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Primary Materials

Primary Materials. There are four types of iron ore : Hematite is reddish color and contains 70% iron Limonite is brownish color and contains 55% iron Magnetite is grayish color and contains 40% iron Taconite is hard rock and contains 33% iron. 1. Iron Ore.

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Primary Materials

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  1. Primary Materials

  2. There are four types of iron ore : Hematite is reddish color and contains 70% iron Limonite is brownish color and contains 55% iron Magnetite is grayish color and contains 40% iron Taconite is hard rock and contains 33% iron 1. Iron Ore

  3. The second raw material used by the steel industry is bituminous or soft coal. Most coal is mined deep in the ground. Coal as it comes from the earth cannot be used in the iron-making furnace. It must first be changed into coke. 2. Coke

  4. Coke Oven

  5. is the third raw material needed in making iron and steel. It is obtained from quarries. • Limestone acts as a kind of chemical sponge in the blast furnace and steel-making furnaces. • It takes up impurities liberated during the furnace operations to form a scum called slag 3. Limestone

  6. Steel classification • Molten iron as it comes from the blast furnace has some impurities. • To change the iron into steel, the impurities must be turned out. • It is done in three different kinds of furnaces Steel manufacturing process are: • 1. Bessemer converter • 2. Open hearth furnace • 3. Electric furnace

  7. Bessemer Converter (Capacity 25 Ton)

  8. Open Hearth Furnace (Capacity 130-550 Ton)

  9. Electric Furnace (Capacity 100 Ton)

  10. A. Primary industry: an industry involved in the initial processing of raw materials into standard stock B. Primary material : a material in the form of standard stock which is utilized in secondary processing C. Processing of material 1. Extraction: open pit mining operations for most metals ( magnesium is converted from sea ) water I. PRIMARY MATERIAL

  11. 2. Refining: ore is a compound of metal and oxygen or sulfur ore is refined to remove unwanted minerals • 3. Converting: Metal oxides are reduced to pure metals via blast furnace or electrolysis Pure metals are in the form of pigs (iron) and are processed to make steel ingots • 4. Steel ingots and nonferrous ingots undergo various deformation processes to produce standard stock forms.

  12. A. Tensile strength :Ability of metal to resist being pulled apart • B. Ductility: Ability of a metal to be changed in shape without breaking • C. Toughness :The property that enables a metal to withstand heavy impact forces of sudden shock without fracture • D. Hardness : Property of metal to resist indentation, penetration or scratching • E. Malleability : The ability of a metal to be permanently deformed by rolling, pressing or hammering • F. Machine-ability :The ease or difficulty of cutting metal with a cutting tool. II . Properties of Metals

  13. A. Cast Iron B. Carbon Steels C. Alloy Steel D. Metal Numbering System III. Ferrous Metals

  14. A. Cast Iron 1. Gray cast iron 1.7% to 4.5% carbon, 1% to 3% silicon Heat resistance, wear resistance, Corrosion resistance 2. White cast iron Low ductility, compressive strength is high (200,000 PSI) Low resistance to impact load Maximum wear resistance 3. Chilled cast iron Gray iron castings with edges of white cast iron Rapid cooling results in the formation of cementite and white cast iron along the edge. III. Ferrous Metals

  15. 4. Alloy cast iron Gray or white casting with alloying elements Increase in properties such as: strength, wear, corrosion, heat resistance Tensile strength is above 70,000 PSI 5. Malleable cast iron Produced by annealing of white iron castings 6. Nodular cast iron (Ductile iron) (Also known as spheraidal graphite iron) Alloyed with magnesium or cerium . Tensile strength is 60,000 to 80,000 PSI

  16. 1. General Characteristics Iron with carbon content of 0.05 % to 1.5%; as carbon content increases, hardness and tensile strength increases and ductility and weld ability decrease. • 2. Classification of Carbon Steel • low-carbon steel(mild steel) carbon content 0.05% to 0.30%; tensile strength 51,000 - 70,000 PSI • Medium-carbon steel carbon-content 0.30% to 0.6%; tensile strength 70,000 to 98,000 PSI • High-carbon steel(tool steels) carbon content 0.60% to 1.5%; tensile strength 98,000 to 142,000 PSI B. Carbon Steels

  17. 1. Over 25 common alloying elements exist 2. Alloying effects of manganese Increases from 0.30% to 1.5%; so does hardenability, strength, toughness, shock resistance. 3. Alloying effects of nickel Increases from 3% to 3.7%; so does wear, corrosion resistance, toughness, and strength. 4. Alloying effects of chromium Increases from 0.3% to 1.6%; chromium steels require additional hardening. C. Alloy Steel

  18. 5. Alloying effects of molybdenum Increases up to 9%; so does toughness and shock resistance; in addition, heat treatment and hardenability would be improved. 6. Alloying effects of vanadium Increases from 0.03% to 0.20%; so does tensile strength, yield strength, wear resistance, and impact toughness. 7. Alloying effects of cobalt Increases from 5% to 12%; so does hardness and wear resistance. 8. Alloying effects of tungsten Improves heat treatment quality and wear resistance.

