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Introduction
Metals form about a quarter of the earth crust by weight One of the earliest material used dated back to pre-historic time Some of the earliest metals used include copper! bron"e and iron Stone age #ron"e age $ %disco&ery% of steel Industrial 'e&olution in the 1(th century )ll metals e*cept gold are generally found chemically combined with other elements in the form of o*ides and sulphates+ ,ommonly known as ores+
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,lassification
Metals can be di&ided into 2 groups Metals
Ferrous Metals Iron ;ow ,arbon Steel Medium ,arbon Steel <igh ,arbon Steel ,ast Iron Stainless Steel /ool Steels Others Non- Ferrous Metals )luminum ,opper #rass #ron"e 3inc ;ead /in Others
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0*traction of Iron
>Iron is found in iron o*ide in the earth+ >/hree primary iron ores magnetite! hematite! taconite >Iron is e*tracted using blast furnace >Steps in e*traction of iron Ores is washed! crushed and mi*ed with limestone and coke /he mi*ture is fed into the furnace and is then melted ,oke1a product of coal! mainly carbon2 is used to con&ert the iron o*ides to iron
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0*traction of Iron
;imestone helps to separate the impurities from the metal /he liquid waste is known as slag that floats on the molten iron /hey are then tapped off 1separated2 /he iron produced is only about @AB to @:B pure+ /he iron is then further refined using the basic o*ygen furnace and the electric arc furnace to produce steel which is widely used now+
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#last Furnace
0*traction of Iron
A blast furnace
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> Ore! coke! and limestone are CchargedD in layers into the top of a blast furnace > Ore is the source of the iron ! ,oke is the source of the carbon 1coke is deri&ed from coal! by heating in a coking o&en2 > ;imestone acts as a flu*ing slag to remo&e impurities like sulphur and silica > 11AA-deg+ air blown into bottom of furnace! burns o*ygen off the iron o*ides! causing temperature in furnace to get abo&e the melting point of iron 1appro* -AAA degrees2
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> Molten iron sinks to bottom of furnace! where it is tapped off from furnace and cast into large ingots called CpigsD$pigs contain high carbon content 17B or so2! plus many impurities! such as sulphur and silica which wasn%t remo&ed by the limestone+
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/ypes of Steel
Steel >;ow carbon steel 1mild steel2 >Medium carbon steel ><igh carbon steel 1tool steels2 >,ast iron Alloy Steels >Stainless steel ><igh speed steel
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,ast Iron
,ontains 2B-7B of carbon Hery hard and brittle Strong under compression Suitable for casting Ican be pour at a relati&ely low temperatureJ 0ngine block! engineer &ices! machine parts
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Cast Iron
White: <ard and brittle! good wear resistance Eses rolling 8 crunching 0quipment Grey: Kood compressi&e 8 tensile strength! machinability! and &ibration-damping ability Eses machine bases! crankshafts! furnace doors! 0ngine #locks
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Ductile: <igh strength and ductility Eses engine and machine parts
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Stainless Steel
Steel alloyed with chromium 11(B2! nickel 1(B2! magnesium 1(B2 <ard and tough ,orrosion resistance ,omes in different grades Sinks! cooking utensils! surgical instruments
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Stainless Steels
Main types: Ferritic chromium: &ery formable! relati&ely weakL used in architectural trim! kitchen range hoods! Fewelry! decorations! utensils Krades 7A@! 7-A! and other 7AA Austentitic nic el-chromium: non-magnetic! machinable! weldable! relati&ely weakL used in architectural products! such as fascias! curtain walls! storefronts! doors 8 windows! railingsL chemical processing! food utensils! kitchen applications+ series+ Krades -A1! -A2! -A-! -A7! -1=! and other -AA series+
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Martensitic chromium: <igh strength! hardness! resistance to abrasionL used in turbine parts! bearings! kni&es! cutlery and generally Magnetic+ Krades 1?-7! 71A! 71=! 72A! 77A and other 7AA series Mara!in! "super alloys#: <igh strength! high /emperature alloy used in structural applications! aircraft components and are generally magnetic+ )lloys containing around 1(B 9ickel+
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<eat /reatment
) process used to alter the properties and characteristics of metals by heating and cooling+ ,old working induce stress in metal lead to work hardening pre&ent further work from taking place /hree stages of heat treatment 1+ <eat the metal to the correct temperature 2+ Neep it at that temperature for a the required length of time 1soaking2 -+ ,ool it in the correct way to gi&e the desired properties
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<eat /reatment
/ypes of heat treatment )nnealing 9ormali"ing <ardening /empering ,ase hardening
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)nnealing
)nnealing is the process whereby heat is introduced to mobilise the atoms and relie&e internal stress )fter annealing! it allows the metal to be further shaped It in&ol&es the re-crystalli"ation of the distorted structure
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9ormali"ing
/his process is only confined to steel+ It is used to refine the grain due to work hardening It in&ol&es the heating of the steel to Fust abo&e Its upper critical point+
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<ardening
<ardening is the process of increasing the hardness of steel by adding a high amount of carbon /he degree of hardness depends on the amount of carbon present in steel and the form in which it is trapped during quenching+ Once hardened! the steel is resistant to wear but is brittle and easily broken under load+
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/empering
/empering is the process to reduce hardness and brittleness slightly of a hardened steel workpiece+ It helps to produce a more elastic and tough steel capable of retaining the cutting edge after tempering .rior to tempering! the steel must be cleaned to brightness with emery cloth so that o*ide colour is &isible when reheated /empering temperature 14O hardness /empering temperature O toughness
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/empering
,ase <ardening
,ase hardening is a process used with mild steel to gi&e a hard skin /he metal is heated to cherry red and is dipped in ,arbon powder+ It is then repeated 2-- more times before Puenching the metal in water to harden the skin+ /his allows the surface of mild steel to be able to subFect to wear but the soft core is able to subFect to Sudden shock e+g+ the tool holders
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> /hose steels in which the residual elements 1carbon! manganese! sulphur! silicon! etc+2 are controlled! but in which no alloying elements are added to achie&e special properties+
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> For years! the workhorse all-purpose steel for nearly all structural CshapesD 1beams! channels! angles! etc+2! as well as plates and bars! has been