Spring 2019

ISyE 415

Introduction to Manufacturing
Systems Design and Analysis

Lecture 2: Iron and Steel Making

Recall
 https://www.youtube.com/watch?v=BHZALtqAjeM
 Material Properties 101

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Metals
 With properties that satisfy a wide variety of design
requirements, e.g.,
 High stiffness and strength
 High toughness
 Good electrical and thermal conductivity
 Easy improvement by alloying
 …
 LOW COST

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Iron and Steel (Ferrous Metal)
 Iron was discovered sometime during the Bronze Age,
probably uncovered from ashes of fires built near iron ore
deposits
 Iron Age:1200 BC
 Iron melting furnaces found:1300 BC (Israel)
 Iron swords and tools:1000 BC
 Large-scale production: 19th century
 Railroad, ship, construction, machinery, and military needs
 Steel making: before WWII (Europe & US)

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Learning Goals
 Understand the making process for iron and steel
 Get familiar with the properties of various iron and steel
alloys

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Making Iron from Stone
Fe2O3

 Raw materials
 Iron ore
 Hematite (Fe2O3), magnetite (Fe3O4), siderite
(FeCO3), limonite (Fe2O3-xH2O)
Fe3O4
 Coke (C)
 Limestone (CaCO3)

FeCO3

Fe2O3-xH2O
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Ironmaking Product
 Pig Iron: iron with 4% carbon and
impurities:
 Silicon (Si): 0.3-1.3%
 Manganese (Mn): 0.5-2%
 Phosphorus (P): 0.1-1%
 Sulfur (S): 0.02-0.08%
 Cast Iron: 2.1-4% carbon and
impurities (1-3% Si)
 Steel: 0.02%-2.11% carbon and
impurities (some elements added for
specific properties)
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Ironmaking Process
 https://www.youtube.com/watch?v=DBBt7IhHOFQ
 A simple way to make iron
 Think about
 What are the key steps?

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Industry Process (Blast Furnace)

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Reaction
 Key reactions
 Remove oxygen from ore with coke through a
reduction process
 Remove impurities as slag with limestone

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Steelmaking Process
(Basic Oxygen Furnace)
 Materials
 Pig iron or steel scrap, lime (CaO)
 Key reactions
 Further burn off impurities by
oxygen

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Entire Steelmaking Process
 https://vimeo.com/125266132
 Pohang Steel

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Exercise 1
 What is the range of carbon percentages for steel? Cast
iron?
 In ironmaking, what is the usage of coke? Limestone?
 In steelmaking, what is the usage of oxygen?

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Mechanical Properties
 Cast iron & steel

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Various Steels
 Plain carbon steels (C)
 Low alloy steels (A)
 Stainless steels (S)
 Tool steels (T)
 Specialty steels

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 Effect of Alloys on Steel
 Plain carbon steels
 Carbon as principal alloying element,
with only small amounts of other
elements (0.4% Manganese and lesser
amounts of others)
 Low carbon steel: <0.2% carbon
High carbon
 Medium carbon steel: 0.2-0.5% carbon
 High carbon steel: >0.5% carbon Medium carbon

 Increasing the carbon percentage

increases the tensile strength and
hardness Low carbon

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 Effect of Alloys on Steel
 Low alloy steels
 Alloys containing additional alloying elements in amounts totaling
less than about 5% by weight
 Common alloying elements
 Chromium (Cr): improves strength, hardness, wear resistance, and hot
hardness
 Manganese (Mn): improves strength and hardness of steel
(hardenability is improved during heat treat)
 Molybdenum (Mo): increases toughness and hot hardness
 Nickel (Ni): improves strength and toughness
 Vanadium (V): inhibits grain growth during elevated temperature
processing and heat treatment, which enhances strength and toughness

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Video Illustration
 https://www.youtube.com/watch?v=zCznMbj2Yn4
 Various steels

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Effect of Alloys on Steel
 Stainless steel
 Highly alloyed steels designed to provide high corrosion resistance.
 Principal alloying element: Chromium usually above 15%, also Nickel,
Molybdenum.
 Rust resistant, hard, strong
 Tool steels
 Highly alloyed steels designed for use as industrial cutting tools, dies, and
molds.
 Hard, strong
 Contains levels of Chromium and Vanadium
 Specialty steels
 Maraging steels: Nickel 15-25%, used for missiles, machinery, dies, etc.
 Free-machining steels: formulated to improve machinability.
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Exercise 2
 What is the major element rather than iron in stainless steel?
 What is the carbon percentage in low/medium/high carbon
steel?
 List all the elements we listed for improving strength of
steel

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