This document provides an overview of metallurgy and its history. It discusses the extraction and processing of metals through techniques like mineral processing, pyrometallurgy, hydrometallurgy, and physical metallurgy. The history of metallurgy is traced from early use of gold and copper thousands of years ago to modern developments in steel production and welding. Key events highlighted include the development of bronze and iron working and innovations in the 18th-19th centuries that enabled large-scale steel production.
Metallurgy is the study of physical and chemical behavior of metals and their alloys. The earliest evidence of metallurgy dates back 5000 years to ancient civilizations like ancient Egypt and Mesopotamia. Throughout history, metallurgy advanced with innovations like extracting copper and tin to make bronze around 3500 BC, and iron around 1200 BC. Metals are extracted from ores through processes like mining, crushing, concentration, and smelting, and shaped using techniques like casting, forging, rolling, and machining. The properties of metals can be modified through heat treatments and alloying with other elements.
Deoxidation is the process of removing residual oxygen from refined steel to prevent defects. Sources of oxygen in steel include rust, oxygen blowing during manufacturing, slag, and atmospheric oxygen during teeming. The kinetics of deoxidation involve the dissolution of deoxidizers like aluminum, their reaction with oxygen, and the nucleation and growth of deoxidation products. Effective deoxidizers are then removed from the steel through flotation and absorption into slag. Common deoxidizers include aluminum, silicon, and manganese. Calcium injection can be used to modify inclusions and produce cleaner steels.
CHAPTER 3 MINERALS ORES AND METHODES OF SEPARATION.pdfWeldebrhan Tesfaye
i. Introduction
ii. Minerals and ores
iii. Sources of metals
iv. Methods of beneficiation of ores and miners
a. Comminution
Size reduction by crushing and grinding
Minerals, ores and methods of beneficiation
Liberation
Laws of crushing and grinding
Sizing
b. Classification and concentration
c. Classification and concentration
d. Magnetic separation
e. Electro- static separation
f. Flotation
This document provides an overview of manganese extraction and metallurgy. It discusses the major manganese mineral pyrolusite and deposits in South Africa, which produces 80% of the world's manganese. Beneficiation processes for manganese ores include hand sorting, jigging, magnetic separation, and hydrometallurgical or pyrometallurgical processes to remove gangue and impurities. Agglomeration through briquetting, sintering or pelletizing improves ores for blast furnace processing to extract manganese metal.
This document provides information on the physical and chemical properties of zinc, as well as its various applications and production processes. Some key points:
- Zinc has a melting point of 419.6°C and boiling point of 906°C. It has a crystal structure of HCP and density of 7.14 g/cm3.
- Its main uses include galvanization to prevent corrosion, die casting due to its low melting point, and in producing alloys like brass and bronze.
- Zinc is extracted from zinc ores through mining, crushing, roasting, and pyrometallurgical or hydrometallurgical processes to produce zinc metal.
- Its alloys have applications in
Metals ions play critical roles in human health and disease. Some metals like iron, zinc, and copper are essential nutrients but can cause diseases if deficient. Iron deficiency leads to anemia, zinc deficiency causes growth retardation, and copper deficiency results in brain and heart diseases. However, some metals like mercury and lead are toxic even in small amounts and can damage organs. While metals like chromium, nickel, and cadmium are known carcinogens. Metals are found naturally in water and soil and their levels in the human body must be carefully regulated for health.
Metallurgy is a domain of materials science and engineering that studies the physical and chemical behavior of metallic elements, their intermetallic compounds, and their mixtures, which are called alloys. Metallurgy is also the technology of metals: the way in which science is applied to the production of metals, and the engineering of metal components for use in products for consumers and manufacturers. The production of metals involves the processing of ores to extract the metal they contain, and the mixture of metals, sometimes with other elements, to produce alloys. Metallurgy is distinguished from the craft of metalworking, although metalworking relies on metallurgy, as medicine relies on medical science, for technical advancement.
