o cf. DIN EN 1753 (1997-08)
I 0
1 ) Delivery forms: B bars, e.g. round bars; T tub es; D stam ped part
2 ) M material con dition F20 R m = 10 •20 = 200 N/ m m2
M a g n e s i u m c a s t in g a l lo y s (selection)
Mate- Tensile Yield Elong. at
strength strength
Designation 1* Material- M2> rial- Hardness fracture Properties,
number1' condi- HB Am N/mm2 EL application
tion3) N/mm2
%
S F 50-65 160 90 2 Very good castability,
T6 50-65 240 90 8 dynamically loadable,
MCMgAI8Zn1 MC21110 K 2 weldable;
« K F 50-65 160 90 8 gear and m otor
D T4 50-65 160 90 < 7 housings
F 60-85 200-250 140-160
S F 55-70 160 90 6 High-strength,
T6 60-90 240 150 2 good sliding properties,
MCMgAI9Zn1 MC21120 K
K F 55-70 160 110 weldable;
D T6 60-90 240 150 2 automotive and aircraft
F 65-85 200-260 140-170
2 manufacturing,
1-6 armatures
MCMgAI6Mn MC21230 D F 55-70 190-250 120-150 4-14 Fatigue resistant, dynam-
MCMgAI7Mn MC21240 D F 60-75 200-260 130-160 3-10 ically loadable, high tem-
MCMgAI4Si MC21320 D F 55-80 200-250 120-150 3-12 perature resistant, gear
and motor housings
1 ) For simp lification, designations and material numbe rs are writte n wit hou t the EN - prefix,
e.g. MCMgAIBZnl instead of EN-MCMgAI8Zn1.
2 ) M casting me thod: S sand casting; K permane nt mo ld casting; D die casting
3 ) Material condition , see design ation of alum inum ca sting alloys, page 168
T i t a n i u m , t i t a n i u m a l l o y s (selection) cf. DIN 17860 (1990-11)
Designation Material- Df<€Dilirvme>1)ry Sheet Hard- Tensile- Yield Elong. at
number thickness ness strength strength fracture Properties,
S BT HB
s Am N/mm2 EL application
mm N/mm2
%
290-410
Til 3.7025 0.4-35 120 390-540 180 30
Ti2 3.7035 150 460-590 250 22 Weldable, solderable,
Ti3 3.7055 170 320 18 glueable, machinable,
290-410
TilPd 3.7225 0.4-35 120 390-540 180 cold and hot workable,
Ti2Pd 3.7235 150 250 30 fatigue resistant,
> 1070 22 corrosion resistant-
TiAI6V6Sn2 3.7175 <6 320 > 1000 1000
6-50 320 950 weight saving designs
>920 10 in machine construction,
T1AI6V4 3.7165 <6 310 >900 870 8 electrical engineering,
6-100 310 830
> 1050 precision engineering,
iAI4Mo4Sn2 3.7185 6 -6 5 350 1 05 0
8 optics and medical tech-
8 nology, chemical indus-
try, food industry, air-
9 craft manufacturing
1 ) Delivery forms: S sheet and strip; B bars, e.g. round bars; T tubes 174/431
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Material science: 4.9 Heavy non-ferrous metals 173
Overview of the heavy non-ferrous m etals
Heavy non-ferrous metals have a density q > 5 k g / d m3. However, in technical literature q ; >4.5 kg/dm3 is also used
as limit for non-ferrous metals.
• Construction materials in mac hine and plant construction: copper, tin, zinc, nickel, lead and their alloys
• Metals used for alloys: chro miu m, va nad ium, cobalt (for effects of alloying m etals, see page 129)
• Precious metals: gold, silver, platinu m
Pbausreedmoentamlsa: teHrioaml otygpeicnaelopursopsetrruticetsu,ree;.gl.ogwoosdtreenlegcthtrsic, allecssoenrduimctpivoirtyta. nce as a cons truction material; usually used
Heavy non-ferrous m etal alloys: Improved properties com pared to base metals, such as higher strength, higher hard-
ness, better machinability and corrosion resistance, construction materials for various application. Classified accord-
ing to m a n u f ac t u r e i n t o w r o u g h t a ll o y s an d casting alloys.
O v e r v i e w o f c o m m o n h e av y n o n - fe rr o u s m e t a l s an d a ll o y s
Metal, alloy Main characteristics Application examples
group
Copper (Cu) High electrical condu ctivity and therma l conduc- Pipes in heating and plum bing equipm ent,
tivity, inhibits bacteria, viruses and molds, corro- cooling and heating coils, electrical wiring,
sion resistant, good appearance, easily recyclable electrical parts, cookware, building facades
CuZn Wear-resistant, corrosion-resistant, good hot • Wrought alloys: deep-drawn parts, screws,
(brass) and cold workability, good machinability, polish- springs, pipes, instrument parts
able, shiny golden, medium strengths
CuZnPb • Casting alloys: armature housings,
CuZn plain bearings, precision mechanical parts
multi-alloy
CuSn Very goo d ma chinability, limited cold work ability, Automatic screw machine parts, precision
(bronze)
very good hot w orkability mechanical parts, fittings, hot-pressed parts
CuAl
Good hot workability, high strengths, Armature housings, plain bearings, flanges,
CuNi(Zn) wear-resistant, weather-resistant valve parts, water housings
Zinc (Zn) Very corrosion-resistant, good sliding properties, • Wrought alloys: hardware, screws,
ZnTi good wear-resistance, strength resulting from springs, metal hoses
ZnAICu cold working is highly variable
Tin (Sn) • Casting alloys: spindle nuts,
SnPb worm gears, solid plain bearings
SnSb
Nickel (Ni) High strength and toughness, very corrosion • Wrought alloys: highly stressed lock
NiCu resistant, salt water resistant, heat resistant, nuts, ratchet wheels
NiCr highly cavitation resistant
Lead (Pb) • Casting alloys: armatures in the chemical
PbSn industry, pump bodies, propellers
PbSbSn
Extremely corrosion resistant, silvery Coins, electrical resistors,
appearance, good machinability, polishable, heat exchangers, pumps, valves in
cold workable salt water cooling systems, ship building
Resistant to atmospheric corrosion Corrosion protection of steel parts
Good workability, joinable by soft soldering Roofing, gutters, downs pouts
Very good castability Thin walled, finely articulated die castings
Good chemical resistance, non-toxic Coating of steel sheet
Low viscosity Soft solder
Good dry running properties Small, dimensionally precise die castings,
Corrosion resistant, high temperature resistant plain bearings with average loading
Corrosion protection layer on steel parts
Extremely corrosion resistant and high temp, resist. Equipment, condensers, heat exchangers
Extremely corrosion resistant and very high temper- Chemical installations, heating tubes,
ature resistant and nonscaling, e.g. age hardenable boiler internals in power plants, gas turbines
Shields against x-ray and gamma rays, corrosion Shielding, cable sheathing,
resistant, toxic tubes for chemical e quipmen t
Low viscosity, soft, good dry running properties Soft solder, slidin g sheaths
Low viscosity, corrosion resistant, good running plain bearings, small, dimensionally precise die
and sliding properties (low friction) castings such as pendulums, parts for measuring
equipment, meters
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174 Ma terial science: 4.9 Heavy non -ferrous me tals
Designation of heavy non-ferrous m etals
Designation system (excerpt) cf. DIN 1700(1954-07)1)
Exam ple: NiCu30Fe F45 Special properties
Manufacture, application GD - Sn80Sb
F45 minim um tensile strength
E Chemical composition R m = 10 •4 5 N / m m 2
G SEalencdtriccaasl timngaterial Example Comment
GC Continuous casting 2
GD Die casting NiCu30Fe Ni-Cu alloy,
GK Permanent mo ld casting 30% Cu, trace iron a =ag4e5 0haNrd/menmed
GZ Centrifugal casting 9 annealed
L Solder Sn80Sb Sn-Sb alloy, 80% Sn, h hard
S Welding filler alloys approx. 20% Sb ka naturally aged
ku cold worked
1 ) The standard has been withdrawn. However the material designations are ta partially age hardened
still used in individual standards. wa artificially aged
wu hot worked
zh drawn hard
Designation system for copper alloys cf. DIN EN 1982 (2008-08) and 1173 (2008-08)
Examples: CuZn31Si - R620
CCuuZSnn3181PPbb22 - C -G S C as ting method
GS Sand casting GM Permanent mold casting
GZ Centrifugal casting GC Continuous casting
Chemical composition GP Die casting
Example Meaning Product form
CuZn31Si Cu alloy, 31% Zn, trace Si C Material in the form of castings
B Material in ingot form
CuZn38Pb2 Cu alloy 38% Zn, 2% Pb
Wrought alloys (without code letter)
CuSnl1Pb2 Cu alloy 1 1% Sn, 2% Pb
Material c on dition (selec tion)
Example Meaning Example Meaning
A007 Elongation at fracture EL = 7 % Y450 Yield strength R p = 45 0 N /m m 2
D M Manufactured condition, witho ut specified
Drawn, with out specified mechanical properties
mechanical properties Min imu m tensile strength R m = 6 20 N / m m 2
H160 Vickers hardness HV = 160 R 62 0 cf. DIN EN 1412(1995-12)
Material num bers for copper and copper alloys
Example: C W 024 A
Code letters for material groups
Letter Material group Letter Material group
A or B Copper-nickel alloys
C or D Copper H Copper-zinc alloys
Copper-tin alloys
E or F Copper alloys, percentage of the J Copper-zinc binary alloys
alloying element < 5% K Copper-zinc-lead alloys
G Copper-zinc mu lti-alloys
Copper alloys, percentage of the Lor M
alloying elements > 5% N or P cf. DIN EN 12844(1999-01)
Copper-aluminum alloys R or S
M a t e r i a l n u m b e r s f o r c a s t i n g s o f z in c a l l o y s
Example: Z P 0 4 1 0
Z Zinc alloy I Content of the next higher
P Casting alloying element
0 = next higher alloying
Al content Cu content
04 = 4% aluminum 1 = 1% copper element < 1%
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M aterial science: 4.9 Heavy non -ferrous me tals 175
Copper alloys
Wrought copper alloys
Designation, C2> Bars Hardness Tensile Yield Elong. at Properties,
Material 03) HB strength strength fracture application examples
n u m b e r 11
mm Am N/mm 2 EL
N/mm 2 %
1 Copper-zinc alloys cf. DIN EN 12163(1998-04)
CuZn28 R310 4-80 - 310 120 27 Very good cold workability, good
(CW504L) R460 4-10 460 420 hot workability, machinable,
85-115
H085 4-80 > 145 - very easily polished;
H145 4-10 - instrument parts, bushings
CuZn37 R310 2-80 - 310 120 30 Very good cold workab ility, good
(CW508L) R440 2-10 440 400 hot workability, machinable,
70-100
H070 4-80 > 140 - - - very easily polished; deep-drawn
H140 4-10 parts, screws, springs, press rollers
CuZn40 R340 2-80 340 260 25 Very goo d hot workab ility,
(CW509L) H080 machinable; rivets, screws
> 80
1 Copper-zinc alloys (multi-alloys) cf. DIN EN 12163 (1998-04)
CuZn31Si R460 5-40 - 460 250 22 Good cold workability; hot wo rkable,
(CW708R) R530 5-14 530 330 12 machinable, good sliding properties;
115-145
H115 5-40 > 140 - - sliding parts, bearing bushings,
H140 5-14
-
guides
CuZn38Mn1 Al R490 5-40 - 490 210 18 Good hot workability, cold
(CW716R) R550 5-14 550 280 10 workable, m achinable, sliding
120-150
H120 5-40 > 150 - properties, weather resistant;
H150 5-14 - sliding elements, guides
- 460 270
CuZn40Mn2Fe1 R460 5-40 540 320 20 Good hot workab ility, cold wo rkable,
(CW723R) R540 5-14 110-140 8 machinable, average strength,
> 150 - - weather resistant;
| 5-40 - equipment manufacturing,
5-14 architecture
H110
H150
I Copper-zinc-lead alloys cf. DIN EN 12164(2000-09)
CuZn36Pb3 R340 40-80 90 340 160 20 Excellent mac hinability, limited cold
(CW603N) R550 2-4 150 550 450 workability; automatic lathe parts
CuZn38Pb2 R360 40-80 90 360 150 25 Excellent machinability, good cold and
(CW608N) R550 2-6 150 550 420 hot workability; screw machine parts
CuZn40Pb2 R360 40-80 90 360 150 20 Excellent machinability, good hot
(CW617N) R550 2-4 150 550 420 workability; stamping blanks, gears
I Copper-tin alloys cf. DIN EN 12163(1998-04)
CuSn6 R340 2-60 — 340 230 45 High chemical resistance,
(CW452K) R550 2-6 550 500 good strength;
85-115
H085 2-60 > 180 - - springs, metal hoses, pipes and
H180 2-6
—
bushings for suspension bodies
CuSn8 R390 2-60 - 390 260 45 High chemical resistance,
(CW453K) R620 2-6 620 550 high-strength, good sliding
90-120
H090 2-60 > 185 — properties; plain bearings, rolled bear-
H185 2-6
—
ing bushings, contact springs
R390 2-60 - 390 260 45 Excellent sliding properties, high
R620 2-6 620 550 wear-resistance, endurance strength;
CuSn8P
(CW459K) H090 2-60 90-120 highly stressed plain bearings in auto-
H185 2-6 > 185 - - motive and machine manufacturing
1 ) Material nu mbe rs acco rding to DIN EN 1412, see page 174.
