TOPIC 2

FERROUS
METAL

INTRODUCTION
There are a lot of metals
used
in
engineering,
however those based on
iron
are
the
most
important and widely used.
Steel is a ferrous metal
because
its
main
constituent is iron. A quick
and easy way to tell if
metal is ferrous or not, is to
use magnet.

2.1 METAL
PRODUCTION

2.1.1 CONTENT OF IRON ORE

Iron ore

Compositi
on

Colour

Magnetite
(Fe3o4)

Contain
70% of iron

Dark
grey,
black

Hematite
(Fe2o3)

Contain
40% - 65%
of iron

Rusty
red

limonite

Contain
20% - 55%
of iron

Rusty
brown

carbonate

Contain
30% of iron

grey

2.1 METAL
PRODUCTION
2.1.2 PROCESS OF IRON PRODUCTION
USING BLAST FURNACE
The iron itself is chemically combined with oxygen and
is called iron oxide in order to remove all of the
impurities the iron ore has to be smelted, and this is
done using a Blast furnace

2.1 METAL
PRODUCTION
2.1.2 PROCESS OF IRON PRODUCTION
USING BLAST FURNACE
The blast furnace process:
1. The iron ore, coke and limestone(the charge), is
conveyed to the top of the furnace.
2. Hot air is then blown through pipes called
tuyeres, to fire the mixture.
3. The coke burns to increase the temperature in
the furnace
4. The limestone attracts the impurities in the iron
ore and form slag. The slag is lighter than the
molten iron and so floats on top of it.
5. As the furnace fills, the molten iron is tapped
off. The slag is also tapped off at regular
intervals.
6. Most iron is taken straight from the blast
furnace to the steel mill, but some is poured
into buckets called pigs. The iron is called pig
iron and is used to make cast iron.

2.2 STEEL
PRODUCTION
2.2.1 PROCESS OF STEEL PRODUCTION
Steel is made from iron mixed with carbon.
The two methods of producing steel from
iron are;
a. Basic Oxygen furnace

There are six steps in the production of

steel using the Basic Oxygen Furnace
process. During each stage, the furnace
is turned in different directions. This is
shown clearly in the accompanying
diagram

2.2 STEEL
PRODUCTION
Basic Oxygen Furnace process

2.2 STEEL
PRODUCTION
2.2.1 PROCESS OF STEEL PRODUCTION
b. Electric Arc Furnace

The Electric arc furnace is heated by

electricity, similar to arc welding and so
large amount of electricity are needed.

2.2 STEEL
PRODUCTION
Electric Arc Furnace process

Tapping

2.3 PLAIN CARBON

STEEL
2.3.1 EQUILIBRIUM PHASE DIAGRAM UP TO
1.7% CARBON

2.3 PLAIN CARBON

STEEL
2.3.1 EQUILIBRIUM PHASE DIAGRAM UP TO
1.7% CARBON
Phase in Iron Carbon Phase Diagram
a. Ferrite
At 0% carbon is pure iron.
BCC crystal structure. The
( iron)
maximum solubility of carbon
is 0.02% carbon at 723C
b. Austenit
e
( iron)

FCC crystal structure. High

solubility for carbon
compared to ferrite. The
solubility reaches a maximum
of 2.0% carbon at 1147C.

c. Pearlite
( + Fe3C)

It is eutectoid mixture
containing 0.8% carbon and
is form at 723C. A lamellar
structure of ferrite and
cementite

d. Cementi Unlike ferrite and austenite,

te
cementite is a very hard
(Fe3C)
intermetallic compound
consisting of 6.7% carbon and
the remainder iron.

2.3 PLAIN CARBON

STEEL

Carbon steel, also called plain-carbon steel, is

steel where the main interstitial alloying constituent
is carbon
Classificatio
n

compositio
n

Properties

Application

Low Carbon
steel and
Mild steel

0.02 - 0.3
%C

Low carbon steel

contains approximately
0.050.15% carbon and
mild steel contains
0.160.3%. has a
relatively low tensile
strength, but it is cheap
and malleable; surface
hardness can be
increased through
carburizing

Sheets,
wires, pipes,
car body
and etc.

Medium
Carbon
steel

0.3 - 0.6 %C.

Approximately 0.30
0.6% carbon content.
ductility and strength
and has good wear
resistance

Used for
large parts,
forging and
automotive
components.

High Carbon
steel

0.6 - 1.7 %C.

Approximately 0.6
1.7% carbon content.
Steels that can be
tempered to great
hardness

Used for
special
purposes
like (nonindustrialpurpose)
knives, axles
or punches
and spring.

