FerrousMetalsandAlloys-MechanicalEngineering.pptVIP

Chapters 5 and 6: Ferrous and Nonferrous Metals Group 5 Patrick Pace Michael Linley Bryan Estvanko Matthew Sallee Ferrous Metals and Alloys Production - General Properties - Application Introduction What is a ‘ferrous metal’ or ‘ferrous alloy’? It is simply a metal or alloy that contains Iron (the element ferrous) as the base (starting) metal. 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. 5.2 Production of Iron and Steel Raw Materials for Production Iron Ore Limestone ----------? Coke Iron Ore Abundant, makes up 5% of earth’s crust Is not found in ‘free state’, must be found in rocks and oxides, hence Iron ore. After mining, the ore is crushed and the iron is separated, then made into pellets, balls or briquettes using binders, such as water. The pellets are typically 65% iron, and about 1” in diameter. Coke – (…The black, legal kind) Coke is formed by heating coal to 2100*F (1150 C), then cooling it in quenching towers. You need more than Iron? Why coke is used… 1. Generates high heat, needed in order for chemical reactions in ironmaking to take place. 2. Produces CO (carbon monoxide) which reduces iron-oxide to Iron. Lastly, Limestone Limestone (calcium carbonate) is used to remove impurities. When the metal is melted, limestone combines with impurities and floats to the top of the metal, forming slag. The slag can then be removed, purifying the iron. Ironmaking Raw Materials ? Pig Iron The three raw materials are dumped into a blast furnace. Hot air (2000*F) is blasted into the furnace, which helps drive the chemical reaction. The coke forms CO and the CO reduces the iron oxide to iron. The slag floats to the top and the metal is transferred to