INTRODUCTION

Background of the Study

A Short History Of Metals:

Process metallurgy is one of the oldest applied sciences. It’s history can be

traced back to 6000 BC. Admittedly, it’s form at that time was rudimentary, but, to

gain a perspective in process metallurgy, it is worthwhile to spend a little time

studying the initiation of mankind's association with metals. Currently there are 86

known metals. Before the 19th century only 24 of these metals had been discovered

and, of these 24 metals, 12 were discovered in the 18th century. Therefore, from the

discovery of the first metals - gold and copper until the end of the 17th century, some

7700 years, only 12 metals were known. Four of these metals, arsenic, antimony, zinc

and bismuth were discovered in the thirteenth and fourteenth centuries, while

platinum was discovered in the 16th century. The other seven metals, known as the

Metals of Antiquity, were the metals upon which civilisation was based. These seven

metals were: (1) Gold (ca) 6000BC; (2) Copper, (ca) 4200BC; (3) Silver, (ca)

4000BC; (4) Lead, (ca) 3500BC ;(5) Tin, (ca) 1750BC; (6) Iron, (ca) 1500BC; (7)

Mercury, (ca) 750BC. These metals were known to the Mesopotamians, Egyptians,

Greeks and the Romans. Of the seven metals, five can be found in their native states,

e.g., gold, silver, copper, iron (from meteors) and mercury. However, the occurrence

of these metals was not abundant and the first two metals to be used widely were gold

and copper. And, of course, the history of metals is closely linked to that of coins and

gemstones.

Metallurgy weapons could be made from it, however, it needed the discovery

of tin to become the alloy of choice. Native Tin is not found in nature. The first tin
artifacts date back to 2000 B.C., however, it was not until 1800 B.C. that tin smelting

became common in western Asia. Tin was reduced by charcoal and at first was

thought to be a form of lead. The Romans referred to both tin and lead as plumbum

where lead was plumbum nigrum and tin was plumbum candidum. Tin was rarely

used on its own and was most commonly alloyed to copper to form bronze. The most

common form of tin ore is the oxide casserite. By 1400 BC. bronze was the

predominant metal alloy. Tin's symbol is Sn from the stannum. Tin is highly

malleable and ductile and has two allotropic forms which lead to tin initially having

its own disease (tin pest or blight) which was actually formation of alpha-tin below 13

C. As alpha-tin is a highly friable cubic structure with a greater specific volume than

beta-tin, during the phase change, which is kinetically limited, nodules of alpha-tin

become visible on the surface of beta-tin giving rise to early belief of sickness and the

first true doctors of metallurgy. Tin is highly crystalline and during deformation is

subject to mechanical twinning and an audible tin cry. Tin is also quite resistant to

corrosion. Tin is found as vein tin or stream tin. The tin ore is stannic oxide and is

generally found with quartz, feldspar or mica. The ore is a hard , heavy and inert

substance and is generally found as outcroppings as softer impurities are washed

away.

Aluminum or Steel

Aluminium is mostly used metal in construction, appliances and technologies,

it was first produced by Christian Oersted in 1825. However it was not until 20 years

later that significant quantities were produced. Wohler fused anhydrous aluminum

chloride with potassium to set free aluminum. Later Ste Claire Deville in 1854 put

together a production process using sodium instead of potassium. The current from

Galvanic cells were also used for electroplating. This was first practiced in the 1830's
when silver was deposited on baser metals. After silver plating, copper and nickel

plating was developed. In the middle of the 18th century it was found that metallic

separation could be carried out by the application of galvanic electricity. The current

was passed from an anode made of an impure , crude metal into a suitable electrolyte

and the pure material plated out onto a resistant cathode. Impurities present in the

crude cathode dropped to the bottom of the vessel and formed a sludge. From this

short review of metallurgical developments it can be seen that as the early

metallurgists became more sophisticated their ability to discover and separate all the

metals grew. However in all of their work it was necessary for all the basic steps to be

carried out e.g. the ore had to be identified, separated from gangue, sized,

concentrated and reduced in a manner which accomplished a phase separation.

