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PDHonline Course M415

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Steelmaking from scrap metals involves melting scrap metal, removing impurities and casting it into the desired shapes. Electric arc furnaces (EAF) are often used. The EAFs melt scrap metal in the presence of electric energy and oxygen. The process does not require the three step refinement as needed to produce steel from ore. Production of steel from scrap can also be economical on a much smaller scale. Frequently mills producing steel with EAF technology are called mini-mills. EOF was developed to replace the electric arc and other steelmaking furnaces. The Electric Oxygen Furnace (EOF) is an oxygen steelmaking process. Carbon and oxygen react to preheat scrap metal, hot metal and/or pig iron. These furnaces reduce capital and conversion costs, energy consumption and environmental pollution, while increasing input flexibility. After the molten metal is released from either the BOF, EAF or EOV, it must be formed into its final shape and finished to prevent corrosion. Traditionally, steel was poured into convenient shapes called ingots and stored until further shaping was needed. Current practices is continuous in casting methods, where the steel is poured directly into semifinished shapes. Continuous casting saves time by reducing the steps required to produce the desired shape. After the steel has cooled in its mold, continued shaping is done with hot or cold forming. Hot forming is used to make slabs, strips, bars or plates from the steel. Heated steel is passed between two rollers until it reaches the desired thickness. 4.1 Metal Forming: Cold forming is used to produce wires, tubes, sheets and strips. In this process the steel is passed between two rollers, without being heated, to reduce the thickness. The steel is then heated in an annealing furnace to improve the ductile properties. Cold rolling is more time consuming, but the products have better mechanical properties, better machinability, and can be more easily manipulated into special sizes and thinner gauges. After rolling is completed, the steel pieces are finished to prevent corrosion and improve properties of the metal. 4.2. Sheet Metal: Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental forms used in metalworking, and can be cut and bent into a variety of different shapes. Thicknesses can vary significantly, although extremely thin thicknesses are considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are considered plate. Sheet metal is available in flat pieces or as a coiled strip. The coils are formed by running a continuous sheet of metal through a roll slitter. The thickness of the sheet metal is called its gauge. Commonly used steel sheet metal ranges from 30 gauge to about 8 gauge. The larger the gauge number, the thinner the metal. Sheet metal also has applications in car bodies, airplane wings, medical tables, roofs for buildings (architectural) and many other things. 2012 Jurandir Primo Page 11 of 116

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