METAL AND ALLOYS

FERROUS & NON FERROUS METALS

1. Ferrous Metal
 Mainly consist of iron with small addition of
other elements (impurities Or alloys)
 These are commonest and cheapest engineering
materials
 pure iron not obtains in nature, present in
combination with non-mettallic elements called
Ores
 Most of these ores are the oxides of iron are
found mixed with large amount of earthly waste
called Gangue
 MAGNETIDE
HEMATIDE (HIGH GRADE ORE)
(HIGH GRADE ORE)
ONLY 20 TO 45%
ONLY 20 TO 45%
GANGUE
GANGUE

LOMONITE SIDERITE
LOW GRADE ORE UP TO 80% GANGUE
 RAW MATERIALS IN THE PRODECTION OF IRON AND STEEL
(PIG IRON)
MAIN RAW MATERIALS – 1. IRON ORE 2. COKE
3.LIMESTONE( CaCO3) OR
BURNT LIME (CaO)

Limestone or burnt lime used as a fluxing material that form a

slag on the top of molten metal

OTHER MATERIALS ARE

1. Carbon – use for hardening
2. Metal manganese (0.03-1%) - remove unwanted oxygen
3. Sulphur(0.05%)- which is controlled by manganese makes
brittle
4. Phosphorse (0.04%) –increase the strength and hardness but
in large quantity decrease ductylity which cause cracks during
cold working
5. Silicon (0.3-0.5%) – increase strength and toughness
Basic process of iron making and steel making
 CLASSIFICATION OF IRON
1. Pig Iron
i. Grey Pig Iron -
•Soft
•Biggest crystal size
•Contain almost all the carbon free as graphite
•Silicon is equal to free carbon
•Graphite more than 3% & combined carbon less than 1%
ii. Mottled Pig Iron -
•Mottled appearance and average hardness
•It is in between the grey and white pig iron
iii. White Pig Iron -
•Contain almost all the carbon in combine form
•Silicon is less than 1%
•Combined carbon is more than 3% and free carbon less than 1%
•It is hard and strong
•Can be easily melted

2. Wrought iron
•95.5 to 99.9% iron
•For practical purposes it is considered as pure iron
•Carbon is 0.02 to 0.1%
•Very soft, tough, malleable and ductile
•Melting point is 1530 deg c
•Easily forged and welded
•Bolts, nut chain hook, railway coupling water and
steam pipes are made from wrought iron
 3. Cast iron
•Cast iron has highly carbon contents rang from 2 to 4%
•The carbon is in combined form
•It is non malleable, hard and brittle
•Types discuss in detail later
Pig iron
+
Lime stone

Remelting
( in Cupola
Furnace)

CAST IRON
 CAST IRON

•Contain 2% to 4.3% carbon

•In addition with silicon,

manganese, phosphorous,
and sulphur
 EFFECT OF ALLOYING ELEMENTS
• Carbon – Reduce the melting point, improve harness and
strength, higher quantity increase brittleness, improve
machinability.
• Silicon – helps in formation of graphite, reduce blow holes
• Sulphur – it stabilizes the cementite and hence help in
producing a white iron, increase brittless
• Manganese – also helpin stabilizing the cementite and
increase tensile strength
• phosphorus – it lower the melting point
• Nickel – added from 0.5% to 20%. Up to 3% increase
machinability, 5 to 20% makes corrosion resistance
• Chromium – increase corrosion resistance, increase
hardness and tensile strength
 TYPES OF CAST IRON

1. Grey cast iron

2. White cast iron
3. Mottled cast iron
4. Malleable cast iron
5. Alloy cast iron
 1. Grey cast iron
• Carbon present as free carbon in the shape of small flakes.
• Greyish dark colour
Composition
C = 2.5 to 3.8%
Si = 1.1 to 2.85
Mn = 0.4 to – 1%
P = 0.15 -1%
S = 0.02- 0.15%
PROPERTES –
1. lowest melting point(1315-1093 deg C),
2. good casting qualities,
3. wear resistance,
4. good vibration damping property,
5. avg. corrosion resistance,
6. high compressive strength
1.Grey cast iron

USES –
1. machine tool parts bed, frames,
2. cylinder block and head of ic engine,
3. cam shaft clutch plate and brake drums etc
4. Gas or water pipes
5. House hold appliances.
 2. White cast iron
•Low silicon %
•Carbon is in combined form
•All carbon bonded with iron as iron carbide( Fe3C)
•Iron carbide (cementite) is very hard and brittle
Composition
C = 1.8 to 3.6%
Si = 0.5 to 2%
Mn = 0.24 to – 0.8%
P = 0.18%
S = 0.1%
PROPERTES-
1. Hard and unmachinable
2. Very brittle
3. Excellent wear resistance
4. Solidification rang is 1399-1130 dec C
2. White cast iron

Uses-
1. For making malleable iron casting
2. Making of hard components
3. For making grind mill parts
4. For making cement and bricks plants
equipments

3. Mottled cast iron

It is in between grey and white cast iron and no so
much important
 3. Malleable cast iron
•It is obtained from white cast iron ( hard and brittle) by suitable
annealing process.