2 ) C Material con dition acc ording to DIN EN 1173, see page 174. In manu factured c ond ition M all alloys can be deliv-
ered up to diameter D = 80 m m.
3 ) D Diameter for round bars, width across flats for square bars and hexagonal bars, thickness for flat bars.
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176 Ma terial science: 4.9 Heavy non-fe rrous me tals
Copper and refined zinc alloys
Designation, C2> Bars Hardness Tensile Yield Elong. at Properties,
Material 03) HB strength strength fracture application examples
number1'
mm Am N/mm2 EL
N/mm 2 %
Copper-aluminum alloys cf. DIN EN 12163 (1998-04) I
CuAI10Fe3Mn2 R590 10-80 — 590 330 12 Corrosion-resistant, wear-resistant,
(CW306G) R690 10-50 690 510 6 fatigue-resistant, high-temperature
10-80 140-180 — resistant; screws, shafts, gears, worm
CuAI10Ni5Fe4 H140 10-50 > 170 - -
(CW307G) H170 gears, valve seats
10-80 - 680 480
R680 740 530 10 Corrosion resistant, wear-resistant,
R740 10-80 170-210 8 nonscaling, fatigue resistant, high tem-
> 200 -
H170 perature resistant; capac itor bases,
H200
control parts for hydraulics
I Copper-nickel-zinc alloys cf. DIN EN 12163(1998-04)
CuNi12Zn24 R380 2-50 380 270 38 Extremely good cold workability,
R640 2-4 640 550 machinable, easily polished;
(CW430J) H090 2-50 90-130 — deep-drawn parts, flatware, applied
H190 2-4 > 190 — arts, architecture, spring contacts
CuNi18Zn20 R400 2-50 — 400 280 35 Good cold workability, machinable,
(CW409J) R650 2-4 650 580 non-tarnishing, easily polished;
100-140 membranes, spring contacts,
H100 2-50 > 200 - flatware
H200 2-4
1 > Mate rial num bers acc ording to DIN EN 1412, see page 174. 2 ) C Material con dition acc ording to DIN EN 1173, see page 174.
3) D Diameter for round bars, width across flats for flat bars and hexagonal bars, thickness for flat bars.
| Cast copper alloys cf. DIN EN 1982 (1998-12) |
Designation, Tensile Yield s trength Elong. at Hardness Properties , applic ation
strength Nf/lpm0m,22 fracture HB
11
N Am 2 A
Material number /mm %
CuZn15As-C 160 70 20 45 Excellent soft and hard solderability,
(CC760S) salt water resistant; flanges
CuZn32Pb2-C 180 70 12 45 Good machinability, resistant to indus-
(CC750S) trial water up to 90°C; armatures
CuZn25AI5Mn4Fe-C 750 450 8 180 Very high strength and hardness,
(CC762S) good machinability; plain bearings
CuSn12-C 260 140 7 80 High wear-resistance;
(CC483K) spindle nuts, worm gears
CuSnl1Pb2-C 240 130 Wear-resistant, good dry running
(CC482K) 5 80 properties; plain bearings
CuAI10Fe2-C 500 180 18 100 Mechanically stressed parts;
(CC331G) levers, housings, bevel gears
CuAI10Ni3Fe2-C 500 180 18 130 Corrosion stressed parts;
(CC332G) armatures, propellers
CuAI10Fe5Ni5-C 600 250 13 140 Strength and corrosion
(CC333G) stressed parts; pumps
1) Material numb ers according to DIN EN 1412, see page 174. More cast Cu alloys for plain bearings, see page 261.
Strength values apply to separately sand-cast test specimens.
High-grade cast zinc alloys cf. DIN EN 12844(1999-01)
ZP3 (ZP0400) 280 200 10 83 fVoerrydigeocoadstcinagsstability; preferred alloys
ZP5 (ZP0410) 330 250 5 92
ZP2 (ZP0430) 335 270 5 102 Good castability; very good
ZP8 (ZP0810) 370 220 8 100 machinability, universally applicable
ZP12 (ZP1110) 400 300 5 100 Injection, blow, and deep-draw molds
ZP27 (ZP2720) 120 for plastics, sheet metal working tools
425 300 2.5
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Material science: 4.10 Other materials 177
Composite m aterials, Ceramic m aterials
Composite materials
Composite Base Fiber Density Tensile Elong. at Modulus Service
material mate- content strength tear of tempe-
r i a l 11 e rature
% elasticity Application examples
g/cm 3 up to °C
ob £r 2
N/mm 2 N/mm
EP 60 365 3.5 Shafts, joints, conne cting bars,
ship hulls, rotor blades
UP 35 1.5 130 3.5 10800 50 Containers, tanks, pipes,
dome lights, body parts
PA 66 35 1.4 1602> 53) 5000 190 Large-area, stiff housing parts,
PC 30 power plugs
PPS 30
FRP 1.42 902) 3.53) 6000 145 Housings for printers, c ompu ters,
(Fiberglass televisions
reinforced
plastic)
1.56 140 3.5 11200 260 iLnaemlpecstroicckael tesqaunipdmceonilts
PAI 30 1.56 205 7 11700 280 Bearings, valve seat rings,
seals, piston rings
1.44 155 2.2 10300
PEEK 30 1.45 190 2.5 17150 Light construction materials in
1.42 205 6 11700 315 aerospace applications, metal
1.44 210 1.3 13000
substitute
CFRP PPS 30 260 Like FRP-PPS
PAI 30
(Carbon PEEK 30 180 Like FRP-PAI
fiber
315 Like FRP-PEEK
reinforced
plastic)
1 ) EP epoxide UP unsaturated polyester PA 66 polyam ide 66, semi-crystalline PC polycarbonate
PPS polyphenylene sulfide PAI polyamideimide PEEK polyetheretherketone
2 ) ay yield stress 3 ) es elong ation at yield stress
| Ceramic materials
Mater ial Density Flexural Modulus Coefficient
strength of of linear
e expansion Properties, application exam ples
Ob elasticity
Name Desig- g/cm 3 a
nation N/mm 2 N/mm 2
1/K
Alu- C130 2.5 Hard, wear-resistant, chemical and heat resistant,
minum 160 100000 0.000005 high insulating resistance;
silicate
insulators, catalytic conve rters, refractory hous ings
Alu- C799 3.7 Hard, wear-resistant, chemical and heat
minum 300 300000 0.000007 resistant;
oxide
ceramic inserts, wire drawing dies, biomedicine
Zirconium Zr02 5.5 High stability, high strength, heat and chemical
oxide 800 210000 0.000010 resistant, wear-resistant;
drawing dies, extrusion dies
Silicon Hard, wear-resistant, thermal-shock resistance,
carbide SiC 3.1 600 440000 0.000005 corrosion-resistant even at high temp eratures;
abrasives, valves, bearings, combu stion chambers
Silicon Si3N4 3.2 High stability, thermal-shock resistance,
nitride 900 330000 0.000004 high strength; cutting ceramics, guide and runner
blades for gas turbines
Alu- High thermal c onductivity, high electrical
minum AIN 3.0 200 300000 0.000005 insulation property;
nitride
semicondu ctors, hous ings, heatsinks, insulating parts
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178 Material science: 4.10 Other materials
Sintered m etals
Designation s ystem for sintered metals cf. DIN 30910-1 (1990-10)
Des ignation ex ample: Sint - A 1 0 sintered smo oth
Code letters for material class 1. 1st numb er for chemical comp osition
Code letter Volume ratio Area of application Number Chemical composition
AF R x i n mass fraction in %
A <73 Filter
75 ±2.5 plain bearings Sintered iron , sint. steel, C u < 1 % w i t h or w i t hout C
B plain bearings Sintered steel, 1 to 5% Cu w, ith or without C
80 ± 2.5 Formed parts w ith Sintered steel, Cu >5% , with or without C
sliding properties
Sintered steel, with or without C uor C ,other
C 85 ± 2.5 plain bearing, formed parts alloying elements < 6% , e. g N. i
D 90 ± 2.5 Formed parts
E 94 ± 1.5 Formed parts Sintered steel, with or without C uor C ,other
F >95.5 Sintered forged aSlilnotyeirnegdeallelomyesn, tsC> u>6%60, %e, . ge .N. gi ,s.Cinrtered CuSn
formed parts 6 Sintered nonferrous heavy metals, except for no. 5
7 Sintered light alloys, e. g s. intered aluminum
3,9 Reserved numbers
Treatment condition
Treatment condition of the material Treatment condition of the surface
• sintered • steam treated • sintered smo oth • machined
• calibrated • sintered forged • calibrated smooth • surface treated
• heat treated • isosta tically pressed • sized and coined smooth