Metallurgy is subdivided into ferrous metallurgy (sometimes also known as black metallurgy) and non-ferrous metallurgy or colored metallurgy. Ferrous metallurgy involves processes and alloys based on iron while non-ferrous metallurgy involves processes and alloys based on other metals. The production of ferrous metals accounts for 95 percent of world metal production.
This document discusses phase transformations that occur during welding of different materials. It covers topics like weld CCT diagrams, carbon equivalent calculations for preheating requirements of steels, welding metallurgy of stainless steels, and Schaeffler and DeLong diagrams. The objectives are to understand weld metal microstructure development, factors affecting weldability, and predicting weld metal phase constitution. Keywords discussed include CCT diagrams, carbon equivalent values, Schaeffler and DeLong diagrams, and microstructures of welded joints.
Metallurgy is the study of physical and chemical behavior of metals and their alloys. The earliest evidence of metallurgy dates back 5000 years to ancient civilizations like ancient Egypt and Mesopotamia. Throughout history, metallurgy advanced with innovations like extracting copper and tin to make bronze around 3500 BC, and iron around 1200 BC. Metals are extracted from ores through processes like mining, crushing, concentration, and smelting, and shaped using techniques like casting, forging, rolling, and machining. The properties of metals can be modified through heat treatments and alloying with other elements.
Deoxidation is the process of removing residual oxygen from refined steel to prevent defects. Sources of oxygen in steel include rust, oxygen blowing during manufacturing, slag, and atmospheric oxygen during teeming. The kinetics of deoxidation involve the dissolution of deoxidizers like aluminum, their reaction with oxygen, and the nucleation and growth of deoxidation products. Effective deoxidizers are then removed from the steel through flotation and absorption into slag. Common deoxidizers include aluminum, silicon, and manganese. Calcium injection can be used to modify inclusions and produce cleaner steels.
CHAPTER 3 MINERALS ORES AND METHODES OF SEPARATION.pdfWeldebrhan Tesfaye
i. Introduction
ii. Minerals and ores
iii. Sources of metals
iv. Methods of beneficiation of ores and miners
a. Comminution
Size reduction by crushing and grinding
Minerals, ores and methods of beneficiation
Liberation
Laws of crushing and grinding
Sizing
b. Classification and concentration
c. Classification and concentration
d. Magnetic separation
e. Electro- static separation
f. Flotation
This document provides an overview of manganese extraction and metallurgy. It discusses the major manganese mineral pyrolusite and deposits in South Africa, which produces 80% of the world's manganese. Beneficiation processes for manganese ores include hand sorting, jigging, magnetic separation, and hydrometallurgical or pyrometallurgical processes to remove gangue and impurities. Agglomeration through briquetting, sintering or pelletizing improves ores for blast furnace processing to extract manganese metal.
This document provides information on the physical and chemical properties of zinc, as well as its various applications and production processes. Some key points:
- Zinc has a melting point of 419.6°C and boiling point of 906°C. It has a crystal structure of HCP and density of 7.14 g/cm3.
- Its main uses include galvanization to prevent corrosion, die casting due to its low melting point, and in producing alloys like brass and bronze.
- Zinc is extracted from zinc ores through mining, crushing, roasting, and pyrometallurgical or hydrometallurgical processes to produce zinc metal.
- Its alloys have applications in
Metals ions play critical roles in human health and disease. Some metals like iron, zinc, and copper are essential nutrients but can cause diseases if deficient. Iron deficiency leads to anemia, zinc deficiency causes growth retardation, and copper deficiency results in brain and heart diseases. However, some metals like mercury and lead are toxic even in small amounts and can damage organs. While metals like chromium, nickel, and cadmium are known carcinogens. Metals are found naturally in water and soil and their levels in the human body must be carefully regulated for health.
