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Chapter III
FERROUS METALS AND ITS ALLOYS
Chapter III
FERROUS METALS AND ITS ALLOYS
Topics:
- Introduction
- Classifications of ferrous material
- Cast Iron and it’s classifications
- Effects of impurities in CI
- Effects of alloying elements on the properties of CI
- Steel
- Steel name as per standards
Topics:
- Introduction
- Classifications of ferrous material
- Cast Iron and it’s classifications
- Effects of impurities in CI
- Effects of alloying elements on the properties of CI
- Steel
- Steel name as per standards
Introduction:
-A ferrous metal is a metal primarily made of
iron.
-Ferrous metals are metals or metal alloys
that contain the iron as a base.
- Ferrous metals are good conductors of heat
and electricity.
Introduction:
-A ferrous metal is a metal primarily made of
iron.
-Ferrous metals are metals or metal alloys
that contain the iron as a base.
- Ferrous metals are good conductors of heat
and electricity.
Introduction:
- Metal alloys have high resistance to shear,
torque and deformation. Corrosion resistance
property makes them useful in food processing
plants, e.g., steel.
Classification of Ferrous metal:
Ferrous Metals
Iron
Low Carbon Steel
Medium Carbon SteelMedium Carbon Steel
High Carbon Steel
Cast Iron
Stainless Steel
Tool Steels
Extraction of Iron
Cast Iron:
-Cast iron is iron or a ferrous alloy which has been
heated until it liquefies, and is then poured into a mould
to solidify. It is usually made from pig iron.
-Cast iron is made by re-melting pig iron, scrap iron,
scrap steel, lime stone, carbon (coke) and taking various
steps to remove undesirable contaminants.
-Cast iron is one of the oldest ferrous metals used in
construction and outdoor ornament. It is primarily
composed of iron (Fe), carbon (C) and silicon (Si), but
may also contain traces of sulphur (S), manganese (Mn)
and phosphorus (P).
- It has a relatively high carbon content of 2% to 5%. It
is hard, brittle, non-malleable.
-Cast iron is iron or a ferrous alloy which has been
heated until it liquefies, and is then poured into a mould
to solidify. It is usually made from pig iron.
-Cast iron is made by re-melting pig iron, scrap iron,
scrap steel, lime stone, carbon (coke) and taking various
steps to remove undesirable contaminants.
-Cast iron is one of the oldest ferrous metals used in
construction and outdoor ornament. It is primarily
composed of iron (Fe), carbon (C) and silicon (Si), but
may also contain traces of sulphur (S), manganese (Mn)
and phosphorus (P).
- It has a relatively high carbon content of 2% to 5%. It
is hard, brittle, non-malleable.
Properties of Cast Iron:
- Higher Tensile strength,
- Compressive Strength good
- Low cost
- Lower melting point
- Easy to machining
Properties of Cast Iron:
- Higher Tensile strength,
- Compressive Strength good
- Low cost
- Lower melting point
- Easy to machining
Classification of Cast Iron:
Classification of Cast Iron:
White CI:
Has a white crystalline fracture
surface because fracture occurs
along the iron carbide plates.
Considerable strength,
insignificant ductility.
A type of cast iron that has a
graphitic microstructure. It is
named after the gray colour of
the fracture it forms.
Grey CI:
Classification of Cast Iron:
Ductile CI:
Also known as nodular cast
iron, ductile iron has much
more impact and fatigue
resistance, due to its nodular
graphite structure.
Malleable iron is cast as White
iron, the structure being a
metastable carbide in a
pearlitic matrix.
Malleable CI:
Classification of Cast Iron:
Alloy CI:
-It is alloys of Ni, Cr, Mo, Cu, Si, Mn.
- It is very strong material.
- Corrosion resistant.
- Wear resistant.
- Electricity resistant.
Classification of Cast Iron:
Alloy CI:
-It is alloys of Ni, Cr, Mo, Cu, Si, Mn.
- It is very strong material.
- Corrosion resistant.
- Wear resistant.
- Electricity resistant.
Effects of alloying element in Cast Iron:
Silicon:
• It may be present in cast iron upto 4%.
• It provides the formation of free graphite which makes the
iron soft and easily machinable.
