CONSTRUCTION MATERIAL

Chapter 6 metallic materials

By: Eng. Abdulwali
Types of Metal: Engineering Material
Metals

Ferrous Non-
Ferrous
Iron Copper &
Alloys
Pig iron
Aluminium
Cast iron
Zinc
Wrought
iron
Tin
Steel

Lead
Metals
 Metals

• There are two groups of Metals

1. Ferrous – consist mainly of IRON

2. Non Ferrous – contain NO IRON

 Where do metals come from?

•Metals come from rocks in the ground

called ORE
• The ORE is mined from the ground
• The metal must then be taken from the Ore
and a big Furnace does this.
 Iron

• Iron comes from Iron Ore which is

excavated from the ground.

• The furnace used to separate the Iron from

the rocks is called a BLAST FURNACE
Blast Furnace
Blast Furnace Charge
1. Iron Ore

2. Coke
(fuel)

3. Limestone
(Keeps waste bits together)
Iron Ore

• Iron ore is a rock that contains iron

combined with oxygen.

• Some of the world's highest quality iron ore

comes from Australia.
 Coke

• Coke is made from coal. Once mined, the coal

is crushed and washed.

• Coal is then baked in coke ovens for about 18

hours.

• During this process, by-products are

removed and coke is produced.
Flux

• Flux is a term for minerals used to collect

impurities during iron and steelmaking.

• Limestone and dolomite are fluxes.

• The flux causes a chemical reaction and

elements not needed for steelmaking join
together to form slag.
Blast Furnace

Tuyeres are the nozzles

that the hot air is
blown through

Tuyeres
Blast Furnace operation
• The Charge is fed in at the top,

• Bell Doors open (One at a time)

• Coke burns & makes Carbon Monoxide,

• The Carbon Monoxide mixes with the Oxygen in

the Iron Ore (leaving Iron),
Blast Furnace

• The Molten Iron falls to the bottom of the

Furnace,

• The limestone joins with the impurities to

make Slag and floats on top of the Molten
Iron.
Blast Furnace

• The slag and the Molten Iron are tapped off

regularly,
Blast Furnace Waste

• Slag, Ammonia, Light Oils and Coal Tars are

waste from the Furnace,

•They make raw

materials for cements,
plastics and
fertilisers.
Blast Furnace Iron
• Special rail cars bring the Molten Iron away,
• The liquid iron typically flows into a channel
and indentations in a bed of sand.

• Once it cools,
this metal is known
as pig iron.
Why is Pig Iron called Pig Iron ?
• PIG IRON is raw iron in an ingot form.

• It is the result of smelting Iron Ore, Coke and

Limestone in a blast furnace.

• It is a hard but brittle mix of iron (90% or more) and

carbon (typically 4-5%), manganese, sulfur,
phosphorus, and silicon (roughly 3% in total).

• The name is derived from the time when the iron ran
into moulds. A row of moulds was said to resemble a
litter of suckling pigs, so the single ingots were referred
to as pigs.
To create a ton of pig Iron
We start with 2 tons of
ore, 1 ton of coke and
½ ton of limestone.
The fire consumes 5 tons
of air.
The temperature reaches almost 3000 deg
F (about 1600 degrees C) at the core of
the blast furnace!
• Pig iron contains 4 percent to 5 percent carbon
and is so hard and brittle that it is almost
useless.

We do one of two
things with pig iron:

• You melt it, mix it with slag and hammer it to

eliminate most of the carbon (down to 0.3
percent) and create wrought iron.
Wrought Iron

• Wrought iron is the stuff a blacksmith works

with to create tools, horseshoes and so on.
When you heat wrought iron, it is malleable,
bendable, weldable and very easy to work
with.

• Or we can create steel.

Steel

• Steel is iron that has most of the impurities

removed.
• Steel also has a consistent concentration of
carbon throughout (0.5 percent to 1.5 percent).
• Impurities like silica, phosphorous and sulfur
weaken steel tremendously, so they must be
eliminated.
• The advantage of steel over iron is greatly
improved strength.
Blast Furnace Iron

• The Iron must go into a second furnace to

make it into a better quality metal (Steel)

• At the Steel making factory, it is mixed with

recycled steel and other alloys to make new
steel
Iron into Steel

• The Iron that comes from the Blast Furnace

requires further treatment to produce Steel,

• This is done in:

1. The Bessemer Converter or
2. The Basic Oxygen furnace.
Metal
s
 Properties of Metals
Metals appear to the left of the dark ziz-zag line on the
periodic table. Most metals are solid at room temperature.
 Properties of
Metals
Metals have
luster. This
means they are
shiny
 Properties of
Metals
Ductile
metals can be
drawn into wire.
Properties of
Metals Malleable
metals can
be hammered
into sheets
 Properties of
Metals

Metals have a high melting point. They

are also very dense.
 Properties of
Metals
Conductors
Metals are
good
conductors of
electricity and
heat
 Properties of
Metals
A chemical property
of metal is its
reaction with
water and oxygen.
This results in
corrosion and
rust.
Properties of materials

Mechanical properties of materials

Strength, Toughness, Hardness, Ductility,
Elasticity, Fatigue and Creep

Physical properties
Density, Specific heat, Melting and boiling point,
Thermal expansion and conductivity,
Electrical and magnetic properties

Chemical properties
Oxidation, Corrosion, Flammability, Toxicity, …
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