MATERIAL
Evolution of Materials
MATERIALS
polymers composites... Casting , moulding
PROCESSES
powder methods, machining... Flat and dished sheet
SHAPES
prismatic, 3-D
Metals
Cu-alloys Ni-alloys Ti-alloys Alumina Si-Carbide PE, PP, PC PA (Nylon)
Ceramics, glasses
Soda-glass Pyrex
GFRP CFRP
Polymers, elastomers
Butyl rubber Neoprene
Composites
KFRP Plywood
Woods
Foams
Ceramic foams Glass foams
Natural materials
Natural fibres: Hemp, Flax, Cotton
1. LOGAM
1. LOGAM
Ikatan Logam:
Keuntungan
Moduli (stiff) relatif tinggi Dapat diperkuat dengan cara alloying dan working Umumnya ulet Ketangguhannya relatif tinggi Bersifat magnet dan non magnet (para & fero) Konduktornya baik
Kerugian
Kerusakan umumnya fatik Sangat peka terhadap lingkungan (corrosion dan oxidation).
Metal
Ferrous Metals
Examples of Application
Perkakas, kontruksi, automotive, transmission tower Cylinders, piston, motor blocks, construction, wear-resistant materials Off shore drilling rigs, naval construction, chemical transport, food preparation, medical instruments Aerospace, construction, transport, packaging, electrical conductors Aerospace, automotive, sporting equipment Aerospace, chemical industry Electrical conductors heat exchangers, chemical & maritime industry Pressure vessels, fittings Aerospace (turbines), money
8
Light Alloys
Copper Alloys
Nickel Alloys
Grey cast iron Based on composition White cast iron Carbon steel Nodular cast iron Alloy steel Malleable cast iron Based on application Stainless steels Tool steels, Wear resistant steels, etc Based on production Hot rolled/cold rolled steels Cast stainless steels Based on their strength High strength low alloy steels Duplex stainless steels
Ferrous Alloys
Iron Carbon Phase Diagram
1500 () 1300
Melt
Temperature Co
Melt + cementite
1100
Eutectic
Austenite + cementite
Austenite () (
900
+ ()
700
Eutectoid
500
723 C
0.8
2.0
3.0
4.0 4.3
6.7
(Fe3C)
Hypo eutectoid
Steels Hyper
Cast iron
Carbon content wt %
10
11
12
13
The first two digits indicate carbon steel and the last two digits digits indicate the nominal carbon content in hundreths of a percent
14
15
Stainless Steels
Iron based alloys > 10.5% Cr plus Ni, Mn, Mo, Co, etc. Mn, Classification of Stainless Steels Ferritic stainless steels Martensitic stainless steels Austenitic stainless steels Duplex stainless steels Precipitation hardening (age hardenable) stainless steels hardenable)
16
Alloying elements in stainless steel families associated with their properties 303, 303 Se
Ni-Cr-Fe alloys Add Ni for corrosion resistance In high-temperature environments 309, 310, 314, 330 Increase Cr, lower Ni for higher strength Add S or Se for machinabilty Duplex stainless steels
Add Cr,Mo
430
347
Add Cr and Ni for strength and oxidation resistance 304 (18-8) Fe-18 to 20Cr-8 to 10 Ni Add more Mo for Pitting resistance
321
316L
317L
Add more Mo for Pitting resistance Add Ni, Mo, N for corrosion resistance
317
17
18
19
20
10
21
22
11
23
Tool Steel
24
12
25
Dengan Cr > 10 % , Ditambah Ni dan Mo Kekuatan tinggi Tahan korosi Penampilan menarik
26
13
27
Struktur mikro FC
28
14
Mudah permesinan/ machinability (Frais, Bubut, Potong) Besi tuang kelabu juga tidak meneruskan getaran (dumping capasity baik) Penggunaannya yaitu pada komponen automotiv seperti pada blok silinder, tutup silinder, rumah engkol, brake drum
29
Turunnya sifat mekanis ini akibat adanya grafit berbentuk serpihan (flakes) menyebabkan terjadinya konsentrasi tegangan, sehingga jika mendapat beban bagian tersebut akan mudah patah.
