[IE 21] - 1.4 - Ferrous and Nonferrous Metals

Steel Production

Oxidation process; reduces the amount of carbon, silicon, manganese, phosphorus, and sulfur

Bessemer process

• Air is passed through the molted iron and iron scrap

• The oxygen in the air oxidizes the iron into steel

Basic oxygen steelmaking

• Self-sufficient in energy

• Majority of global steel production (67%)

Electric arc furnace

• Cold scrap metal only

• Electric arc used to melt the scrap

• Oxygen is blown into the elt to produce steel

Alloying steel

Steel that is combined with a variety of elements

Manganese

Added to steel to enhance strength, hardness, and corrosion resistance

Sulfur

Used to manufacture fertilizers, lead-acid batteries, and pigments

Nickel

Used in coins and measuring devices

Chromium

Used in chrome plating and stainless steel

Molybdenum

Used for high-heating elements, extrusion toolds, and glass melting furnace components.

• Increases strength properties particularly dynamic and high-temperature characteristics

• In larger amounts: Imparts hardness even at red heats

Vanadium

Primarily used for armor plate, axles, tools

Boron

• Used in the car industry, around door frames, and in reclining seats

Tungsten

• In tool steels and some air-hardening steels

• More effective than Molybdenum in producing hardness at very high temperatures

Silicon

In magnetic circuits in electrical equipment

Copper

*Alloying with steel

Used extensively in low-carbon sheets, especially thin gauges, and in certain structural steels; imparts corrosion resistance

Cast Iron

Alloy of primarily iron, carbon, and silicon

Nonferrous metals

• Do not contain iron as a principal ingredient

• Inferior strength and siffness to steel

Copper

*Material

Source: Sulfide and oxide ores

Properties:

• High electrical conductivity

• High ductility

• Good corrosion resistance

Aluminum

Source: bauxite ore

Properties:

• Corrosion resistance

• Good electrical conductivity

• Good thermal conductivity

• Soft

• Ductile

Magnesium

Source: dolomite or magsenite ore or sea water

Properties:

• Weak in pure state

• Lightweight

• Good machining characteristics

• Poor corosion resistance

Zinc

Source: Sphalerite

Properties:

• Softens at a relatively low temp

• Brittle at low temp

Nickel

Source: Sulfide ore and oxide ore

Properties:

• Corrosion resistance

• Ferromagnetic

Tin

Source: Cassiterite

Properties:

• Corrosion resistance

• Ability to coat other metals

Lead

Source: galena

Properties:

• Dense

• Soft

• Low melting point

• Corrosion resistance

Brass

Copper-Zinc Alloy

Properties:

• Good corrosion resistance

• Excellent cold-working properties

• Produces good salt water corrosion resistance with Tin

Bronze

Copper-Tin Alloy

Properties:

• More expensive due to Tin

Silicon Bronzes

• Good strength properties

• Readily formable and machineable

• Corrosion resistance

Aluminum Bronzes

• Brittle

• Excellent wearing properties

Copper-Beryllium Alloy

• Very expensive

• Very high strengths

Aluminum Alloys

• Electrical conductivity

• Not as a good corrosion resistance as pure aluminum

Magnesium-Base Alloys

• Lightweight

• Easily cast

• Best machinability

• Moderately good corrosion resistance

Nickel-Base Alloy

• Good strength and corrosion resistance at high temp

Monel

• Best overall corrosion resistance

• Resistance to salt water corrosion

Lead-Tin Alloys

Used as bearing metals or solders