4.

1 Properties and importance of metals

Metals as important raw materials A raw material is used in primary production or manufacturing of a good. Raw materials are often natural resources such as oil, iron and wood. Before being used in the manufacturing process raw materials are often altered to be used in different processes. Iron is an important raw material for making steel. It has lots of uses e.g. cars, machinery, cooking utensils, tools, etc. Physical and chemical properties of metals Some physical properties of metals are that they are malleable (can be beaten into thin sheets), Ductile (can be stretched into wire) It is also shiny and is a solid at room temperature. Some chemical properties are that they usually have 1 to 3 electrons in there outer shell, lose their valence electrons easily, forms oxides that are basic, are good reducing agents and have lower electronegativities.

4.2 Reactivity series

Reactive metals with water or steam ( Highest to lowest ) 1. Potassium Reacts violently with cold water. Floats and catches fire. 2. Sodium Very vigorous reaction with cold water. Floats. Can be lit by a lighted splint. 3. Calcium Less vigorous with cold water. 4. Magnesium Very slow with cold water but vigorous with steam. 5. Zinc Quite slow with steam. 6. Iron Slow with steam. 7. Copper No reaction with steam.

Reactive metals with dilute hydrochloric acid ( Highest to lowest ) 1. Magnesium Reacts vigorously with a stream of gas evolving. 2. Zinc Reacts slowly with a steady stream of gas evolving. 3. Iron Slow reaction with a gentle stream of gas evolving. 4. Copper - No Reaction.

The reduction of their oxides with carbon Magnesium oxide with carbon forms magnesium with carbon. monoxide Zinc oxide with carbon forms zinc and carbon monoxide. Iron oxide with carbon forms iron and carbon dioxide. Copper oxide heated with carbon forms carbon dioxide and copper. Describe the reactivity series as related to the tendency of a metal to form its positive ion, illustrated by its reaction, if any, with the aqueous ions In another reaction, metals compare with each other for other anions. This type of reaction is called a displacement reaction. The reactivity series can be used to predict which of the metals will win. In a displacement reaction, a more reactive metal will displace a less reactive metal from a solution of its salt. Oxidation and reduction always occur together. They are call redox reactions. The zinc is oxidised to zinc ions in aqueous solution, while the copper ions are reduced. The oxides of the other reactive metals

Account for the apparent unreactivity of aluminium in terms of the oxide layer which adheres to the metal Aluminium reacts so steadily with the oxygen in the air, a protective oxide layer is formed on its surface. This often prevents any further reaction and disguises aluminiums true reactivity. This gives us the use of a light and strong metal. Deduce an order of reactivity from a given set of experimental results

4.3 Extraction of metals

Describe the ease in obtaining metals from their ores be relating the elements to the reactivity series In order to extract a metal, the ore or compound of the metal must undergo a process called reduction to free the metal i.e. the positive metal ion gains negative electrons to make the neutral metal atom, or the oxide loses oxygen, to make the free metallic atoms. the method of extraction depends on where the metal stands in the reactivity series. The reactivity series of metals can be presented to include two non-metals, carbon and hydrogen, to help predict which method could be used to extract the metal. Name the main ore of aluminium Bauxite is an aluminium ore and is the main source of aluminium. Describe, in outline, the manufacture of aluminium from pure aluminium oxide in molten cryolite Aluminium is too high up in the reactivity series to extract it from its ore using carbon reduction. Instead, it is extracted by electrolysis. The ore is first converted into pure aluminium oxide by the Bayer Process, and this is then electrolysed in solution in molten cryolite another aluminium compound. The aluminium oxide has too high a melting point to electrolyse on its own. Describe the essential reactions in the extraction of iron from hematite Iron is extracted mainly from its oxides, haematite and magnetite in a blast furnace. These ores contain aleast 60 percent iron. The blast furnace is a steel tower approximately 50 metres high lined with heat-resistant bricks. It is loaded with the charge of iron ore (usually haematite), coke (made by heating coal) and limestone (calcium carbonate).