Metallurgy is a domain of materials science and engineering that studies the physical and chemical behavior of metallic elements, their intermetallic compounds, and their mixtures, which are called alloys. Metallurgy is also the technology of metals: the way in which science is applied to the production of metals, and the engineering of metal components for use in products for consumers and manufacturers. The production of metals involves the processing of ores to extract the metal they contain, and the mixture of metals, sometimes with other elements, to produce alloys. Metallurgy is distinguished from the craft of metalworking, although metalworking relies on metallurgy, as medicine relies on medical science, for technical advancement.
Metallurgy is subdivided into ferrous metallurgy (sometimes also known as black metallurgy) and non-ferrous metallurgy or colored metallurgy. Ferrous metallurgy involves processes and alloys based on iron while non-ferrous metallurgy involves processes and alloys based on other metals. The production of ferrous metals accounts for 95 percent of world metal production.
This document discusses phase transformations that occur during welding of different materials. It covers topics like weld CCT diagrams, carbon equivalent calculations for preheating requirements of steels, welding metallurgy of stainless steels, and Schaeffler and DeLong diagrams. The objectives are to understand weld metal microstructure development, factors affecting weldability, and predicting weld metal phase constitution. Keywords discussed include CCT diagrams, carbon equivalent values, Schaeffler and DeLong diagrams, and microstructures of welded joints.
Alloys used in metal ceramics /orthodontic courses by Indian dental academy Indian dental academy
Description :
The Indian Dental Academy is the Leader in continuing dental education , training dentists in all aspects of dentistry and
offering a wide range of dental certified courses in different formats.for more details please visit
www.indiandentalacademy.com
This document provides an overview of dental casting alloys. It begins with a brief introduction to the use of metals in dentistry and a history of important developments in dental casting alloys from 1907 to 1999. The document then covers interatomic bonds, physical properties, common metallic elements used in alloys, classifications of alloys, and descriptions of specific alloy types including gold casting alloys, metal ceramic alloys, and base metal alloys.
This document discusses phase transformations that occur during welding of different materials. It covers topics like weld CCT diagrams, carbon equivalent calculations for preheating requirements of steels, welding metallurgy of stainless steels, and Schaeffler and DeLong diagrams. The objectives are to understand weld metal microstructure development, factors affecting weldability, and predicting weld metal phase constitution. Keywords discussed include CCT diagrams, carbon equivalent values, Schaeffler and DeLong diagrams, and microstructures like grain boundary ferrite and Widmanstatten ferrite.
IN THIS PPT U WILL LEARN ABOUT THE FOLLOWING SUB-TOPICS OF MANGANESE:-
-Uses
-Distribution
-Eco Significance
-Reserves in India
-Agencies exploring it
-Problems related to its exploitation
-Marketing and Production strategy
-Export and Import
There are four main types of hydrides: saline (ionic), metallic, covalent, and dimeric. Saline hydrides contain hydrogen as a negatively charged ion that reacts violently with water to produce hydrogen gas. Metallic hydrides consist of hydrogen ions and metal atoms in an electron sea. Covalent hydrides involve shared electron pairs between hydrogen and nonmetals, forming volatile liquids and gases. Hydrides have many applications including use as reducing agents, bases, drying agents, and hydrogen storage in batteries and fuel cells.
This document discusses inclusion control for clean steel production. It defines inclusions as non-metallic compounds that form separate phases in steel. Strict inclusion control is important for producing quality steel products. Inclusions are assessed and controlled by examining their source, shape, composition and distribution. Common inclusions include oxides, sulfides, and carbides. Modification techniques aim to make inclusions less harmful by modifying their shape, composition and dispersion in the steel matrix. Calcium additions are often used to modify alumina and manganese sulfide inclusions. Proper inclusion control is important at all stages of steelmaking and processing to achieve clean steel.
The document discusses the extraction of iron and aluminum. Iron is extracted through carbon reduction in a blast furnace, while aluminum must be extracted through electrolysis due to its high position on the reactivity series. Both processes are described in detail, including inputs, reactions, and outputs. Recycling of metals is also discussed for its environmental and economic benefits.
1. Describes the principles of the Bessemer and basic oxygen processes used in the production of steel from pig iron, which involve blowing oxygen through pig iron to lower the carbon content and produce steel in a rapid process.
