Iron

(pig iron, cast iron,

wrought iron)
 INTRODUCTION
Metals are useful engineering materials. They do not exist in nature in pure state
and are present in the form of ores inside the earth. Ores are impure forms of
metals existing as compounds such as oxides,sulphides,carbonates etc.The
ores are extracted by forming mines. The ores are subjected to various
processes to give pure metals.

CLASSIFICATION OF METALS
• Ferrous Metals
• Non-Ferrous Metals

FERROUS METALS
These are metals containing iron as the main ingredient. There are two
important types of ferrous metals:-
1. Iron
2. Steel
 IRON

Iron does not occur as a free metal in nature.It occurs in the form of ores as oxides. The ores are:-
Magnetite (contains 73% iron)
Haematite (contains 70% iron)
Limonite (contains 60% iron)
Iron Pyrites (contains 47% iron)
Siderite (contains 48% iron)

o TYPES OF IRON
Pig iron
Cast iron
Wrought iron

PIG IRON
It is also known as crude iron.
Used as raw material for manufacturing other varieties of iron such as cast iron, wrought iron and
steel
 MANUFACTURE
OF PIG IRON

1. Dressing of ores
(process of breaking
ores)

2. Roasting/Calcining the
ores (process of
heating ores in
presence of air)

3. Smelting (process of
melting the ores)
CHARACTERISTICS OF PIG IRON
BRITTLENESS
 Pig iron is a very brittle metal, due to the high carbon content
and the other impurities that form in it.
 The other elements found in pig iron also weaken its structure.
 Although iron is thought of as very solid, pig iron will split and
fracture if it is dropped.
MELTING POINT
 Pig iron has a much lower melting point than wrought iron or
steel due to the high carbon content.
 CAST IRON
PROPERTIES-
 Hard, brittle and non-ductile
 Does not easily rust.
 Can’t be magnetized.
 Shrinks on cooling.
 Cannot be welded or riveted.

USES-
 In manufacture of railings, chairs, carriage wheels, machinery parts.
 In manufacture of cisterns, water and gas pipes, sewers, man-hole covers,
sanitary fittings
 PRODUCTION

 Cast iron is made by re-melting pig iron, often along with

substantial quantities of scrap iron and scrap steel and
taking various steps to remove undesirable contaminants
such as phosphorus and sulphur.
 Depending on the application, carbon and silicon content
are reduced to the desired levels, which may be anywhere
from 2 to 3.5% and 1 to 3% respectively.
 Other elements are then added to the melt before the final
form is produced by casting.
 USE OF CAST IRON IN BUILDINGS
 Cast iron are used as columns which enabled architects to build tall buildings without the
extremely thick walls required to construct masonry buildings of any height.
 Such flexibility allowed tall buildings to have large windows, manufacturing buildings were
built with cast iron columns to allow daylight to enter.

Cast iron drain, waste and vent piping

ADVANTAGE & DISADVANTAGES OF CAST IRON
ADVANTAGES
cast iron's high carbon content makes it
easy to melt, weld, machine and cast using
common metalworking processes.
iron contains graphite flakes that provide a
high level of stability and minimize
shrinking during the casting process.
The metallurgy of gray iron also makes it
resistant to corrosion.
DISADVANTAGES
 cast iron's extremely low tensile strength makes it a
poor shock resistor relative to newer, less rigid iron
alloy varieties
 Blasting cast iron can weaken castings by causing
residual stress.
 cast iron may be too brittle for some applications,
including instances when a casting must be especially
thin or flexible.
 ORNAMENTAL WORK

Cast Iron Railing

STRUCTURES MADE BY CAST IRON

The iron bridge over the River Severn at Coalbrookdale, England

 WROUGHT IRON
It is a very pure variety of iron containing very small quantities of carbon (less than 0.15%).It is
manufactured by melting and refining pig iron in a furnace (Puddling furnace).

PROPERTIES
• It is malleable, ductile, tough and elastic.
• Crushing strength is 2000kg/sq cm
• Melting point is 1500deg Celsius.
• Cannot be cast as it fuses with difficulty.
• Cannot be easily welded.
• Resists corrosion.
• Bluish in color, with a silky luster. Wrought Iron Grill
•
USES
•In manufacture of rivets, chains, ornamental iron work,
water and steam pipes, pipe fittings, bars, bolts, nuts,
handrails, anchors. hooks etc.
•In manufacture of hard steel.
Rivets
 DEFECTS OF WROUGHT IRON
 Wrought iron is redshort if it contains sulfur in excess quantity.
It has sufficient firmness when cold, but cracks when bent or
finished at a red heat. It is therefore useless for welding or
forging.

 Coldshort iron, also known as cold shear . contains excessive

phosphorus. It is very brittle when it is cold. It cracks if bent. It
may, however, be worked at high temperature.
 STRUCTURES MADE BY WROUGHT IRON

The Eiffel tower is constructed from Iron pillar at Delhi, India,

puddle iron, a form of wrought iron containing 98% wrought iron
MAJOR MANUFACTURURS
COMPANYS MAKING I,T,C SECTIONS
 S.A.I.L
 JINDAL
 Y.S.P.
 VISHAK
COMPANYS MAKING L SECTIONS
 PRITHVI
 JAI BHARAT
 RANA
 MARKET SURVEY
G.I. CORRUGATED SHEET-
AVAILABLE LENGTH:-8’, 10’, 12’
AVAILABLE WIDTH:-32” (COVERS 30”)
AVAILABLE THICKNESS:- 0.25MM
TO 0.8MM
G.I. PLAIN SHEET-
AVAILABLE LENGTH:-3’, 6’, 8’, 10’
AVAILABLE WIDTH:- 3’, 3.5’, 4’
AVAILABLE THICKNESS:-0.25MM TO
0.8MM

RATE-

LIGHTSHEET:- Rs. 75/KG
HEAVY SHEET:- Rs. 65/KG
DIM. ARE IN INCHES
 L SECTION

AVILALBLE SIZES : 40X40X5 ,25X25X3, 32X32X3

ALL D IM. ARE IN MM 35X35X5 , 40X40X6, 50X50,5
50X50X6 .

RATES OF L SECTION FROM SIZE : RS.42.00,50.00,

 SQUARE HOLLOW TUBE

WELD

HOLLOW SQUARE TUBE