METALS

Metal is an element, compound or alloy that is a good conductor of both

electricity and heat

Metal crystal structure and specific metal properties are determined by

metallic bonding force, holding together the atoms of a metal

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.

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 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

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

Ferrous metals are metals that consist mostly of iron and small amounts
of other elements. Ferrous metals are prone to rusting if exposed to
moisture. Ferrous metals can also be picked up by a magnet. The rusting
and magnetic properties in ferrous metals are both down due to the iron.
Typical ferrous metals include mild steel, cast iron and steel.
Examples:
1. Mild Steel.
2. Cast Iron.
3. High Carbon Steel.
4. High Speed Steel.
5. Stainless Steel.
Iron

Iron (Fe) atomic number 26

most widely used of all metals as base metal in steel and cast iron

Pig iron

the intermediate product of smelting iron ore with a high-carbon fuel

such as coke, usually with limestone as a flux

Semi-finished metal produced from iron ore in blast furnace, containing

92 percent iron, high amounts of carbon (typically up to 3.5 percent),
and balance largely manganese and silicone plus small amounts of
phosphorus, sulfur, and other impurities. Pig iron is further refined in a
furnace for conversion into steel. It gets its name from the shape of
trough (resembling a pig) in which it used to be cast in the 19th
century.

Extraction of Iron

Iron is found in iron oxide in the earth.

Three primary iron ores: magnetite, hematite, taconite

Iron is extracted using blast furnace

Steps in extraction of iron

Ores is washed, crushed and mixed with limestone and coke

The mixture is fed into the furnace and is then melted

Coke (a product of coal, mainly carbon) is used to convert the iron

oxides to 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)

The iron produced is only about 90% to 95% pure.

The iron is then further refined using the basic oxygen furnace and the
electric arc furnace to produce steel which is widely used now.

Ore, coke, and limestone are charged in layers into the top of a blast
furnace

Ore is the source of the iron , Coke is the source of the carbon (coke is
derived from coal, by heating in a coking oven)

Limestone acts as a fluxing slag to remove impurities like sulphur and silica

1100-deg. air blown into bottom of furnace, burns oxygen off the iron oxides,
causing temperature in furnace to get above the melting point of iron (approx
3000 degrees)

Molten iron sinks to bottom of furnace, where it is tapped off from furnace
and cast into large ingots called pigspigs contain high carbon content
(4% or so), plus many impurities, such as sulphur and silica which wasnt
removed by the limestone.

Metal Type.

Mild Steel.
o A ductile and malleable metal. Mild steel will rust quickly if it is
in frequent contact with water.
o Metal Uses. Used as Nuts and bolts, Building girders, car
bodies, gates, etc.
o Melting Point. 1600C

Cast Iron.
o

Is a very strong metal when it is in compression and is also

very brittle. It consists of 93% iron and 4% carbon plus other
elements.

Metal Uses. Used as car Brake discs, car cylinders, metalwork

vices, manhole covers, machinery bases eg: The pillar drill.

Melting Point. 1200C

Cast iron is derived from pig iron

White cast iron is named after its white surface when fractured, due
to its carbide impurities which allow cracks to pass straight through.

Grey cast iron is named after its grey fractured surface, which occurs
because the graphitic flakes deflect a passing crack and initiate
countless new cracks as the material breaks.

Wrought iron - iron alloy with a very low carbon content, in

comparison to steel, and has fibrous inclusions (slag). Tough,
malleable, ductile and easily welded

High Carbon Steel .

o

It is a very strong and very hard steel that has a high

resistance to abrasion. Properties Up to 1.5% carbon
content. Very tough.

Metal Uses. Used for hand tools such as screwdrivers,

hammers, chisels, saws, springs and garden tools.

Melting Point. 1800C

High Speed Steel.

o

HSS is a metal containing a high content of tungsten,

chromium and vanadium. However it is very brittle but is also
very resistant to wear.

Metal Uses. Used for drill bits and lathe cutting tools. It is
used where high speeds and high temperatures are created.

Melting Point. 1400C

Stainless Steel.
o

Stainless steel is very resistant to wear and water corrosion

and rust. Properties It is an alloy of iron with a typical 18%
chromium 8% nickel and 8% magnesium content.

