Professional Documents
Culture Documents
Metals
Metals
Non-Ferrous
Metals
Ferrous
Metals
Non-Ferrous
Alloys
Aluminu
m
Pig Iron
Brass
Copper
Cast Iron
Bronze
Zinc
Wrought
Iron
Duralumi
n
Lead,
Tin, etc
Steel
German
Silver
3
Iron
Iron is available in abundance, but it does not
occur freely in nature. The iron content of
main ores are:
Magnetite (Fe3O4)
70-75% iron
Haematite (Fe2O3)
70% iron
60% iron
47% iron
Siderite (FeCO3)
40% iron
Fracture
Ultimate
tensile
strength
Elasti
c
Permanen
t strain
Hardening
Hardening involves heating a metal/steel and
cooling rapidly (quenching) in a suitable fluid
e.g. oil, water or air.
After the hardening treatment, steel is often
harder than needed and is too brittle for most
practical uses.
Also, severe internal stresses are set up
during the rapid cooling from the hardening
temperature.
Tempering
To relieve the internal stresses and reduce
brittleness, tempering is needed.
Tempering is heating the steel to a specific
temperature (below its hardening
temperature), holding it at that temperature
for the required length of time, and then
cooling it, usually instill air.
The resultant strength, hardness, and ductility
depend on the temperature to which the steel
is heated during the tempering process.
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Coke
Limestone
Blast
furnace
Pig iron
Open hearth
furnace
Slag
Pig iron
casting
Basic oxygen
furnace
Molten
steel
Continuous
casting
Ingots
Electric arc
furnace
Alloying
agents
Soaking
Primary
pits
rolling
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Pig iron
It is the basic material from which, wrought
iron and steel are manufactured.
Iron ore is crushed to 50 mm size. Impurities
are knocked off. Ore is calcined to drive off
moisture and then smelted in blast furnace.
Iron is deoxidized and limestone is added as
flux to remove sulphur (Flux is a substance
charged into blast furnace to lower the
melting point of ore and to remove impurities
such as ash, sulphur, etc).
The refined molten metal is tapped from
furnace and cast in the form of bars called
pigs. Hence the product is called pig iron.
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Pig iron
Pig iron is the crudest form of iron. Pig iron
contains 3-4 % carbon, 0.5-3.5 % silicon, 0.5-2
% manganese, 0.02-0.1 % sulphur and 0.03-1
% phosphorus.
Pig iron is hard and brittle with fusion
temperature of 1200oC and melts easily.
Its compressive strength is high but is weak in
tension and shear.
Pig iron does not rust.
It can not be riveted or welded.
It is most suitable for making columns, base
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plates, door brackets, etc.
Cast iron
Pig iron is re-melted with limestone (flux) and
coke and poured into molds of desired shapes
and sizes to get purer product called cast iron.
Methods of casting
Sand casting
Hollow casting
Vertical sand casting
Centrifugal casting
Die casting
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Cast iron
Classification: grey, white, malleable,
mottled, chilled and toughened cast iron
Uses: castings, rain water pipes, gutters,
gratings, railings, cisterns, manhole
covers and balustrades
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Wrought iron
All carbon and other elements in pig iron
oxidized to obtain wrought iron
Carbon reduced below 0.25%
All impurities reduced below 0.5%
Uses
Roofing sheets, corrugated sheets, rods, gas
and water pipes, boiler tubes, plain and
ornamental iron work like grills, gates,
railings, window guards, electromagnets
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Steel
In steel the carbon content is in chemically
combined form and may exist up to 1.5%
For a material to be classified as steel there
should be no free graphite in its composition.
Any free carbon makes it as cast iron
Steel categories
Dead mild steel
less than 0.15% carbon
Mild, soft, low carbon steel 0.15 to 0.3% carbon
Medium carbon steel
0.3 to 0.8% carbon
High carbon steel
Classification of steel
Steel
Carbon Steels
Alloy Steels
Mild Steel
Stainless Steel
High Carbon
Steel
Nickel Steel
High Tension
Steel
Vanadium Steel
Reinforcing
Steel
Tungsten Steel
Manganese Steel
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Mild steel
Steel with carbon content 0.15 to 0.3%
Called mild steel, low carbon steel or soft steel
Uses
Used in construction work as rolled sections, I-sec,
T-sec, channels, angle irons, etc
MS round bars used in RCC as reinforcement
Plain and corrugated sheets as roofing
Used in manufacture of various tools, equipment,
machine parts
Rail tracks, towers and industrial buildings
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Mild steel
Fibrous structure with dark bluish color
Ductile and malleable
Tough and elastic than cast and wrought iron
More prone to rusting and corrodes easily
Can be permanently magnetized
Easily forged, welded and riveted
Withstands shocks and impacts
Not much affected by saline water
Equally strong in tension, compression and shear
Difficult to harden and temper
Specific gravity is 7.8
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Reinforcing steel
Reinforcing Steel
Mild steel or high tension steel is embedded
as reinforcement in plain cement concrete
to provide tensile strength
Flat, square and round bars used
Welded wire mesh also used as
reinforcement
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Alloy steels
Stainless Steel
Nickel Steel
Vanadium Steel
Tungsten Steel
Manganese Steel
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Stainless steel
Structural steel with copper content of
0.2% resists atmospheric corrosion
better than structural steel with no
copper
Chromium is most effective ingredient
for corrosion resistance. Corrosion
protection is due to dense film of oxide
formed over metal surface.
