MetalandMetalAlloy.pptVIP

* /files/blades_big.jpg * * * Coke acts as reducing agent to reduce iron oxides to produce raw pig iron which contain 4% of carbon along with other impurities. Basic Oxygen furnace: pig iron + 30% of steel scrap. Oxidizing the carbon and other impurities in the pig iron until the carbon content of the iron is reduced to the required level. Cupola furnace: metal, coke and flux Steel: up to 1.2% of carbon, Cast iron: contain 2-4% of carbon * The molten steel is either cast in stationary mold or continuously cast into long slabs from which long sections are periodically cut off (called ingot). The ingots are heated in a soaking pit and hot-rolled into slabs, billets, or blooms. The slabs are subsequently hot- and cold-rolled into steel sheet and plate. The billets are hot- and cold-rolled into bars, rods, and wire, while blooms are hot- and cold-rolled into shapes such as I beams and rails. * Sand casting: mix sand with clay, organic binder or inorganic binder. suitable for the production of 1) small quantities of identical castings, 2) complex castings with intricate core, 3) large castings, 4) structural castings. Die casting: using metal molds. advantage 1) parts die cast are almost finished and can be produced at high rates, 2) dimensional tolerances of each cast part can be more closely held than with any other major casting process, 3) SMOOTH SURFACES ON THE CASTING, 4) Rapid cooling of the casting produced fine grain structure Steel casting Most popular High production rate Ingot ? slab Casting processes Continuous casting Die casting Sand casting Investment casting Casting processes Casting processes: advantages and limitations Process Advantages Limitations Sand Almost any metal is cast; no limit to size, shape or weight; low tooling cost. Some finishing required; somewhat coarse finish, wide tolerances. Investment Intricate shapes; close tolerance parts; good surface finish. Part size limited; expensive patterns, molds, and labor. Die Excellen