•During this carbon % is reduced to 2%

•For this two methods are employed
1. white heart process
2. black heart process

Composition
C = 2 to 3%
Si = 0.6 to 1.3%
Mn = 0.2 to – 0.6%
P = 0.15%
S = 0.1%
3. Malleable cast iron

PROPERTES-
1. High yield strength
2. Low co efficient of thermal expansion
3. Good wear resistance and vibrating damping
4. Solidification rang is 1400 to 1130deg C
5. Good tensile and compressive strength
6. Good toughness but low ductility

USES
1. Fitting parts for gas water and air pipes
2. For boxes
3. Parts of agriculture and textile machinery
4. Railway coupling
5. Gears , pipes
 4. Alloy cast iron
The alloying elements use are
1. Nickel
2. Chromium
3. Copper
4. Molybdenum

But nickel is most important element. Increased nickel content

change the microstructure and properties of cast iron
 STEEL
• Steel is the alloy of iron and carbon
•Carbon up to 1.5% , in the form of iron carbide (Fe3C)
•Higher the % of carbon higher will be hardness, toughness,
and strength

•Other elements
•Silicon
•Sulpher
•Phosphorous
•Manganese
 TYPES OF STEEL
A. PLAIN CARBON STEEL-

1. Low carbon steel

• Dead mild steel ( 0.05% - 0.15% carbon)
• Mild steel (0.15%-0.3% carbon)

2. Medium carbon steel (0.3-0.7% carbon)

3. High carbon steel ( 0.7-1.5% carbon)

Steel having 15 to 1.5% carbon also called CARBON

TOOL STEELS
 1. Low Carbon Steel
a. Dead mild steel – b. Mild steel –
• carbon 0.05 to 0.15% • Carbon 0.15 to 0.3%
• Soft and ductile • Harder and less ductile
• Not easy to • Good machining, and
machining but can weldability
be weld easily • Tensile strength 420-550
• Tensile strength 390 N/mm2
N/mm2 • Hardness 125-140BHN
• Hardness 115BHN USES
USES • Used for low stressed parts
• Tubes • Bars for machining and
• Bar of rivets forging
• Steel wires • Cam shaft
• Screws and nails, • Fan blades etc
chain
2. Medium carbon steel
•Carbon -0.3 to 0.7%
•Harder, stronger
•Less ductile than mild steel
•Tensile strength 1230
N/mm2
•Hardness 200BHN
USES
•Used for components which
required
good load bearing and
resistance to abrasion
•Gear shaft , axles
•Crankshaft, clutch discs
•Connecting rod
3. High Carbon steel
•Carbon 0.7 to 1.5%
•Maximum strength 1400N/mm2
•Hard, less ductile
•Difficult to weld
•Machined only in annealed
condition
USES
•Used for hard tools
•Press tool
•Machine parts, files
•Metal cutting saws
•Drill tool
 STEEL ALLOYING
PURPOSE
Effect of different alloying in steel
 ALLOY STEEL
The steel which has some specific properties by adding some elements
(alloy elements) other than Carbon, even in the presence of carbon , the
alloying elements are highly important

1. Low Alloy Steel – having alloying elements upto 5%

2. Medium Alloy Steel – 5% to 10%
3. High Alloy Steel – alloying elements more than 10%

SPECIAL STEELS
1. High Speed Steel (H.S.S)
2. Stainless Steel
3. Silicon Steel
4. Heat Resistance Steel
5. Spring Steel
 1. High Speed Steel (H.S.S)
Plain carbon steel is not suitable for high speed machining
because of production of heat at high speed. HSS has good
harness at high temperature it retain its hardness and cutting
ability at 6000C

There are three types of special steel

1. 18-4-1 high speed steel
2. Molybdenum high carbon steel
3. Super high speed steel
1. 18-4-1 High Speed 2. Molybdenum High Speed
Steel Steel
Composition Composition
•Tungusten 18% •Molybdenum 6%
•Chromium 4% •Tungusten 6%
•Vanadium 1% •Chromium 4%
•Carbon 0.75% •Vanadium 1%
USES – it is widely used for making
•Drills tool •High toughness, cutting
•Tool for lathes, shapers, ability
slotter
•Milling cutters USES
•Threading dies, punches •General high speed tools
•Drilling operation
•Tapping operation