30
15
FC 10 FC 15 FC 20 FC 25 FC 30 FC 35
32
16
33
34
17
35
36
18
37
Tembaga (Cu)
Produk tembaga dan paduannya
38
19
Paduan Tembaga
Generic name Coppers High-copper alloys Brasses Yellow Brasses Leaded Brasses Tin Brasses Bronzes Phosphor Bronzes Lead Phosphor Bronzes Copper-Phosphorous Copper-Silver-Zinc Alloys Aluminum Bronzes Silicon Bronzes/Brasses Other copper-zinc alloys Major components >= 99.3% Cu 96% ~ 99.3% Cu Cu-Zn Cu-Zn-Pb Cu-Zn-Sn-Pb Cu-Sn-P Cu-Sn-Pb-P Cu-P, Cu-P-Ag Cu-Ag-Zn Cu-Al-Ni-Fe-Si-Sn Cu-Si-Sn Cu-Zn- Cu-Ni-Fe C70000C73499 C73500C79999 UNS number C10100C15999 C16000C19999 C21000C28999 C30000C39999 C40000C49999 C50000C52999 C53000C54999 C55000C55299 C55300C60799 C60800C64699 C64700C66199 C66200C69999
39
Tembaga (Cu)
Sifat
Berat jenis: 8930 kg/m3, lebih berat dibanding baja dan diogolongkan sebagai logam berat (heavy metals) Titik lebur: 1083 oC Titik didih: 2593oC Warna: merah kecoklatan Penghantar panas/listrik terbaik kedua setelah perak (Ag)
40
20
Tembaga (Cu)
Sifat mekanik:
Kekuatan tidak terlalu tinggi Lunak (mudah dibentuk) Mudah ditempa (malleable) dan ulet (ductile) karenanya mudah dibentuk Tahan korosi (tapi permukaannya teroksidasi) Ketahanan fatik, mulur (creep) dan aus relatif lebih tinggi dibandingkan dengan paduan Al. Mudah disambung dan difabrikasi/pemesinan
41
Aluminium
Sifat Fisik : Warna Berat atom Titik lebur Titik uap Kalor jenis Hantaran listrik Jenis kristal Koef. pemuaian Susut linier Massa jenis
: putih mengkilap : 26,98 : 660 oC : 1800 oC : 0,2226 kal/g oC : 64,94 %, baik sekali : FCC (kubus pusat muka) : 23,86 x 10-6 /oC : 660 20 oC = 1,8 % : 2,702 g/cm3
42
21
43
Klasifikasi Aluminium
Wrought Aluminium (aluminium yang sudah dideformasi)
Series 1xxx 2xxx 3xxx 4xxx 5xxx 6xxx 7xxx 8xxx 9xxx Unsur Paduan Utama Al murni ( 99 % atau lebih) Tembaga ( Cu) Manganese ( Mn) Silicon (Si) Magnesium(Mg) Silicon dan Magnesium Zinc (Zn) Unsur lain-lain Serie yang tidak digunakan
Standar AISI / AA
Universitas Indonesia Teknik Metalurgi & Material
44
22
)) SeF A(( c a emrre n SeF A c a em e n ))iiiiSeF5llllA(( ciiiillllllllattttemrrettttniiii SeF A c a em e n asaf kutnebmem eF % 50 0 sa a d eF % 50 0 sa a d eF % 50,,,,0 satttta iiiid eF % 50 0 sa a d nahuggna ek nahuggna ek nahuggnattttek nahuggna ek naknurruneM naknu uneM naknurruneM naknu uneM y sorrop nak akgn neM y so op nak akgn neM yttttiiiisorrop nakttttakgniiiineM y so op nak akgn neM sa d u naknurruneM sa d u naknu uneM sattttiiiidiiiiullllffff naknurruneM sa d u naknu uneM nasa egek nasa egek nasattttegek nasa egek naktakgnineM
nasategek
ggn pme ggn pme ....iiiiggniiiitttt pmetttt ggn pme adap peerc nanaha ek adap pee c nanaha ek adap peerrc nanahatttek nak akgn neM nak akgn neM nakttttakgniiiineM nak akgn neM rae oh nanaha ek raett ttoh nanahattek nak akgn neM nak akgn neM nakttttakgniiiineM nak akgn neM nasarrekek nad nasa ekek nad nasarrekek nad nasa ekek nad nataukek naktakgnineM
nataukek nad nasarekek
upmam naktakgnineM
