ME 3215

Engineering Metallurgy
Ferrous Metallurgy

Lecture 02

Department of Mechanical Engineering, KUET A H M Fazle Elahi, Lecturer, ME, KUET

  It is a branch of heavy industry encompassing a group of interrelated
subdivisions: ferrous metallurgy production (blast-furnace
production, steel production, rolling);
 pipe, tubing, and hardware production; mining, concentration, and
sintering of ore materials;
What is Ferrous  production of ferroalloys and refractory materials;
Metallurgy?  mining of non-ore materials for the industry; and secondary
treatment of iron and steel. The industry’s most important products
are hot-rolled and cold-rolled products, steel pipe and tubing, and
hardware.
 Ferrous metallurgy is the basis for the development of most branches
of the national economy.

 Ref: The great Soviet Encyclopedia

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  Metal that are not mixed with any other materials are known as pure
metals. Metals listed in the Periodic Table are pure metals.
e.g. Iron (Fe), Copper (Cu) and Zinc (Zn)

 Alloys are mixtures of two or more metals formed together with

Pure Metals other elements/materials to create new metals with improved
and Alloys Mechanical Properties and other properties of the base metal.
e.g. Brass (Copper and Zinc), Stainless steel (steel and chromium)

 Alloy = metal A + metal B + … + other elements

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  Ferrous metals are metals that contain iron
( Primary base metal is iron)
E.g. Steel (iron and carbon)
Ferrous Metals
& Non-Ferrous
 Non-ferrous metals are metals that do not contain iron (Primary
Metals base metal does not contain iron)
E.g. Zinc (pure metal), Bronze (Copper and tin)
(non-ferrous may contain slight traces of iron)

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 Metals

Ferrous metals Non-ferrous metals

Steels Cast Irons

Plain carbon steels Grey Iron

Classification of Low carbon steels White Iron

Metals
Medium carbon steels Malleable & Ductile Irons

High carbon steels

Low alloy steels

High alloy steels

Stainless & Tool steels

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  Contains 2%-4% of carbon
 Very hard and brittle
 Strong under compression
 Suitable for casting [can be pour at a relatively low temperature]
 Application: Engine block, engineer vices, machine parts

Cast Iron

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 Cast Iron has Three categories:
 White:
 Hard and brittle, good wear resistance
 Uses: rolling & crunching
 Equipment
Ductile iron used in drain grids
Cast Iron  Grey:

(Cont’d)  Good compressive & tensile strength, machinability, and

vibration-damping ability
 Uses: machine bases, crankshafts, furnace doors, Engine Blocks
 Ductile & Malleable:
 Ductile: High strength and ductility Uses: engine and machine
parts.
 Malleable means: Heat-treated version of white cast iron

Department of Mechanical Engineering, KUET Properties and constituents of all types of cast iron: Self Study
  A tough, malleable form of iron suitable for forging or rolling rather
than casting, obtained by puddling pig iron while molten. It is nearly
pure but contains some slag in the form of filaments.
 Has approx. 0.05% carbon
 Used since about 2000 BC
 Is stronger than most other pure metals.
 Made into weapons, armour, cooking pots and vessels
Wrought Iron  Main limitation to wider uses due to processing (no way of making
large items and no welding)

Department of Mechanical Engineering, KUET Wrought Iron bridge

 • Also known as mild steel
• Contain 0.05% -0.32% carbon

• Tough, ductile and malleable

• Easily joined and welded
• Poor resistance to corrosion
•
Steel Often used a general purpose material

• Nails, screws, car bodies, Wire, Rivet, Nut, Bolt,

Low Carbon Steel
• Structural Steel used in the construction industry

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 • Contains 0.35% - 0.60% of carbon

• Offer more strength and hardness but less ductile and

malleable

• Structural steel, rails and garden tools, Wire, Nut, Bolt,

Springs, Wire ropes etc.
Steel
Medium Carbon Steel

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 • Also known as ‘tool steel’ Contain 0.55%-1.5% carbon

• Very hard but offers Higher Strength Less ductile

and less malleable

• Hand tools (chisels, punches) Saw blades,

Steel
High Carbon Steel

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 Alloy steel means it owes it’s distinctive properties chiefly to some
elements other than carbon or jointly to such other element and
carbon.

Three types of Alloy steels.

1. Low Alloy Steels
Alloying content up to 5%
Steel
2. Medium Alloy Steels
Alloy Steel Alloying content up 5 to 10%
3. High Alloy Steels
Alloying content above 10%
Most important high alloy steel used in daily life is Stainless Steel

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 • Steel alloyed with
chromium (18%), nickel (8%), magnesium (8%)
• Hard and tough
• Corrosion resistance
• Comes in different grades
• Sinks, cooking utensils, surgical instruments and many
more

Steel
Stainless Steel

Department of Mechanical Engineering, KUET Properties and Advantages of Stainless Steel : Self Study
 • Medium Carbon steel alloyed with Tungsten, chromium,
vanadium

• Very hard
• Resistant to frictional heat even at high temperature
• Ability to resist softening at high temperature.

Steel • Machine cutting tools (lathe and milling)

• Drills
High Speed Steel

Department of Mechanical Engineering, KUET Properties and Advantages of Stainless Steel : Self Study
 • 18.4.1 High Speed Steel:
Contains 18% Tungsten, 4% Chromium, 1% Vanadium

• Molybdenum High Speed Steel:

Uses Molybdenum as principal constituent.
Cheaper than other high speed steels
Contains 6% Tungsten, 6% Molybdenum, 4% Chromium, 2%
Steel Vanadium

High Speed Steel • Super High Steel:

Classification Contains 20% Tungsten, 4% Chromium, 2% Vanadium, 12%
Cobalt
Used for heavy cutting operations
Impose high pressure and temperature on the tool

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 Carbon content Properties Applications
wt %
0.01 - 0.1 Soft, ductile, no useful hardening Pressings where high
by heat treatment except by formability required
normalizing, but can be work-
hardened. Weldable.
0.1 - 0.25 Strong, ductile, no useful General engineering uses for
Properties of hardening by heat treatment
except by normalizing, but can
a mild steel

carbon Steel be work-hardened. Weldable.

Ductile-brittle transition
temperature is just below room
temperature
0.25 - 0.6 Very strong, heat treatable to
produce a wide range of
properties in quenched and
tempered conditions. Difficult
to weld. Can become brittle
below room temperature.
Bars and forgings for a wide
range of engineering
components.
Connecting rods,
springs, hammers, axle
shafts requiring strength
and toughness.
 Carbon content Properties
wt%
0.6 - 0.9 Strong, whether heat treated or Used where maximum
not. Ductility lower when
less carbon is present
Properties of
carbon Steel
(Cont’d)
0.9 - 2.0 Wear resistant and can be
made very hard at expense
of toughness and ductility.
Cannot be welded. Tend to
be brittle if the structure is
not carefully controlled
Applications
strength rather than
toughness is
important. Tools,
wear resisting
components ( piano
wire and silver steels
are in this group).
Cutting tools like wood
chisels, files, saw
blades.
 Next Class
Manufacturing
Process of Cast iron
Thank You
and Steel

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