Sintered metals (selection, soft ma gne tic sintered me tals not inclu ded ) cf. DIN 30910-2-6 (1990-10)
Designa- Hardness Tensile strength Chemical composition Properties,
tion Rm N / m m2 application examples
HB mjn
Filter parts for gas and
Sint-AF 40 — 80-200 Sintered steel. Cr 16-19%, Ni 10-14% liquid filters
Sint-AF 50 40-160 Sintered bronze, Sn 9 -1 1 %, rem. Cu Bearing materials with
exceptionally large pore vol-
Sint-A 00 >25 > 6 0 Sintered iron, C < 0.3% , Cu < 1% ume for the best emergency
running properties; bearing
Sint-A 20 >40 >150 Sintered steel, C < 0.3%, Cu 15 -2 5% liners, bearing bushings
Sint-A 50 >25 >70 Sintered bronze, C < 0.2%, Sn 9 - 1 %, rem. Cu
Sint-A 51 >18 >60 Sintered bronze, C 0. 2- 2% , Sn 9- 1 1 %, rem. Cu Plain bearings with very
good dry running properties,
Sint-B 00 >30 >80 Sintered iron, C < 0.3% , Cu < 1% low stressed formed parts
Sint-B 10 >40 >150 Sintered steel C < 0.3%, Cu 1 - 5 %
Sint-B 50 >30 >90 Sintered bronze, C < 0.2%, Sn 9-11 %, rem. Cu Plain bearings, formed parts
Sint-C 00 >45 >150 Sintered iron, C < 0.3% , Cu < 1% with average stress w ith
Sint-C 10 >60 >200 Sintered steel C < 0.3%, Cu 1 - 1 , 5 % good sliding properties; auto
Sint-C 40 >100 >300 Sintered steel. Cr 16-19%, Ni 10-14%, Mo 2% parts, levers, clutch parts
Sint-C 50 >35 >140 Sintered bronze, C < 0.2%, Sn 9-11 %, rem. Cu
Sint-D 00 >50 >250 Sintered iron, C < 0.3% , Cu < 1% Formed parts for higher
Sint-D 10 >80 >300 Sintered steel C < 0.3%, Cu 1 - 5 % stresses; wear-resistant
Sint-D 30 >110 >550 Sintered steel C < 0.3%, Cu 1- 5 % , Ni 1- 5 % pum p parts, gears, some are
Sint-D 40 >100 >450 Sintered steel Cr 16- 19% , Ni 10 -14 % , Mo 2% corrosion-resistant
Sint-E 00 >60 >200 Sintered iron, C < 0.3% , Cu < 1% Formed parts for precision
Sint-E 10 >100 >350 Sintered steel C < 0.3%, Cu 1- 5 % engineering, for household
Sint-E 73 >55 >200 Sintered aluminum Cu 4 - 6 % appliances, for the electrical
Sint-F 00 >140 >600 Sinter forged steel, containing C and Mn industry
Sint-F 31 >180 >770 Sinter forged steel, containing C, Ni, Mn, Mo
Sealing rings, flanges for
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Material science: 4.1 a s t is
Overview of plastics
General Advantages: Disadvantages:
properties • lower strength and heat resistance in
• low density
Classification • electrically insulating comparison to metals
Processing • heat and sound ab sorbing • some are combustible
• decorative surface • some are nonresistant to solvents
F a b r i c a t io n • economical forming • limited material reutilization
Recycling
• weather and chemical resistance Elastomers
Thermoplastics Thermosets
Hot workable Not workable Not workable
Weldable Non-weldable Non-weldable
Generally glueable Glueable Glueable
Machinable Machinable Machinable at low tempera-
tures
Injection mo lding Pressing Pressing
Injection blow molding Transfer molding Injection molding
Extruding Injection molding , m olding Extruding
Easily recyclable Not recyclable, Not recyclable
Structure
possible reuse as filler
Temperature behavior
Amorphous thermoplastica brittle hard thermo- thermo- viscous
elastic plastic
V> .O range of use
elongation at
fracture
Filamentary macromolecules 20°C a welding range; b hot-working;
without cross-linking temperature T c injection molding, extrusion
Semi-c r y s talline ther mop las tic
/ —^.lamella (crystalline)
Crystalline areas have amorphous 20°C a welding range; b hot-working,-
greater cohesive forces intermediate te mp e ra tu re T — c injection molding, extrusion
layers
F i l am e n t a r y t h e r m o s e t p l as t i c s
hard
tensile strength
*OJ gro1 range of use
elongation^ fracture^
Macromolecules with 20°C 50°C temperature T-
many cross-links
brittle rubber-elastic
Filamentary elastomers hard
_«to
t range of use
to 0
—.QJ cNnJ
Macromolecules in random 0°C 20°C
condition w ith few cross-linkages temperature J •
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180 Material science: 4.1 a s ti s
Basic polymers, fillers and reinforcing m aterials
Designations for basic polym ers cf. DIN EN ISO 1043-1 (2002-06)
Desig- Meaning T y p e11 Desig- Meaning T y p e 11 Desig- Meaning T y p e11
nation nation nation
ABS Acrylonitrile PAK Polyacrylate T PTFE Polytetrafluoroethylene T
butadiene styrene
T PAN Polyacrylonitrile T PUR Polyurethane D
AM MA Acrylonitrile-methyl-
methacrylate PB Polybutene T PVAC Polyvinyl acetate T
T PBT Polybutylene terephthalate T PVB Polyvinyl butyral T
ASA Acrylonitrile-styrene-acrylate T PC Polycarbonate T PVC Polyvinyl chloride T
CA Cellulose acetate T PCTFE Polychlorotrifluoroethylene T PVDC Polyvinylidene chloride T
CAB Cellulose acetate butyrate T PE Polyethylene T PVF Polyvinyl fluoride T
CF Cresol-formaldehyde D PET Polyethyleneterephthalate T PVFM Polyvinyl formaldehyde T
CMC Carboxymethyl cellulose MNM PF Phenol formaldehyde D PVK Poly-N-vinylcarbazole T
CN Cellulose nitrate MNM PIB Polyisobutene T SAN Styrene-acrylonitrile T
CP Cellulose propionate T PMMA Polymethylmethacrylate
EC Ethyl cellulose POM Polyoxymethylene; T SB Styrene-butadiene T
EP Epoxide MNM
D Polyformaldehyde T SI Silicone D
SMS Styrene-a-methylstyrene T
EVAC Ethylene-vinyl acetate E PP Polypropylene T UF Urea-formaldehyde D
MF Melamine formaldehyde D PS Polystyrene T UP Unsaturated polyester D
PA Polyamide T PSU Polysulfone T VCE Vinyl chloride-ethylene T
1 ) MN M modified natural materials; E elastomers; D thermoset plastics; T thermo plastics
Code letters for desig nation of special properties cf. DIN EN ISO 1043-1 (2002-06)
CL 1' Special CL 1> Special CL 1> Special CL 1> Special
properties properties properties properties
B block, brominated F flexible; liquid N normal; novolak T temperature
C chlorinated; crystalline H high; homo O oriented U ultra; no plasticizers
D density I impact tough P plasticized V very
E foamed; L linear, low R raised; resol; hard
M moderate, molecular S saturated; sulphonated w weight
elastomer
X cross-linked, cross-linkable
PVC-P: Polyvinylchloride , p lasticized; PE-LLD :Linear Polyethylene low density
1 ) code letter
C o d e l e t t er s a n d a b b r e v i a t i o n s f o r f i l le rs a n d r e in f o r c in g m a t e r i al s cf. DIN EN ISO 1043-2 (2002-04)
A b b r e v i a t i o n f o r m a t e r i a l 11
Desig- Material Desig- Material Desig- Material Desig- Material
nation nation nation nation
B Boron G Glass P Mica T Talc
C Carbon W Wood
K Calcium carbonate Q Silicate
D Alum inum trihydrate L Cellulose R Aramid X not specified
E Clay M Mineral, metal2' S Synthetic materials z other
Abb rev iations for s hape and s truc ture
Desig- Shape, structure Desig- Shape, structure Desig- Shape, structure Desig- Shape, structure
nation nation nation nation
B pearls, balls, G ground stock N nonwoven (thin) VV veneer
beads H whiskers P paper W woven
K knitwear R roving X not specified
C chips, shavings L laminates S peelings, flakes Y yarn
M matted, thick T spun yarn, cord Z other
D powder
F fibers
= > GF: glass fiber; CH :carbon w hisker; M D :mineral powder 182/431
1 1 The materials can be further designated, e.g. by its chemical symbol or another symbol from relevant inter-
national standards.
2 ) For metals (M) the type of metal mu st be specified by the chemical sym bol.