y ban hcam nak akgn neM y ban hcam nak akgn neM yttttiiiilllliiiibaniiiihcam nakttttakgniiiineM y ban hcam nak akgn neM egakn rrhs naknurruneM egakn hs naknu uneM egakniiiirrhs naknurruneM egakn hs naknu uneM s ne arreb naknurruneM s ne a eb naknu uneM siiiinejjjj ttttarreb naknurruneM s ne a eb naknu uneM sa d u nak akgn neM sa d u nak akgn neM sattttiiiidiiiiullllffff nakttttakgniiiineM sa d u nak akgn neM rrae oh ae oh rraetttt ttttoh ae oh padahrre nanaha ek nak akgn neM padah e nanaha ek nak akgn neM padahrretttt nanahattttek nakttttakgniiiineM padah e nanaha ek nak akgn neM nasarrekek nasa ekek nasarrekek nasa ekek nahuggnatek naknuruneM nad nataukek naktakgnineM esnopser gn ega nak akgn neM esnopser gniiega nakttakgniineM raet toh nanahatek naktakgnineM ytilibanihcam ikiabrepmeM nasarekek nasa ekek ...nasarrekek nad na aukekek nak akgn neM nad na aukekek nak akgn neM nad nattttaukekek nakttttakgniiiineM nad na aukekek nak akgn neM nahuggnatek naknurruneM naknu uneM naknurruneM naknu uneM sa d u naknurruneM sa d u naknu uneM sattttiiiidiiiiullllffff naknurruneM sa d u naknu uneM
nakurubeK nakurubeK nakurubeK nakurubeK
46
45
23
)eF( iseB
naktakgnineM roc
)nZ( gneS gneS gneS gneS a m K rrusnU a m K usnU aiiiimiiiiK rrusnU a m K usnU
Co 2141 o o o
) S( )iiS( nokiliS
)uC( )uC( )uC( )uC(
no sorrrroc no so oc noiiiisorrrroc no so oc gn p nan kgnumek gn p nan kgnumek gniiiittttttttiiiip naniiiikgnumek gn p nan kgnumek naktakgnineM
rroc upmam naknurruneM oc upmam naknu uneM rroc upmam naknurruneM oc upmam naknu uneM
egaknirhs naknurrunem amrre naknu unem am e naknurrunem llllamrretttt naknu unem am e aum eok naknurruneM aum eok naknu uneM iiiiaum ffffffffeok naknurruneM aum eok naknu uneM nasarrekek nad nasa ekek nad nasarrekek nad nasa ekek nad nataukek naktakgnineM ggn u a rre nasa egek ggn u a e nasa egek iiiiggniiiitttt ullllallllrretttt nasattttegek ggn u a e nasa egek nakbabeynem apna nakbabeynem apna nakbabeynem apnatttt nakbabeynem apna na aukek nak akgn neM nattaukek nakttakgniineM isorok nanaha ek nak akgn neM nanaha ek nak akgn neM nanahattttek nakttttakgniiiineM nanaha ek nak akgn neM ggn pme ggn pme iiiiggniiiitttt pmetttt ggn pme nanaha ek nak akgn neM nanaha ek nak akgn neM nanahattttek nakttttakgniiiineM nanaha ek nak akgn neM
iggnit ulalret CCS dh CCS dh nasa egek nakbabeynem nasa egek nakbabeynem CCS dhtttt CCS dh nasattttegek nakbabeynem nasa egek nakbabeynem nanaha ek naknurruneM apna na aukek nak akgn neM C 496 nanaha ek naknu uneM apna na aukek nak akgn neM C 496 nanahattttek naknurruneM apnatttt nattttaukek nakttttakgniiiineM Co 496 nanaha ek naknu uneM apna na aukek nak akgn neM C 496 nakurrubeK naku ubeK nak abeK nak abeK rrubeL k T ubeL k T nakurrubeK naku ubeK nakiiiiabeK nak abeK rrubeL kiiiittttiiiiT ubeL k T
Aplikasi Aluminium
48
47
24
Co 2541 o o o
) N( )iiN( lekiN
))nM(( nagnaM nM nagnaM ))nM(( nagnaM nM nagnaM )gM( mu sengaM mu sengaM muiiiisengaM mu sengaM a m K rrusnU a m K usnU aiiiimiiiiK rrusnU a m K usnU
49
Keuntungan
Modulus (stiff) tinggi Kekuatan tinggi Ketahanan abrasi Titik lebur tinggi Tahan Korosi dan oksidasi Transparan Insulator listrik yang baik Getas
Kerugian Kekuatannya tidak merata Kekuatan kompresi = 15x kekuatan tarik Sensitif terhadap takik
50
25
51
52
26
BATA ; BETON ; PAVING JALAN ; DLL INSULATOR LISTRIK ; CUTTING TOOLS ; MESIN TURBIN ; GELAS
SIFAT KERAMIK : KERAS ,TAHAN PANAS , ISOLATOR , STABIL DALAM LINGKUNGAN KIMIA
53
TANAH LIAT : Al2O3 ; SiO2 GELAS : Bahan dasar SiO2 SEMEN : Al2O3 ; SiO2 ; CaO KERAMIK TEKNIK : Al2O3 ; SiC ; Si3N4 ; ZrO2
54
27
3. POLYMERS
Contoh: KAYU , KATON, WOOL , TULANG, PROTEIN, SEL ORGANIK, PRODUK PLASTIK , KARET,DLL.