2. Explains centrifugal casting which involves rotating a permanent mold at high speeds to cast cylindrical shapes by throwing molten metal against the inner mold wall where it solidifies.
3. Describes cold working which refers to plastic deformation, usually at room temperature, that strengthens metals by reducing grain size but makes them more brittle.
Direct gold has been used as a dental restorative material since the 15th century. It exists in various forms such as gold foil, electrolytically precipitated mat gold, and granular gold. Gold is biocompatible with tissues and exhibits excellent marginal integrity due to its ability to be cold welded. It is durable but technique sensitive. While gold is highly durable when placed properly, it has disadvantages such as cost and lack of esthetics. Direct gold is best for small class I, II, III, V, VI cavities where esthetics is not a concern and occlusal forces are not heavy.
Corrosion and corrosion inhibition of aluminum and aluminum alloys in acid me...mohammed rida
This document provides an introduction to aluminum, its key characteristics, aluminum alloys, corrosion of aluminum in acid solutions, and corrosion prevention methods. It discusses the low density, strength, corrosion resistance, conductivity, and other beneficial properties of aluminum. It describes common aluminum alloying elements like copper, magnesium, silicon, and their effects. The document also examines various types of localized corrosion that can affect aluminum, such as pitting, crevice, and galvanic corrosion. Finally, it outlines approaches for corrosion prevention, including alloy selection, coatings, use of inhibitors, and design considerations.
This document discusses the differences between metals and non-metals. It defines metals as materials that are lustrous, malleable, and good conductors of heat and electricity. Non-metals lack these properties and include materials like carbon and sulfur. The document outlines several physical and chemical properties of metals and non-metals, such as their reactions with water, oxygen, acids, and bases. Metals react with these substances to form oxides, hydroxides, or salts, while non-metals generally do not react or only react under certain conditions.
The document describes various properties of metals. It discusses the physical properties of metals, including their high melting and boiling points, malleability, ductility, and ability to conduct heat and electricity well. It also describes alloys as mixtures of metals that are stronger than pure metals. Additionally, the document outlines some chemical properties of metals, such as their reactivity patterns and reactions with water, steam, and acids according to the reactivity series. It provides examples of equations to represent these reactions.
The document discusses the principles of metallurgy and metal extraction processes. It defines metals, non-metals and metalloids based on their properties. The processes involved in metal extraction include mining, crushing, concentration, roasting, reduction and refining. Concentration methods separate the metal ore from gangue using techniques like gravity separation, magnetic separation or froth flotation. Reduction converts the metal oxide into pure metal using carbon or aluminothermic processes. Refining further purifies the metal using techniques like liquation, distillation, electrolysis or poling. Overall, the document provides an overview of the key concepts and steps involved in extracting and processing metals from their ores.
Metals are generally found as compounds in nature called minerals. Ores are minerals that metals can be extracted from readily and profitably. Ores occur as oxides, sulfides, carbonates, sulfates, chlorides, and silicates. Flux is added to slag off impurities during smelting. Metals are refined through vapor phase, electrolytic, or zone refining. Common metal extraction processes involve concentration, roasting, smelting, and reduction. Metals have various uses as alloys and in electroplating, machinery, jewelry, and other applications.
The document summarizes extraction and uses of magnesium. It describes common magnesium minerals like dolomite and magnesite. It discusses challenges in extracting magnesium through pyrometallurgical and electrometallurgical processes. The Pidgeon and Magnetotherm processes are described for pyrometallurgical extraction. The Dow process extracts magnesium from seawater through precipitation and electrolysis. Magnesium has non-structural uses like alloying, deoxidation, and cathodic protection. Structural uses include aircraft and transportation applications due to magnesium's high strength to weight ratio.