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Material science: 4.1 a s ti s
Identification, Distinguishing characteristics
Metho ds for identifying plastics
Floating test Solubility in Visual test Behav ior wh en
solvents heated
Solution density Plastics Appearance of the specimen is
in g/cm3 floating
transparent cloudy
0.9-1.0 PB, PE, PIB, PP Thermosets and CA, CAB, CP, ABS, ASA, • Thermopl. soften and melt
1.0-1.2 ABS, ASA, CAB, CP, PTFE are not solu- EP, PC, PS, PA, PE, • Thermosets and elastomers
PA, PC, PM MA , ble. PMMA, PVC, POM, PP, decompose without soften-
1.2-1.5 PS, SAN, SB SAN PTFE ing
1.5-1.8 Other thermo-
1.8-2.2 CA, PBT, PET, plastics are solub le Touch Burning test
POM, PSU, PUR in certain solvents;
e.g. PS is soluble in Waxy to the touch: • flame color
Organically filled benzene or ace- PE, PTFE, POM , PP • fire behavior
molding material tone. • soot formation
• odor of the smoke
PTFE
Distinguishing characteristics of plastics
Desig- Density Burning behavior Other characteristics
n a t i o n 1' g/cm 3
ABS = 1.05 Yellow flame, soots strongly, smells like Tteoturagchhelolarisdteic, , sisounnodt sdidsuslol lved by carbon
CA 1.31 coal gas Pleasant to the touch, soun ds d ull
CAB 1.19
MF 1.50 Yellow, sputtering flame, drips, smells like Sounds dull
PA distilled vinegar and burnt paper Very brittle, rattling sound
PC ~ 1.10 (compare to UF)
1.20 Yellow, sputtering flame, drips burning, Tough elastic, not brittle, sounds dull
smells like rancid butter
Tough hard, not brittle, rattling sound
Very flammable, chars with white
edges, smells like ammonia
Blue flame with yellow edges, drips
in fibers, smells like burnt horn
Yellow flame, goes out after flame is
remove d, soots, smells like phen ol
PE 0.92 Light flame w ith blue core, drips off b urning, Wfinagxerlnikaeils, unrofatcber,itctalen, bweosrkcirnagtched with the
PF odor like paraffin, smoke hardly
PMMA
POM visible (compare with PP) temperature > 230°C
PP
1.40 Very flammable, yellow flame, chars, Very brittle, rattling so und
smells like phenol and burnt wood
1.18 Luminous flame, fruity odor, Clear when uncolored, sounds dull
crackles, drips
1.42 Bluish flame, drips, sm ells like Not brittle, rattling sound
formaldehyde
0.91 Light flame with blue core, drips off burning, Cannot mark with fingernail,
odor like paraffin, smoke hardly not brittle
visible (compa re wi th PE)
PS 1.05 Ylikeellocwoafllagmase,, dsroipostsosfftrbounrgnlyin, gsmells swe et Bbyritctlaer,bsoonuntedtsralcikhelotrinidney ammeotnagl, iosthdeisrssolved
Waxy surface
P TF E 2.20 Non flamm able, strong odor whe n red hot Polyurethane, rubber elastic
Polyurethane foam
PUR 1.26 Yellow flame, very strong odor
PVC-U « 0.05 Rattling sound (U = hard)
Very flamm able, extinguishes after the flame
1.38 is removed, smells like hydrochloric acid, chars Rubbery flexible, no sou nd (P = soft)
PVC-P 1.20-1.35 Can be more flammable than PVC-U, depending Tough elastic, is not dissolved by carbon
on plasticizer, smells like hydrochlo ric acid, chars tetrachloride
Not as brittle as PS, is disso lved by
SAN 1.08 Yellow flame, soots strongly, sm ells carbon tetrachloride a mong other things
like coal gas, drips off burning Very brittle, rattling sound
(compare to MF)
SB 1.05 Yellow flame, soots strongly, smells like
Very brittle, rattling so und
coal gas and rubber, drips off burning
UF 1.50 Very flammable, chars with white
edges, smells like ammonia
UP 2.00 Lum inous flame, chars, soots, smells
like styrene, glass fiber residue
1 ) Compare to page 180
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182 Material science: 4.1 a s t i s
Thermoplastics (selection)
Working
Abbrev- Density Tensile- Impact temperature,
iation strength11 toughness long-term2 Application examples
Designation Trade name
g/cm3 N/mm2 mJ/mm2 °C
ABS Acrylonitrile- Terluran, « 1.05 35-56 80- 85-100 Telephone housings,
1.14 43 n.f.3' instrument panels,
butadiene-styrene Novodur 1.14 57 n . f . 3)
0.96 20-30 surf boards
0.92 8-10 214)
PA 6 Polyamide 6 Durethan, 1.18 70-76 80-100 Gears,
Maranyl, n.f.3' 80-100 plain bearings,
A 66 Polyamide 66 Resistane, 1.42 50-70 n.f.3> 80-100 screws,
Ultramid, 60-80 cables,
Rilsan 18 housings
70-100
PE-HD Polyethylene, 100 Battery cases,
high density fuel containers,
Hostalen, n.f.3' garbage cans,
PE-LD Polyethylene, Lupolen, pipes,
lo w density 13-20
Vestolen A fcilambsle, insulation,
bottles
PMMA Polymethyl- Plexiglas,
methacrylate Degalan, Optical lenses,
Lucryl warning lights,
dials,
lighted letters
POM Polyoxy- Delrin, 95 Gears,
methylene; Hostaform, 100-110 plain bearings,
Ultraform valve bodies,
55-85 housing parts
PP Polypropylene HNoosvtoalleenn, PP, 0.91 21-37
Procom, Heating ducts,
Vestolen P washing machine
parts,
Styropor, fittings,
pump housings
PS Polystyrene Polystyrol, 1.05 40-65
Packaging material,
Vestyron flatware,
film cartridges,
insulating boards
PTFE Polytetrafluor- Hostaflon, 2.20 15-35 n.f.3' 280 Maintenance free
ethylen Teflon, 24) 60-80 bearings,
Fluon n.f.3' <60 piston rings,
seals, pumps
Polyvinylchloride, 1.20
-1.35 Hoses,
PVC-P plasticized Hostalit, 20-29 seals,
PVC-U cable sheathing,
Vinoflex, pipes,
fittings,
Vestolit, containers
Polyvinylchloride Vinnolit,
no plasticizers Solvic 1.38 35-60
SAN Styrene- Luran, 1.08 78 23-25 85 Graduated dials,
acrylnitrile Vestyron, battery housings,
copolymer Lustran headlight housings
Styrene- Vestyron, 1.05 22-50 40 - 55-75 Television housings,
SB cbouptaodlyiemneer Styrolux n.f.3' packaging material,
clothes hangers,
distribution boxes
1 1 Values depend on temperature and test speed. 184/431
2 ) Duration of temperature application has a significant effect.
3 ' n.f. = no fracture of t he specimen
4 ' Impact toughnes s
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Material science: 4.1 a s ti s
Designation of thermop lastic molding m aterials
Polyethylene PE cf. DIN EN ISO 1872-1 (1999-10)
Polypropylene PP cf. DIN EN ISO 1873-1 (1995-12)
Designation system
Name Standard
block: number block
Example:
Therm oplastic ISO 1873 PP-R EL 06-16-003 ISO 8773
Data block 1
In data block 1 the mo lding material is designated by its abbre viation PE or PP after the hyphe n.
For polypropylene the additional information follows: PP-H homopolymers of t he propylene, PP-B thermoplastic,
impact tough PP (so-called block-copolymer); PP-R thermoplastic, static copolymers of the propylene.
Data block 2
Intended applications and/or Important properties , additiv es and c oloring
processing meth ods for PE and PP fo r PE and PP
Sym- Position 1 Sym- Position 1 Sym- Positions 2 to 8 Sym- Positions 2 to 8
bol bol bol bol
CB CBalolewndmeorilndging ML MInojencotfioilanmm. oeldxitnrugsion AB APnrotci-ebsloscsktianbgiliazgeer nt NL LNiagthutrasltacboilliozresr
E Extrusion Q Stamping C Artificial color P Impact tough
F Extrusion (films) R Rotomolding D Powder R Mold release agent
C General use S Powder sintered E Blowing agent S Sliding and lubricating agent
H Coating X Unspecified F Fire extinguisher T Increased transparency
Y Fiber production3'
K Cable insulation C Pellets X Cross-linkable
H Thermal aging stabilizer Y Increased electr. co ndu ctivity
Z Static inhibitor
D ens ity of PE in k g /m 3 Data block 3 Melting m ass flow rate in g/10 min
Modu lus of elas tic ity
for PP in MPa (N /m m 2)
Sym- above-to Sym- above-to Con ditions for PE Sym- fo r PP an d PE
bol bol Load bol
-901 Temp, above-to
00 901-906 000
03 906-911 in °C in kg 001 -0.1
08 003 0.1-0.2
911-916 02 - 4 0 0 190 0.325
13 916-921 06 4 0 0 - 8 0 0 190 2 1 6 006 0.2-0.4
18 921-925 10 8 0 0 - 1 2 0 0 190 5.00 012
23 190 21 6 022 0.4-0.8
925-930 16 1 2 0 0 - 2 0 0 0 0,45 0.8-1.5
27 930-936 28 2000-3500 090 1.5-3.0
33 936-942 40 3500 200 3.0-6.0
40 400
Impact toughness for PP in kJ/m2 6-12
02 -3 12-25
05 3 - 6 25-50
4550 994428--994584 0195 6-12 700 50
12-20
57 9 5 4 - 9 6 0 25 2 0 - 3 0
62 960 35 30
Data block 4 for PE and PP
Position 1: Sym bol f or f iller/ reinf orcer grade Position 2 : Symbol for p hysical form
Symbol Material Symb ol Material Symbol Form Symbol Form
B Boron S Synthetic, B Pearls, balls S Lamina
C Carbon organic D Powder Flakes
G Glass F Fiber
T Talcum X Not specified
K C h a lk G Ground stock
L Cellulose W Wood H Whiskers Z Other
X Not specified
M Mineral, metal z Other
Position 3: Mass percentage of the filler material
Thermoplastic ISO 1873-PP-H, M 40-02-045, TD40: Polypropylene molding material, homopolymer,
fabricated by injection molding, modulus of elasticity 3500 MPa; Impact toughness 3 kJ/m 2, melting mass
flow rate 4.5 g/10 min, filler 40% talcu m powd er
1 > Data block 5 optional - entry of additiona l requirements 2 ) 2 com mas - data block missing 3 ) only for PP
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184 Material science: 4.1 a s ti s
Thermoset molding m aterials, Laminated m aterial
Designation and properties of therm oset plastic molding materials
Type Type Resin Filler Flexural Impact Water
DIN 7708-2 ISO 14526 strength1' toughness1' absorption
(old stan-
cf. N/mm2 kJ/m2 mg
dard) page 180
Pourable phenolic plastic m oldin g m aterials (PF PMC) cf. DIN EN ISO 14526 3 (2000-08)
31 PF (WD30+ 30% wood flour Q: >40 Q >4.5 < 100
MD20) 20% mineral flour M: > 50 M >5.0 < 150
< 150
51 PF (LF20+ 20% cellulose fibers Q: > 40 Q >4.5 <200
MD25) 25% mineral flour M: > 50 M >5.0
<30
84 PF (SC20+ 20% synthetic chips Q: > 35 Q >5.5
M: >45 M >6.5
LF15) Phenolic 15% cellulose fibers
Q: > 30 Q >7.0
74 PF (SS40 (formalde- 40% (to 50%) flaky M: >45 M >9.0
to SS50) hyde)-resin organ, synthesis product
Q: > 30 Q >2.5
13 PF(PF40 (PF) 40% (to 60%) M: >40 M >3.5
to PF60) mica fibers
83 PF(LF20+ 20% cellulose fibers Q: > 35 Q >5.5 < 150
MD25) 25% mineral fibers M: > 45 M >6.0 <30
12 PF (GF20+ 20% fiber glass Q: > 50 Q >6.0
GG30) 30% glass grist M: >60 M >7.0
= > PMC ISO 14 526 - PF(WD30+MD20), M: Pourable molding compound (PMC), phenolic (formaldehyde)
resin (PF), approx. 30% of wood flour (WD30), approx. 20% of mineral flour (MD20); recommended
machining process: injection molding (M)1)
U r ea f o r m a l d e h y d e m o l d i n g m a t e r i al s (U F P M C) a n d cf. DIN EN ISO 14527 3 (2000-08)
u r e a / m e l a m i n e f o r m a l d e h y d e m o l d i n g m a t er i al s ( U F /M F - P M C ) ( U F / M F -P M C )
131.5 UF(LD10+ Urea 20% cellulose po wder Q: > 45 Q: > 5.0 < 150
M D 3 0 ) , X , E 2) (formal- 30% mineral flour M: > 55 M: > 7.5
131 dehyde) < 150
130 UF(LD10+ 20% cellulose fibers Q: > 45 Q: > 5.0 <200
MD30) resin 30% mineral flour M: > 55 M: >7.5 < 100
UF(WD30+ (UF)
MD20) 30% wood flour Q: > 35 Q: > 4.5
UF/MF Urea/me- 20% mineral flour M: >40 M: > 5.0
(LF20+S10) lamine
20% cellulose fibers Q: > 6.5
(formalde- 10% organic M:-
hyde) resin synthesis product
PMC ISO 14527 - UF(LD20+MD20), M: Pourable molding compound (PMC), urea formaldehyde resin
(UF), approx. 20% of cellulose powder (LD20), approx. 20% of mineral flour (MD20); recommended
machining process: injection molding (M)1)
Laminated materials 3* cf. DIN EN 60893 (2004-12)
Resin types Types of reinforcing materials
Type of resin Designation Abbreviation Designation
EP Epoxy resin CC Cotton fabric
MF Melamine (formaldehyde) resin CP Cellulose paper
PF Phenolic (formaldehyde) resin CR Com bined reinforcing material
UP Unsaturated polyester resin GC Glass fiber fabric
SI Silicone resin GM Fiber glass mat
PI Polyim ide resin WV Wood veneer
Nominal
thicknesses 0.4; 0.5; 0.6; 0.8; 1.0; 1.2; 1.5; 2; 2.5; 3; 4; 5; 6 ; 8; 10; 12; 14; 16; 20; 25; 30; 35; 40; 45; 50; 60; 70; 80; 90; 100
t in mm
Board IEC 60893 - 3 - 4 -PF CP 201,10 x 500 x 1000 :Board m ade of phenolic (formaldehyde) resin/cellulose
paper (PF CP 201) according to IEC standard 4* 60893-3-4 with f= 10 mm, w = 500 mm, / = 1000 mm .
