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Lecture 4 Ferrous Metal
Lecture 4 Ferrous Metal
Lecture 4 Ferrous Metal
MECHANICAL BLOCK
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Introduction
Metals form about a quarter of the earth crust by weight
One of the earliest material used dated back to
pre-historic time
Some of the earliest metals used include:
copper, bronze and iron
Stone age Bronze age … ’discovery’ of steel
Industrial Revolution in the 18th century
All metals except gold are generally found chemically
combined with other elements in the form of
oxides and sulphates. Commonly known as ores.
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Pure Metals and Alloys
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 other elements/materials to create new metals with
improved properties and characteristics.
E.g. Brass (Copper and Zinc),
Stainless steel (steel and chromium)
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Ferrous Metals & Non-Ferrous
Metals
Ferrous metals are metals that contain iron
E.g. Steel (iron and carbon)
Iron Aluminum
Others Others
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PRODUCTION OF FERROUS METAL
Raw Materials used in production of Pig Iron
1.Iron Ore – the most important material needed in the production of
iron, is a chemical sedimentary rock that people have used as an
important source of metal
1. Hematite – a reddish ore although may vary from blue, black to
purple and brick red. Contains 70% of iron
2. Limonite – Typical of the several oxide ore which contains more
or less chemically combined water. Color may vary from yellow to
dark brown, in pure state it contains about 60% iron
3. Magnetite – colored black, it contais highest percentage of iron
about 725 iron
4. Taconite – contains 32% iron
2.Coke – Acts as fuel in the blast furnace
3.Limestone – minerals which provide chemical reaction with the
impurities
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4.Air – used for burning the coke
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Taconite
Extraction of Iron
•Iron is found in iron oxide in the earth.
•Three primary iron ores: magnetite, hematite, taconite
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Extraction of Iron
Limestone helps to separate
the impurities from the metal
The liquid waste is known as slag
that floats on the molten iron
They are then tapped off (separated)
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Extraction of Iron
A blast furnace
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Blast Furnace Temperatures
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• Ore, coke, and limestone are “charged” in layers into the
top of a blast furnace
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• Molten iron sinks to bottom of furnace,
where it is tapped off from furnace and
cast into large ingots called “pigs”…pigs
contain high carbon content (4% or so),
plus many impurities, such as sulphur and
silica which wasn’t removed by the
limestone.
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BLAST FURNACE – Used for the production of pig
iron
The Blast Furnace is basically a huge steel shell,
lined with fire bricks, some are as high as ten
storey building
1.Ore processing begins in the blast furnace.
2.A mixture of iron ore, coke and limestone is
brought to the top of the furnace and dumped into
it. The mixture is called charge.
3.Air that has been dried and heated to about 1250
deg, Fahrenheit is then blown into the furnace at
its base.
4.As the coke burn in this air, it generates heat and
gases which melts the charge.
5.Impurities in the charge are absorbed by
limestone and formed a substance called slag.
6.The temperature at the base of the furnace rises
to approximately 3500 deg. Fahrenheit and the
iron and slag in this area becomes liquefied.
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7. Since the molten slag is lighter than the molten
iron, it floats on the top of the iron.
8. Tapping or removing the molten iron from the
furnace is done every 4 to 5 hours. From 150 to300
tons of pig iron can be drawn off at a time
9. It is interesting to note that it takes almost 2 tons of
ore 1 ton of coke and nearly ½ ton of limestone and a
little less than 4 tons of air to make just 1 ton of pig
iron.
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Principal processes for remelting or refining pig iron
Molten or cast pig iron
Aston
process Carbon and alloy Malleable iron
steel 0.1% - 2% C casting 2.0% – 2.5% C
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Ferrous Metals - Iron and Steel
Pure iron is soft and ductile to be of much practical use.
BUT when carbon is added, useful set of alloys are produced.
They are known as carbon steel.