Steel with chromium over 16% called as
stainless steel
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Stainless steel
Group-1
Chromium less than 16% and carbon less than
0.4%. Respond to heat treatment, are not brittle,
can be machined and welded. Resist weather and
water
Group-2
Chromium higher than 16% and carbon less than
0.4%. Do not respond to heat treatment, are brittle.
Can be forged, rolled, cold drawn and machined.
Can be welded and resist corrosion.
Group-3
Sufficient chromium to make it non-magnetic. Very
tough and do not respond to heat treatment. Can
be forged, rolled, cold drawn but machined with
difficulty.
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Nickel steel
Contains 0.5 to 1.0% carbon and 3.5%
nickel which imparts hardness,
toughness, strength and reduces rust
formation
Used in manufacture of automobile
parts, airplane parts, cables and
propeller shafts.
Steel with high nickel content (30 to
40%) is called invar, with very low
coefficient of thermal expansion, and is
used to make delicate instruments
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Vanadium steel
Contains 0.1 to 2.0% vanadium
Very strong and ductile
Capable of resisting shocks
High elastic limit
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Tungsten steel
Contains 14 to 20% tungsten, 3 to 8%
chromium and very small amount of
carbon, vanadium and molybdenum
Also called high speed steel
Hardens at high temperature and
retains temper
Used for making drilling machines and
high speed cutting tools
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Manganese steel
Contains 12 to 15% manganese
Very hard, tough and non-magnetic
Used for making machine parts and
points and crossings in rail tracks
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Preservation of steel
Rusting: Oxidation of iron at the surface,
which is activated by presence of
moisture and carbon dioxide and
accelerated by atmospheric pollution
Iron ferrous bicarbonate ferric
bicarbonate hydrated ferric oxide
Corrosion: Phenomenon of slow but
steady eating away of metal due to rust
formation
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Preservation of steel
Tarring: dipping of iron in hot coal tar to
form a film on metal. Pipes or pole ends
Painting: application of lead paints on
exposed metal surfaces like roof
trusses, bridge structure, etc
Enameling: smaller surfaces treated
with enamel
Galvanizing: depositing a fine film of
zinc or iron surface
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Preservation of steel
Sheradizing: acid solution washed metal
surface is covered with zinc dust and
heated in furnace to form a thin layer of
molten zinc
Tin plating: dipping in bath of molten tin
Electroplating: depositing a thin film of
nickel, chromium, cadmium, copper or
zinc by the electrolysis process. Metal
surface is cathode and deposition metal
is anode
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Property
Cast Iron
Wrought
Iron
Steel
Compositio
n
Crude. 2-4%
carbon
Purest. Less
than 0.25%
carbon
0.5 to 1.5%
carbon
Structure
Crystalline
Fibrous, silky
luster
Granular
Sp Gravity
7 to 7.50
7.70
7.85
Melting
point
1200C
1500C
1300 to 1400C
Hardness
Quite hardened
by heating and
cooling
Can not be
hardened or
tempered
Can be
hardened and
tempered
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Property
Cast Iron
Wrought
Iron
Steel
Strength
Compressive 6.3
to 7.1 ton/cm2
Tensile 1.26 to
1.57 ton/cm2
Compressive
6.3 to 2.0
ton/cm2
Tensile 3.15 to
3.94 ton/cm2
Compressive
4.72 to 25.2
ton/cm2
Tensile 5.51 to
11.02 ton/cm2
Shock
reaction
Absorbs shocks
Magnetizati
on
Can not be
magnetized
Temporary
magnetization
only
Permanent
magnets
Rusting
Rusts more
than cast iron
Rusts easily
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Property
Cast Iron
Wrought Iron
Tough,
malleable,
ductile and
moderately
elastic
Steel
Malleability
ductility
Neither malleable
nor ductile
Forging and
welding
Can be rapidly
forged or welded
Uses
Water pipes,
sewers, drain
pipes, lamp posts,
columns, railings
Reinforcement in
RCC and RBC,
structural
members, bolts,
rivets, sheets,
files, machine
tools
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Chains, crane
hooks, railway
couplings,
components
under constant
shock
Tough, malleable
and ductile