Subject

Basic Technology

Topic
Processing of materials
Sub-Topic

METAL
Class
JSS3
Performance Objectives
At the end of this class, You should be able to:

 Describe different ways of processing,

 Explain the advantages and disadvantages of the different

metal processing methods.

 Identify metal alloys.

 Explain the uses of common metal alloys.

Metal is produced from iron-ore
(mineral-ore usually occurring in rocks).

The first stage in the production of

metal is Extraction.

The iron -ore is dug up or mined from

the ground using drilling and
excavating equipment.

Ore
In its natural state the iron-ore
extracted from the ground cannot be
used because it contains lot of
impurities. For pure metal to be
obtained from the iron-ore(impure
metal), the iron-ore have to be
processed during which the impurities
are removed and other substances are
added
Method of Processing metals
The six basic methods of processing metals include the following:

i. Smelting

ii. Casting

iii. Alloying

iv. Forming

v. Shaping

vi. Finishing
Smelting

Blast Furnace: Smelting simply refers to the

technique of removing impurities from iron ore.

The blast furnace is a smelting (burning) plant

used for processing iron ore into pig –iron. To

smelt iron – ore in the blast furnace, other

chemicals like coke (which serves as fuel) and

limestone (which removes impurities) are added to

the iron – ore so that most of the impurities may

be removed.
The molten iron is then cooled to form the first metal called pig iron

The pig iron in it state cannot be used until further processing because the
pig iron contains saturated iron and carbon(3% to 5% carbon) and also due
to it poor electrical, magnetic and physical properties.

Production of steel

The further processing of pig-iron yields a new product called steel(which

contains less than 2% of carbon)

The furnace used for this purpose is called “Bessemer converter”

The Bessemer converter:

This is the furnace used for smelting pig – iron into

steel by further burning off of impurities in the
right percentage. It was developed by Henry
Bessemer. Since steel is categorized into three
groups, the Bessemer converter is used for this
purpose. When pig iron is fed into the Bessemer
converter, it de-carbonises it to obtain various
grades of steel as either low, medium or high
carbon steel.
Bessemer converter
Classes of steel and their application

Mild or low carbon steel: contains 0.05% to 0.3% carbon. it has low tensile
strength and it is used for car bodies and light structure.

Medium carbon steel: it carbon content is between 0.3% - 0.6%. Mainly used
for making light springs and power transmission device.

High carbon steel: it is usually very hard. it carbon content is between 0.9%
and 1.4%. it is used for making cutting tools like files, punches, chisel

Apart from the Bessemer converter, other furnaces used for smelting iron-
ore to steel are:
The basic oxygen furnace

In this furnace, scrap metal is used to charge the

system before molten metal is introduced. Oxygen is
forced into the furnace through a water-cooled
lance. At a point lime is added to act as flux in the
furnace This system is used for producing stainless
steel

Advantages

• Uses heat of molten iron as energy source

therefore saving cost and energy

• Production cost for steel is less for large scale

production as compared to other furnace

• It’s a faster for mass production

Disadvantages

 The initial cost of setup for basic oxygen furnace is very high
because it needs a blast furnace

 Costly for small production

 Produces high amount of polluting gases as compared to other

furnace
The electric-arc furnace for cast iron products

Another alternative to producing steel is to feed

steel scraps into the electric arc furnace. This
furnace has three carbon electrodes which are
electrically powered for heating scrap and molten
metal for producing stainless steel. Lime, fluorspar
and iron oxide are added at a point. Depending on
the class of metal to be produced alloying materials
are added to a correct proportion
Advantages
 doesn't require large amounts of fuel for combustion
 improved efficiency

Disadvantages
• The quality of molten steel is greatly affected by scrap steel
• the smelting period is longer.
• the power consumption is large.
Open hearth furnace

In this furnace pig iron and scrap are stored in a large hearth. It
makes use of hot gas and air to melt the content put into it.
Ferromanganese is added to make the correct aggregate of
stainless steel.

Advantages

• Produces high quality and wide variety of smelted steels,

• The process is easier to control and sample for quality

assessment.
Disadvantages

 Very slow compared to the Bessemer furnace

 Greater cost of operation than the Bessemer

converter due to cost of labor, repairs and fuel

This three methods listed above make use of iron

oxide at high temperature (16000 C) to remove
impurities from pig iron into steel or stainless
steel.
Casting
metals are cast into shapes from the molten stage.

The hot molten (liquid) metal is poured into container of different sizes
called mould. It is left there to solidify and take up the shape of the
mould. This is called casting.

Casting can be done in many ways, these include:

 Pressure die-casting,

 Investment casting,

 Sand casting.
Alloying
This is the mixing of two or more metals to obtain an improved metal.

This process is carried out so as to improve the quality of certain metals in

engineering.