1> Q = compression molding co mpou nd; M = injection molding comp ound
2 ) X = machin ing process not specified; A = free of am mon ia; E = specific electric properties
3 ) Applications: insulators for electrical equipm ent, for instance, or bearing liners, rollers and gears for machine co nstruction
4 ) IEC = International Electrotechnical Com mission (international standard)
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Material science: 4.1 a s ti s
Elastom ers, Foam m aterials
Elastomers (rubber)
Abbre- Density Tensile Elong: at Working Properties,
via- Designation g/cm 3 s t r e n g t h 2' fracture temperature application examples
tion1'
N/mm 2 % °C
BR Butadiene 0.94 2(18) 450 -6 0 to +90 High abrasion resistance;
rubber 1.27 5(15) tires, belts, V-belts
-1.36
CO Epichlorhydrin 1.25 11 (25) 250 -30 to +120 Vibration damping, oil and gasoline
rubber 1.25 18 (20) -10 to +120 resistant; seals, heat
4(25 ) resistant dampers
0.86
CR Chloroprene 400 -3 0 to +110 Oil and acid resistant, very flamma ble,
CSM rubber seals, hoses, V-belts
EPDM
Chlorosulfonated 300 -3 0 to +120 Aging and weather resistant, oil resistant;
polyethylene insulating material, molded goods, films
Ethylene- Good electrical insulator, not resistant
propylene rubber 500 -5 0 to +120 against oil and gasoline; seals, profiles,
bumpers, cold water hoses
FKM Fluoro rubber 1.85 2(15) 450 - 1 0 to +190 Aaebrraosspioancereasnisdtaanut,tobemsot ttihveerminadl ursetsriisetasn; ce;
rotary shaft seals, O-rings
IIFt Isobutene- 0.93 5(21) 600 -30 to +120 Weather and ozone resistant;
IR Isoprene cable insulation, autom otive hoses
NBR rubber
NR 0.93 1 (24) 500 -60 to +60 Low resistance to oil, high strength;
Isoprene truck tires, spring elements
rubber
1.00 6(25) Abrasion resistant, oil and gasoline resistant,
Acrylonitrile- 450 - 2 0 t o + 1 1 0 electr. condu ctors, O -rings, hydraulic hoses,
butadiene
rubber rotary shaft seals, axial seal
Natural rubber 0.93 22 (27) 600 -6 0 to +70 Low resistance to oil, high strength;
Isoprene rubber truck tires, spring elements
PUR Polyurethane 1.25 20 (30) 450 -3 0 to +100 Elastic, wear-resistant; timing belts,
SIR rubber 1.25 1 (8) seals, couplings
Styrene-lsoprene Good electr. insulator, water repellant
rubber 250 -8 0 to +180 O-rings, spark plug caps, cylinder
head and joint sealing
SBR Styrene-Butadiene 0.94 5(25) 500 -3 0 to +80 Low resistance to oil and gasoline;
rubber tires, hoses, cable sheathing
1 ' cf. DIN ISO 1629 (1992-03) 2 ) Value in parentheses = with additive or filler reinforced elastomer
Foam materials cf. DIN 7726 (1982-05)
Foam materials consist of open cells, closed cells or a mixture of closed and open cells.
Their raw den sity is lower than that of the structural substance. A distinction is made between hard, med ium hard,
soft, elastic, soft elastic and integral foam material. Max. working Thermal Water absorp-
temperature conductivity tion in 7 day s
Stiffness, Raw m aterial base of the Cell structure Density
hardness foam material kg/m 3 o C 1) W/(K • m ) Vol.-
Hard Polystyrene Predominantly 15 -30 75(100) 0 .0 35 2-3
Polyvinylchloride closed 50 -1 30 60 (80) 0 . 03 8 <1
Polyethersulfone cell 4 5 -5 5 180 (210) 0.05 15
Polyurethane 20-100 80(150) 0.021 1-4
130 (250) 0 . 02 5 7 -1 0
Phenolic resin Open cell 40 -1 00 90(100) 0.03 20
Urea-formaldehyde resin 5-15 up to 100 0.036 1-2
0 .0 3 6
Medium- Polyethylene Predominantly 25 -40 -6 0 to +50 0.033 1-4
hard Polyvinylchloride closed 50 -70 up to 150 approx. 1
Melamine resin cell 10.5 -11.5
to soft- Polyurethane polyester type -40 to +100 0.045
elastic Polyurethane polyether type Open cell 20-45
1 ) Long-term working temperature, short-term in parentheses
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186 Material science: 4.1 a s t is
Plastics processing
Injection m olding and extrusion
Injection molding Tolersince grou|p 1 > for
temperalture in °C
Abbre- Injection pres- E x t r u s i o n Shrinkage Gen- Dimeiisions
viation in eral w iith
sure process tole-
1.5-3.5 deviaitions
Substance Mold in bar temperature 0.8-23' rances Series 12»Series 2 2 1
0.2-0 .5
in °C 1-2 .5
0.3-0.7
PE 160-300 20-7 0 5 00 1 9 0 - 2 3 0 150 140 130
PP 170-300 20-10 0
PVC, hard 170-2 10 4' 30- 60 1200 235-270 150 140 130
PVC, soft 170-2 00 4' 20-6 0
PS 180-250 30- 60 1000-1800 170-190 130 120 110
3 00 1 5 0 - 2 0 0 --
- 180-220 130 120 110
SB 180-250 20-70 - 180-220 0.4-0.7 130 120 110
SAN 200-260 40- 80 180-200 0.5 -0.6 130 120 110
ABS 200-240 40- 85 800-1800 180-220 0.4-0.7 130 120 110
PMMA 200-250 50-9 0 400-1200 180-250 0.3-0.8 130 120 110
PA 210-290 80-120 700-1200 230-275 1- 2 130 120 110
POM 180-2304' 50-120 800-1 700 180-22 0 1-3 .5 140 130 120
PC 280-3204' 80- 120 >80 0 240 -290 0.7-0 .8 130 120 110
p F5) 9 0 — 1 1 0 4) 170-190 800-2500 0.5-1.53) 140 130 120
MF 6> 95-1104) 160-180 1500-2500 - 0.6-1.73> 130 120 110
5 95-11 0 150-160 1500 -2500 0.4 -0.6 140 130 120
UF >
1 ) See table below 2 ) Series 1: Can be mainta ined w itho ut special effort, S eries 2: Requires h igh finishing effort
3 ) Transverse and longitud inal shrinkage may differ 4 ) With scre w in je ctio n mo ld in g ma ch in e
5 ) W ith organic filler material 6 ) W ith inorganic filler material
Tolerances for plastic m old ed parts cf. DIN 16901 (1982-11)
Tolerance Nominal dimension range over - up to in mm
group
Code- 0-1 1-3 3-6 6-10 10-15 15-22 22-30 30-40 40-53 53-70 70-90 90- 120-
from table letter 1' 120
above 160
General tolerances
A ±0.23 ±0.25 ±0.27 ±0.30 ±0.34 ±0.38 ±0.43 ±0.49 ±0.57 ±0.68 ±0.81 ±0.97 ±1.20
150 B ±0.13 ±0.15 ±0.17 ±0.20 ±0.24 ±0.28 ±0.33 ±0.39 ±0.47 ±0.58 ±0.71 ±0.87 ±1.10
140 A ±0.20 ±0.21 ±0.22 ±0.24 ±0.27 ±0.30 ±0.34 ±0.38 ±0.43 ±0.50 ±0.60 ±0.70 ±0.85
B ±0.10 ±0.11 ±0.12 ±0.14 ±0.17 ±0.20 ±0.24 ±0.28 ±0.33 ±0.40 ±0.50 ±0.60 ±0.75
130 A ±0.18 ±0.19 ±0.20 ±0.21 ±0.23 ±0.25 ±0.27 ±0.30 ±0.34 ±0.38 ±0.44 ±0.51 ±0.60
B ±0.08 ±0.09 ±0.10 ±0.11 ±0.13 ±0.15 ±0.17 ±0.20 ±0.24 ±0.28 ±0.34 ±0.41 ±0.50
Tolerances for dimensions with deviations
140 A 0.40 0.42 0.44 0.48 0.54 0.60 0.68 0.76 0.86 1.00 1.20 1.40 1.70
B 0.20 0.22 0.24 0.28 0.34 0.40 0.48 0.56 0.66 0.80 1.00 1.20 1.50
130 A 0.36 0.38 0.40 0.42 0.46 0.50 0.54 0.60 0.68 0.76 0.88 1.02 1.20
B 0.16 0.18 0.20 0.22 0.26 0.30 0.34 0.40 0.48 0.56 0.68 0.82 1.00
120 A 0.32 0.34 0.36 0.38 0.40 0.42 0.46 0.50 0.54 0.60 0.68 0.78 0.90
B 0.12 0.14 0.16 0.18 0.20 0.22 0.26 0.30 0.34 0.40 0.48 0.58 0.70
110 A 0.18 0.20 0.22 0.24 0.26 0.28 0.30 0.32 0.36 0.40 0.44 0.50 0.58
B 0.08 0.10 0.12 0.14 0.16 0.18 0.20 0.22 0.26 0.30 0.34 0.40 0.48
1 ) A For dimensions which do not depend on mold dimensions; B For dimensions which depend on mold dim ensions
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Material science: 4.1 a s ti s
High-temperature plastic s, Polyblends, Reinforcing fibers
High-temperature plastics
Abbre- Designation Tensile Working Special properties Application examples
viation strength temperature
N / m m 2 f ro m t o High-temperature strength Bearings, seals, coatings, high-
PTFE Polytetra- frequency cable, chemical
-2 0 to 260 °C, astnrdencghtehm, ihcaarldrneessisstaanncde, low equipment
tf rl uaodree tnyal emnee 10 short-term to coefficient of friction
"Teflon" High-temperature strength Bearings, gears, seals, air and
300 °C and chemical resistance, go od space travel (instead
PEEK Polyether- sliding behavior of metals)
etherketone -65 to 250°C,
97 short-term to
300 °C
Polyphenylen- -200 to 220°C, High strength, hardness, stiff- Pump housings,
sulfide
PPS 70 short-term to ness, high chem ical, weather bearing bushings, space travel,
260 °C and radiation resistance nuclear power stations
PSU Polysulfone -40 to 150°C, High strength, hardness, stiff- Microwave dishes, spools,
140-24 0 short-term to ness, high chemical and radia- circuit boards, oil level indica-
tion resistance, clear tors, needle bearing cages
200 °C
Polyimide 75-100 -2 40 to 360 °C, High strength in large Jet engines, aircraft noses,
PI trade name short-term to temperature range, piston rings, valve seats, seals,
400 °C radiation resistant, dark, non- electronic connection
"Vespel" transparent components
Polyblends
Polyblends (also know n as "blen ds") are mixtures of different therm oplastics. The special properties of these copo ly-
mers result from num erous possible combina tions of the properties of the original materials.
