PRODUCT AND INDUSTRIAL DESIGNE

INRODUCTION TO THE INDUSTRIAL DSIGNE

Materials Technology III

Classification and properties of various alloys, (a) Plain carbon steel (b) Low alloy steels (c) Stainless steels (d) Aluminum alloys (e)Copper alloys (f) Mg, Ti and Ni alloys. Uses of the alloys in following fields of engineering (1)surgical industry, (2) aerospace industry and other industries Material selection for design of various products using metallic materials Comparison of metallic materials with other materials

MANUFACTURING OF PIG IRON

Blast furnace is used for the manufacturing of pig iron from iron ore. Smelting of iron ore takes place for this purpose. It runs for 5-7 years continuously having daily capacity of 600 -1000 tons of pig iron per 24 hours. It has 30 m height and 6m in dia.

1. Hot blast from stoves 2. Melting zone (bosh) 3. Reduction zone of ferrous oxide (barrel) 4. Reduction zone of ferric oxide (stack) 5. Pre-heating zone (throat) 6. Feed of ore, limestone, and coke 7. Exhaust gases 8. Column of ore, coke and limestone 9. Removal of slag 10. Tapping of molten pig iron 11. Collection of waste gases

Fe2O3 + 3CO 2Fe + 3CO2 CO2 + C 2CO

Blast furnace placed in an installation 1. Iron ore + limestone sinter 2. Coke 3. Elevator 4. Feedstock inlet 5. Layer of coke 6. Layer of sinter pellets of ore and limestone 7. Hot blast (around 1200C) 8. Removal of slag 9. Tapping of molten pig iron 10. Slag pot 11. Torpedo car for pig iron 12. Dust cyclone for separation of solid particles 13. Cowper stoves for hot blast 14. Smoke outlet (can be redirected to carbon capture & storage (CCS) tank) 15: Feed air for Cowper stoves (air pre-heaters) 16. Powdered coal 17. Coke oven 18. Coke 19. Blast furnace gas downcomer

Iron and its alloys

Iron ore. Processing of iron ore in blast furnace. It leads to the production of PIG iron. Pig iron is further treated to produce a) Cast Iron b) steel

Cast Iron
grey cast iron White cast iron Malleable cast Iron Alloy Cast Iron Ductile Cast Iron Chilled cast Iron Meehanite Cast Iron

Steel
Steel is an alloy that consists mostly of iron and has a carbon content between 0.2% and 2.1% by weight, depending on the grade. Carbon is the most common alloying material for iron, but various other alloying elements are used, such as manganese, chromium, vanadium, and

Steel
Tungsten. Carbon and other elements act as a hardening agent, Varying the amount of alloying elements and the form of their presence in the steel controls qualities such as the hardness, ductility, and tensile strength of the resulting steel. Steel with increased carbon content can be made harder and stronger than iron, but such steel is also less ductile than iron.

Steel
Types of steels
The carbon steel may be divided into two groups a) Free cutting steel b) Plain carbon steel Free Cutting Steel Free cutting steel, these consists of B1111, B1112 and B1113 they differ in S content. High S content in theses grades promotes machineability. High S and P content leads to some problems.

Free Cutting Steel

Poor properties
1. 2. 3. 4. 5.
1. 2. 3. 4.

Poor welding Low conductivity Low malleability Poor fatigue Brittle under impact load.

Good Things
High machineability High quality surface finish in machining Tool life is 2-2.5 times greater than when carbon steels of the same carbon content are machined These steels are more susceptible to corrosion

Plain Carbon Steel

It consists of basic open hearth steel from C1006 to C1095 These are cheaper than alloy steels but adequate in properties These are of higher purity, and perfect for Heavy rails, structural shapes for building and bridges, boiler plates, axels, gears etc.

Plain Carbon Steel

Plain carbon steels are classified according to their carbon content Low carbon steel or mild steels ( .15 - .30 %) Medium Carbon steel ( C= .3 - .8 % ) High carbon steels ( C= .8 1.5 % )

Types of Steel according to De-Oxidation Practice

Killed Steel:
These are strongly deoxidized characterized by high composition and property uniformity. Forging steels are killed steel and contain .25 % C

Semi Killed Steel:

C % .15 to .25 and in semi killed steel the aim is to produce metal free from surface holes. Surface should have sound skin of considerable thickness

Rimmed steel:
Partially deoxidized and less than .15 % C, aim is to produce clean surface in low carbon steel. It is good for deep drawing. These steels are ideal for rolling . The good cold forming characteristics

MANUFACTURING OF STEEL
The different grades of steel are manufactured by the following processes a) b) c) d) e) f) g) h) Cementation Process Crucible process Bessemer Process Open Hearth Process Electric Steel Making Process L D Process Duplex process Kaldo process

BOS OR LD PROCESS
The basic oxygen furnace or LD converter (originating from the Linz-Donawitz process started in 1956) is based on oxygen injection by a lance into the melt of hot metal. Scrap and lime are charged into the converter to cool the melt and remove phosphorus, silicon and manganese. The converter is lined with dolomite or magnesite refractory which best resists erosion by slag and heat during oxygen blowing. The life of a converter lining is about 800 to 1400 heats. The oxygen burns out the carbon as carbon monoxide CO and carbon dioxide CO2 gas which is collected in the chimney stack and cleaned of its dust (Fe203, and lime particles, etc.). The elements Mn, Si and P are oxidized and combine with lime (CaO) and FeO formed by the oxidation of Fe to form a molten slag.

BOS OR LD PROCESS
As these oxidation reactions are highly exothermic, the process needs cooling in order to control the temperature of the melt. This cooling is done by charging scrap (recycled plant and mill scrap) and by adding iron ore during the blowing process. The oxygen blowing takes 15 to 20 minutes, regardless of the size of the converter (70 to 400 t) because the oxygen flow rate of the lance is adjusted to the melt weight. The charging and discharging of steel and slag, including sampling for temperature and analysis of the melt, extends the tap to tap time of a converter to 40 60 minutes. The process is characterized by high productivity and steel of low impurity content.

BOS OR LD PROCESS
The steel is tapped to the ladle through a taphole by tilting the furnace. During this operation ferroalloys for control of the steel composition are added to the ladle. A major development in the oxygen lance blowing technique, known as Lance Bubbling Equilibrium (LBE) was developed in the midseventies and has been widely adopted. Neutral gas, typically argon, is injected through permeable elements in the bottom of the converter, stirring the melt and slag.

BOC

Electric Steel Making Process

In the electric arc furnace process, the cold metallic charge, mainly scrap, is melted by the energy of electric arcs generated between the tips of graphite electrodes and the conductive metallic charge. The three electrodes and the furnace roof are raised and swung away from the furnace shell to allow the charging of scrap. The electrodes maintain the arc in accordance with the voltage and current level selected to produce the desired power input at the desired arc length for melting and refining. As the noise generated by the arcs is high during the melt-in-period, special protection is provided to the operators cabin and the furnace has a special enclosure.

Electric Steel Making Process

The three phase AC current is supplied by the low voltage side (300 - 700V) of a high power transformer. The nominal transformer rating, expressed as KVA/t, extends from 300 to 500 KVA/t for high power furnaces and from 500 KVA/t upwards for Ultra High Power (UHP) furnaces. These furnaces have an inner diameter of 6 to 9 metres with a capacity of 100 to 200 tons of steel. The tap-to-tap time for these furnaces is 90 to 110 minutes. The traditional role of the EAF process is producing alloy, tool and carbon steels, and it has been extended by the UHP furnace to mass steel production. Thus, the concept of the Mini-Mill was born.