:

: Classification of Steel

BasedOn Manufacturing
Methods.
Dr.Muhmmad
Mubashar Omar.
ENERGY SYSTEM
ENGINEERING (GIRLS)
FMP-301 ( FARM
MACHINERY AND POWER)
“Steel is an alloy made up of iron with typically a few tenth of
a percent of carbon to improve its strengthen”
 TYPES OF STEEL
1. Pudding Steel
2. Bessemer Steel
3. Open Hearth Steel
4. Electric Arc Steel
5. Crucible Steel
6. Induction Steel
7. Electrolytic Steel
 It is a type of steel which is manufactured by
PUDDLING PROCESS.
“ In pudding process , the pig iron is converted into
wrought iron with the help of heat”
 COMPOSITION :
i. Carbon lesser than 0.01%
ii. Manganese lesser than 0.02%
iii. Silicon is from 0.28-0.02%
iv. Phosphorous is from 0.41-0.02%
v. Sulphur is from 0.054-0.04%
 :
The pudding furnace is a metal making technology
used to create wrought iron or steel from the pig iron
produced in a blast furnace.
 MANUFACTURING PROCESS :
 First we need to prepare pudding furnace . Then a
charge of 1500 Ibis of pig iron is thrown from the door
of furnace and heat up at melting point. Allowing for
oxides to being mixing this usually takes 30 minutes
 The mixture is subjected to a strong current of air
and stirred with long bars with hooks on one end
called puddling bars .
 This help the charge to mix properly . More fuel is
then added and the temperature raised.
 Iron starts to melt , and carbon starts to melt off. Iron
oxide react to form carbon dioxide and cause bubbles.
This cause the mass to appear to boil. This cause the
slag to puff up on top giving a visual indication of
progress of combustion .
 Mixture temperature rises because of carbon
melting from 1150 to 1540 degree celsius. The melting
point increases since the carbon atoms within the
mixture act as a solute in solution which lowers the
melting point of the mixture.
 The iron and the slag are separated and take out of
the furnace into different trays. Then the iron is
converted into steel by further processing .
 It is the type of steel which is manufactured by
BESSEMER PROCESS.
“ It is the removal of impurities from the iron by
oxidation with air being blown through the
molten iron”
HISTORY :
 In 1856, Henry Bessemer developed the process
to purify iron ore.
 The bessemer process was first inexpensive
industrial process for the mass production of
steel from molten pig iron before the
development of open hearth furnace.
 :
 The Bessemer steel process was a method of
producing high quality steel by shooting air in molten
steel to burn off carbon and other impurities.
 The bessemer converter is a cylindrical steel pot
approximately (20 feet) 6 meters high, originally lined
with a siliceous refractory.
 Air is blown in through tubers near the bottom,
creating oxides of silicon and manganese, which
become part of slag and are carried out in stream of
air.
 Within few minutes and ingot of steel can be
produced.
 The conversion process , called the “blow” was
completed in approximately 20 minutes. The oxidation
of impurities was judged by the appearance of flame.
 After the blow, the liquid metal was decarburized to
the desire point and other alloying materials were
being added, depending upon the desire product.

 USES:
Bessemer steel was used for railroad rails , it is used
during the construction of the brooklyn bridge,
crucible steel , barbed wire etc
“The steel that can be made by different electrolysis
process is known as electrolytic steel”

In chemistry and manufacturing, electrolysis is a

technique that uses electric current (DC) to drive an
otherwise non-spontaneous chemical reaction. The
voltage that is needed for electrolysis to occur is called
decomposition potential.
 MANUFACTURING PROCESS:
 The key process of electrolysis is the interchange of
atoms and ions by the removal or addition of electrons
due to applied current.
 The desired products are often in different physical
states.
 The quantity of products is proportional to the
current , and when two or more electrolytic cells are
connected in series to the same power source ,the
products produced in the cells are proportional to their
equivalent weight . These are known as FARADAY’S
LAW OF ELECTROLYSIS.
 Magnesium , the element , is
Produce commercially by
electrolysis from the
electrolyte using a cell
similar to electrolyte.
 :
For the prevention of corrosion
To reduce friction
To protect from radiations
In commercial applications
In conduction of electricity e.t.c
“Open heart furnace are the furnace in which
excess carbon and other impurities are burnt out
of pig iron to produce steel’’
 MANUFACTURING.
 Open heart furnace is uses the heat of combustion of
gaseous or liquid fuels to convert a charge of scrap and
liquid blast-furnace iron to liquid steel.
 High temperature is require for melting.
 It is obtain by the preheating the combustion air and
some time the fuel gas.
 :
 Open hearth produce great flexibility, the possibility
to use it on production scale.
 less requirement of initial material.
 Simplicity of monitoring and control of the smelting
process.
 High quality and wide variety of smelted steel.
‘Steel that can be made by electric arc furnace
is known as electric arc steel’
o Arc Furnace (EAF). Electric
 This furnace heart charged material by an electric arc.
 It is as different range of capacities for different
purposes.
 Oxygen is blown into the furnace , and lime and other
materials are added to combine with impurities and
form slag.
 Molten iron is extracted and poured out through a
tapping spout.
 USES:
 It is use to reduce iron from iron ore.
 It is used in steelmaking , foundries, ferroalloy
production , and some nonferrous metallurgical
applications.
 It is also used for the production of calcium carbide
and phosphorous.
 The minimum amount of energy require to melt a
scrap steel is 300 KWH.
 The typical (EAF) without oxyfuels burners uses
475KWH/Tons
 We can power an arc through three large plugs behind
the machine.
‘‘Crucible steel is made by melting pig iron, iron
, and sometime steel with glass , sand , ashes,
and other fluxes , in a crucible’’
 In accident time steel and iron were
impossible to melt using charcoal and coal
fire which could not produce temperature
high enough.
 :
 There are many way for making crucible steel.
 It is produce by heating wrought iron with materials
rich in carbon such as charcoal in closed vessel.
 It is made from ceramic material.
 it is always a high carbon steel.

USES:
 It is use in laboratory to contain chemical compound
when heated to extremely high temperature
 It is used for high end premium pocket knives.
 .

‘‘The steel made by induction furnace is called

induction steel.’’
o INDUCTION FURNACE.
‘‘ Induction furnace is an electric furnace in
which heat is applied by induction heating of
metal’’
 Induction furnace use to melt iron , steel ,
copper, iron and aluminum metal.
 .
 It is clean , energy efficient , and well controlled
melting process compared to most other means of
metal melting.
 WORKING OF INDUCTION FURNACE.
 A coil carrying alternating electrical current surrounds
the container or chamber of metal.
 Eddy current are induced in the metal , the circulation
of these current producing extremely high
temperature for melting the metal and for making the
alloy of exact composition