Abbre- Designation Components Special Application examples
viation properties
90% polystyrene, Stacking boxes, fan
S/B Styrene/butadiene 10% butadiene rubber Brittle hard, at low tem pe- housings, radio housings
ratures not impact tough
ABS Acrylonitrile/butadiene/ 90% styrene-acrylonitrile, Brittle hard, impact tough Telephones, dash-boards,
styrene 10% nitrile rubber even at low temperatures hub caps
PPE + Polyphenylenether + various com positions; High hardness, high cold Radiator grill, computer
PS Polystyrene possibly can be reinforced impact toughness to parts, medical equipment,
with 30% glass fiber -40°C, physiologically solar panels,
PC + Polycarbonate + harmless trims
ABS Acrylnitrile/Butadiene/ various
Styrene compositions High strength, hardness, Instrument panels,
PC + toughness, dimensional fenders, office machine
PET Polycarbonate + Poly- different stability under heat, housings, lamp housings
ethyleneterephthalate compositions impact tough, shock-proof in motor vehicles
Exceptional impact tough- Motorcycle helmets,
ness and shock resistance automotive parts
Reinforcing fibers
Designa- Density Tensile Elongation Application examples
tion kg/dm 3 strength at fracture Special properties
N/mm 2 %
Glass fiber 2.52 3400 4.5 Isotropic1', good strength, high- Body parts, aircraft manufac-
GF
temp. strength, inexpensive turing, sailboats
Aramide 3400 Lightest reinforcing fiber, Highly stressed light parts,
fibers -3800
AF3' 1.45 2.0-4.0 ductile, fracture to ugh , strongly crash helmets,
anisotropic1', radar-penetrable bulletproof vests
Carbon 1750 0.35-2.12' Ext remely anisot ropic 1', high- Parts for racing cars, sails for
fiber - 50002'
CF 1.6-2.0 strength, light, corrosion resist- racing yachts,
ant, goo d electr. cond uctor aerospace applications
Thermosets (e.g. UP and EP resins) and thermoplastics with high working temperatures (e.g. PSU, PPE, PPS, PEEK,
PI) are used as embedding materials (so-called matrix).
1 ) Isotropic = the same ma terial properties in all directions; anisotropic = material properties in the direction of the
fibers are different from those transverse to fibers
2 ) Depends significantly on the fiber defect sites occurring du ring the manu facturing process
3 ) Trade name "Kev lar"
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188 M a t e ri a l s cie n ce : 4 .1 a t e r i a l s
Material testing m ethods - Overview
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M a t e ri a l s cie n ce : 4 .1 a t e r i a l s 189
Materi al testing methods - Overview
Illustration Process Applications, notes
Hardness test by Sho re page 195
The testing device (durometer) is pressed on Control of plastics (elastomers).
the test piece with contact pressure F It is hardly possible to derive any relation-
Tinhteo tshperintegstlopaiedceed indenter penetrates sshhoiprse thoaordthneerssm. aterial properties from the
Working tim e 15 s
The shore hardness is displ. directly on the device
Shear test page 191
Cylindrical specimens are loaded in standard- Used to determine the shear strength rse, e.g.
ized equipmen t until fractured due to shearing
- for strength calculations of shear loaded
Breaking strength is determined from the parts, e.g. pins
maximum shearing force and cross-sectional
area of the test sp ecimen - to predict cutting forces in formin g
Notched-bar impact bending test page 191
Notched test specimens are subjected to - To test me tallic materials for behav ior after
bending load by pendulum impact and are impact bending loads
fractured
Notch impact toughne ss = energy required - To monitor heat treatment results, e.g.
to deform and fracture the test specime n with quenching and tempering
- To test the tempe rature be havior of steels
Eric hs en c upping tes t page 191
Sheet metal clamped on all sides is - For testing of sheet metal and strip for
deformed until crack forma tion by a ball their deep drawing capability
The deformation depth until crack propaga-
- Evalua tion of the sheet surface for
tion is a measure of deep drawing capability changes during cold w orking
Fatigue test Cylindrical specimens with polished surface Used to determine material properties with
are alternately loaded with constant mean dynamic loading, e.g.
A? 5 stress a m and variable alternating stress
am plitude oA, until fracture. The grap hical - fatigue strength, fatigue endurance and
representation of the series of tests yields fatigue strength under alternating stresses
the Woh ler (S-N) curve
- endurance limit
Ultrasonic testing
A transducer sends ultrasonic signals - Nonde structive testing of parts, e.g. for
through the workpiece. The waves are cracks, cavities, gas holes, inclusions, lack
reflected by the front wa ll, the back wall and of fusion, differences in microstructure
by defects of a certain size - To determine the type of defect, the size
and the location of the defect
The screen of the testing device displays the - To measure wall and layer thicknesses
echoes
The test frequency determines the detectable
defect size which is limited by the grain size
of the test spe cimen
Metallography
Etching metallographic test specimens (microsec- - To check the crystalline stru cture
tions) develops the microstructure which can then - To mo nitor heat treatments, formin g and
Sbepeocbimseernvepdreupnadreartitohne: m etallographic m icroscope. - jTooindinegterpmroinceesgsreasin distribution and
Removal avoid structural transformation grain size
- Defect testin g
Embedding -»• sharp edged microsections
Grindin g removal of layers of deforma tion
Polish ing -»• high surface qua lity
Etching -* structural developm ent
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190 M a t e ri a l s cie n ce : 4 .1 a t e r i a l s
Tensile test, Tensile test sp ecimens
Tensile test cf. DIN EN 10002-1 (2001-12)
Stress-strain diagram EL elongation at fracture Sq initial cross section Tensile stress
with distinct yield point, F tensile force of the test specime n
F m m a xim u m f orce Tensile strength
e.g. for s oft s teel F e force at yield S u smallest test P ^m
specimen cross Mm = 7T"
EL strength limit
strain e in % — • Fpo.2 force at yield section after fracture Yield s trength
Stress-strain diagram e norma l strain R F 6
without distinct yield point, strength limit Z reduction of area at e S ~
e .g . fo r q u e n c h ed a n d at 0.2% strain offset
tempered steel L0 initial gage length fracture Yield strength at
Lu gage length a z tensile stress 0.2 strain offset
0.2 E L after fracture R m tensile strength
strain £ in % d0 initial diameter of R e yield strength
the test specimen ftpo.2 yield strength at
0.2% strain offset
Vs yield strength ratio
Tensile test specimens
Normally, round proportional bars with an initial gage
lUennmgtahcohfin Le0d =s 5p e•c dim0 eanres uasreeda. llowed wit h
- uniform cross sections, e.g. for specimens of sheet
metal, profiles, wires
-cast test specimens, e.g. of cast iron materials or
non-ferrous casting alloys
Elongation at fracture EL
If tensile test specimens are used that contract during
the test, the initial gage leng th L 0 has an effect on the
elongation at fracture EL.
Smaller initial gage length L0 -» greater elongation at
fracture EL
Yield s tr e n g th r a tio : \/s = Re (fpl0.2) / ^ m
dItitpiornovoidf ethseinsftoeremlsa:tion about the heat treatment con-
normalized 14 0.5-0.7
quenched & tempered Vs 0. 7- 0. 95
Tensile test specimens cf. DIN 50125 (2004-01)
Shape A Round tens ile tes t s pec imens w ith s m oot h c y lindric al ends , s hapes A and B
d0 4 5 6 8 10 12 14 Shapes, application
Lo 20 25 30 40 50 60 70 Shape A: Machined test spe-
Lc 24 30 36 48 60 72 84 cimens for clamping in the
Shape A f 1 5 6 8 10 12 15 17 tensioning wedge
Shape B: Machined test spe-
M 65 80 95 115 140 160 185 cimens with threaded heads
hape B ^ M6 M8 M10 M12 M16 M18 M20 produce more precise mea-
40 50 60 75 90 110 125 surement of the elongation
Tensile test specimens, other shapes
a 3 4 5 6 7 8 10 Shapes, application
Shape E b 8 10 10 20 22 25 25 Flat specimens with heads
Shape E L0 30 35 40 60 70 80 90 for tensioning wedges,
12 15 15 27 29 33 33 tensile test specimens of
B 38 45 50 80 90 105 115 strips, sheets, flat bars and
115 135 140 210 230 260 270 profiles
c
MMaacchhiinneedd rroouunndd tteesstt ssppeecciimmeennss wwiitthh csohnoiucladleerenddsends
Lt Unmachined sections of round bars
Shape C
Shape D
Shape F
Shape G Unm achined sections of flat bar steel and profiles
Shape H Flat specimens for testing sheets with thicknesses between 0.1 and 3 mm
Tensile test specim en DIN 50125 - A10x50: Shape A, dQ = 10 mm, L0 = 50 mm 192/431
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M a t e ri al s cie n ce : 4 .1 a t e r i a l s 191
Shear test, Notched bar impact bending test, Cupping test
Shear test cf. DIN 50141 (2008-07), w ithd raw n
hardened 1 Fm ma xim u m she a r fo rce So initial cross section Shear strength
bushings T d0 initial diameter of of the test specimen
the test specimen r s B shear strength
/ specim en length
The test is carried out on tensile test machines with
standardized shear devices.
Shear test specimens
do 3 4 5 6 8 10 12 16
-0.040 -0.013 -0.016 -0.016
Limit -0.020 -0.020 -0.030 -0.030 -0.370 -0.186 -0.193 -0.193
deviations -0.370 -0.370 -0.390 -0.345
50 110 110 110
I 50 50 50 50
cf. DIN EN 10045 (1991-04)
Charpy im pact test
pendulum KU Notch impac t energy in J, measured on a test specim en with U-notch
KV Notch impa ct energy in J, measured on a test specim en with V-notch
Test specimen
The test specimen m ust be com pletely mach ined. Fabrication of the test m aterial
shou ld alter the material's m icrostructure as little as possible. No notch sho uld be
visible with the naked eye at the notch root which runs parallel to the notch axis.
