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All metals in engineering can be categorized into

two categories
1.c Ferrous
2.c Non Ferrous

÷

  
— ese are metals w ic contain iron. — ey may ave
small amounts of ot er metals or ot er elements
added, to give t e required properties.
All ferrous metals are magnetic and give little
resistance to corrosion

÷

  
— ese are metals w ic do not contain any iron.
— ey are not magnetic and are usually more
resistant to corrosion t an ferrous metals.
Examples are aluminum, copper, lead, Zinc and tin.

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Rron Ores deposits in our country (Pakistan) are
found in Kalabag , C iniot,and Pac in Ko

C igendik.
Main Rron ores are


  ÷
  

  
Hematite Fe2O3 Oxide 66

Magnetite Fe3O4 Oxide 62
2
Limonite Fe2O3.H2O Oxide 4
6
Rron Pyrite FeS2 Sulp ide 3
4
Siderite FeCO3 Carbonate 35
5
Goet ite FeO(OH) Hydroxide 28
39

  


÷  Hard Coke is mainly used as fuel for
metallurgy of iron and production of steel because
coke is c eap and a good reducing agent.
÷   Flux is added to remove impurities in t e
form of slag. Example includes Limestone and
dolomite.

  ÷
 


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— e air blown into t e bottom of t e furnace is

eated using t e ot waste gases from t e top. Heat
energy is valuable, and it is important not to
waste any.

— e coke (essentially impure carbon) burns in t e

blast of ot air to form carbon dioxide
a
strongly exot ermic reaction. — is reaction is t e
main source of eat in t e furnace.

 
  


At t e ig temperature at t e bottom of t e
furnace, carbon dioxide reacts wit carbon to
produce carbon monoxide.

Rt is t e carbon monoxide w ic is t e main

reducing agent in t e furnace.

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Rn t e otter parts of t e furnace, t e carbon

itself also acts as a reducing agent. Notice t at
at t ese temperatures, t e ot er product of t e
reaction is carbon monoxide, not carbon dioxide.

— e temperature of t e furnace is ot enoug to

melt t e iron w ic trickles down to t e bottom
w ere it can be tapped off.

      ÷ 


Rron ore isn't pure iron oxide
it also contains

an assortment of rocky material. — is wouldn't melt
at t e temperature of t e furnace, and would
eventually clog it up. — e limestone is added to
convert t is into slag w ic melts and runs to t e
bottom.

— e eat of t e furnace decomposes t e limestone to

give calcium oxide.

— is is an endot ermic reaction, absorbing eat

from t e furnace. Rt is t erefore important not to
add too muc limestone because it would ot erwise
cool t e furnace.

Calcium oxide is a basic oxide and reacts wit

acidic oxides suc as silicon dioxide present in
t e rock. Calcium oxide reacts wit silicon dioxide
to give calcium silicate.

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— e calcium silicate melts and runs down t roug

t e furnace to form a layer on top of t e molten
iron. Rt can be tapped off from time to time as
slag.

Slag is used in road making and as "slag cement"

a final ground slag w ic can be used in cement,
often mixed wit Portland cement.

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

Pig iron as very ig carbon content, typically
3.5±4.5, w ic makes it very brittle and not
useful directly as a material except for limited
applications.



Cast iron is very runny w en it is molten and
doesn't s rink muc w en it solidifies. Rt is
t erefore ideal for making castings
ence its
name. However, it is very impure, containing about
4 of carbon. — is carbon makes it very ard, but
also very brittle.




Rf all t e carbon is removed from t e iron to give
ig purity iron, it is known as wroug t iron.
Wroug t iron is quite soft and easily worked and
as little structural strengt .

 
Steel is an alloy t at consists mostly of iron and
as carbon content between .2 and 2.1 by weig t,
depending on t e grade. Rt may also ave ot er
metals to give extra qualities to steel.
— e following are types of steel

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   Dead Mild Steel is iron containing

up to .15 of carbon.
   Mild steel is iron containing up to
about .25 of carbon. — e presence of t e carbon
makes t e steel stronger and arder t an pure iron.
— e ig er t e percentage of carbon, t e arder t e
steel becomes.
 
  Rt .5
.8 carbon. Rt is
strong as compared to Mild steel
!
  Hig carbon steel contains up to
about 1.5 of carbon. — e presence of t e extra
carbon makes it very ard, but it also makes it
more brittle!
   Alloy steels are formed w en ot er
metals are added in some proportion to t e steel to
give added properties to steel.

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Ferrous materials are very important in daily life

and for engineering purposes.

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Alloy steels are very important nowadays because of
t eir properties.
Different alloying elements give different
properties to steel. Some of t e alloying elements
and t eir alloying properties are given below.
(a)c
 "  Rmproves toug ness, tensile strengt ,
ductility and corrosion resistance
(b)c 
 Rmproves corrosion resistance,
ardness and toug ness.
(c)c    En ances magnetic properties of
steel and provides rigidity.
(d)c   Rt increase wear resistance,
ability to retain magnetic properties at ig
temperature.
(e)c r Rmproves tensile strengt , elastic
limit and s ock resistance
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Some special steels are given below

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       $ 
  
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Stainless C romium and Resists cutlery,
kitc ens sinks,
steel Nickel Corrosion industrial
equipments
—itanium —itanium Wit stands Gas turbines
Steel ig temp. & spacecrafts
Manganese Manganese Very ard Rock breaking
mac inery,
Steel
military
equipments

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