• It also produces sound castings free from blow-
holes, because of its high affinity for oxygen.
Sulphur:
• It makes the cast iron hard and brittle.
• Since too much sulphur gives unsound casting, therefore,
it should be kept well below 0.1% for most foundry
purposes.
Manganese:
• It makes the cast iron white and hard.
• It is often kept below 0.75%.
• It helps to exert a controlling influence over the harmful
effect of sulphur.
Effects of alloying element in Cast Iron:
Silicon:
• It may be present in cast iron upto 4%.
• It provides the formation of free graphite which makes the
iron soft and easily machinable.
• It also produces sound castings free from blow-
holes, because of its high affinity for oxygen.
Sulphur:
• It makes the cast iron hard and brittle.
• Since too much sulphur gives unsound casting, therefore,
it should be kept well below 0.1% for most foundry
purposes.
Manganese:
• It makes the cast iron white and hard.
• It is often kept below 0.75%.
• It helps to exert a controlling influence over the harmful
effect of sulphur.
Effects of alloying element in Cast Iron:
Phosphorus:
• It aids fusibility and fluidity in cast iron, but induces
brittleness.
• It is rarely allowed to exceed 1%.
• Phosphoric irons are useful for casting.
Carbon:
• The quantity of carbon in pig iron varies from 4 to 4.5%.
Source of carbon in steel is coal.
• Carbon is present in pig iron either in free state as
graphite or in combined state as iron carbide.
• Carbon in pig iron increases its hardness.
Effects of alloying element in Cast Iron:
Phosphorus:
• It aids fusibility and fluidity in cast iron, but induces
brittleness.
• It is rarely allowed to exceed 1%.
• Phosphoric irons are useful for casting.
Carbon:
• The quantity of carbon in pig iron varies from 4 to 4.5%.
Source of carbon in steel is coal.
• Carbon is present in pig iron either in free state as
graphite or in combined state as iron carbide.
• Carbon in pig iron increases its hardness.
Steel:
• Steel is an alloy of iron and carbon that is widely
used in construction and other applications because of
its high tensile strength and low cost.
• The carbon in typical steel alloys may contribute up
to 2.1% of its weight.
• Steel is one of the world's most-recycled materials,
with a recycling rate of over 60% globally.
• Steel are used widely in the construction of roads,
railways, other infrastructure, appliances, and
buildings.
Steel:
• Steel is an alloy of iron and carbon that is widely
used in construction and other applications because of
its high tensile strength and low cost.
• The carbon in typical steel alloys may contribute up
to 2.1% of its weight.
• Steel is one of the world's most-recycled materials,
with a recycling rate of over 60% globally.
• Steel are used widely in the construction of roads,
railways, other infrastructure, appliances, and
buildings.
Types of Steel:
1) Carbon Steels:
It contain trace amounts of alloying elements and
account for 90% of total steel production. Carbon steels
can be further categorized into three groups depending
on their carbon content:
Low Carbon Steels/Mild Steels contain up to 0.3% carbon
Medium Carbon Steels contain 0.3 – 0.6% carbon
High Carbon Steels contain more than 0.6% carbon
Types of Steel:
1) Carbon Steels:
It contain trace amounts of alloying elements and
account for 90% of total steel production. Carbon steels
can be further categorized into three groups depending
on their carbon content:
Low Carbon Steels/Mild Steels contain up to 0.3% carbon
Medium Carbon Steels contain 0.3 – 0.6% carbon
High Carbon Steels contain more than 0.6% carbon
2) Alloy Steels:
• Alloy steels contain alloying elements in varying
proportions in order to change 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.
Types of Steel:
3) Stainless Steels:
Stainless steels generally contain between 10-20%
chromium as the main alloying element and are valued
for high corrosion resistance.
With over 11% chromium, steel is about 200 times more
resistant to corrosion than mild steel.
4) Tool Steels:
Tool steels contain tungsten, molybdenum, cobalt and
vanadium in varying quantities to increase heat
resistance and durability, making them ideal for cutting
and drilling equipment.
Types of Steel:
3) Stainless Steels:
Stainless steels generally contain between 10-20%
chromium as the main alloying element and are valued
for high corrosion resistance.
With over 11% chromium, steel is about 200 times more
resistant to corrosion than mild steel.