Notch impact test specimens
Designation Notch Testd imensic)n in mni or degree (°)
Normal test specimen shape
I /w h b hk r a
U 55
Test specimen cross section 40 10 10 5 1.0 -
1 i <=- Normal test specimen V 55 40 10 10 8 0.25 45°
DVM test specim en 11 1.0
/// U 55 40 10 10 7 -
b Explanation
1 ) Deutscher Verband fur M aterialprufung
% Notc h shapes ^ (German Association for Material Testing)
ifu v KU = 115 J: Norm al test specim en wit h U-no tch, Notch
impact energy 115 J, work capacity of the
a pendulum impact tester 300 J
Erichsen cupp ing tes t KV150 = 85 J: Norm al test specimen w ith V-notch, Notch
impact energy 85 J, work capacity of the pen-
dulu m impact tester 150 J
cf. DIN EN ISO 20482 (2003-12), replacement for DIN 50101 and 50102
IE Erichsen cupping depth value in m m D hole diame ter of the die
F sheet metal holding force in kN d ball diame ter of the punch
I length of the test sheet t thickness of the test sheet
te st specimen die w width of the test sheet
F D I Ft
Test specimens
The test specimens must be flat and not have any burrs. Before clamping, the
sheets are to be lightly greased over wi th a graphite lubricant.
MM To o ls a n d te st sp e cime n d ime n s io n s
Abbre- Tool dimen;sions Test speci m e n d i mlensions
viation /w f
Dd F Application
mm mm mm
m m m m kN
IE 27 20 10 >9 0 >9 0 0.2 -2 Standard test
IE40 40 20 10 > 90 >90 2-3 Tests on
IE21
sheet metal punch 21 15 10 >w 55-90 0.2-2 thicker or
holder E11 narrower
11 8 10 > b 30-55 0.1-1 strips
IE = 12 m m: Erichsen cu pping depth = 12 mm , standard test
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192 M a t e ri a l s cie n ce : 4 .1 a t e r i a l s
Hardness test by Brin ell
Hardness tes t by Brinell cf. DIN EN ISO 6506-1 (2006-03)
D test load in N Impression diameter
if D ball diameter in mm
d_d1+d2
-4 1 d diameter of the impression in mm 2
dy, d2 individua l measurement values of the
Brinell hardness
impression diameter in mm
HBW = 0.204 • F
h depth of impression in mm
s minim um thickness of the test specimen ji • D • {D-\/d2 -d2
in mm
a distance from edge in mm
Tes t c on ditions
Impression diameter
0 .2 4- D < d < 0 . 6 D
Minimum test specimen thickness s > 8 • h
Distance from edge a > 3 • d
Test specimen surface: metallic bright
Des ignation ex amples : 610800 HHBBWW 2 .15//36 20 . 5 / 2 5
Hardness value Indenter Ball Test force Impact time
W carbide ball diameter
Brinell hardness 180 62.5 • 9.80665 N = 612.9 N Unspecified: 10 to 15 s
Brinell hardness 600 2.5 mm 30 • 9.80665 N = 294.2 N Value entry: 25 s
1 mm
Degree of loading, ball diam eter, test loads and test m aterials
Degree of Test load Fin N
loading
wit h ball diam eter D 1 ) iri m m Test range haBrrdinneelsl s
0.102 • FID2 HBW
1 2.5 5 10 Materials
30 < 650
294.2 1839 7355 2942 0 Steel, nickel and titanium alloys > 140
15 Cast iron >200
Copper, copper alloys
10 >35
- - - 14710 Light metal, light metal alloys
<140
98.07 612.9 2452 9807 Cast iron > 35
Light metal, light metal alloys 35-200
Copper, copper alloys
< 35
5 49.03 306.5 1226 4903 Copper, copper alloys 35-80
Light metals, light metal alloys
2.5 24.52 153.2 612.9 2452 Light metals, light metal alloys < 35
1 9.807 61.29 245.2 980.7 Lead, tin
-
1 ) Sma ll ball diameters for fine-grained materials, thin specimen s or hardness tests in the outer layer. For hardness tests
on cast iron, the b all diameter D must be s 2.5 mm . Hardness values are only com parable if the tests were carried ou t
with the same degree of loading.
Minimum thickness s of the specimens
Ball diameter 0.25 0.35 0.5 M inim um t hickness s in m m f or im pression diam et er d 1 > in m m
D in mm 0.6 0.8 1.0 1.2 1.3 1.5 2.0 2.4 3.0 3.5 I 4.0 I 4.5 I 5.0 I 5.5 I 6.0
.13 0.25 0.54 0 8 Example: D= 2.5 mm, d= 1.2 mm
0.23 0.37 0.67 1.07 s= m1i.n2i3mmumm specimen thickness
2.5 453r V12 1.46 2 0
0.58 0.69 0.92 1.67 2.45 4.0
10 1.17 1.84 2.53 3.34 4.28 5.36 6.59 8.0
1 ) Table fields with ou t thickness indicated lie outside of the test range 0.24 • D< d< 0.6 • D
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M a t e ri a l s cie n ce : 4 .1 a t e r i a l s 193
Hardness test by Ro ck w ell, Hardness test by Vickers
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194 M a t e ri a l s cie n ce : 4 .1 a t e r i a l s
Martens hardness, Conversion of hardness values
Martens hardness by penetrant testin g cf. DIN EN ISO 14577 (2003-05)
indenter F test load in N
test h depth of penetration in m m
specimen s specim en thickness in m m
T est specimen surface Martens hardness
Material Average roughnes s Ra at F
0.1 N 2 N 100 N
Aluminum 0.13 0.55 4.00
Steel 0.08 0.30 2.20
Carbide 0.03 0.10 0.80
Designation: HM 0 5 / 20 / 20 = 5700 N /m m 2
Test method Test load Test duration Application of load M a r t e n s h a r d n . v a lu e
Martens hardness 0.5 N 20 s within 20 s 5700 N/mm2
Test range Conditions Applications
Macro range 2 N < F< 30 kN Universal hardness test, e.g. for all m etals,
Micro range F < 2 N or H > 0.2 pm plastics, carbides, ceramic materials;
micro and nano ranges: thin layer measurement,
ano range h < 0.2 pm microstructure components
C o n v e r s io n t a b l e s fo r h a rd n e s s v a lu e s an d t en s i l e s t r e n g t h 1) cf. DIN EN ISO 18265 (2004-02)
Tensile Vickers Brinell R<ockwell hardnej;s Tensile Vickers Brinell RockweHI hard-
strength hardness hardness HRC HRA HRB 2> HRF2> strength hardness hardness ne ss
Am HV HB30 Am HV HB30 HRC HRA
N/mm2 F 2; 98 N) N/mm2 F £ 98 N)
255 80 76 1155 360 342 37 69
285 90 86 48 83 1220 380 361 39 70
320 100 95 - - 56 87 1290 400 380 41 71
350 110 105 62 91 1350 420 399 43 72
385 120 114 67 94 1420 440 418 45 73
415 130 124 71 96 1485 460 437 46 74
450 140 133 - 75 99 1555 480 456 48 75
480 150 143 79 (101) 1595 490 466 48 75
510 160 152 - 82 (104) 1665 510 485 50 76
545 170 162 85 (106) 1740 530 504 51 76
575 180 171 87 (107) 1810 550 523 52 77
610 190 181 90 (109) 1880 570 542 54 78
640 200 190 92 (110) 1955 590 561 55 78
675 210 199 - - 94 (111) 2030 610 580 56 79
705 220 209 95 (112) 2105 630 599 57 80
740 230 219 97 (113) 2180 650 618 58 80
770 240 228 20 61 98 (114) 670 59 81
800 250 238 22 62 100 (115) 690 60 81
835 260 247 24 62 (101) 720 61 82
865 270 257 26 63 (102) 760 63 83
900 280 266 27 64 (104) 800 64 83
930 840 - 65 84
965 290 276 29 65 (105) 880 66 85
1030 920 68 85
1095 300 285 30 65 940 68 86
320 304 32 66 - -
340 323 34 68
1> Applies to unalloyed and low alloy steels and cast steel. Special tables of this standard are to be used for
q u e n ch e d a n d te mp e r e d , c o ld wo r ke d a n d h ig h - sp e e d ste e ls, a s we ll a s fo r va r io u s ca r b id e typ e s. Co n sid e r a b le
deviations are to be expected for high-alloyed and/or work-hardened steels.
2 ) The values in parentheses lie outside of the meas ureme nt range.
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M a t e ri a l s cie n ce : 4 .1 a t e r i a l s 195
Testing of p lastics: Tensile properties. Hardness testing
Determination of the tensile prop erties on plastics cf. DIN EN ISO 527-1 (1996-04)
Typical stress-strain maximum force L 0 gage length Tensile strength
curves S 0 initial cross section
Fy yield stress otm tensile strength rr -
AZ-FM change in length with oy yield strength Yield strength
maximum load £M maximum elongation
Ey yield strain
A L F Y change in length with
yield strength
Fy
CT Y S
ductile wifhouf Test Specimens Maximum elongation
yield point
For each property, e.g. tensile strength, yield strength,
EM 1 E Y 2 e M 2 £M3 yield strain, at least five test specimens m ust be tested.
strain e Application
- thermo plastic injection mold ed and extrusion
Test specimens
molding materials
- thermo plastic slabs and films Yield strain
- thermoset mold ing materials /-n
- thermoset slabs
- fiber reinforced compo site materials, thermo plastic
and thermose t plastic
Test speed Test specimen accordingI t o
DIN EN ISO 527-2 for molding mater ials DIN EN ISO 527-3 fo r films
Test speed Toler- Type 1A 1B 5A 5B 2 4 5
in mm/min
ance Lq m m 50 ± 0.5 50 ± 0.5 20 ± 0.5 10 ±0.2 50 ± 0.5 50 ± 0.5 25 ± 0.25
1 2 5 10 ±20% h mm 4 ±0.2 4 ± 0.2 > 2 > 1 < 1 < 1 < 1
20 50 100 200 ±10% b m m 10 ±0.2 10 ±0. 2 4 ± 0.1 2 ±0.1 1 0 - 2 5 25.4 ±0.1 6 ±0.4
= > Tensile test ISO 527-2/1 A/50: Tensile test according to ISO 527-2; specimen type 1A; test speed 50 mm/min
Hardness test o n plastics cf. DIN EN ISO 2039-1 (2003-06)
B a ll i n d e n t a t i o n t e s t F0 preload 9.8 N h depth of penetration s specimen thickness
F m test load a distance from edge
Test Specimens
distance from edge a > 10 mm, m inim um specimen thickness s > 4 mm
Test load Ball indentation hardness H i n N / m m 2 for indentation depth h in m m
Fm >n N 0 16 0 18 0 2 0 0 22 0.24 0 26 0 28 0.30 0.32 0.34
49 22 19 16 15 13 12 11 10
132 59 51 44 39 35 32 30 27 25 24
358 160 137 120 106 96 87 80 74 68 64
961 430 370 320 290 260 234 214 198 184 171
Test specimen Ball inden tation hardness ISO 2039-1 H 132: H= 3 1 N / m m 2 at M = 132 N
Hardness test by Sho re on plastics cf. DIN EN ISO 868 (2003-06)
F Test a contac t pressure in N h depth of penetration s specimen thickness
a distance from edge
specimen F test load
Test Specimens
Distance from edge a > 9 mm, m ini m um specimen thickness s > 4 m m
Tes t c onditions for the Shore A and Shore D m ethods
Indenters for Test Fmax Fa Application
Shore A method in N in N
Shore D 7.30
o A 40.05
"SL D 10 if Shore hardness wi th Type D is < 20
50 if Shore hardness wi th Type A is > 90
= > 85 Shore A :Hardness value 85; test m ethod Shore A
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196 Mat er i al science: 4.13 Cor r osi on , Cor r osi on pr ot ec t i on
Corrosion
Electrochemical series of metals
In galvanic corrosion the same processes occur as in electrical elements where the base metals are corroded. The
voltage produced between two dissimilar metals under influence of a conducting liquid (electrolyte) can be taken
from the standard p otentials of the electrochemical series. Standard p otential refers to the voltage produced between
the electrode material and a platinum electrode immersed in hydrogen.
