Ferrous Materials and Non-Ferrous Metals and Alloys

1 14 Manufacturing ProcessesCHAPTER 2 Ferrous Materials and Non-FerrousMetals and INTRODUCTIONF errous Materials / Metals may be defined as those Metals whose main constituent is ironsuch as pig iron , wrought iron , cast iron , steel and their Alloys . The principal raw materialsfor Ferrous Metals is pig iron . Ferrous Materials are usually stronger and harder and areused in daily life products. Ferrous material possess a special property that theircharacteristics can be altered by heat treatment processes or by addition of small quantityof alloying elements.

2 Ferrous Metals possess different physical properties according totheir carbon iron AND STEELThe Ferrous Metals are iron base Metals which include all varieties of iron and common engineering Materials are Ferrous Materials which are Alloys of iron . Ferrousmeans iron . iron is the name given to pure ferrite Fe, as well as to fused mixtures of thisferrite with large amount of carbon (may be ), these mixtures are known as pig ironand cast iron . Primarily pig iron is produced from the iron ore in the blast furnace fromwhich cast iron , wrought iron and steel can be CLASSIFICATION OF CARBON STEELSP lain carbon steel is that steel in which alloying element is carbon.

3 Practically besidesiron and carbon four other alloying elements are always present but their content is verysmall that they do not affect physical properties. These are sulphur, phosphorus, siliconand manganese. Although the effect of sulphur and phosphorus on properties of steel isdetrimental, but their percentage is very small. Sulphur exists in steel as iron sulphidewhich produces red shortness or manganese sulphide which does affect its Processesforging dies. Likewise for production of cold chisels, punches and dies. Springs,broaches and reamers can be produced for steel containing carbon.

4 As the percentageof carbon further increases, it can be used for production of milling cutters, anvils,taps, drills, files, razors, metal cutting tools for lathes, shapers, planner and WROUGHT IRONThe meaning of wrought is that metal which possesses sufficient ductility in order topermit hot and/or cold deformation. Wrought iron is the purest iron with a small amountof slag forged out into fibres. The typical composition indicates 99 per cent of iron andtraces of carbon, phosphorus, manganese, silicon, sulphur and slag.

5 During the productionprocess, first all elements in iron (may be C, S, Mn, Si and P) are eliminated leavingalmost pure iron molten slag. In order to remove the excess slag, the final mix is thensqueezed in a press and reduced to billets by rolling milling. The resulting materialwould consist of pure iron separated by thin layers of slag material. The slag characteristicof wrought iron is beneficial in blacksmithy/forging operations and provides the materialits peculiar fibrous structure. Further, the non-corrosive slag constituent makes wroughtiron resistant to progressive corrosion and also helps in reducing effect of fatigue causedby shocks and iron is tough, malleable and ductile and possesses ultimate tensile strengthof 350 N/mm2.

6 Its melting point is 1530 C. It can neither be hardened nor tempered likesteel. The billets of wrought iron can be reheated to form bars, plates, boiler tubing,forgings, crane hook, railway coupling, bolts and nuts, chains, barbed wire, coal handlingequipment and cooling towers, CAST IRONIt is primarily an alloy of iron and carbon. The carbon content in cast iron varies from 4 per cent. Small amounts of silicon, manganese, sulphur and phosphorus are alsopresent in it. Carbon in cast iron is present either in free state like graphite or in combinedstate as cementite.

7 Cast iron contains so much carbon or its equivalent that it is notmalleable. One characteristic (except white cast iron ) is that much of carbon content ispresent in free form as graphite . Largely the properties of cast iron are determined bythis point of cast iron is much lower than that of steel. Most of the castingsproduced in a cast iron foundry are of grey cast iron . These are cheap and widely characteristics of cast iron which make it a valuable material for engineeringapplications are: Ferrous Materials and Non- Ferrous Metals and Alloys17(1) Very good casting characteristics.

8 (2) Low cost(3) High compressive strength(4) Good wear resistance(5) Excellent machinabilityThe main limitation of this metal is brittleness and low tensile strength and thuscannot be used in those components subjected to varieties of cast iron in common use are:(1) Grey cast iron (2) White cast iron (3) Malleable cast iron (4) nodular cast iron (5) Chilled cast iron (6) Alloy cast Cast IronIt is the iron which is most commonly used in foundry work. If this iron is machined orbroken, its fractured section shows the greyish colour, hence the name grey cast grey colour is due to the fact that carbon is present in the form of free graphite .

9 Avery good characteristic of grey cast iron is that the free graphite in its structure acts asa lubricant. This is suitable for those components/products where sliding action is other properties are good machinability, high compressive strength, low tensilestrength and no view of its low cost, it is preferred in all fields where ductility and high strengthare not required. The grey cast iron castings are widely utilized in machine tool bodies,automobile cylinder blocks and flywheels, Cast IronIt is so called due to the whitish colour shown by its fracture.

10 White cast iron containscarbon exclusively in the form of iron carbide Fe3C (cementite). From engineering pointof view, white cast iron has limited applications. This is because of poor machinabilityand possessing, in general, relatively poor mechanical properties. It is used for inferiorcastings and places where hard coating is required as in outer surface of car crushing rolls are made of white cast iron . But it is used as raw material for productionof malleable cast Cast IronMalleable cast iron is produced from white cast iron .