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Types of Steel
Steel
•Stainless steel
•High speed steel
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Low Carbon Steel
Also known as mild steel
Contain 0.05% -0.32% carbon
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Medium Carbon Steel
Contains 0.35% - 0.5% of carbon
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High Carbon Steel
Also known as ‘tool steel’
Contain 0.55%-1.5% carbon
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Cast Iron
Contains 2%-4% of carbon
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Cast Iron
White:
Hard and brittle, good wear resistance
Uses: rolling & crunching
Equipment
Grey:
Good compressive & tensile strength, machinability,
and vibration-damping ability
Uses: machine bases, crankshafts, furnace doors,
Engine Blocks
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Ductile:
High strength and ductility Uses: engine and machine parts
Malleable:
Heat-treated version of white cast iron
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Stainless Steel
Steel alloyed with
chromium (18%), nickel (8%), magnesium (8%)
Hard and tough
Corrosion resistance
Comes in different grades
Sinks, cooking utensils, surgical instruments
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Stainless Steels
Main types:
Ferritic chromium:
very formable, relatively weak;
used in architectural trim, kitchen range hoods, jewelry,
decorations, utensils Grades 409, 430, and other 400
Austentitic nickel-chromium:
non-magnetic, machinable, weldable, relatively weak;
used in architectural products, such as fascias, curtain
walls, storefronts, doors & windows, railings; chemical
processing, food utensils, kitchen applications.
series. Grades 301, 302, 303, 304, 316, and other 300
series.
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Martensitic chromium:
High strength, hardness, resistance to abrasion; used in
turbine parts, bearings, knives, cutlery and generally
Magnetic. Grades 17-4, 410, 416, 420, 440 and other
400 series
Very hard
Resistant to frictional heat even at high temperature
Can only be ground
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Heat Treatment
A process used to alter the properties and characteristics
of metals by heating and cooling.
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Heat Treatment
Annealing
Normalizing
Hardening
Tempering
Case hardening
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Annealing
Annealing is the process whereby heat is introduced
to mobilise the atoms and relieve internal stress
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Normalizing
This process is only confined to steel.
It is used to refine the grain due to work hardening
Phase diagram of
Iron-Carbon
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Hardening
Hardening is the process of increasing the hardness
of steel by adding a high amount of carbon
The degree of hardness depends on the amount of
carbon present in steel and the form in which it is
trapped during quenching.
Once hardened, the steel is resistant to wear but
is brittle and easily broken under load.
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Tempering
Tempering is the process to reduce hardness and
brittleness slightly of a hardened steel workpiece.
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Tempering
230 C = 446 F
300 C = 572 F
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Case Hardening
Case hardening is a process used with mild steel to
give a hard skin
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Case Hardening - Carburizing
Carburizing involves placing the mild steel in box
packed with charcoal granules, heated to 950 º C (1742 oF)
and allowing the mild steel to soak for several hours.
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Carbon Steels Used for
Construciton
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2. Malleability is the ability of a material to withstand
heating or hammering into thin wire or
sheets
become permanently distorted or to deform in
compression without collapse.
3. Ductility is the ability of material to sustain large
permanent deformation indentation as drawing into
thin wire.
4. Hardness is the property of a material to resist cutting,
penetration or indentation
5. Elasticity is the property of material to resist permanent
change of form, recovering original form after removal
of load.
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6. Plasticity is the property of material that permit it,s
being easily moved or its ability to attain
large permanent distortion upon removal of load.
7. Toughness is the ability of material to withstand high
unit deformation.
8. Brittleness property of material to shatter or fracture
before much deformation is noticeable.
9. Stiffness is the property of material to resist
deformation.
10. Durability property of material to resist deterioration
in quality.
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Alloy Steel are steel that contain beside carbon it also contain some
alloying element to give special properties
1.Nickel is added to increase strength and toughness. It also helps to
prevent the steel from rusting and resist chemical attack
2.Manganese added to produce clean metal. It also add to the strength
of material and helps in heat treatment
3.Chromium add hardness, toughness and resistance to wear
4.Silicon make steel more elastic
5.Tungsten use with chromium, vanadium, molybdenum or manganese
to produce high speed steel
6.Molybdenum is added to increase strengthVanadium is added to
produce steel with an excellent shock resistance
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