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Metals are natural materials that

- Have good conductivity

- Are malleable

- Have a shiny appearance when polished

2 Types of Metals

- Ferrous (consists of Iron)

- Non-Ferrous (contains no Iron)

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List of Ferrous Metals

Steel

- Stainless Steel

- Mild Steel

- High Carbon Steel

- High Speed Steel

Cast Iron

Any Alloys containing Iron

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List of Non-Ferrous Metals

Aluminium

Copper

Lead

Nickel

Tin

Titanium

Zinc

Gold

Any Alloys not containing Iron

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Alloys are metals that consist of two or more metals into one metal. This is done to get the best properties from one metal and the best properties from another metal into one metal.

List of Alloys
• Brass (Copper + Zinc)
• Bronze (Copper + Tin)
• Solder (Lead + Tin)
• Steel (Iron + Carbon)

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If you leave Iron or Steel outside in the rain, it will corrode or rust.

Ways to prevent corrosion or rust:

Painting the Material

Dipping it in powder plastic

Galvanising it (cover it with Zinc)

Anodize it

Lacquer it

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Properties are characteristics of metals

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This property allows a material to be extended in all directions without rupture.

It is usually increased by heat.

E.g. Lead

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A material that will not be marked or scratched easily

E.g. Cast Iron and Diamond

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This property enables a material to withstand blows or an impact.

The amount of energy it takes to fracture is an indicator of toughness.

E.g. Brass

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A material is ductile when it can be permanently stretched without fracture.

A metal must be ductile to enable it to be drawn into wire.

E.g. Copper

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The opposite of tough.

A brittle material can be easily fractured by impact

E.g. Glass, Perspex (Acrylic)

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This is the ability of a material to allow heat or electricity to flow through it.

E.g. Silver, Copper, Tungsten and Aluminium

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Non-Conductive

E.g. Rubber and Wood

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A material that can't be stretched or squashed easily

E.g. Steel

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This is the ability of a material to return to it's original shape when freed from a force that was distorting it.

E.g. Spring Steel

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The Basic Oxygen Furnace is the most common way in which Steel is produced in the world.

There are 6 main steps in how Steel is produced in this furnace.

1. First, scrap Iron and Steel are fed into the furnace

2. Molten Pig Iron is then poured into the furnace.

3. The Oxygen Lance is then lowered into the furnace for oxygen to be blown into the furnace to increase the heat. The oxygen also makes slag in the furnace.

Water runs through the lance to stop it from melting in the furnace.

4. Samples are taken from time to time to check the quality of the Steel.

5. the lance is removed and rolled on it's side to allow the Molten Iron to be poured through the tapping hole.

6. Then it is rolled over to allow the slag to be poured out of the slagging hole.

In the past, a blacksmith used a hand bellows to make the forge hotter. This is the same.

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End Result: Steel for general use

A charge of Iron and Scrap Steel is fed into the furnace.

The Carbon Electrodes are then lowered into the furnace and current is supplied through the power cables.

The current jumps or arcs from the tips of the Electrodes onto the Iron and Steel. This produces heat and causes the metals to melt.

Like the Basic Oxygen Furnace, samples are taken from time to time to check the quality of the Steel.

When it is time to remove the slag, the backdoor is opened allowing the slag to flow out.

Once the slag is gone, the furnace is tilted forward allowing the Molten Steel to flow out through the Tapping Hole.

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End Result: Pig Iron

A charge is made up of Iron Ore.

Limestone and Coke is put in the furnace.

Hot air is blown into the furnace by the tuyere to increase heat.

The fire bricks (aka Refractory Lining) help keep the heat in the furnace.

As the mixture melts, Molten Iron sinks to the bottom of the furnace.

The Limestone makes the waste (Slag) float on top of the Molten Iron.

The Slag is taken out of the furnace from time to time. (It can be used as a fertilizer for farming)

The Molten Iron, now known as Pig Iron, is removed from the furnace.

How does it keep heat in?

Cup and Cone Arrangement.

This is made up of two cones that can be raised and lowered.

When the furnace is off they are pulled up and the furnace is air-tight.

When you add more charge, only the top cone drops down.

Since the bottom cone is still pulled up, the heat has not escaped.

Once all the charge is loaded in, the top cone is pulled back up.

Now the bottom cone is dropped down and all the charge falls into the furnace.

Once all the charge is in the furnace the bottom cone is pulled back up.

When Pig Iron comes out of The Blast Furnace, it is very brittle and has no use in industry. It must first be refined in another furnace to turn it into steel.

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Plasticity is the ability of a solid material to undergo plastic deformation without fracture.

A metal needs to be plastic when it is being forged.

The plasticity of metals can be increased by heating them.

E.g. Coins (Copper Nickel and Zinc) and Copper Wire