SUBJECT: Engineering Materials

MODULE No. 01
Topic: Ships Iron and Steel
Time Frame: Week 4
Lesson 3.1:
3.1 Pig iron and Iron Ore
3.2 Production of Pig Iron from Iron Ore
3.3 Production of Steel
3.4 Production and Properties of Cast Iron
3.5 Categories of Wrought Steels Prepared by: Sir Sherwin V. Borja
INTRODUCTION
At the end of this lesson, you are expected to:
3.1. Describe in simple terms the production of pig iron from
iron ore
3.2. Describe the principles of the open-hearth, the
Bessemer, and more modem processes used in the production of
steel from pig iron
3.3. Evaluate the production methodologies of the following:
- Production of Pig Iron
- Production of Cast Iron
- Properties of Cast Iron
3.4. Evaluate the processes involved in steelmaking
3.5. Assess the categories of wrought steels with emphasis on
the following:
- Plain carbon steels
- Low alloy steels
- High alloy steels
- Alloying limits for low alloy steels
- General characteristics of various tool steels
Prepared by: Sir Sherwin V. Borja
INSTRUCTIONS

1.The subject entails a lot of readings. Be patient!

Patience is a virtue. In reading, you BECOME MORE!
2. Please read the various texts carefully so that you can
comprehend easily.
3. You can consult google or dictionaries for clearer
understanding of terms and concepts met in the texts.
4. Do the different activities required. Do not leave any
activity undone.
5. Please follow instructions. Feel free to ask me via
messenger (Sherwin Villamil Borja) or text (09197836157) for
clarification on directions.

Prepared by: Sir Sherwin V. Borja

 6. Answer questions with all honesty. Success does not come
from copying from others. It is made possible by trying hard on
your own so that you can learn even from your mistakes.
7. Review your answers. It is safe to go back and think
about what you have written. This can help you lessen if not
avoid errors.
8. Do not delay in doing and submitting your requirements.
This can help you avoid having a pile of unfinished activities.
9. Have fun as you learn. When you are having fun, you can
surely learn the lessons.

Prepared by: Sir Sherwin V. Borja

CHECKING OF ATTENDANCE
Note: Open/start your camera. If your name is called, say
“state your last name, PRESENT” (e.g. LUNA, PRESENT) for initial
checking of attendance.

Prepared by: Sir Sherwin V. Borja

PRESENTATION OF THE LESSON

IRON ORE PIG IRON

STEEL

Which of the following is the raw material

and the product material?
Prepared by: Sir Sherwin V. Borja
IRON ORES

Prepared by: Sir Sherwin V. Borja

IRON ORE
- are rocks and minerals from which
metallic iron can be economically
extracted.
- usually rich in iron oxides and
vary in color from dark gray, bright
yellow, deep purple to rusty red.
- iron ores is the raw material used to
make pig iron, which is to make steel.

Prepared by: Sir Sherwin V. Borja

PIG IRON

Prepared by: Sir Sherwin V. Borja

PIG IRON
- is produced by smelting iron ore in
a blast furnace.
- usually 43% iron, 26% carbon, 9%
manganese, 15% silicon, 6% phosphorous
and 1% Sulphur.

Prepared by: Sir Sherwin V. Borja

PIG IRON
- used for producing different types
of cast iron.
- foundry pig iron contains higher
amount of silicon and manganese to have
reasonably good fluidity.

Prepared by: Sir Sherwin V. Borja

PRODUCTION
OF IRON
a. PIG IRON
b. WROUGHT IRON
c. CAST IRON

Prepared by: Sir Sherwin V. Borja

Prepared by: Sir Sherwin V. Borja
 Before iron ore can be used in blast furnace it must be extracted
from the ground and partially refined to remove most of the
impurities.
Much of the world’s iron ore is extracted through open pit mining in
which the surface of the ground is removed by machines.
Prepared by: Sir Sherwin V. Borja
 The mined ore is crushed and sorted the best grades. The lesser are
treated or refined by crushing and washing with water to float sand
and clay away magnetic separation.
The refined ore is transported to the blast furnace site.

Prepared by: Sir Sherwin V. Borja

 After refining the iron ore is blended with coke and limestone and
goes to the blast furnace
The mixture of iron ore coke and limestone enters to the top of the
furnace. At the bottom of the furnace a very hot hair is blown or
blasted through the nozzles.
Prepared by: Sir Sherwin V. Borja
 PROPERTIES
OF CAST IRON

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PROPERTIES OF CAST IRON
Good compressive stress and
Brittle and less ductile poor tensile and shear strength

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PROPERTIES OF CAST IRON
Lower melting point Easy to cast due to high
(1150°C - 1250°C) fluidity.

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PROPERTIES OF CAST IRON
Good corrosion resistance Cheap among other alloy.

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PRODUCTION
OF STEEL

Prepared by: Sir Sherwin V. Borja

BESSEMER PROCESS

The Bessemer Process was the first inexpensive industrial process

that allowed for the mass production of steel. The process used a
molten pig iron to melt iron. The real difference with this process
was that air was forced through the molten iron to remove impurities.
Prepared by: Sir Sherwin V. Borja
OPEN-HEARTH PROCESS

The Open-hearth furnace is the extreme heat that can be obtained

from them due to their regenerative process. The charge of pig iron,
steel scrap, iron ore and flux are together kept in shallow container
with a flame above it.
Prepared by: Sir Sherwin V. Borja
ELECTRIC ARC PROCESS

The electric arc furnace uses high voltage electric arc struck
between carbon electrodes and the charge becomes the source of a very
high temperature.

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SYNTHESIS
Note: Proceed to GOOGLE CLASSROOM under CLASSWORK SECTION
and take your activity in the “PRELIM ACTIVITIES”.
File name: ACTIVITY 3 (Lesson 3.1)

Prepared by: Sir Sherwin V. Borja

EVALUATION

Note: Proceed to EDMODO CLASSROOM.

File name: QUIZ 3 (Lesson 3.1)
This quiz consists of multiple-choice, true or false, fill in the
blanks, matching type, multiple answers and short essay questions. To
be successful with the weekly quizzes, it’s important to thoroughly
read PRELIM MODULE (Lesson 3.1). It will also be extremely useful to
study the key terms at the end of the chapter and review the ACTIVITY 3
(Lesson 3.1). Keep the following in mind:

Only one response per student- You will have a single and reliable
result for this quiz the highest score being recorded in the grade
book.
Timing - You will need to complete the first attempt in one sitting, as
you are allotted 1 (one) hour to complete the quiz.

To start, click the "QUIZ 3 (Lesson 3)" button. When finished, click
the "SUBMIT" button.
Only registered, enrolled students can take the graded quiz.
REFERENCES

Villalas, Beteliano Jr. S., Eugene S. Ylala., Calvin Y. Parba. (2019). E-MAT
III Engineering Materials for College of Marine Engineering. Quezon City:
Wiseman.
https://www.youtube.com/watch?v=k6vut9m-5xU
https://www.youtube.com/watch?v=ydQKRHpbCg4