4) Tool Steels:
Tool steels contain tungsten, molybdenum, cobalt and
vanadium in varying quantities to increase heat
resistance and durability, making them ideal for cutting
and drilling equipment.

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Chapter iii mt_dme303

  • 1. Chapter III FERROUS METALS AND ITS ALLOYS Chapter III FERROUS METALS AND ITS ALLOYS
  • 2. Topics: - Introduction - Classifications of ferrous material - Cast Iron and it’s classifications - Effects of impurities in CI - Effects of alloying elements on the properties of CI - Steel - Steel name as per standards Topics: - Introduction - Classifications of ferrous material - Cast Iron and it’s classifications - Effects of impurities in CI - Effects of alloying elements on the properties of CI - Steel - Steel name as per standards
  • 3. Introduction: -A ferrous metal is a metal primarily made of iron. -Ferrous metals are metals or metal alloys that contain the iron as a base. - Ferrous metals are good conductors of heat and electricity. Introduction: -A ferrous metal is a metal primarily made of iron. -Ferrous metals are metals or metal alloys that contain the iron as a base. - Ferrous metals are good conductors of heat and electricity.
  • 4. Introduction: - Metal alloys have high resistance to shear, torque and deformation. Corrosion resistance property makes them useful in food processing plants, e.g., steel.
  • 5. Classification of Ferrous metal: Ferrous Metals Iron Low Carbon Steel Medium Carbon SteelMedium Carbon Steel High Carbon Steel Cast Iron Stainless Steel Tool Steels
  • 7. Cast Iron: -Cast iron is iron or a ferrous alloy which has been heated until it liquefies, and is then poured into a mould to solidify. It is usually made from pig iron. -Cast iron is made by re-melting pig iron, scrap iron, scrap steel, lime stone, carbon (coke) and taking various steps to remove undesirable contaminants. -Cast iron is one of the oldest ferrous metals used in construction and outdoor ornament. It is primarily composed of iron (Fe), carbon (C) and silicon (Si), but may also contain traces of sulphur (S), manganese (Mn) and phosphorus (P). - It has a relatively high carbon content of 2% to 5%. It is hard, brittle, non-malleable. -Cast iron is iron or a ferrous alloy which has been heated until it liquefies, and is then poured into a mould to solidify. It is usually made from pig iron. -Cast iron is made by re-melting pig iron, scrap iron, scrap steel, lime stone, carbon (coke) and taking various steps to remove undesirable contaminants. -Cast iron is one of the oldest ferrous metals used in construction and outdoor ornament. It is primarily composed of iron (Fe), carbon (C) and silicon (Si), but may also contain traces of sulphur (S), manganese (Mn) and phosphorus (P). - It has a relatively high carbon content of 2% to 5%. It is hard, brittle, non-malleable.
  • 8. Properties of Cast Iron: - Higher Tensile strength, - Compressive Strength good - Low cost - Lower melting point - Easy to machining Properties of Cast Iron: - Higher Tensile strength, - Compressive Strength good - Low cost - Lower melting point - Easy to machining
  • 10. Classification of Cast Iron: White CI: Has a white crystalline fracture surface because fracture occurs along the iron carbide plates. Considerable strength, insignificant ductility. A type of cast iron that has a graphitic microstructure. It is named after the gray colour of the fracture it forms. Grey CI:
  • 11. Classification of Cast Iron: Ductile CI: Also known as nodular cast iron, ductile iron has much more impact and fatigue resistance, due to its nodular graphite structure. Malleable iron is cast as White iron, the structure being a metastable carbide in a pearlitic matrix. Malleable CI:
  • 12. Classification of Cast Iron: Alloy CI: -It is alloys of Ni, Cr, Mo, Cu, Si, Mn. - It is very strong material. - Corrosion resistant. - Wear resistant. - Electricity resistant. Classification of Cast Iron: Alloy CI: -It is alloys of Ni, Cr, Mo, Cu, Si, Mn. - It is very strong material. - Corrosion resistant. - Wear resistant. - Electricity resistant.