Universitas Indonesia Teknik Metalurgi & Material
55
3. POLYMERS
Ikatan Covalent
Keuntungan
Kekuatan dapat ditingkatkan Deformasi elastisnya tinggi (flexible) Koefisien friksinya rendah Tahan korosi Mudah dibentuk Dapat diwarnai
Kerugian
Creep pada T ruang Sifatnya sangat terpengaruh temperatur Titik leburnya rendah Modulusnya rendah Sulit untuk didaur ulang
56
28
Jenis Polymers
Secara umum ada plastics (plastik) dan rubbers (karet) plastik) karet) Untuk klasifikasi secara teknis :
1. Thermoplastics: Polyethylene, polyvinylchloride, polypropylene, polystyrene, and nylon Phenolics, epoxies, and certain polyesters Phenolics, Natural rubber (vulcanized) Synthetic rubbers, which exceed the tonnage of natural rubber
57
58
29
DENSITAS RENDAH < 1 1,5 Gr/cm3 KEKAKUAN RENDAH < 5 GPa KEKUATAN RENDAH < 100 MPa KETANGGUHAN RENDAH < 5 MPa TEMPERATUR LELEH RENDAH DIBANDINGKAN LOGAM DAN KERAMIK
59
60
30
4. KOMPOSIT
61
62
31
63
KOMPOSIT
PARTIKULIT
FIBER
STRUKTURAL
64
32
65
66
33
67
penguat
Glass Fiber - fiberglass Carbon fiber - graphitic and amorphous C Aramid fiber - Kevlar, highly linear polymer chain
Matrix
polyester and vinyl esters - fiberglass epoxies - aerospace applications, stronger, resistant to moisture polyimides - high temperature high temperature thermoplastics - PEEK, PPS, PEI, aerospace
68
34
69
70
35
71
72
36
4. KOMPOSIT
Ikatan bervariasi
Keuntungan
Kerugian
Kombinasi dari daya tarik Mahal beberapa material Sulit untuk disambung Banyak digunakan dalam Terkadang sulit untuk di teknik fabrikasi Ringan Kaku Kuat
73
74
37
75
76
38
SIFAT MATERIAL
77
SIFAT MEKANIS
78
39
lo
Thermal conduction
x
T1
Area A
Heat flux, Q/A
To
Q joules/sec
Brittle materials
Stress
Expansion: Expansion coeff. , 1/K Conduction: Thermal conductivity , W/m.K Electrical Conductor? Insulator?
1 Polymers
0.1 Elastomers
0.01 0.1
10 1 Density (Mg/m3)
100
80
40
Mechanical Properties
Bulk Modulus Compressive Strength Ductility Elastic Limit Endurance Limit Fracture Toughness Hardness Loss Coefficient Modulus of Rupture Poisson's Ratio Shear Modulus Tensile Strength Young's Modulus 4.1 55 0.06 40 24 2.3 100 0.00950 0.38 0.85 45 2.5 4.6 GPa 60 MPa 0.07 45 MPa 27 MPa 2.6 MPa.m1/2 140 MPa 0.026 55 MPa 0.42 0.95 GPa 48 MPa 2.8 GPa
$
Potential applications Successful applications
81
Test
Test data
Design data
Characterisation
Metals Fabrication
Shaping
Casting, Powder metallurgy
Metal Working
Rolling, extrusion, drawing, forging, pressing Hot working cold working
Machining
Cutting, grinding, drilling
Joining
Welding, soldering, brazing
Thermal Processing
Heat treatment
82
41