The document discusses various principles and processes involved in the isolation of elements through metallurgy. It describes how elements are found in nature, either in native state or combined state in minerals and ores. It then explains the metallurgical processes of crushing and grinding ores, concentrating the ore through various methods, converting the concentrated ore into metal oxides through calcination or roasting. Finally, it discusses reducing the metal oxides into metals through reduction processes using suitable reducing agents, based on the reactivity and position of metals in the Ellingham diagram.
Schiff base is a compound formed by the condensation reaction of a carbonyl group with a primary amine. The document discusses various methods for preparing Schiff base ligands and complexes, and techniques for characterizing them including UV-visible spectroscopy, IR spectroscopy, NMR, EPR, mass spectrometry, TGA/DTA, and elemental analysis. Schiff base ligands and their complexes have applications in areas like biology, catalysis, materials science, and more.
Ladle Metallurgy: Basics, Objectives and ProcessesElakkiya Mani
Worldwide steel production in 2019 reached 1869 million tons, with China as the largest producer at 996 million tons. India was the second largest steel producer at 111 million tons. Ladle metallurgy involves further refining of molten steel in a ladle after tapping from a converter or electric furnace. It allows for homogenization, deoxidation, desulfurization, and other processes. Key ladle metallurgy techniques include ladle furnace treatment, argon stirring, vacuum degassing, and alloy additions to adjust steel chemistry and properties.
Magnesium can be extracted through pyrometallurgical or hydrometallurgical processes. Pyrometallurgical extraction involves high temperature reduction processes like the Pidgeon, Bolzano, and Magnetherm processes. However, these processes have high energy usage. Hydrometallurgical processes like the Dows process use aqueous solutions but require large water usage. Alternative processes under development include the Mintek, SOM, and carbothermic routes which aim to provide more sustainable magnesium production. Overall, new technologies are needed to lower the energy consumption of magnesium extraction from its oxides.
Metallurgy is the process of extracting metals from ores and purifying them. It involves various physical and chemical steps. Key physical steps include crushing ores, concentrating them using processes like magnetic separation or flotation, and mechanically separating gangue from ores. Chemical steps include roasting or calcination to remove impurities, reduction of metal oxides using coke or other reducing agents, and electrolytic refining to obtain pure metals. The overall metallurgy process allows extraction of metals from ores on a commercial scale.
International Journal of Metallurgy and Alloys
concerns with the recent advances in the metallurgical science and different types of metallurgy processes. The journal is determined to give its readers a concise reading material with good amount resource that is essential for the developing technology and ongoing research.
Alloys used in metal ceramics /orthodontic courses by Indian dental academy Indian dental academy
Description :
The Indian Dental Academy is the Leader in continuing dental education , training dentists in all aspects of dentistry and
offering a wide range of dental certified courses in different formats.for more details please visit
www.indiandentalacademy.com
This document provides an overview of dental casting alloys. It begins with a brief introduction to the use of metals in dentistry and a history of important developments in dental casting alloys from 1907 to 1999. The document then covers interatomic bonds, physical properties, common metallic elements used in alloys, classifications of alloys, and descriptions of specific alloy types including gold casting alloys, metal ceramic alloys, and base metal alloys.
This document discusses phase transformations that occur during welding of different materials. It covers topics like weld CCT diagrams, carbon equivalent calculations for preheating requirements of steels, welding metallurgy of stainless steels, and Schaeffler and DeLong diagrams. The objectives are to understand weld metal microstructure development, factors affecting weldability, and predicting weld metal phase constitution. Keywords discussed include CCT diagrams, carbon equivalent values, Schaeffler and DeLong diagrams, and microstructures like grain boundary ferrite and Widmanstatten ferrite.
IN THIS PPT U WILL LEARN ABOUT THE FOLLOWING SUB-TOPICS OF MANGANESE:-
-Uses
-Distribution
-Eco Significance
-Reserves in India
-Agencies exploring it
-Problems related to its exploitation
-Marketing and Production strategy
-Export and Import
There are four main types of hydrides: saline (ionic), metallic, covalent, and dimeric. Saline hydrides contain hydrogen as a negatively charged ion that reacts violently with water to produce hydrogen gas. Metallic hydrides consist of hydrogen ions and metal atoms in an electron sea. Covalent hydrides involve shared electron pairs between hydrogen and nonmetals, forming volatile liquids and gases. Hydrides have many applications including use as reducing agents, bases, drying agents, and hydrogen storage in batteries and fuel cells.