  • 13. Effects of alloying element in Cast Iron: Silicon: • It may be present in cast iron upto 4%. • It provides the formation of free graphite which makes the iron soft and easily machinable. • It also produces sound castings free from blow- holes, because of its high affinity for oxygen. Sulphur: • It makes the cast iron hard and brittle. • Since too much sulphur gives unsound casting, therefore, it should be kept well below 0.1% for most foundry purposes. Manganese: • It makes the cast iron white and hard. • It is often kept below 0.75%. • It helps to exert a controlling influence over the harmful effect of sulphur. Effects of alloying element in Cast Iron: Silicon: • It may be present in cast iron upto 4%. • It provides the formation of free graphite which makes the iron soft and easily machinable. • It also produces sound castings free from blow- holes, because of its high affinity for oxygen. Sulphur: • It makes the cast iron hard and brittle. • Since too much sulphur gives unsound casting, therefore, it should be kept well below 0.1% for most foundry purposes. Manganese: • It makes the cast iron white and hard. • It is often kept below 0.75%. • It helps to exert a controlling influence over the harmful effect of sulphur.
  • 14. Effects of alloying element in Cast Iron: Phosphorus: • It aids fusibility and fluidity in cast iron, but induces brittleness. • It is rarely allowed to exceed 1%. • Phosphoric irons are useful for casting. Carbon: • The quantity of carbon in pig iron varies from 4 to 4.5%. Source of carbon in steel is coal. • Carbon is present in pig iron either in free state as graphite or in combined state as iron carbide. • Carbon in pig iron increases its hardness. Effects of alloying element in Cast Iron: Phosphorus: • It aids fusibility and fluidity in cast iron, but induces brittleness. • It is rarely allowed to exceed 1%. • Phosphoric irons are useful for casting. Carbon: • The quantity of carbon in pig iron varies from 4 to 4.5%. Source of carbon in steel is coal. • Carbon is present in pig iron either in free state as graphite or in combined state as iron carbide. • Carbon in pig iron increases its hardness.
  • 15. Steel: • Steel is an alloy of iron and carbon that is widely used in construction and other applications because of its high tensile strength and low cost. • The carbon in typical steel alloys may contribute up to 2.1% of its weight. • Steel is one of the world's most-recycled materials, with a recycling rate of over 60% globally. • Steel are used widely in the construction of roads, railways, other infrastructure, appliances, and buildings. Steel: • Steel is an alloy of iron and carbon that is widely used in construction and other applications because of its high tensile strength and low cost. • The carbon in typical steel alloys may contribute up to 2.1% of its weight. • Steel is one of the world's most-recycled materials, with a recycling rate of over 60% globally. • Steel are used widely in the construction of roads, railways, other infrastructure, appliances, and buildings.
  • 16. Types of Steel: 1) Carbon Steels: It contain trace amounts of alloying elements and account for 90% of total steel production. Carbon steels can be further categorized into three groups depending on their carbon content: Low Carbon Steels/Mild Steels contain up to 0.3% carbon Medium Carbon Steels contain 0.3 – 0.6% carbon High Carbon Steels contain more than 0.6% carbon Types of Steel: 1) Carbon Steels: It contain trace amounts of alloying elements and account for 90% of total steel production. Carbon steels can be further categorized into three groups depending on their carbon content: Low Carbon Steels/Mild Steels contain up to 0.3% carbon Medium Carbon Steels contain 0.3 – 0.6% carbon High Carbon Steels contain more than 0.6% carbon 2) Alloy Steels: • Alloy steels contain alloying elements in varying proportions in order to change 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.
  • 17. Types of Steel: 3) Stainless Steels: Stainless steels generally contain between 10-20% chromium as the main alloying element and are valued for high corrosion resistance. With over 11% chromium, steel is about 200 times more resistant to corrosion than mild steel. 4) Tool Steels: Tool steels contain tungsten, molybdenum, cobalt and vanadium in varying quantities to increase heat resistance and durability, making them ideal for cutting and drilling equipment. Types of Steel: 3) Stainless Steels: Stainless steels generally contain between 10-20% chromium as the main alloying element and are valued for high corrosion resistance. With over 11% chromium, steel is about 200 times more resistant to corrosion than mild steel. 4) Tool Steels: Tool steels contain tungsten, molybdenum, cobalt and vanadium in varying quantities to increase heat resistance and durability, making them ideal for cutting and drilling equipment.