Group 7: Steel and Steel Alloy

What is Metal?

When the earth was formed the molten mass contained the many different metals which today
we extract and use in huge quantities. Most of the metals combined with rock when molten, to form
metallic ores. The most common of these are bauxite, from which aluminium is extracted, and iron ore
from which iron is extracted. More than seventy different metals are extracted and used in the
manufacturing industries today. Some, like copper and lead for example, can be used in their pure state,
to take advantage of their natural properties. But often, we combine different metals, or metal with
other materials to form alloys. By making alloys, we can change the properties of a metal to suit our
particular needs.

Metals and alloys can be used in many ways. They are important for the transport,
telecommunications, machinery, construction and manufacturing industries.

Classification of Metals

There are two major classification of metals in engineering studies namely:

 Ferrous Metals
 iron is the main constituent (Cast iron, wrought iron and different forms of steels)
 not directly obtained from iron ores
 Ferrous metals contain iron, and are known for their strength. Think steel, stainless
steel, carbon steel, cast iron. Ferrous metals are used in both architectural and industrial
fabrication, such as skyscrapers, bridges, vehicles, and railroads. Thanks to their
magnetic properties, ferrous metals are also used in appliances and engines. (Yep—
thanks to ferrous metals, you can display your child’s report card or your shopping list
with a magnet on your refrigerator door.) Ferrous metals also have a high carbon
content, which generally makes them prone to rust. The exceptions are stainless steel,
because of chromium, and wrought iron because of its high pure iron content.\
 Examples: Steel, Carbon steel, Stainless steel, Cast iron and other alloy steels

 Non-Ferrous Metals
 Iron is not the main constituent
 Non-ferrous metals have been used since the Copper Age, around 5,000 B.C. Since non-
ferrous metals don’t contain iron, they’re usually more corrosion-resistant than ferrous
metals. Some examples of non-ferrous metals are aluminum, aluminum alloys, and
copper, which are often used in industrial applications such as gutters, roofing, pipes,
and electrical. Non-ferrous metals also include brass, gold, nickel, silver, tin, lead, and
zinc. Other common properties of non-ferrous metals are non-magnetic, malleable, and
lightweight. This makes them ideal for use in aircraft and other applications.
 Examples: Aluminum, Lead, Tin and Zinc
 Ferrous Vs Non-Ferrous Metal

1. Iron Content

The defining difference between ferrous and non-ferrous metals is in their iron content. Both
types may be pure or alloys. In general, ferrous metals contain iron. The very word ferrous comes from
the Latin word for iron, ferrum. This is the reason iron is given the abbreviation Fe in the periodic table
of elements. They may be cast iron, steel, or another type of iron-containing metal. Stainless steel is a
common form of ferrous metal. Non-ferrous metals, on the other hand, do not contain any iron. These
metals may be raw metals, purified metals, or alloys. Common non-ferrous metals include aluminum,
copper, tin, and precious metals like gold and silver.

2. Magnetism

Ferrous metals are usually magnetic while nonferrous metals are not. This property allows the
two types of metals to be identified and sorted easily.The reason for this is that iron is a very polar
molecule. The electrons in its atomic ring are not symmetrical. When iron encounters a magnetic field,
its electrons are pulled to one sign of the atom. This creates the attraction between ferrous metals and
magnets. Non-ferrous metals generally are only attracted to a magnet when an electrical field is run
through them, which polarizes their electrons.

3. Oxidation

Another key feature of ferrous metals is that they can be oxidized, which we commonly call
rusting. Because of the polarity of iron, it is highly likely to lose an electron to other polar molecules
such as water. This makes the iron atom more positive, and thus more likely to bond to the oxygen in
water, creating iron (III) oxide. Iron (III) oxide is the powdery red metal we call rust.

Some ferrous metals, such as stainless steel, do not rust. This is because they have been
combined with a nonferrous metal that balances the iron atom and makes it less likely to lose an
electron and begin the process of forming rust. Nonferrous metals do not rust.

4. Tensile Strength

A last distinguishing feature of ferrous metals is that they usually have very high tensile strength.
Steel, for example, is one of the strongest metals in the world. Tensile strength is the ability to undergo
a great deal of force without breaking or deforming. This is due to a mixture of strength and flexibility.
While there are some very strong non-ferrous metals, such as titanium, few metals are as capable of
bearing weight or undergoing force as iron alloys.

Ferrous and non-ferrous metals are very different because they have different atomic chemistry
and interact with their environment in unique ways. Both types of metal are important to the modern
world and used in a variety of ways.
Types of Ferrous Metals
 Pig Iron
 From iron ore
 iron is the metallic ore that contains 90% of iron
 Impure form of metal
 Not suitable for any mechanical use unless it is converted into cast iron, wrought iron, or
steel
 Cast Iron
 Pig iron re-melted with limestone and coke and poured into molds of desired shapes
and sizes to get purer product
 Carbon content: varies from 2 to 5%
 During the re-melting of pig iron, scrap iron may also be added for economy
 Alloy of iron and 2.5% carbon, 1-3% silicone and traces of magnesium, sulfur &
phosphorus
Properties of Cast Iron
o Brittle, non-ductile, non-malleable and cracks when subjected to shocks
o It cannot be magnetized
o Does not rust
o Strong in compression but weak in tension and shear
o Melting point: 12000C
o Specific Gravity: 7.5
Uses of Cast Iron
o Cannot be used in construction (weak in tension)
o Used for parts of pumps, motors, engines, etc.
o Can be used for pipes to some extent because of corrosion resistance

 Wrought Iron
 Melted pig iron in such a way as to remove all of the carbon and other impurities
 Good quality wrought iron contains 99.5 % iron, less than 0.1 % of Silicon, 0.01 % of
Sulfur, 0.07 % of phosphorus and 0.03 % of manganese
Properties of Wrought Iron
o Very malleable and ductile
o Its tensile strength is 20-26 tons /in 2
o It is strong in compression but not so strong as steel
o It can be easily worked, welded and is tough
o Its melting point is 28000F
o Wrought iron became pasty and very plastic at red heat and could be easily
forged at about 16500F
Uses of Wrought Iron
o Since mild steel has replaced the wrought iron, therefore it is no longer
produced in large extent. Still in use for roof sheets, wires and metal ornaments,
etc.
 Steel
 An alloy of iron and carbon
 Pure iron’s strength remarkably increases when alloyed with carbon
 Tensile strength increases with increasing carbon content but the ductility reduces
 Steel can be machined, welded, and forged, all to varying degrees, depending on the
type of steel.
 Plain Carbon Steel – steel having its properties because of the presence of carbon alone
 Properties of Steel
o Steel has tensile strength of 45,000 psi (310,275 kPa) for low-carbon steel
o 80,000 psi (551,600 kPa) for medium-carbon steel
o 99,000 psi (692,605 kPa) for high-carbon steel
o 150,000 psi (1,034,250 kPa) for alloyed steel
o and a melting point of 2800° F (1538°C).

 Uses of Steel
o Steel is used to make nails, rivets, gears, structural steel, roles, desks, hoods,
fenders, chisels, hammers, etc.