This document discusses inclusion control for clean steel production. It defines inclusions as non-metallic compounds that form separate phases in steel. Strict inclusion control is important for producing quality steel products. Inclusions are assessed and controlled by examining their source, shape, composition and distribution. Common inclusions include oxides, sulfides, and carbides. Modification techniques aim to make inclusions less harmful by modifying their shape, composition and dispersion in the steel matrix. Calcium additions are often used to modify alumina and manganese sulfide inclusions. Proper inclusion control is important at all stages of steelmaking and processing to achieve clean steel.
The document discusses the extraction of iron and aluminum. Iron is extracted through carbon reduction in a blast furnace, while aluminum must be extracted through electrolysis due to its high position on the reactivity series. Both processes are described in detail, including inputs, reactions, and outputs. Recycling of metals is also discussed for its environmental and economic benefits.
1. Describes the principles of the Bessemer and basic oxygen processes used in the production of steel from pig iron, which involve blowing oxygen through pig iron to lower the carbon content and produce steel in a rapid process.
2. Explains centrifugal casting which involves rotating a permanent mold at high speeds to cast cylindrical shapes by throwing molten metal against the inner mold wall where it solidifies.
3. Describes cold working which refers to plastic deformation, usually at room temperature, that strengthens metals by reducing grain size but makes them more brittle.
Direct gold has been used as a dental restorative material since the 15th century. It exists in various forms such as gold foil, electrolytically precipitated mat gold, and granular gold. Gold is biocompatible with tissues and exhibits excellent marginal integrity due to its ability to be cold welded. It is durable but technique sensitive. While gold is highly durable when placed properly, it has disadvantages such as cost and lack of esthetics. Direct gold is best for small class I, II, III, V, VI cavities where esthetics is not a concern and occlusal forces are not heavy.
Corrosion and corrosion inhibition of aluminum and aluminum alloys in acid me...mohammed rida
This document provides an introduction to aluminum, its key characteristics, aluminum alloys, corrosion of aluminum in acid solutions, and corrosion prevention methods. It discusses the low density, strength, corrosion resistance, conductivity, and other beneficial properties of aluminum. It describes common aluminum alloying elements like copper, magnesium, silicon, and their effects. The document also examines various types of localized corrosion that can affect aluminum, such as pitting, crevice, and galvanic corrosion. Finally, it outlines approaches for corrosion prevention, including alloy selection, coatings, use of inhibitors, and design considerations.
This document discusses the differences between metals and non-metals. It defines metals as materials that are lustrous, malleable, and good conductors of heat and electricity. Non-metals lack these properties and include materials like carbon and sulfur. The document outlines several physical and chemical properties of metals and non-metals, such as their reactions with water, oxygen, acids, and bases. Metals react with these substances to form oxides, hydroxides, or salts, while non-metals generally do not react or only react under certain conditions.
The document describes various properties of metals. It discusses the physical properties of metals, including their high melting and boiling points, malleability, ductility, and ability to conduct heat and electricity well. It also describes alloys as mixtures of metals that are stronger than pure metals. Additionally, the document outlines some chemical properties of metals, such as their reactivity patterns and reactions with water, steam, and acids according to the reactivity series. It provides examples of equations to represent these reactions.
The document discusses the principles of metallurgy and metal extraction processes. It defines metals, non-metals and metalloids based on their properties. The processes involved in metal extraction include mining, crushing, concentration, roasting, reduction and refining. Concentration methods separate the metal ore from gangue using techniques like gravity separation, magnetic separation or froth flotation. Reduction converts the metal oxide into pure metal using carbon or aluminothermic processes. Refining further purifies the metal using techniques like liquation, distillation, electrolysis or poling. Overall, the document provides an overview of the key concepts and steps involved in extracting and processing metals from their ores.
