Ferrous and non ferrous Metals Engineering.ppt

Metals

1. FERROUS METAL
AND
NON-FERROUS METAL
Ar. RinoD.A. Fernandez, uap
Class Instructor

2. A metal containing iron as a primary material
FERROUS METAL
-Iron
-Cast Iron
-Steel
-Stainless Steel
-Wrought Iron

3. A metal containing little or no iron
NON-FERROUS METAL
-Aluminum
-Bronze
-Brass
-Copper
-Lead

4. Iron is a metal extracted mainly from the iron
ore hematite. It oxidizes readily in air and water
to form Fe2O3 and is rarely found as a free
element.
Iron is believed to be the sixth most abundant
element in the universe
IRON

5. SMELTING TECHNIQUE

6. Pig ironis the intermediate product of smelting
iron ore with coke and resin
Cast into pigs in preparation for conversion into
cast iron, wrought iron or steel
Pig iron has a very high carbon content,
typically 3.5 -4.5%, which makes it very brittle
and not useful directly as a material except for
limited applications

7. FERROUS METALS
CAST IRON
A hard, brittle, nonmalleable iron-based alloy
containing 2%-4.5% carbon and 0.5%-3%
silicon

8. FERROUS METALS
CAST IRON
APPLICATION:
-Piping & Fittings
-Ornamental Ironwork
-Hardware
-Base Metal for Porcelain Enameled Plumbing Fixtures
-Floor & Wall Brackets for Railings
-Circular Stairs
-Manhole Cover
-Gratings

9. FERROUS METALS
WROUGHT IRON
Commercially pure iron, containing only
approximately 0.2% carbon
A fibrous material due to the slag inclusions,
that gives it a "grain" resembling wood, which is
visible when it is etched or bent to the point of
failure
A tough, malleable, readily soft iron that is easily
forged & welded. Fatigue & corrosion resistant

10. FERROUS METALS
WROUGHT IRON
Literally means “worked iron”
APPLICATION:
-Piping & Fittings for Plumbing,
Heating & Air-conditioning
-Ornamental Ironwork

11. FERROUS METALS
GALVANIZED IRON (G.I.)
Iron coated with zinc to prevent rust. The
process is achieved thru hot-dip galvanizing

12. FERROUS METALS
GALVANIZED IRON
APPLICATION:
-Metal Decking
-Roofing & Accessories
-Ceiling Framing
-Wall Framing
-Piping

13. FERROUS METALS
STEEL
Alloys of iron and carbon
Carbon content is no more than 2%
Alloy elements is composed of phosphorous,
sulfur, oxygen, nitrogen, manganese, silicon,
aluminum, copper, nickel, etc.
Can be wrought, rolled, cast, and welded, but
not extruded

14. ALLOY ELEMENTS & IT’S PURPOSE/S:
1. Aluminum for surface hardening
2. Chromium for corrosion resistance
3. Copper for resistance to atmospheric corrosion
4. Manganese in small amounts for hardening; in larger
amounts for wear resistance
5. Molybdenum, combined with other alloying metals
such as chromium & nickel, to increase corrosion
resistance and to raise tensile strength without reducing
ductility.
FERROUS METALS

15. ALLOY ELEMENTS & IT’S PURPOSE/S:
6. Nickel to increase tensile strength without reducing
ductility; in high concentrations, to improve corrosion
resistance
7. Silicon to strengthen low alloy steels and improve
oxidation resistance; in larger amounts to provide hard,
brittle castings resistant to corrosive chemicals
8. Sulfur for free machining, especially in mild steels
9. Titanium to prevent intergranular corrosion of
stainless steels
10. Tungsten, vanadium, and cobalt for hardness and
abrasion resistance

16. FERROUS METALS
Types of Steel:
Carbon Steel
Alloy Steel
-Stainless Steel
-HSLA Steel (high-strength low-alloy)
-Weathering Steel

17. Unalloyed steel in which the residual element
as carbon, manganese, phosphorus, sulfur and
silicon are controlled.
Any increase in carbon content increase the
strength and hardness but reduces its ductility
and weldability.
Carbon Steel
FERROUS METALS

18. FERROUS METALS
Carbon Steel
APPLICATION:
-Structural Steel
-Concrete Reinforcement
-Decking and Panels
-Roofing & Accessories
-Windows & Doors
-Hardware

19. FERROUS METALS
Carbon Steel
APPLICATION:
-Structural Steel
I-beam
W-shape
S-shape
Channels
Angles
Plates
Pipes & Tubing

20. An alloy steel containing a minimum of 12%
chromium & additional nickel, manganese, and
molybdenum alloy elements
Resistance to heat, oxidation & corrosion
Does not stain, corrode or rust as ordinary steel,
but not stain-proof
Stainless Steel
FERROUS METALS