2.4 ALLOY STEEL

2.4.1 Define term and purpose of alloy
steel
Alloy steel is steel alloyed with a variety of
elements in total amounts of between 1.0% and
50% by weight to improve its mechanical properties
Effect of alloying element to steel properties
1. Increase hardenability
2. Formation of new carbides
3. Solubility of solid solution
4. Improvement in corrosion resistance
5. Stability of austenite and ferrite
Alloy element of steel and how this element
effecting
metal properties
Alloy
material
Composition
Effect
Manganese

1-1.5%

-Increases
hardenability

Sulfur

0.08 0.15%

- Improve
machinability

Nickel

2-5% or 12
20%

-increase
touhgness and
improve
corrosion
resistance

Chromium

< 2%

- Improve Heat
resistance and

2.4 ALLOY STEEL

2.4.3 Identify the characteristic of alloy
steel.
Type of steel
alloy

Characteristics

1. Structural
steel

Structural steel is steel

construction material, a profile,
formed with a specific shape or
cross section and certain standards
of chemical composition and
mechanical properties.
Application: I-beam

2. Corrosion
Resistance
steel or
stainless
steel

Steel alloy with minimum of 10%

chromium
Why is it stainless?
The Cr react with oxygen to form a
tough , adherent, invisible and
passive layer of Cr2O3 film.
Application: Household utensils,
automotive exhaust, kitchen sink
and etc

2.4 ALLOY STEEL

2.4.3 Identify the characteristic of alloy
steel.
3. Heat
resistance
steel or High
speed steel

Capable of cutting metal at much

higher rate than carbon steel. Used
to cut other metals/alloys and
continues to cut and retain its
hardness even when the point of
the tool is heated to a low red
temperature.
Application: Milling tool, tool bits
and etc

4.Tool and
mould steel.

Wear resistance, capable of holding

sharp cutting edge and very hard.
Application: Concrete drill, drawing
dies and etc.

2.5 CAST IRON

2.5.1 Explain cast iron position in iron-carbon
phase diagram.
Family of ferrous alloy
Typical compositions: 2-4% of carbon and 1-3%
silicon
2.5.2 Explain the effect of each factor below
on cast iron properties:
a. Cooling rate
- Rapid cooling discourages the nucleation
graphite and encourages the formation of
metastable iron carbide.Longer holding times at
higher temperatures and slower cooling and the
addition of certain alloying elements encourage
the formation of stable iron-graphite phase.
b. Carbon content
- High carbon content metals can, under controlled
conditions, solidify as stable iron-graphite
systems or metastable iron-carbide systems.

2.5 CAST IRON

2.5.2 Explain the effect of each factor
below on cast iron properties:
c. Element content
- Cast iron contains significant amounts of
silicon in addition to the high carbon
content.Cast irons are therefore really
iron-carbon-silicon alloys. The presence of
silicon in iron carbon alloys promotes the
formation of graphite

2.5 CAST IRON

2.5.3 Expain the characteristic and
applications of the cast iron:
Grey cast iron
a. Named as a Grey cast iron because its
fracture has a grey appearance.
b. Carbon content: 2.5 4.0% carbon and 1-3%
silicon
c. Microstructure: Graphite presence in the form
of flake or rossete

d. Properties: High compressive strength,

hardness and moderate machinability.
e. Application: Engine block, cylinder block,
clutch plate and gear boxes

2.5 CAST IRON

2.5.3 Expain the characteristic and
applications of the cast iron:
White cast iron
a. Named as a Grey cast iron because its
fracture has a white/silver appearance.
b. Carbon content: < 4.3% of carbon and
presence of manganese and silicon
c. Microstructure: Carbon + Fe presence in the
form of cementite

d. Properties: High wear and abrasion

resistance.
e. Application: Brake shoes, ball mills and
extrusion nozzle

2.5 CAST IRON

2.5.3 Expain the characteristic and
applications of the cast iron:
Malleable cast iron
a. Produced by annealing White cast iron at
900-1060C for 50 -80 hour (Slow cooling to
room temperature)
b. Two groups of malleable cast iron are
specified,( black and white) differentiated by
chemical composition, temperature and time
cycles of the annealing process, the
annealing atmosphere and the properties and
microstructure resulting there from.
Microstructure: Carbon + Fe presence in the
form of cementite.
c.
Properties: increase ductilty of white cast
iron
d.
Casting mould, railroad and pipe fitting

2.5 CAST IRON

2.5.3 Expain the characteristic and
applications of the cast iron:
Malleable cast iron(Black)
a. The microstructure of blackheart malleable
cast iron has a matrix essentially of ferrite

Malleable cast iron(Black)

a. Cast iron, which has a pearlite matrix. By
adding manganese to the structure, carbon is
retained in the form of cementite.

2.5 CAST IRON

2.5.3 Expain the characteristic and
applications of the cast iron:
Ductile Cast Iron (Nodular Cast Iron):
This structure is developed from the melt.
The carbon forms into spheres when
cerium, magnesium, sodium, or other
elements are added to a melt of iron with
a very low sulfur content that will inhibit
carbon from forming. The control of the
heat-treating process can yield pearlitic,
ferritic, martensitic matrices into which
the carbon spheres are embedded.

Figure 6. Photomicrograph of Nodular Cast

iron