Primary Materials

1
Primary Materials

2

3
(No Transcript)
4
1. Iron Ore

• 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

5
2. Coke

• 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.

6
Coke Oven
7
3. Limestone

• 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

8
(No Transcript)
9

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

10
Bessemer Converter (Capacity 25 Ton)
11
Open Hearth Furnace (Capacity 130-550 Ton)
12
Electric Furnace (Capacity 100 Ton)
13
I. PRIMARY MATERIAL

• 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

14

• 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.

15
(No Transcript)
16
(No Transcript)
17
(No Transcript)
18
(No Transcript)
19
(No Transcript)
20
(No Transcript)
21
II . Properties of Metals

• 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.

22
III. Ferrous Metals

• A. Cast Iron
• B. Carbon Steels
• C. Alloy Steel
• D. Metal Numbering System

23
III. Ferrous Metals

• 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.

24

• 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

25
B. Carbon Steels

• 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

26
C. Alloy Steel

• 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.

27

• 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.

28
D. Metal Numbering System

• 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

29

• 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

30
IV. Nonferrous metals

• A. Copper-base alloys
• B. Nickel-Base Alloys (Incanel metal)
• C. Aluminum-Base Alloys
• D. Zinc

31
IV. Nonferrous metals

• 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

32

• 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

33

• 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

34
2. Properties of Aluminum-base alloy

• 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

35
IV. Plastic as an Industrial Material

• 1)Thermosetting
• 2)Thermoplastics
• 3) Elastomer

36
IV. Plastic as an Industrial Material

• 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.

37

• 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

38
elastomer

• 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).

39

• 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

40
THERMOSETTING COMPOUNDS

• 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)

41

• 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)

42

• 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

43
TERMOPLASTIC COMPOUNDS

• 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

44

• 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

45

• 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

46

• 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

47

• Have a good day