Ferrous Metals and

Alloys

By-
Abhishek Singh
ME-2
1401440004
Contents
 ferrous metals
 pig iron
 cast iron
 types of cast iron
 wrought iron
 steels
 Effects of elements in steels
 carbon steel
 alloy steel
 Ferrous Metals

Ferrous metals are those in which the chief

constituent is iron . Hence iron , steel and their
alloys fall under these category.

 26th element 
Iron or Ferrous 
55.85 Atomic Mass
Pig Iron
 it is crude form of iron and used as a
raw material for production of various
other metals such as cast iron, steel
etc.
 The main raw materials required are –
– iron ore
– Coal
– flux
Ironmaking
Blast Furnace
Working
 The three raw materials are dumped into a blast
furnace.

 Hot air (2000*F) is blasted into the furnace, which helps

drive the chemical reaction. The coke forms CO and the
CO reduces the iron oxide to iron.

 The slag floats to the top and the metal is transferred to

molds and cools. It is now pig iron, ready for more iron
work or steelmaking.
Cast Iron

 Contains 2%-4% of carbon

 Very hard and brittle
 Strong under compression
 Suitable for casting [can be pour at a
relatively low temperature]
 Engine block, engineer vices, machine
parts
Types of cast iron
 Gray cast iron
 White cast iron
 Malleable cast iron
 Nodular cast iron
 Alloy cast iron
Gray Cast Iron
 Compositions- (other than iron)
– Carbon= 3 - 4.5 %
– Silicon= 1 – 2.75 %
– Manganese = 0.4 – 1 %
– Phosphorous = 0.15 – 1 %
– Sulphur = 0.02 - 0.15 %
 Uses –
– cylinder blocks , fly wheel , pipes , etc
White Cast Iron
 Compositions –
– carbon = 1.75 – 2.5 %
– silicon = 0.85 – 1.2 %
– manganese = 0.1 - 0.4 %
– phosphorous = 0.05 - 0.2 %
– sulphur = 0.12 – 0.35 %
 Uses-
– Use as raw materials , break shoes ,
pumps
Malleable Cast Iron
 Obtain from white cast iron by
annealing process
 It separate free graphite into nodular
form
 Uses-
– hubs of wagon wheel , pipes fittings , etc
Nodular Cast Iron
 Also known as ductile cast iron
 Can be produced in thicker part than
malleable cast iron
 uses –
– in cast parts where density and pressure
tightness is highly desired quality . Ex –
valves , hydraulic cylinders
Alloy Cast Iron
 Produced by adding alloying elements
such as Ni , Cr , Mo , Cu , Si etc
 These elements provide more
strength, corrosion resistance etc
 Uses-
– piston , piston rings , parts of crushing
and grinding etc
Wrought Iron
 Purest form of iron contain atleast 99.5
% iron
 It is tough , malleable ,ductile but
cannot withstand sudden and
excessive shocks
 Uses –
– crane hooks , railway cuppling , etc
Steelmaking
Steel
 It is classified into two types –
– carbon steels
– Alloy steels
Effects of Elements in
Steels
 Carbon : improves hardenability, strength,
hardness, and wear resistance; it reduces ductility,
weldability, and toughness.

 Chromium : improves toughness, hardenability,

wear and corrosion resistance, and high-
temperature strength; it increases the depth of the
hardness penetration resulting from heat treatment
by promoting carburization

 Cobalt : improves strength and hardness at

elevated temperatures. Calcium : Deoxidizes
steels, improves toughness, and may improve
formability and machinability.
 Copper : improves resistance to atmospheric
corrosion and, to a lesser extent, increases strength
with little loss in ductility; it adversely affects the
hot-working characteristics and surface quality.

 Lead : improves machinability; it causes liquid-

metal embrittlement.

 Magnesium : has the same effects as cerium.

 Manganese : improves hardenability, strength,

abrasion resistance, and machinability; it deoxidizes
the molten steel, reduce shot shortness, and
decreases weldability.

 Molybdenum : improves hardenability, wear

resistance, toughness, elevated-temperature
strength, creep resistance, and hardness; it
minimizes temper embrittlement.
 Nickel : improves strength, toughness, and
corrosion resistance; it improves hardenability.

 Phosphorus : improves strength, hardenability,

corrosion resistance, and machinability; it severely
reduces ductility and toughness.

 Silicon : improves strength, hardness, corrosion

resistance, and electrical conductivity; it decreases
magnetic-hysteresis loss, machinability, and cold
formability.
Carbon Steels
 Carbon steels are group
by their percentage of
carbon content per weight.
The higher the carbon
content the greater the
hardness, strength and
wear resistance after heat
treatment.

 Low-carbon steel , also

called mild steels, has less
than 0.30% carbon. Used
in everyday industrial
products like bolts, nuts, High Carbon Steel Nails
sheet, plate and tubes.
 Medium-carbon steel has 0.15-
0.30% to 0.60% carbon. Used for jobs
requiring higher strength such as
machinery, automotive equipment
parts, and metalworking equipment.

 High-carbon steel has 1- 0.60 %

carbon. Used parts that require the
highest strength, hardness, and wear
resistance. Once manufactured they
are heat treated and tempered
Alloy Steels
 Alloy steels are steels that contain
significant amounts of alloying
elements.

– Nickel alloy steel

– Chromium alloy steel
– Stainless steel
– high speed steel
Nickel Alloy Steel
 compositions –
– Nickel = 2 – 5 %
– Carbon = 0.1 – 0.5 %
 imposes tensile strength, improves
resistance to corrosion and heat
 Uses –
– boiler tube , crank shaft , spark plug for
patrol engine
Chromium Alloy Steel
 compositions –
– Chromium = 0.5 – 2 %
– Carbon = 0.1 – 1.5 %
 increases strength , hardness ,
resistance to corrosion
 uses –
– dies , axles , gears
Stainless Steels

 Stainless steels are

primarily know for their
corrosion resistance,
high strength, and
ductility and chromium
content.
 It contain 12 – 14 % Cr
and 0.1 – 0.35 %
carbon
 Stainless Steels

 The reason for the name stainless is due to the

fact that in the presence of oxygen, the steel
develops a thin, hard, adherent film of
chromium.
– Even if the surface is scratched, the protective film is
rebuilt through passivation.
 For passivation to occur there needs to be a minimum
chromium content of 10% to 12% by weight.
Stainless Steels
 Stainless steels tend to have lower
carbon content since increased carbon
content lowers the corrosion
resistance of stainless steels.
– Since the carbon reacts with chromium it
decreases the available chromium
content which is needed for developing
the protective film.
 Stainless Steels
 Using stainless steels as reinforcing bars, has
become a new trend, in concrete structures such
as highways buildings and bridges.
– It is more beneficial than carbon steels because it is
resistant to corrosion from road salts and the concrete
itself.

Rebar corrosion
in concrete
High Speed Steel
 Compositions –
– tungsten = 18 %
– chromium = 4 %
– vanadium = 1 %
 Acts as a cutting tools at
high temperature
 Uses –
– cutting , drilling , lathe tools,
etc