A lot of chemical reactions occur in the blast furnace - The limestone begins to decompose - The carbon dioxide gas produced reacts with hot coke higher up in the furnace, producing carbon monoxide in an endothermic reaction. - Carbon monoxide is a reducing agent. It rises up the furnace and reduces the iron (II) oxide ore. This takes place at a temperature of around 700 degrees Celsius. - The calcium oxide formed from the limestone reacts with acidic impurities, for example silicon (IV) oxide, in the iron ore to form a liquid slag, which is mainly calcium silicate. Describe the conversion of iron into steel The Iron obtained from the blast furnace contains between 3% and 5% of carbon and other impurities such as sulphur, silicon and phosphorus. These impurities make the iron tough and brittle. To improve the quality if the metal, most of the impurities have to be removed and if u do this steel is produced. Impurites are removed in the basic oxygen process, which is the most important of the steel making process. In this process: - Molten iron from the blast furnace is poured into the basic-oxygen furnace. - A water cooled lance is introduced into the furnace and oxygen at 5-15 atm pressure is blown onto the surface of the molten metal. - Carbon is oxidised to carbon monoxide and carbon dioxide, while sulphur is oxidised to sulphur dioxide. They turn into gases and escape. - Silicon and phosphorus are oxidised to silicon (IV) oxide and phosphorus pentoxide which are both solid oxides. - Some calcium oxide is added to remove these solid oxides as slag. - The amount of carbon in the furnace is constantly checked. When the required amount of carbon has been reached the blast of oxygen is turned off.

Describe in outline, the extraction of zinc from zinc blend The main source of zinc is zinc sulphide or zinc blende. This ore occurs mainly in Australia, Canada and the US. The zinc ore is first concentrated by a precess call froth flotation.

4.4 Uses of metals

Name the uses of aluminium in the manufacture of aircraft because of its strength and low density; in food containers because of its resistance to corrosion Low density and strength make aluminium ideal for construction of aircraft. An alloy of aluminium called duralumin is often used instead of pure aluminium because of its improved properties. It is also used on aircrafts because it is corrosion resistant and easily shaped. Name the uses of zinc for galvanising and for making brass Zinc is alloyed with copper to make the useful metal brass (electrical plug pins). Brass alloy is stronger and more hardwearing than copper and not as brittle as zinc. Some steel girders used in the construction of bridges and buildings are galvanised. Coal bunkers and steel dustbins are also galvanised. This involves dipping the object into molten zinc. The thin layer of the more reactive zinc metal coating the steel object slowly corrodes and loses electrons to the iron therefore protecting.

Describe the reasons for the use of copper and (steel-cored) aluminium in cables, and why plastics and ceramics are used as insulators Copper is a very good conductor of electricity so it is used in electrical cables and is a very good conductor of heat. Copper is also resistant to corrosion. Aluminium is also a good conductor of electricity and heat. It is low in density and is also resistant to corrosion. Ceramics or general ceramics are used to insulate materials that do not conduct electricity. Fine-ceramics include packages for surface-mounted electronic components such as, quartz, crystal oscillators and surface acoustic wave (SAW) filters. Plastics are good thermal insulators because heat does not travel through them easily. Name the uses of copper related to its properties; electrical wiring and in cooking utensils Copper has a lot of properties like - An excellent electrical conductor - An excellent thermal conductor - corrosion resistant - anti-bacterial - easily joined - ductile - tough - non-magnetic - an attractive colour - easy to alloy - recyclable Copper wires allow electric current to flow without much loss of energy. This is why copper wires are used in mains cables in houses and underground (although overhead cables tend be aluminium because it is less dense).

Describe the idea of changing the properties of iron by the controlled use of additives to form steel alloy

Name the uses of mild steel and stainless steel Mild steel is cheap, strong and easily shaped. It is the main metal for construction. Stainless steel is an alloy of iron. Stainless steel is strong and hard, with a very high resistance to corrosion (due to chromium). It is used for cookware, cutlery and industrial chemical plant. Identify representatives of alloys from diagrams of structures

Explain why metals are often used in the form of alloys They can be used for more things. Metallurgists have designed alloys to suit a wide variety of different uses.

4.5 Corrosion and its prevention

Describe the methods of rust prevention: paint and other coatings to exclude oxygen To prevent iron from rusting it has to stop oxygen (from the air) and water coming into contact with it. There are several ways of doing this. Iron structures are painted to prevent rusting. The paint keeps the air and water away from the structure. However if the paint is scratched the iron beneath it will start to rust and then corrosion can spread under the paintwork. It is necessary to keep the paint in good condition and is checked regularly. The iron and steel in the moving parts of machinery are coated with oil to prevent them from coming into contact with air or moisture. This is the most common way of protecting moving parts of machines. Describe the sacrificial protection in terms of the reactivity series of metals and galvanising as a method of rust preventation Some steel construction parts of buildings and bridges are galvanised. This involves the object to be dipped in molten zinc. The thin layer of the more reactive zinc metal coating the steel object slowly corrodes and loses electrons to the iron, thereby protecting it. Sacrificial protection is when bars of zinc are attached to hulls of ships and to oil rigs. Zinc bars remain in contact with the iron structure. The structure will be protected from rusting. On a ship the zinc bar is sacrificed to protect the steel. Electrons released from the dissolving zinc cause reduction to occur at the surface of the hull.