USES OF FERROUS

METALS & ALLOYS

STEELS
Steel
-is analloy of iron and
carbon in which the
carbon content does
not exceed 1.7%.

-Produced from Pig

Iron and Scraps.
Pig Iron

Scraps
 Classification
0.05 - 0.15 % carbon Very low carbon
steel
0,15 – 0.30 % carbon Low carbon steel

0.30 – 0.60 % carbon Medium carbon

steel
0.60 – 0.90 % carbon High carbon steel

0.90 – 1.5 % carbon Very high carbon

steel
 Methods
Cementation
Crucible
Bessemer
Acid open-hearth
Basic open-hearth
Electric
Oxygen converter
Manufacture of Steel
Melted Pig iron and
scrap has its
impurities removed
by oxidation.
 Slag
• is the glass-like by product left over after a
desired metal has been separated from its
raw ore.
 Uses of Slag

• To absorb and retain the oxidize impurities.

• To lie upon the top of the bath as a blanket

to protect from excessive oxidation.

• To oxidize the impurities of the bath.

Deoxidation and Rimming
 Deoxidation
• Is a method used in metallurgy to
remove the oxygen content during
steel manufacturing
 Rimming
• Partially deoxidized or non
deoxidized low carbon steel evolving
sufficient amount of carbon
monoxide during solidification.
Processes in Steel Making
• Cementation
• Crucible Process
• Bessemer Process
• Direct Oxygen Process
• Open Hearth Process
• Duplex Process
• Electric Refining Process
Cementation
 Cementation
• is an obsolete technology for
making steel by carburization of iron.
Cementation Furnace
 Crucible Processes
•  Is a process of refining steel by
melting cast iron, and
sometimes steel, often along
with sand, glass, ashes, and
other fluxes, in a crucible.
BESSEMER PROCESS
Henry Bessemer
-Invented a process
for refining pig iron
by blowing air
currents through
the molten bath.
Bessemer Process
Bessemer Converter
Formed slag blown through the
mouth of the Bessemer
Converter
William Kelly of Kentucky
American Railways
Direct Oxygen Process
Direct Oxygen Process or LD
process (Linz-Donawitz)
-Process of refining pig iron using pure
oxygen to oxidize impurities.
Direct Oxygen Process
Oxygen Converter
Open Hearth Process
Siemens Brothers
-Invented a
process for
refining steel on a
large scale by
melting pig iron in
the hearth of a
furnace in
contact with
proper fluxes.
Pierre-Emile Martin
-Developed
regenerative
furnace.
Open Hearth Process
Open Hearth Process
• Regenerative
Chambers-
Separate
compartments
connected with a
furnace; they are
arranged for
preheating the gas
and the air used
for fuel
Brick checker-
where the hot
exhaust gases
from furnace
pass, giving up
their heat to
brickwork.
Regenerative Furnace
Limestone flux
Fluor Spar

Steel Ingot
molds
Duplex Process
Duplex Process
• Combination of acid Bessemer basic
open-hearth processes.
• Larger part of manganese and of the
silicon is removed in the converter
• Phosphorus and Carbon are removed
in the open hearth
Duplex Process
Electric Refining Process
Electric Refining Process
• If extremely pure steel is desired
• When electrical energy is cheap
• The heat is produced by electrical
energy
• The bath is not subjected to excessive
oxidation
• The temperature can be very closely
controlled
Three types of electric furnaces
used:
1. Arc furnace with
electrodes above the bath
2. The bath competes the circuit
between electrodes
3. Induction furnace
Ingot molds
Ingots
• After the steel has been refined, it id
poured either into ingot molds or
directly into a mold to form a finished
casting. But most steel is poured in
ingot form.
Large ingot molds
• Usually filled
through the top
from a ladle
which has a gate
in the bottom.
Smaller ingot molds
Usually set in groups
of 15 to 20 upon
concrete base; in
this are embedded
refractory tubes
leading from a
central sprue to each
of the molds.
Ingots
Defects in Ingots