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26th element
Iron or Ferrous
55.85 Atomic Mass
General Categories of Ferrous
Metals and Alloys
Carbon and alloy steels
Stainless steel
Tool and Die steel
Cast Irons
Cast Steels
**Ferrous tools first appear about 4000 to 3000 BC,
made from meteoritic iron. Real ironworking started in
about 1100 BC in Asia Minor, and started the Iron Age.
APPLICATION OF FERROUS
(IRON) METALS / ALLOYS
Production of Iron and Steel
Raw Materials for Production
Iron Ore
Limestone ----------
Coke
Iron Ore
Uses electric arc from electrode to metal to heat and melt it.
Can produce 60-90 tons of steel per day.
Steel is higher quality than open-hearth and BOF
Vacuum Furnace
**Refining
Continuous Casting
-Molten metal skips
ingot step, and goes
directly the furnace to
a “tundish”
-Metal solidifies in the mold
-The metal descends @ about 1”/sec
-The solidified metal then goes through
‘pinch rollers’ that determine the final
form.
Benefits of Continuous Casting
•Stainless Steels
Stainless steels
are primarily know
for their corrosion
resistance, high
strength, and
ductility and
chromium content.
Stainless steel does not readily corrode, rust or
stain with water as ordinary steel does.
However, it is not fully stain-proof in low-
oxygen, high-salinity, or poor air-circulation
environments.
Unprotected carbon steel rusts readily when
exposed to air and moisture. This iron
oxide film (the rust) is active and accelerates
corrosion by making it easier for more iron
oxide to form.
Stainless Steels
Rebar corrosion
in concrete
Tool and Die Steels
Introduction
Aluminum
Magnesium
Copper
Nickel
Superalloys
Titanium
Refractory Metals
Non Ferrous Metals - Introduction
Non-Ferrous 56
Non Ferrous Metals - Introduction
Aluminum, beryllium, and titanium are used in
structural applications. Light metals such as lithium,
magnesium, potassium, and sodium also have
important engineering applications. Nickel and lead
have widespread applications as does copper which is
often chosen for its high thermal and electrical
conductivity. Cadmium, tin, and zinc are often used as
coatings, electrical applications, and for bearing
surfaces. Cobalt and manganese are common alloying
elements in steels. Gold, silver, and platinum, the
precious metals, are used in electrical applications and
jewelry.
Non-Ferrous 57
Non Ferrous Metals - Introduction
Non-Ferrous 58
Non Ferrous Metals - Properties
Non-Ferrous 59
Non Ferrous Metals - Properties
Refractory metals are chosen for their high heat
resistance. They retain their properties at elevated
temperatures. The precious metals are chosen for
their luster in applications such as coinage and
jewelry. Additionally, they may be used in electrical
conductors, contacts, and biocompatible
applications.
Some of these metals are chosen to plate other
metals such as nickel, chromium, and zinc which
are used to provide a resistant outer shell. Copper
is an excellent conductor and used in application
which require high conductivity. Its alloys, brasses
and bronzes, are typically alloyed for specific
purposes.
Non-Ferrous 60
Aluminum and Aluminum
Alloys
Most abundant metallic element (8% crust)
High strength to weight ratio
Resistant to corrosion
High thermal and electrical conductivity
Nonmagnetic
Easy formability and
machinability
Magnesium and Magnesium
Alloys
Lightest of all metals
Not sufficiently strong in pure form but
alloyed to increase strength.
Uses
– Aircraft and missile components, bikes,
luggage, portable power tools…
Designations for magnesium
– A. 1 or 2 prefix letters
– B. 2 or 3 numbers
Copper and
Copper Alloys
First produced in 4000 BC
Properties:
– Best conductors of electricity and heat, good
corrosion resistance, and easily processed.
Uses:
– Electronics, springs, cartridges, plumbing, heat
exchangers, and marine equipment.
Common alloys:
– Brass, Bronze, Beryllium copper
Nickel and Nickel Alloys
Silvery in appearance.
Good strength and ductility at elevated
temperatures.
Good corrosion resistance because of
adherent oxide film.
Used in electronic components and in
nuclear-power reactor applications.
Low neutron absorption.
Low-Melting Alloys
Ductile
Highest electrical and thermal
conductivity of any metal.
Used as tableware, jewelry, coinage,
electroplating, photographic film,
electrical contacts, solders, bearing
linings and food and chemical
equipment.
Sterling silver is an allow of silver and
7.5% copper.
Platinum
Soft, ductile.
Grayish-white metal.
Good corrosion resistance at any
temperature.
Used as electrical contacts, for spark-
plug electrodes, as catalysts for
automobile pollution-control devices,
in filaments, in nozzles as jewelry, and
in dental work.
Shape-Memory Alloys