FERROUS METAL AND NONNON-FERROUS METAL

Ar. Rino D.A. Fernandez, uap Class Instructor

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

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

IRON
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

SMELTING TECHNIQUE

Pig iron is 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

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

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

FERROUS METALS
WROUGHT IRON A tough, malleable, readily soft iron that is easily forged & welded. Fatigue & corrosion resistant 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

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

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

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

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

FERROUS METALS
ALLOY ELEMENTS & ITS 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.

ALLOY ELEMENTS & ITS 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

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

FERROUS METALS
Carbon Steel 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.

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

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

FERROUS METALS
Stainless Steel 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

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

FERROUS METALS
HSLA (High-Strength Low-Alloy) Steel 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

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

FERROUS METALS
Weathering Steel 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

FERROUS METALS
Weathering Steel

Angel of the North (20x54m), Gateshead, United Kingdom

FERROUS METALS
Tools Steel 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

NNON-FERROUS METALS
Aluminum
 

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.

Used as structural framing like the high strength aluminum alloys and secondary building elements such as windows, doors, roofing, flashing, trim and hard wares.

Copper
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.

Used as electrical wiring, piping, flashing and roofing material. Care must be taken in fastening, attaching or supported only by selected brass fittings.

Brass
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.

Lead
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. .

Lead pipe in Roman baths

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.

METAL JOINERY
Soldering is 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.

Brazing is a joining process whereby a filler metal or alloy is heated to melting temperature above 450C (842F), or, by the traditional definition that has been used in the United States, above 800F (425C) 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.

Welding is 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.

A rivet is 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.

PROTECTING METALS Alclad is a trademark of Alcoa used 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 Sherardising is 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.