Carbon Steel

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Carbon steel is an iron-carbon alloy known for its strength and versatility, with carbon being the primary alloying element. It is classified based on its carbon content into three categories: low, medium, and high carbon steel. Each category offers distinct properties such as ductility, weldability, and hardness, making carbon steel suitable for a wide range of applications. From construction materials to cutting tools, carbon steel is a popular choice in industries like automotive, manufacturing, and infrastructure due to its cost-effectiveness and durability.

Carbon Steel Grades

Carbon steel consists mainly of iron and carbon, with low alloy content. The carbon content determines its classification:

Low Carbon Steel (Mild Steel)

Carbon content: Less than 0.25%
Properties: Good ductility, weldability, and formability. It is easy to machine and offers moderate strength, but low wear resistance.
Uses: Structural beams, sheets, pipes, automotive body panels, and other construction materials.

ASTM A36

Tensile strength: 58,000–80,000 psi
Properties: Standard low-carbon steel with excellent weldability and machinability.
Uses: Bridges, buildings, and general structural purposes.

ASTM A283 Grade C

Tensile strength: 55,000 psi
Properties: Lower strength with good formability and weldability.
Uses: General-purpose structural steel, such as tanks and light structures.

Medium Carbon Steel

Carbon content: 0.25–0.60%
Properties: Higher strength and hardness compared to low carbon steel but lower ductility. It can be heat-treated to improve toughness and wear resistance.
Uses: Machinery parts, automotive components (e.g., axles, gears), and railway tracks.

ASTM A572 Grade 50

Tensile strength: 65,000 psi
Properties: High strength, good toughness, and weldability. It offers better yield strength than A36 steel.
Uses: Bridges, construction equipment, and heavy-load structural applications.

ASTM AISI 1045

Tensile strength: 77,000 psi
Properties: Medium carbon steel with higher strength and hardness, suitable for components that require durability.
Uses: Shafts, gears, bolts, and machinery parts.

High Carbon Steel

Carbon content: Above 0.60%
Properties: Extremely strong and hard, with reduced ductility. It can be heat-treated for higher hardness, but it becomes brittle in the process.
Uses: Cutting tools, blades, high-strength wires, springs, and wear-resistant parts.

ASTM AISI 1095

Tensile strength: 85,000 psi
Properties: High carbon steel with excellent wear resistance and strength, but low toughness.
Uses: Cutting tools, springs, and industrial knives.

ASTM AISI 1080

Tensile strength: 80,000 psi
Properties: High carbon steel with good wear resistance, used in applications that require high strength.
Uses: Saws, wires, and wear-resistant industrial components.

Manufacturing Processes for Carbon Steel

Sand Casting

Sand Casting

Sand casting is one of the oldest and most flexible processes for producing aluminum components. A mold is created using a sand mixture, into which molten aluminum is poured. Once the metal cools, the sand mold is broken to extract the cast part. This method is ideal for producing large, complex parts with relatively low production volumes. Sand casting is typically used in the automotive, marine, and construction industries.

Forging

Precision Machining

Precision machining refers to the process of shaping aluminum parts using CNC (computer numerical control) machines. In this process, aluminum billets are cut and shaped with high accuracy and precision. It is commonly used when tight tolerances and fine finishes are required, such as in aerospace, medical devices, and electronics. Machining processes like turning, milling, and drilling help create intricate parts with minimal waste.

Hot Rolling

High-Pressure Die Casting

High-pressure die casting involves forcing molten aluminum into a steel mold under high pressure. This process allows for the rapid production of complex and detailed components with excellent surface finishes. High-pressure die casting is favored in industries requiring high-volume production, such as the automotive sector, where components like engine blocks and transmission cases are mass-produced. The resulting parts are strong, have thin walls, and require minimal post-processing.

Welding

Gravity Casting

In gravity casting, molten aluminum is poured into a mold under the force of gravity, without the use of external pressure. This process is suitable for producing medium- to large-sized parts with relatively simple geometries. Gravity casting provides good dimensional accuracy and mechanical properties, making it popular for components like housings, wheels, and structural parts in various industries.

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The selection of the appropriate grade ensures the best performance for each application. To explore custom manufacturing solutions for carbon steel components, contact Align Manufacturing.

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