1. 2.0 FERROUS MATERIAL STRUCTURE AND BINARY ALLOY SYSTEM
2.1 Understand the metal production
Metal Production Industries
Automated Welding
Robotic Welders
Seam Welders
Spot Welders
Metal Cleaning Equipment
Vacuum Chambers
R O Systems
Foundry Equipment
Automated Molding
Machines
Kilns
Sand Casters
CNC Machine Refit
Mills
Lathes
Cutting Tables
Plasma and laser cutting
X/Y Tables
Press room equipment
Clutch/Brake Punch Press Control
Hydraulic Press Control
Safety Equipment
Press Feeders
Automated Die Monitoring and Control
In Die Transfer Systems
Robotic take away and packaging
Die Monitoring and Control

2. Spin forming
Precision winding
Remote Control Systems
Radio Control Systems
Web Systems
Kilns
2.2 State the content of iron ore
Iron ores are rocks and minerals from which metallic iron can be economically extracted. The
ores are usually rich in iron oxides and vary in color from dark grey, bright yellow, deep purple,
to rusty red. The iron itself is usually found in the form of magnetite (Fe3O4), hematite (Fe2O3),
goethite (FeO(OH)), limonite (FeO(OH).n(H2O)) or siderite (FeCO3). Ores carrying very high
quantities of hematite or magnetite (greater than ~60% iron) are known as "natural ore" or
"direct shipping ore", meaning they can be fed directly into iron-making blast furnaces. Most
reserves of such ore have now been depleted. Iron ore is the raw material used to make pig iron
(Pig iron is the intermediate product of smelting iron ore with a high-carbon fuel such as coke,
usually with limestone as a flux.), which is one of the main raw materials to make steel. 98% of
the mined iron ore is used to make steel. Indeed, it has been argued that iron ore is "more integral
to the global economy than any other commodity, except perhaps oil".
The types of iron ore
a)Magnetite
Magnetite iron - iron of high quality mineral
- Almost 70% of the metal / black metal
b)Iron carbonate
Iron carbonate - a low-grade material.
- Containing 20% iron
c)Hematite
Hematite iron - iron of high quality mineral
- Contains 40-60% iron red
d)Limonite
Limonite iron - containing 20-55% iron
- Brown

3. 2.1.2 Explain the process of iron production by using Blast Furnace.
Liquid pure iron ore resulting from a reduction to pure iron oxide. Among the best method is to
use the blast furnace.
First blast furnace tank filled with iron oxide (ore, pellet, sinter), limestone or dolomite
and fuel (coke) in the funnel above.
Further oxygen gas is injected into the tank to assist combustion.
Oxygen gas will react with coke and produces carbon dioxide gas.
Then the resulting carbon dioxide will react just about menghasilkangas coke carbon
monoxide.
Monoxide gas produced is used to react with iron oxide to produce pure liquid iron and
carbon dioxide. Carbon dioxide is not required and issued through the funnel above.
As a result, the products derived from this furnace is the melting of pure iron which is
accumulated in the bottom of the furnace (hearth) for the heavier mass and liquid slag
(slag) floats on the molten iron. This process is carried out at a temperature of 1500C.
Pure liquid iron will come out through the bottom of the funnel while the slag out of the
funnel slightly on the availability of liquid slag.
'Slag' is the liquid produced during the process of reduction of iron ore, which contains
silica and alumina produced from the reaction of limestone iron oxide and magnesium
oxide.
'Slag' is suitable for the production of construction materials especially cement for
concrete and road making.

4. 2.2 Understand the steel production
2.2.1 Explain the process of steel production by using this method
a)Basic Oxygen Furnace
b)Electric Arc Furnace