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SUMMARY
This topic introduces the methods of irons, steels and cast irons production. It also describes the structure, properties and the usage of irons, steels and cast irons in the engineering field. CLO 1. explain various types of materials used in manufacturing industry. (Cognitive Domain : C2 Comprehension )
2.4 Describe the alloy steel 2.4.1 Define term and purpose of alloy steel 2.4.2 Explain elements in the alloy which influence steel properties. 2.4.3 Identify the characteristic of alloy steel
a. Structure steel
2.1.2 Explain the process of iron production by b. Corrosion resistant steel using Blast Furnace c. Heat resistant steel 2.2 Understand the steel production d. Tool and mould steel e. Magnetic steel 2.2.1 Explain the process of steel production by 2.5 Describe the cast iron using these 2.5.1 Explain position of cast iron in iron-carbon methods phase diagram a. Basic Oxygen Furnace (BOP) b. Electric Arc Furnace 2.5.2 Explain of cast iron properties effect 2.3 Describe the plain carbon steel a. Cooling rate b. Carbon content 2.3.1 Sketch completely the different phases in c. Cross sectional area equilibrium phase diagram up to 1.7% carbon d. Element content 2.3.2 Differentiate between iron, steel and cast 2.5.3 Explain the characteristics and applications iron in the iron-carbon equilibrium phase of the cast iron diagram a. Grey cast iron
b. White cast iron c. Black malleable cast iron d. White malleable cast iron e. Nodular cast iron
LEARNING OUTLINE
Understand metal production iron and steel Understand the process of iron and steel production Understand plain carbon Understand alloy steel Understand cast iron
TOPIC
IRON
STEEL
CAST IRON
Iron (fe)
Iron is an element and can be pure. Iron can be extracted from iron ores such as rocks, mineral. Classification of iron ores: Magnetite Iron Carbonate Hematite Limonite
Iron is obtained by reducing iron oxides into metallic in blast furnaces. Basic constituent of steel.
2.2 Iron Ores Characteristics 1. GRADE containing as much as possible iron oxide 2. COMPACTABILITY not too compact or too brittle 3. PURITY containing as less as possible impurities 4. SIMILARITY containing similar composition to one another
Hematite
Limonite
Magnetite
Iron Ore
Magnetite
Chemical Formula is (Fe3O4). Also called as Black Iron Ore - because the color is black. Percentage of Iron; 72 62% Fe (Iron)
Iron carbonate
Also know as siderite Chemical formula (FeCO3) Its color is yellowish green Percentage of iron; 35 40% Fe (Iron)
HEmatite
Chemical formula (Fe2O3) Also known as Red Iron Ore. Percentage of Iron; 70% Fe (Iron).
limonite
Chemical formula is (FeO(OH).n(H2O)) Also known as Brown Iron Ore
Iron ore
Called as Charge
Coal
Coke
limestone
Blast furnace
The purpose of use blast furnace is to reduce and convert iron oxides into liquid iron called molten iron. The appearance of blast furnace is huge, steel stack lined with refractory brick. The blast furnace is around 30 metres high and lined with fireproof bricks. Iron ores, coke and limestone are put into the top and preheated air blown into the bottom. Iron can be extracted by blast furnace because it can be displaced by carbon. It more efficient and more cost effective.
Iron Ore is smelted in the Blast Furnace in order to remove unwanted impurities such as rocks, clay and sand, and also to separate the Iron from the Oxygen. The result is Iron which is about 95% pure. The remaining impurities are other elements which can be removed later if necessary. A Blast Furnace is about 100ft. high and produces abut 1000 tons of molten Iron a day. It is made from steel.
The charge is placed a giant chimney called a blast furnace. The hot air that was blown into the bottom of the furnace ascends to the top in 6 to 8 seconds after going through numerous chemical reactions. Once a blast furnace is started it will continuously run for four to ten years with only short stops to perform planned maintenance.
The carbon monoxide reduces the iron in the ore to give molten iron:
3CO(g) + Fe2O3(s) 2Fe(l) + 3CO2(g)
The limestone from 2, reacts with the sand to form slag (calcium silicate):
Chapter 2:Ferrous Metals 2.0 Iron Productions 1. Iron ores are main material in iron ingot production. 2. In mining process, the iron ore are in pure state. It also found other substances such as oxide, sulphade, sulphur, silicon, etc.
along with
STEEL
STEEL
Steel is an alloy of iron, containing up to 2% of carbon (usually up to 1%). Its a combination of iron & carbon( 0.01 1%) Contains varying amounts of manganese, phosphorus, sulfur, silicon & 20 other alloys Alloys added to produce steel of different characteristics. To produce useful steel, molten iron need to be oxidized in another furnace at about 1650C. Molten iron is not useful because its weak and brittle although its very hard.
Molten iron
Figure - BOF sequence : (1) charging of scrap and (2) molten iron, (3) blowing, (4) tapping the molten steel, (5) pouring off the slag
BOF Process
a) Charging scrap
the scrap is first to be charged
c) Blowing
starting blowing oxygen and the duration time of blowing about 20 min.
d) Discharging steel
Pouring the steel to a ladle. Special devices (plugs, slag detectors) prevent penetration (carry-over) of the slag into the ladle
e) Discharging slag
De-slagging - pouring the residual slag into the slag pot. The furnace is turned upside down in the direction opposite to the tapping hole.
EAF Process
Plain Carbon Steels Grouped by Carbon Content 1. Low carbon steels - contain less than 0.20% C
Applications: automobile sheetmetal parts, plate steel for fabrication, railroad rails
Eutectoid point is a solid to solid change point where solid Austenite changes into solid Pearlite.
Hypo-eutectoid steel
(< 0.8 %C)
Hyper-eutectoid steel
(0.8% < %C 2.0%)
Alloy steels
Alloy steels are iron-carbon alloys, to which alloying elements are added with a purpose to improve the steels properties as compared to the carbon steels. Alloy steels contain alloying elements (e.g. manganese, silicon, nickel, titanium, copper, chromium and aluminum) in varying proportions in order to manipulate the steel's properties, such as its hardenability, corrosion resistance, strength, formability, weldability or ductility. Applications for alloys steel include pipelines, auto parts, transformers, power generators and electric motors. Contain more than 1.0% of other elements instead of Fe and C. Purpose of alloying
Increase hardenability Improve strength at ordinary temperature Improve mechanical properties at either high or low temperatures Improve toughness at any minimum hardness or strength Increase wear resistance Increase corrosion resistance Improve magnetic properties
Nickel (Ni)
Chromium (Cr)
Improves hardenability, strength and wear resistance, sharply increases corrosion resistance at high concentrations (> 12%).
Improves strength, elasticity, acid resistance and promotes large grain sizes, which cause increasing magnetic permeability. Improves corrosion resistance.