Metal Uses. Used for kitchen sinks, cutlery, teapots, cookware

and surgical instruments.

Melting Point. 1400C

Main types:
Ferritic stainless steels:

Have a chromium content of about 16 to 18% and a low carbon content 0.12
maximum.

Non-hardenable steels

Have good corrosion resistance at high temperature but lose strength under
these condition.

Very formable, relatively weak;

Used in architectural trim, kitchen range hoods, jewelry, decorations, utensils

Grades 409, 430, and other 400

Austentitic nickel-chromium:

Have chromium content of 17 to 19%, a nickel alloying element of 8 to 10%,

and a maximum carbon content of 0.15%

non-magnetic, machinable, weldable, relatively weak, hardened when worked

at cold;

Have high strength and very tough and corrosion resistant.

Have high thermal expansion

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.

Martensitic chromium:

Have chromium content of 11.50 to 13.50% and a carbon content of 0.15%

maximum

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

Maraging (super alloys):

High strength, high Temperature alloy used in structural applications, aircraft
components and are generally magnetic. Alloys containing around 18% Nickel.
Non-Ferrous Metals:
Non-ferrous metals are metals that do not have any iron in them at all.
This means that Non-ferrous metals are not attracted to a magnet and
they also do not rust in the same way when exposed to moisture. Typical
Non-ferrous metals include copper, aluminium (coke cans), tin and zinc.
Examples:
1. Aluminium.
2. Copper.
3. Zinc.
4. Tin.
5. Lead.
6. Silver.
7. Gold.

8. Magnesium.
9. Metal Type.

Aluminium.
o It tends to be light in colour although it can be polished to a
mirror like appearance. It is very light in weight.
o Metal Uses. Used for saucepans, cooking foil, window frames,
ladders, expensive bicycles.
o Melting Point. 660C

Copper.

It is a ductile and malleable metal. It is often red / brown in

colour. It is a very good conductor of heat and electricity.

Metal Uses. Used for plumbing, electric components, cookware

and roof coverings.

Melting Point. 1084

Zinc.
o

It is very resistant to corrosion from moisture. However zinc is

a very weak metal and is used mainly for coating steel.

Metal Uses. Used as a coating on screws, steel buckets etc It is

also used to galvanize steel.

Melting Point. 419C

Tin.
o

It is a very ductile and very malleable metal. It is resistant to

corrosion from moisture. It is bright silver in appearance.
Tinplate is steel with a tin coating.

Metal Uses. Used as a coating on food cans, beer cans. Used as

whistles, tin foil and soldering.

Melting Point. 231C

Lead.
o

It is a soft, malleable metal. It is also counted as one of

the heavy metals. Lead has a bluish-white color after being
freshly cut, but it soon tarnishes to a dull grayish color when
exposed to air.

Metal Uses. Used for roof flashing. Also used for batteries and
for X-ray protection. Lead is used for its weight in many ways.

Melting Point. 327C

Silver.
o

A soft, white, lustrous transition metal, it has the

highest electrical conductivity of any element and the
highest thermal conductivity of any metal. The metal occurs
naturally in its pure, free form.

Metal Uses. Used for jewelry and high quality cutlery. Also
used for currency coins and sports trophies. Used in mirrors as
a reflective metal.

Melting Point. 961C

Gold.
o

Gold is a dense, soft, shiny, malleable and ductile metal. Pure

gold has a bright yellow color and luster traditionally
considered attractive, which it maintains without oxidizing in
air or water. Gold resists attacks by individual acids It won't
tarnish, discolor, crumble, or be affected by most solvents.

Metal Uses. Used mainly for jewelry. Also used in computers as

a conductor. Used for its reflective powers to protect satellites.

Melting Point. 1337C

Magnesium.
o

Magnesium is a fairly strong, silvery-white, light-weight metal

(one third lighter than aluminum) that slightly tarnishes when
exposed to air. In a powder, this metal heats and ignites when
exposed to moisture and burns with a white flame.

Metal Uses. Magnesium is used in pyrotechnic (i.e. fireworks).

It is alloyed with other metals to make them lighter and more
easily welded.

Melting Point. 648C