Aluminium or steel can be recycled by melting it down and recasting into new

products. Currently, 60% of steel 39% of aluminium is recycled worldwide. However,

while recycling is a greener alternative to manufacturing new materials, it has high

energy costs which could be avoided if the metals were reused in their original form.

In this extensive analysis, the researchers gathered information on steel and

aluminium reuse from academic and industry literature, drawing on 200 sources, and

conducted 17 interviews with industry experts. They identified which products use

these materials, the key design requirements for components, and the fraction of end-

of-life components that could be technically reused, considering available strategies

and the physical barriers to the reuse of the remaining components. From this, they

concluded that up to 27% of steel and 33% of aluminium ‘end-of-life’ components

could potentially be reused. At present, there is little reuse of either material.

Information from the interviews revealed that two key factors determine the type of

steel or aluminium component that can be reused and the way in which it is reused:
condition and market demand. If the condition is good and demand is high,

components can be simply ‘relocated’, i.e. transferred to similar product, with little

need for amendment. For example, aluminium car wheels can be transferred to

another vehicle. If the condition is poor and demand is low, the component can be

‘cascaded’ to a different type of product with less demanding use, for example, metals

once used to clad buildings can be reused on agricultural sheds. Alternatively, they

can be ‘reformed’ (or reshaped), as when ship plates are reformed to a reinforcing bar.

High demand but poor quality calls for ‘remanufacturing’, which involves further

disassembly and refurbishment. For steel, the main areas for reuse are the relocation

of building components and the reforming of ship plates and line pipes. For

aluminium, the main areas of reuse are in buildings and car wheels. These areas of

opportunity, if carried out to their full potential, could allow reuse of 180 megatonnes

(Mt) of steel (18% of all steel) and 5.5 Mt of aluminium (12% of all aluminium) per

year. Policymakers seeking to maximise aluminium and steel reuse should prioritise

opportunities to relocate metal, according to the researchers. Their analysis indicates

that the greatest barrier to reuse is component incompatibility, i.e. different models of

domestic appliances and car parts using different components, followed by

degradation, i.e. metal corrosion. Approximately one-fifth of all global steel is used to

reinforce concrete (210 Mt in 2008), which also presents a major challenge for reuse,

as it is difficult to recover the steel bars without damaging them.

Reuse describes the spectrum of activities to bring discarded metal back into use

without melting. Reuse of end of life products is currently dominated by large

constructions or components. Processing is required to disassemble, recondition and

re-assemble products for reuse in similar applications, but much with the original

shape and functionality is retained. Reuse in manufacturing scrap occurs in much

smaller volumes and at shorter length scales, the scrap is processed into a form in

which it can be reused, either by trimming to shape or by joining small pieces to

larger ones. Reuse is not a new concept before the industrial revolution, metal reuse

was normal practice. Barriers to reuse are associated with the reasons why a product

reaches its end of life. Fridges may become aesthetically undesirable, cars may be

scrapped because of unacceptable repair costs; ships may be broken due to changes in

legislation. However the bulk of the metal in this scrapped products is still fit for

purpose; reuse is not limited by any degradation of the metal’s technical

characteristics. This suggests that new design approaches to facilitate reuse could

have significant potential to reduce total carbon emissions in delivering steel and

aluminum goods.

Lampshade is a fixture that covers the lightbulb on a lamp to diffuse the light emits.

Lampshades can be made out of a wide variety of material and one of them is the

reuse metal scraps. Beyond its practical purpose, significant emphasis is also usually

given to decorative and aesthetic features. A lampshade also serves to shade human

eyes form the direct glare of the light bulbs use to illuminate the lamp.

Statement of the Problem

1. What are possible metal scraps that can be reuse in making a lampshade?

2. What are possible designs that will come out after reusing metal scraps?

3. What are the possible effect of reusing metal scraps to our environment?
Objective of the study

General Objective

This study aims to lessen metal scraps by turning or reusing them as material

in making a decorative lampshade.

Specific Objective

1. To enumerate the list of sources of metal scraps to reuse as material in making a

lampshade.

2. To provide some designs as a basis in designing a well reuse metal scrap.

3. To lessen the metal scraps and turning them into something useful.

Significance of the study

Scope and delimitation of the study