PRIMARY MATERIALS
1. IRON ORE
There are four types of iron ore :

Hematite is reddish color and contains 70% iron

Limonite is brownish color and contains 55% iron

Magnetite is grayish color and contains 40% iron

Taconite is hard rock and contains 33% iron
2. COKE

The second raw material used by the steel
industry is bituminous or soft coal.
Most
coal is mined deep in the ground.

Coal as it comes from the earth cannot be used
in the iron-making furnace.

It must first be changed into coke.
COKE OVEN
3. LIMESTONE

is the third raw material needed in making
iron and steel. It is obtained from quarries.

Limestone acts as a kind of chemical
sponge in the blast furnace and steelmaking furnaces.

It takes up impurities liberated during the
furnace operations to form a scum called
slag
Steel classification



Molten iron as it comes from the blast furnace has some
impurities.
To change the iron into steel, the impurities must be turned out.
It is done in three different kinds of furnaces
Steel manufacturing process are:

1. Bessemer converter

2. Open hearth furnace

3. Electric furnace
BESSEMER CONVERTER (CAPACITY 25 TON)
OPEN HEARTH FURNACE (CAPACITY 130-550 TON)
ELECTRIC FURNACE (CAPACITY 100 TON)
I. PRIMARY MATERIAL

A. Primary industry: an industry involved in the initial
processing of raw materials into standard stock

B. Primary material : a material in the form of
standard stock which is utilized in secondary
processing

C. Processing of material
1. Extraction: open pit mining operations for most
metals ( magnesium is converted from sea ) water



2. Refining: ore is a compound of metal and oxygen
or sulfur ore is refined to remove unwanted
minerals

3. Converting: Metal oxides are reduced to pure
metals via blast furnace or electrolysis Pure metals
are in the form of pigs (iron) and are processed to
make steel ingots

4. Steel ingots and nonferrous ingots undergo
various deformation processes to produce
standard stock forms.
II . PROPERTIES OF METALS

A. Tensile strength :Ability of metal to resist being pulled apart

B. Ductility: Ability of a metal to be changed in shape without breaking

C. Toughness :The property that enables a metal to withstand heavy impact
forces of sudden shock without fracture

D. Hardness : Property of metal to resist indentation, penetration or scratching

E. Malleability : The ability of a metal to be permanently deformed by rolling,
pressing or hammering

F. Machine-ability :The ease or difficulty of cutting metal with a cutting tool.
III. FERROUS METALS
A. Cast Iron
 B. Carbon Steels
 C. Alloy Steel
 D. Metal Numbering System

III. FERROUS METALS
A. Cast Iron

1. Gray cast iron
1.7% to 4.5% carbon, 1% to 3% silicon
Heat resistance, wear resistance, Corrosion resistance

2. White cast iron
Low ductility, compressive strength is high (200,000
PSI) Low resistance to impact load Maximum wear
resistance

3. Chilled cast iron
Gray iron castings with edges of white cast iron Rapid cooling
results in the formation of cementite and white cast iron along the
edge.
 4. Alloy cast iron
Gray or white casting with alloying elements
Increase in properties such as: strength, wear, corrosion,
heat resistance Tensile strength is above 70,000 PSI
 5. Malleable cast iron
Produced by annealing of white iron castings
 6. Nodular cast iron (Ductile iron)
(Also known as spheraidal graphite iron) Alloyed
with magnesium or cerium . Tensile strength is
60,000 to 80,000 PSI
B. CARBON STEELS

1. General Characteristics
Iron with carbon content of 0.05 % to 1.5%; as carbon content
increases, hardness and tensile strength increases and ductility and
weld ability decrease.

2. Classification of Carbon Steel

low-carbon steel (mild steel)
carbon content 0.05% to 0.30%; tensile strength 51,000 - 70,000 PSI

Medium-carbon steel
carbon-content 0.30% to 0.6%; tensile strength 70,000 to 98,000 PSI

High-carbon steel (tool steels)
carbon content 0.60% to 1.5%; tensile strength 98,000 to 142,000 PSI
C. ALLOY STEEL

1. Over 25 common alloying elements exist

2. Alloying effects of manganese
Increases from 0.30% to 1.5%; so does hardenability,
strength, toughness, shock resistance.

3. Alloying effects of nickel
Increases from 3% to 3.7%; so does wear, corrosion
resistance, toughness, and strength.

4. Alloying effects of chromium
Increases from 0.3% to 1.6%; chromium steels
require additional hardening.

5. Alloying effects of molybdenum
Increases up to 9%; so does toughness and shock
resistance; in addition, heat treatment and hardenability
would be improved.

6. Alloying effects of vanadium
Increases from 0.03% to 0.20%; so does tensile strength,
yield strength, wear resistance, and impact toughness.