Passivation (formation of protective layers) alters the voltage betwe en the elements.
Electrode co <q OIT) co in CO o Ol CM
materials CN T T or-; o o oCN o«- o o 0d0
++
Mg Al Mn Zn Cr Fe Ni Sn H C+u Ag Pt Au
Mi
-3 -2.5 -2 -1. 5 -1 -0. 5 0 +0.5 +1 +1.5
4 Standard potentials of the electrode materials in vo lts
i
increasingly base increasingly noble
Example: The standard potentials of Cu = +0.34 V and Al = -1.7 V yield a voltage of U = +0.34 V - (-1.67 V) = 2.01 V
>between Cu and Al.
Corrosion behavior of m etallic materials
Resistance in following environment
Materials Corrosion behavior Dry Country Industrial Sea Salt
ambient air air air air water
Unalloyed and Only resist corrosion in dry
alloy steels areas • ©© o o
Stainless Resistant, but not against
steels aggressive chemicals •
Aluminum and Resistant, except the Al
Al alloys alloys containing Cu € •• toe
Copper and Resistant, especially
Cu alloys Cu alloys containing Ni •€ toe
resistant € fairly resistant 0 non-resistant O unusable
Corrosion protection
Preparation of me tal surfaces before coa ting
Processing step Purpose Process
Grinding, brushing, blasting with
Mechanical cleaning Removal of m ill scale, rust and water jet mixed with silica sand
and creating a good dirt
surface for adherence Etching with acid or lye;
degreasing with solvents;
Chemical cleaning and Removal of mill scale, rust and grease chemical or electrochemical polishing
creating an optimal residues
surface finish Roughing or smoothing the surface
Preventative actions for corrosion protection
Actions Examples
Select suitable materials Stainless steel for parts for preparation in the
paper production
Observe corrosion protection principles in design Same material on contact points, insulation layers
between the parts, avoiding gaps
Protective layers: • protective oil or lubricant Oiling sliding tracks and measuring tools
• chemical surface treatment Phosphatizing, burnishing
• protective paint Lacquer coat, possible after previous phosph atizing
Metallic coatings Hot-dip galvanizing,
galvanic metal plating, e.g. chrome plating
Cathodic corrosion protection Part to be protected, e.g. a ship propeller,
is connected to a sacrificial anode
Anodic oxidation of Al materials A corrosion-resistant permanent oxide layer is produced
on the part, e.g. a rim
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Material science: 4.14 Hazardous m aterials 197
Disposal of sub stances*
Waste management laws cf. Closed Substanc e Cycle and Wa ste Ma nag em ent Act (2001-10)
Important principles of recycling manag ement
• Avoid waste, e.g. by in-house recycling man agem ent or a low-wa ste product d esign.
• Utilize material waste, e.g. by recovery of raw m aterials from waste (secondary raw materials).
• Use waste for recovery o f energy (energy use), e.g. use as substitute fuel.
• Waste mus t be recycled properly w itho ut adverse effect on the well being of the general public.
The disposal of waste is subject to monitoring by the responsible authorities (usually the administrative district). In
particular, wastes hazardous to health, air or water, explosive, and flamm able especially need to be mo nitored.
The wa ste producer is responsible for proper disposal and doc um enta tion of disposal.
Examples of wast e requiring special monit oring (hazardous wast e) in met al processing indu st ry 1 '
Disposal Description of the Appearance, description, Special instructions,
code type of waste source actions
150199D1 Packaging contain ing Barrels, canisters, buckets and Emp tied, drip free, brush or spatula clean
hazardous impurities
cans contain residues of conditions are not wastes requiring
paints, lacquers, solvents, special monitoring. They are considered
tcilveeasn,inrugstagaenndtss,ilircuosnt epreventa- sreytsatiel mpaocrkaingimnge.taDl isbpinossaulsuinsginag wthaestdeual
removers, spackle, etc. managem ent company. Bins with dried
paint are similar to house-hold commercial
waste.
Spray cans wit h residual Spray cans should be avoided if possible;
contents they must be disposed as hazardous waste.
160602 Nickel cadmium Rechargeable batteries, e.g. All batteries containing contaminants are
160603 batteries from drills and screwdrivers, etc. labeled. The dealer m ust accept their return
160604 Mercury dry cells at no charge.
Coin cell batteries, mercury Consumers are required to return them to
Alkaline batteries containing monocell batteries the dealer or to a public recycling center.
Non-rechargeable batteries
060404 Mercury containing Fluorescent lamps Can be recycled. Return to dealer or to
120106 waste (so-called "neon tubes") waste disposer.
120107 Do not put in glass recycling
10 Used machining oils, Water free drilling, turning, Avoid cooling lubricants as much as possi-
containing halogens, no grinding and cutting oils, ble, e.g. by
emulsion so-called cooling lubricants
• dry machining
Used machining oils, Old, water free • min imu m quantity cooling lubrication
Separated collection of different cooling
halogen free, no emulsion honing oil lubricants, emulsions, solvents. Inquire
with supplier for reprocessing or
Synthetic machining oils Cooling lubricants from syn- combustion (energy recycling) options.
thetic oils, e.g. on ester-based
1 3 02 0 2 Non- chlorinated machine, Used oil and gear oil, Recycling through supplier or a licensed
gear and lubricating oils hydraulic oil, compressor oil waste disposal service.
Used oils of know n origin may be recycled
from piston air compressors by secondary refining or energy recovery.
Do not mix with other materials
150299D1 Vacuumed and filter mate- For example, used rags, clean- Option of using a rental service for cleaning
rials, wip e cloths and pro- ing cloths; brushes contami- cloths.
tective clothing with haz- nated with oil or wax , oil
ardous contaminants binders, oil and lubricant cans
130505 Other emulsions Condensation water from Use compressor oils with de-emulsifying
compressors properties; inquire about the option of oil
free compressors.
140102 Other halogenated Per (-chloroethane) Recycling by suppliers and test replace-
solvents and solvent Tri (-chloroethene) ment with aqueous cleaning solution.
mixtures Mixed solvents
1 1 Regulation gov ernin g wastes requiring spe cial mo nitorin g - BestbuAbfV (1999-01), App end ix 1: Wastes listed in
the European Waste Catalog (EAK waste) are considered to be especially hazardous. Appendix 2: EAK waste
requiring special monitoring as well as waste types not on the EAK list ( Letter "D" in Disposal code).
*) According to European Standards
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198 Material science: 4.14 Hazardous m aterials
Hazardous m aterials and m aterial characteristics of hazardous gases
Id e n t i f ic a t i o n a n d h a n d l i n g o f h a z ar d o u s m a t e r i al s cf. EC Directive R 67/548/EEC1)
Substance Identificatio n 2 ) Substance Identificatio n 2>
Acetone
Symbol R-phrases S-phrases Tetrachlor- Symbol R-phrases S-phrases
Acetylene ethane ("Per")
Acrylonitrile F, Xi 11; 36; 66; 67 9; 16; 26 Kerosine Xn; N 40; 51/53 23; 36/37;
Phenol 61
Am mon ia
F+ 5; 6; 12 (2); 9; 16; 33 Phosphoric acid T 45 53; 45
Arsenic F, T, N 45; 11; 23/24; 9; 16; 45;
25; 37/38; 41; 53; 61 T;C 23/24/25; 34; 24/25; 26;
Asbestos C; N 43; 51/53 48/20/21/22; 28; 36/37;
Gasoline 34; 50 26; 36/37/39; 68 39; 45
Benzene T; N 61
23/25; 50/53 20/21; 28; 45; C 34 23; 45
T 60; 61
T 45; 48/23 53; 45 Propane F+ 12 9; 16
F; T 45; 65 53; 45
45; 46; 11; 53; 45 Mercury T; N 23; 33; 50/53 7; 45; 60; 61
34; 37 26; 45
Hydrochloric acid C 8 17
Oxygen O
Lead T; N 3264//3285;; 4685/23/ 53; 45; 60; 61 Lubricating grease T 45 53; 45
compounds T; N 53; 45; 60; 61 Lubricating oil T
T+;C 61; 20/22; 33; 45 53; 45
Chromium T 62; 50/53
compounds F+; T
49; 43; 50/53
Hydrofluoric acid
(HF) 26/27/28; 7/9; 26; Sulp horic acid C 35 26; 30; 45
35 36/37; 45 Styrene Xn
Ceramic 10; 20; 36/38 23
mineral fibers 49; 38 53; 45
Carbon 61; 12; 23; 53; 45 Turpentine, oil Xn ; N 10; 20/21 ; 36/37; 46;
monoxide 48/23 36/38; 43; 61; 62
Fiber glass Xn 38; 40 35/37 Trichlorethylene T 51/53; 65 53; 45; 61
Nicotine T+;N (Tri) F+ 45; 36/38; 9; 16; 33
25; 27; 51/53 36/37; 45; 61 52/53; 67
Hydrogen
12
1 1 As per Art. 1a of the Regu lation on Hazardous Materials applicable in German y since 31 October 2005
2 ) Cf. R-phrases on page 199, S-phrases on page 200, Safety signs on page 342; the slash (/) between the num ber indi-
cates a com bination of R-phrases or S-phrases.
Material characteristics of hazardous gases
Gas Density Ignition Lower I Upper
ignition limit Additional information
Acetylene ratio to air temperature
Argon
Butane 0.91 305 °C vol.-% gas in air With a pressure pe > 2 bar self-disintegration
1.5 82 and explosion
1.38 incombustible
2.11 365 °C -- Loss of breath; dang er of suffocation
1.5 8.5 Narcotic effect; suffocating effect
Carbon dioxide 1.53 incombustible - - Liquid CO2 and dry ice lead to serious frostbyte
Carbon mono xide 0.97 605 °C 12.5 74 Potent blood poison; damage to vision,
lungs, liver, kidneys and hearing
Hydrogen 0.07 570 °C 4 Spontaneous combustion with high escaping
75.6 speeds; forms explosive mixtures with air, 0 2
and CI
Nitrogen 0.97 incombustible - Lose of breath in enclosed spaces; danger of
Oxygen 1.1 incombustible - - suffocation
Greases and oils react wit h ox ygen explos ively;
- fire-promoting gas
Propane 1.55 470 °C 2.1 9.5 Loss of breath; liquid propane causes damage
to skin and eyes
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