btech metals

• Metals


  Elementary substances which are crystalline when solid, characterized by opacity, ductility, conductivity, and luster
• Ferrous metals


  Metals having iron as base metal
• History of ferrous metal development


  1. 1000 B.C: Wrought iron used for sculptures and weapons

  2. 5th-15th Century: Development of blast furnace

  3. End of 15th Century: Cast iron developed for cannons

  4. 1700's: Invention of Coke (Coal-Cake)

  5. 1784: Wrought iron further developed by Henry Cort

  6. 1856: Bessemer Process introduced and began mass production of Steel
• Types of ferrous metals


  • Cast Iron
  • Malleable Cast Iron
  • Wrought Iron
  • Steel
• Cast Iron


  • Hard, brittle, non-malleable (non-shapeable or formed by hammering or pressure) iron based alloy with carbon, 2.0% - 4.5%, and silicon, casted in sand mold and machined
• Malleable Cast Iron


  • Cast iron annealed by transforming the carbon content into graphite or removing it completely
• Wrought Iron


  • Tough, malleable, relatively soft iron that is readily forged and welded, having a fibrous structure containing approximately 0.2% carbon and small amount of uniformly distributed slag
• Steel


  • Iron-based alloys having a carbon content less than that of cast iron and more than that of wrought iron
• Advantages of ferrous metals


  • Sturdy and rigid
  • Durable
  • Recyclable material
  • Time saving
  • High strength to weight ratio
  • Versatile
• Disadvantages of ferrous metals


  • Low tolerance to heat which requires fire proofing
  • High production cost
  • Deteriorates by oxidation
  • Heavy (7850 kg/m3)
  • High thermal expansion
• Production of steel


  1. Raw Iron Ore + Coal (undergoes destructive distillation on coke oven) = Coke (used as fuel)

  2. Raw materials + Limestone (used as a flux or cleaning, flowing or purifying agent) = Direct Reduction (Output: Solid, Metallic Iron) + Recycled Metal

  3. Direct Reduction + Electric Arc Furnace + Blast Furnace (Hot air blasted for smelting, Output: Pig Iron) + Blast-Furnace Slag = Basic Oxygen Furnace (Output: Molten Steel)

  4. Molten Steel = Steel Refining Facility
• Pig Iron


  Crude iron that is drawn from a blast furnace and cast into pigs in preparation for conversion into cast iron, wrought iron or steel
• Ingot


  A mass of metal cast into convenient shape for storage or transportation before further processing
• Blooms


  Round or square, more than 230 cm2 in cross-sectional area (≈15cm x 15cm)
• Billets


  Round or square, less than 230 cm2 in cross-sectional area (≈15cm x 15cm)
• Steel working methods


  • Hot-Working (Hot-Rolled, Casting, Die Casting, Forge)
  • Cold-Working (Cold-Rolled, Extrusion, Cold-Drawn)
• Hot-Working


  Metal working at a temperature high enough to permit the metal to recrystallize, to acquire a new granular structure with new crystals because of plastic deformation
• Cold-Working


  Metal working below the temperature at which recrystallization occur
• After production treatment


  • Heat Treatment (Annealed, Quench, Tempered, Case-Hardening)
  • Cladding/Plating
• Cladding/Plating


  Bonding one metal to another; usually used to protect the inner metal from corrosion
• Methods of cladding metals

  • Electroplating
  • Dipped/Dipping
• Types of cladding


  • Sacrificial Anode (Anodize by Electrolysis: Aluminum or Magnesium)
  • Chrome Plate (Chromium)
  • Galvanize or Hot-Dip Galvanize (Zinc)
  • Tin Plate (Tin)
  • Terne Plate (80% Lead, 20% Tin)
• Carbon Steel


  Unalloyed steel with residual elements, such as carbon, manganese, phosphorus, sulfur, and silicon, are controlled
• Types of Carbon Steel