7. Alloying effects of cobalt
Increases from 5% to 12%; so does hardness and wear
resistance.

8. Alloying effects of tungsten
Improves heat treatment quality and wear resistance.
D. METAL NUMBERING SYSTEM

Classification System
B:
C:
D:

Bessemer Steel
Open-Hearth Steel
Electric Furnace Steel
Steel Numbering System
Four digit number
First number indicates alloy group
Second number indicates impurity limits
Last digits indicates specific alloy or purity

Steel Numbering System
10XX plain carbon steel
11XX sulfurized free cutting carbon steel
13XX manganese steels
20XX nickel steel
31XX nickel-chromium steels
41XX molybdenum steels
50XX chromium steel

Explanation: Example C1020
20/100 x 1% carbon
= .2 x 1%
= .2 x .01
= .002
= .02 %
IV. NONFERROUS METALS
A. Copper-base alloys
 B. Nickel-Base Alloys (Incanel metal)
 C. Aluminum-Base Alloys
 D. Zinc

IV. NONFERROUS METALS
 A.
Copper-base alloys
1.
Brass
Red brass (cartridge brass) (5 - 20% zinc)
Yellow brass (20-36% zinc)
Architectural brass (40% zinc)
Naval brass (39% zinc and 1% tin)
Manganese brass (39% zinc plus iron)
has high strength and excellent wear
Lead brass - increase in machinability

2. Bronze (Copper and Tin)
aluminum bronze - strength range 80,000 –
100,000 PSI
silicon bronze - high strength, corrosion
resistance
beryilium bronze - tensile strength 200,000 PSI
 B. Nickel-Base Alloys (Incanel metal)
1. Nickel has good oxidation and corrosion resistance
and
also resistance at high temperatures.
2. Nickel Silver
alloy of copper, nickel and zinc 60-99% nickel
 C. Aluminum-Base Alloys
1. Alloying elements are copper, manganese,
chromium, iron, nickel, zinc, titanium
2. PROPERTIES OF ALUMINUM-BASE ALLOY
Excellent machine-ability; Low weight;
Heat treatable; Suitable for hot and cold
forming processes.
D. Zinc
Low melting point of (750-800 °F)
Excellent for die casting
Moderate strength and toughness
Inexpensive
IV. PLASTIC AS AN INDUSTRIAL MATERIAL
1)Thermosetting
 2)Thermoplastics
 3) Elastomer

IV. PLASTIC AS AN INDUSTRIAL MATERIAL
A.




MAJOR CLASSIFICATIONS
1)Thermosetting
a) Formed to shape with heat and sometimes pressure.
b) When set, the product is permanently hard.
c) Heat causes chemical action (polymerization), which
causes plastic to become irreversibly hard.
2)Thermoplastics
 a) Will consistently remain soft at elevated
temperatures and harden when cooled.
 b) Exhibits no chemical change in molding
cycle.
 c) Will not harden with pressure and heat, but
may be recycled

ELASTOMER
The term elastomer is often used
interchangeably with the term rubber.
 Elastomer comes from two terms, elastic
(describing the ability of a material to return to
its original shape when a load is removed) and
mer (from polymer, in which poly means many
and mer means parts).


RAW MATERIALS
a) Agricultural products
b) Minerals such as limestone, silica (a form of silicon) and sulfur.
c) Organics such as coal, gas, petroleum
d) Color pigments - provide desired color
e) Solvents - soften and improve flow-ability in mold.
f) Lubricants - improve molding characteristics
g) Fillers - minimize shrinkage, improve heat resistance and impact
strength, reduce manufacturing costs
 Examples: wood powder, flour, cotton, rag fibers, asbestos, powder
metals, graphite, glass, clays
THERMOSETTING COMPOUNDS

1. Phenolics
hard, high strength, durable; derived through reaction of
phenol with formaldehyde.
(Particle board, Laminated parts, Electrical parts
,Household)

2. Amino resins –
principally ureaformaldehyde and melamineformaldehyde
Widely used as adhesives for laminating wood and
paper.
(circuit breakers, Table wear, Ignition parts)

3. Furane
Derived through processing of corn cobs, rice hulls, and
cotton seeds with acids. Resins are water resistant, have
good electrical properties.
( Binding agents for floor, Hardening agents for plaster
and graphite)

4. Epoxides
Principal characteristics include: low shrinkage, good
chemical resistance, excellent electrical characteristics,
high strength, excellent adhesive properties, high wear
and impact resistance.
( Casting, Laminating, Paint ingredient Printed
circuit boards)

5. silicones
principal characteristics include: high temperature
resistance, low temperature performance, high
electrical
characteristics, high water resistance, low coefficient
of
friction, high shock resistance, high cost
TERMOPLASTIC COMPOUNDS
1. cellulosics –
derived through treatment of cotton and wood
fibers. low density compounds, highly resistant to
alkalies

2.polystyrene
Formulated for injection molding and extrusion
low gravity, resistant to water and chemicals, high
insulation ability excellent rubber substitute for
electrical insulation


3. polyethylene
Flexible at room and low temperatures, high water and
chemical
resistance
suitable for injection molding, blow molding and extrusion into
sheets, films,

4 . polypropylene (PP)
excellent electrical properties, high impact and tensile
strengths,
high resistance to heat, high resistance to chemicals

5. ABS plastics
Chemical compound of acrylonitrile, butadiene, and
styrene may be compounded to have a very high degree
of hardness or high flexibility and toughness, high
flexibility and toughness good moisture resistance

6. polyamide
available in solid, film, or solution form ,extremely high
heat resistance (750 F or 400 C) low coefficient of
friction, high radiation resistance. good electrical
properties

7. Nylon (polyamides)
good tensile and impact strengths, good heat
resistance , good moisture resistancegood
electrical properties.

8. Acrylic resin (methyl methacrylate), Lucite
(DuPont) excellent light transmission qualities ,
high resistance to moisture ,easily fabricated
Have a good day