21. FERROUS METALS
Stainless Steel
APPLICATION:
-Exterior Wall Finishes
-Interior Wall Finishes
-Railings
-Signage
-Doors & Windows
-Hardware

22. A group of low-carbon steels containing less
than 2% alloys in a chemical composition
specifically developed for increase strength,
ductility, & resistance to corrosion
Much stronger & tougher than ordinary carbon
steel
HSLA (High-Strength Low-Alloy) Steel
FERROUS METALS

23. FERROUS METALS
HSLA Steel
APPLICATION:
-Reinforcement for Pre-stressed Concrete
-High-strength Bolts
-Special Structural Steel
-Cables for Elevators

24. A high-strength, low-alloy steel that forms an
oxide coating when exposed to rain or moisture
in the atmosphere
Best-known under the trademark COR-TEN steel
Weathering Steel
FERROUS METALS

25. Angel of the North
(20x54m),
Gateshead,
United Kingdom
FERROUS METALS
Weathering Steel

26. refers to a variety of carbon and alloy steels
that are particularly suited to be made into tools
Distinctively hard, resistance to abrasion and
deformation, and has ability to hold a cutting
edge
Tools Steel
FERROUS METALS

27. Soft, non magnetic, ductile and malleable silvery white
metal with thermal and electrical conductivity.
Aluminium is the most abundant metal in the Earth's
crust, and the third most abundant element therein,
after oxygen and silicon.
NNON-FERROUS METALS
Aluminum
Used as structural
framing like the high
strength aluminum alloys
and secondary building
elements such as
windows, doors, roofing,
flashing, trim and hard
wares.

28. Ductile, malleable and bright reddish brown color with
high thermal and electrical conductivity.
Posses a “patina”weather reactive surface layer of
insoluble green salt which retards corrosion and used to
alloy bronze and brass to increase strength and
corrosion resistance.
Copper
Used as electrical wiring,
piping, flashing and roofing
material. Care must be taken
in fastening, attaching or
supported only by selected
brass fittings.

30. Lead is a soft, malleable poor metal, also considered to
be one of the heavy metals. Lead has a bluish white
color when freshly cut, but tarnishes to a dull grayish
color when it is exposed to air and is a shiny chrome
silver when melted into a liquid. .
Brass
Lead
Brass is any alloy of copper and zinc. It
has a muted yellow color, somewhat
similar to gold.
It is relatively resistant to tarnishing,
and is often used as decoration and for
coins. In antiquity, polished brass was
often used as a mirror.

31. Lead pipe in
Roman baths

32. Tungsten carbide, WC, or tungsten semicarbide,
W2C, is a chemical compound containing tungsten and
carbon, similar to titanium carbide. Colloquially,
tungsten carbide is often simply called carbide.

33. METAL JOINERY
Solderingis a process in which two or more metal
items are joined together by melting and flowing a
filler metal into the joint, the filler metal having a
relatively low melting point. (below 840deg F)
Annealing
In the cases of copper, steel,
and brass this process is
performed by substantially
heating the material (until
glowing) for a while and allowing
it to cool slowly. The metal is
softened and prepared for
further work such as shaping,
stamping, or forming.

34. Brazingis a joining process whereby a filler metal or
alloy is heated to melting temperature above 450°C
(842°F), or, by the traditional definition that has been
used in the United States, above 800°F (425°C) and
distributed between two or more close-fitting parts by
capillary action.
Soldering is distinguished from brazing by use of a
lower melting-temperature filler metal; it is
distinguished from welding by the base metals not
being melted during the joining process.

35. Weldingis a fabrication process that joins materials,
usually metals or thermoplastics, by causing coalescence.
This is often done by
melting the workpieces
and adding a filler material
to form a pool of molten
material (the weld puddle)
that cools to become a
strong joint, with pressure
sometimes used in
conjunction with heat, or
by itself, to produce the
weld.

36. A rivetis a mechanical
fastener. Before it is installed it
consists of a smooth cylindrical
shaft with a head on one end.
The end opposite the head is
called the buck-tail.
Blind rivets(also known as pop
rivets) The rivet assembly is inserted
into a hole drilled through the parts to
be joined and a specially designed
tool used to draw the mandrel into
the rivet.

38. Alcladis a trademark of Alcoaused as a generic term to
describe corrosion resistant Aluminum sheet formed from
high-purity aluminum surface layers metallurgically
bonded to high strength Aluminum Alloy core material.
These sheets commonly used by the aircraft industry
Sherardisingis a method of galvanizing also called vapor
galvanizing. A layer of zinc is applied to the metal target
object by heating the object in an airtight container with
zinc powder. The temperature that the container reaches
does not exceed the melting point of zinc. Another method
of sherardisation is to expose the intended objects to vapor
from molten zinc using a reducing gas to prevent oxidation.
PROTECTING METALS