  19. Classification System B: Bessemer Steel C: Open-Hearth Steel D: Electric Furnace Steel Steel Numbering System Four digit number First number indicates alloy group Second number indicates impurity limits Last digits indicates specific alloy or purity D. Metal Numbering System

  20. Steel Numbering System 10XX plain carbon steel 11XX sulfurized free cutting carbon steel 13XX manganese steels 20XX nickel steel 31XX nickel-chromium steels 41XX molybdenum steels 50XX chromium steel Explanation: Example C1020 20/100 x 1% carbon = .2 x 1% = .2 x .01 = .002 = .02 %

  21. A. Copper-base alloys B. Nickel-Base Alloys (Incanel metal) C. Aluminum-Base Alloys D. Zinc IV. Nonferrous metals

  22. A. Copper-base alloys • 1. Brass Red brass (cartridge brass) (5 - 20% zinc) Yellow brass (20-36% zinc) Architectural brass (40% zinc) Naval brass (39% zinc and 1% tin) Manganese brass (39% zinc plus iron) has high strength and excellent wear Lead brass - increase in machinability IV. Nonferrous metals

  23. 2. Bronze (Copper and Tin) aluminum bronze - strength range 80,000 – 100,000 PSI silicon bronze - high strength, corrosion resistance beryilium bronze - tensile strength 200,000 PSI

  24. B. Nickel-Base Alloys (Incanel metal) 1. Nickel has good oxidation and corrosion resistance and also resistance at high temperatures. 2. Nickel Silver alloy of copper, nickel and zinc 60-99% nickel C. Aluminum-Base Alloys 1. Alloying elements are copper, manganese, chromium, iron, nickel, zinc, titanium

  25. Excellent machine-ability; Low weight; Heat treatable; Suitable for hot and cold forming processes. D. Zinc Low melting point of (750-800 °F) Excellent for die casting Moderate strength and toughness Inexpensive 2. Properties of Aluminum-base alloy

  26. 1)Thermosetting 2)Thermoplastics 3) Elastomer IV. Plastic as an Industrial Material

  27. MAJOR CLASSIFICATIONS • 1)Thermosetting • a) Formed to shape with heat and sometimes pressure. • b) When set, the product is permanently hard. • c) Heat causes chemical action (polymerization), which causes plastic to become irreversibly hard. IV. Plastic as an Industrial Material

  28. 2)Thermoplastics a) Will consistently remain soft at elevated temperatures and harden when cooled. b) Exhibits no chemical change in molding cycle. c) Will not harden with pressure and heat, but may be recycled

  29. The term elastomer is often used interchangeably with the term rubber. Elastomer comes from two terms, elastic (describing the ability of a material to return to its original shape when a load is removed) and mer (from polymer, in which poly means many and mer means parts). elastomer

  30. RAW MATERIALS a) Agricultural products b) Minerals such as limestone, silica (a form of silicon) and sulfur. c) Organics such as coal, gas, petroleum d) Color pigments - provide desired color e) Solvents - soften and improve flow-ability in mold. f) Lubricants - improve molding characteristics g) Fillers - minimize shrinkage, improve heat resistance and impact strength, reduce manufacturing costs • Examples: wood powder, flour, cotton, rag fibers, asbestos, powder metals, graphite, glass, clays

  31. 1. Phenolics hard, high strength, durable; derived through reaction of phenol with formaldehyde. (Particle board, Laminated parts, Electrical parts ,Household) 2. Amino resins – principally ureaformaldehyde and melamine-formaldehyde Widely used as adhesives for laminating wood and paper. (circuit breakers, Table wear, Ignition parts) THERMOSETTING COMPOUNDS

  32. 3. Furane Derived through processing of corn cobs, rice hulls, and cotton seeds with acids. Resins are water resistant, have good electrical properties. ( Binding agents for floor, Hardening agents for plaster and graphite) • 4. Epoxides Principal characteristics include: low shrinkage, good chemical resistance, excellent electrical characteristics, high strength, excellent adhesive properties, high wear and impact resistance. ( Casting, Laminating, Paint ingredient Printed circuit boards)

  33. 5. silicones principal characteristics include: high temperature resistance, low temperature performance, high electrical characteristics, high water resistance, low coefficient of friction, high shock resistance, high cost

  34. 1. cellulosics – • derived through treatment of cotton and wood fibers. low density compounds, highly resistant to alkalies • 2.polystyrene Formulated for injection molding and extrusion low gravity, resistant to water and chemicals, high insulation ability excellent rubber substitute for electrical insulation TERMOPLASTIC COMPOUNDS

  35. 3. polyethylene Flexible at room and low temperatures, high water and chemical resistance suitable for injection molding, blow molding and extrusion into sheets, films, • 4 . polypropylene (PP) excellent electrical properties, high impact and tensile strengths, high resistance to heat, high resistance to chemicals

  36. 5. ABS plastics Chemical compound of acrylonitrile, butadiene, and styrene may be compounded to have a very high degree of hardness or high flexibility and toughness, high flexibility and toughness good moisture resistance 6. polyamide available in solid, film, or solution form ,extremely high heat resistance (750 F or 400 C) low coefficient of friction, high radiation resistance. good electrical properties

  37. 7. Nylon (polyamides) good tensile and impact strengths, good heat resistance , good moisture resistancegood electrical properties. 8. Acrylic resin (methyl methacrylate), Lucite (DuPont) excellent light transmission qualities , high resistance to moisture ,easily fabricated

  38. Have a good day

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