  • Mild steel or soft steel (0.15% - 0.25% carbon)
  • Medium steel (0.25% - 0.45% carbon)
  • Hard steel (0.45% - 0.85% carbon)
  • Spring steel (0.85% - 1.80% carbon)
• Alloy Steel


  Carbon Steel + Chromium, Cobalt, Copper, Manganese, Molybdenium, Nickel, Tungsten, or Vanadium
• Types of Alloy Steel

  • Stainless Steel (12% chromium, highly resistant to corrosion)
  • High-Strength Low-Alloy Steel (low-carbon steel, less than 2% alloys, for increased strength, ductility, and resistance to corrosion)
  • Weathering Steel (high-strength, low-alloy steel, forms an oxide coating which adheres firmly the base metal)
• Steel products


  • Merchant Bars (I-Beam, Wide Flange, HP-Shape, Channel, Angle, Structural Tee, Zee, Bars, Structural Tube/Pipe)
  • Reinforcements (Deformed Reinforcing Bar, Threaded Steel Bars, Wire Fabric, Corrosion-Resistant Reinforcement, Prestressing Materials)
  • Metal Sheets (Plain sheets, Corrugated Metal, Metal Decking, Expanded Metal, Checkered Plate, Black Plate)
• Merchant Bars


  Common steel shapes that consists of rounds, squares, flats, strips, angles and channels, which fabricators, steel service centers and manufacturers cut, bend and shape into products
• Types of Merchant Bars

  • S-Shape or I-Beam
  • Wide Flange or W-Shape
  • HP-Shape
  • Channel
  • Angle or Angle Iron
  • Structural Tee
  • Zee or Z-Bar
  • Bars
  • Structural Tube/Pipe
• Types of Structural Pipe

  • Standard (Pipe Standard)
  • Extra Strong (Pipe X-Strong)
  • Double-Extra Strong (Pipe XX-Strong)
• Reinforcements

  • Deformed Reinforcing Bar (Rebar)
  • Threaded Steel Bars
  • Wire Fabric
  • Corrosion-Resistant Reinforcement
  • Prestressing Materials
• Deformed Reinforcing Bar (Rebar)


  A reinforcing bar hot-rolled with surface deformations to develop greater bond with concrete
• Standard Rebar Sizes


  • #3 (3/8 inches, 10 mm)
  • #4 (4/8 or 1/2 inches, 12 mm)
  • #5 (5/8 inches, 16 mm)
  • #6 (6/8 or 3/4 inches, 20 mm)
  • #8 (8/8 or 1 inches, 25 mm)
  • #9 (9/8 inches, 28 mm)
  • #10 (10/8 or 1 1/4 inches, 32 mm)
  • #11 (11/8 inches, 36 mm)
• Rebar Identification Markers


  • Rebar Color Coding (White for Grade 33, Yellow for Grade 40, Green for Grade 60, Red for Weldable Rebar)
  • Steel Types ("S" for Billet Carbon Steel, "W" for Low-Alloy Steel, "R" for Rail Steel, "A" for Axle Steel)
  • Main Rib/Lug
  • Producing Mill Symbol
  • Bar Size
  • Grade Mark
• Corrosion-Resistant Reinforcement


  • Epoxy-Coated
  • Galvanized
  • Stainless
  • Cathode Protection
  • Chemical and Mineral Protection
• Prestressing Materials


  • Seven Strand Wire
  • Wire
  • Bars
• Types of Metal Sheets

  • Plain sheets or Flat Sheets
  • Corrugated Metal
  • Metal Decking (Form Decking, Composite Decking, Roof Decking, Cellular Decking, Acoustic Decking)
  • Expanded Metal
  • Checkered Plate
  • Black Plate
• Metal Decking


  Strengthened for use on floor or root decking by cold-rolling a series of ribs or flutes into it, usually galvanized. Span capability depends on the thickness and depth of corrugations
• Metal Decking


  • Depends on the thickness and depth of corrugations
• Types of Metal Decking

  • Form Decking
  • Composite Decking
  • Roof Decking
  • Cellular Decking
  • Acoustic Decking