Usually a base metal, known as the parent metal, has up to 90% of the
alloy material while the other 10% are just alloying agents.

For example:

i. Bronze = copper (78% to 95%) +tin(5 to 22%) +aluminum(5 to 20%)

ii. ii. Brass = Copper (10 to 35%) + Zinc (5 to 22%)

Importance of Alloys

1. For strength.

2. Wear resistance.

3. It provides hardness.

4. Corrosion-resistance.
 Some Alloys, Properties and Applications

S/No Name of Alloy Main Property Applications

1 Cast Iron Brittle metal It is used for making automobile
cylinders and pistons
2 High Carbon Steel It is worked upon in Used for making tools like
hot forming like punches, hammer heads, saws,
forging and it is easily chisels.
tempered
S/No Name of Alloy Main Property Applications
3 Low and Medium A group of Used for making structural steel
Carbon Steel malleable and work, automobile and vehicle
ductile metals. parts

4 Silicon steel Contain very good Used for making laminations in

magnetic property. the construction of transformers

5 High speed steel It can withstand Used for making drill bits and
very high other cutting tools used on the
temperature lathe
without losing its
hardness.
6 Chromium steel High resistance to Best for making stainless steel
rust and corrosion. products like surgical and cutlery
products.
Forming:
This is the method of processing metal either hot or cold into geometrical
shapes by applying compressive or tensile forces of deformation. forming
can be classified into two types

Compressive forming: This is the use of pushing force to change the

original shape of metal to a desired shape.

Tensile forming: This is the method of using a pulling force to change the
shape of a metal. This may include stretching, expanding and recessing of
metals.
Shaping:
This aspect of processing metals involves the use of the lathe
machine to carry out operations such as milling and turning

Metals can be shaped either by bending, twisting, upsetting and

drawing down
 Twisting: This is a
beautification
process in forging
operation.

Upsetting metal for increasing

thickness of metal e.g processing
of bolt head

Bending: Most metalwork project involves bending and

folding, either cylindrically or as square-box shape. This
changes the shape of the metal.
Finishing:
This is the technique of giving metal work a
protective coat, smooth edges and surfaces in
addition to an acceptable , improved final
appearance.

Types of Metal Finishing

a. Buffing: This is the method of using wheels

covered with soft cloth or leather to polish the
surface of metal. buffing
b. Lacquering:

This is the application of lacquer to metal

surface to prevent corrosion.

lacquering
c. Enameling:

This is the application of corrosion-

resistant material, like glass, on metal to
make the surface glossy and hard. E.g.
cooking vessels, steel sinks, and cast-iron
bathtubs
Enamelling
d. Scratching:

This is the use of a thin metal piece and

steel brush for cleaning metal parts
thoroughly to be finished.

e. Electroplating:

This is the protective coating of a metal

with other metal such as tin, zinc or
chromium so as to prevent corrosion.
 Advantages and Disadvantages of the
Processing Methods

Advantages and Disadvantages of Smelting

Advantages Disadvantages

1. Smelting has high adaptability. .It is not easy to easily recycle impurities.

2. It contains high hearth efficiency. There is always threat of environmental

pollution

3. Smelting maintains high thermal efficiency.

 Advantages and Disadvantages of
Casting

Advantages Disadvantages
1. It has better surface finish. The raw materials are relatively
expensive.
2. It has better dimensional tolerances. The process generates noxious fumes
which must be removed.
3. The process can be mechanized. The size and weight range of castings is
limited.
 Advantages and Disadvantages of
Alloying

Advantages Disadvantages

1. Alloying provides alternatives to some Since alloying involves fusing of metals,

costly precious metals. e.g. brass is used as radiation and heat can be hazardous.
alternative to gold.

2. Alloying improves the properties of the In alloying, the alloyed metal is usually costly
base metal. than the base metal.
 Advantages and Disadvantages of Forming

Advantages Disadvantages

1. The process and material is cheap. Most of the parts cannot be made in one
step, most of them need about 3+ steps

2. High efficiency, it can be produced one Complicated shape need lots of tooling.
piece/second.
 Advantages and Disadvantages of Shaping

Advantages Disadvantages

1. In shaping, products have accurate and Metals worked upon using the shaping process
perfect dimensions. gets weakened by the shearing forces of cutting
tools.

2. The machining process can be Special skill is required in shaping. It also needs
automated and computerized so at reduce time and proper supervision. This increases the
labour cost. cost of production at the end of the day.
Evaluation
1. What is iron–ore?

2. How is pig– iron produces from iron – ore

3. State at least three types of furnaces for producing steel.

4. State at least three classes of steel.

5. What is an alloy of metal?

6. State one advantage and disadvantage of the following processing

methods:

(a). Forming (b). Casting (c). Alloying (d). Shaping.

Thank You
For Watching!