Metals are generally found as compounds in nature called minerals. Ores are minerals that metals can be extracted from readily and profitably. Ores occur as oxides, sulfides, carbonates, sulfates, chlorides, and silicates. Flux is added to slag off impurities during smelting. Metals are refined through vapor phase, electrolytic, or zone refining. Common metal extraction processes involve concentration, roasting, smelting, and reduction. Metals have various uses as alloys and in electroplating, machinery, jewelry, and other applications.
The document summarizes extraction and uses of magnesium. It describes common magnesium minerals like dolomite and magnesite. It discusses challenges in extracting magnesium through pyrometallurgical and electrometallurgical processes. The Pidgeon and Magnetotherm processes are described for pyrometallurgical extraction. The Dow process extracts magnesium from seawater through precipitation and electrolysis. Magnesium has non-structural uses like alloying, deoxidation, and cathodic protection. Structural uses include aircraft and transportation applications due to magnesium's high strength to weight ratio.
The document discusses various principles and processes involved in the isolation of elements through metallurgy. It describes how elements are found in nature, either in native state or combined state in minerals and ores. It then explains the metallurgical processes of crushing and grinding ores, concentrating the ore through various methods, converting the concentrated ore into metal oxides through calcination or roasting. Finally, it discusses reducing the metal oxides into metals through reduction processes using suitable reducing agents, based on the reactivity and position of metals in the Ellingham diagram.
Schiff base is a compound formed by the condensation reaction of a carbonyl group with a primary amine. The document discusses various methods for preparing Schiff base ligands and complexes, and techniques for characterizing them including UV-visible spectroscopy, IR spectroscopy, NMR, EPR, mass spectrometry, TGA/DTA, and elemental analysis. Schiff base ligands and their complexes have applications in areas like biology, catalysis, materials science, and more.
Ladle Metallurgy: Basics, Objectives and ProcessesElakkiya Mani
Worldwide steel production in 2019 reached 1869 million tons, with China as the largest producer at 996 million tons. India was the second largest steel producer at 111 million tons. Ladle metallurgy involves further refining of molten steel in a ladle after tapping from a converter or electric furnace. It allows for homogenization, deoxidation, desulfurization, and other processes. Key ladle metallurgy techniques include ladle furnace treatment, argon stirring, vacuum degassing, and alloy additions to adjust steel chemistry and properties.
Magnesium can be extracted through pyrometallurgical or hydrometallurgical processes. Pyrometallurgical extraction involves high temperature reduction processes like the Pidgeon, Bolzano, and Magnetherm processes. However, these processes have high energy usage. Hydrometallurgical processes like the Dows process use aqueous solutions but require large water usage. Alternative processes under development include the Mintek, SOM, and carbothermic routes which aim to provide more sustainable magnesium production. Overall, new technologies are needed to lower the energy consumption of magnesium extraction from its oxides.
Metallurgy is the process of extracting metals from ores and purifying them. It involves various physical and chemical steps. Key physical steps include crushing ores, concentrating them using processes like magnetic separation or flotation, and mechanically separating gangue from ores. Chemical steps include roasting or calcination to remove impurities, reduction of metal oxides using coke or other reducing agents, and electrolytic refining to obtain pure metals. The overall metallurgy process allows extraction of metals from ores on a commercial scale.
International Journal of Metallurgy and Alloys
concerns with the recent advances in the metallurgical science and different types of metallurgy processes. The journal is determined to give its readers a concise reading material with good amount resource that is essential for the developing technology and ongoing research.
This document discusses the metallurgy, physical properties, and manufacturing of arch wires used in orthodontics. It begins with an introduction to metallurgy and the history of metals through the ages. Key topics covered include the structure and bonding of metals, properties of orthodontic wires, ideal wire properties, common wire materials like stainless steel, nickel titanium, and beta titanium. The document also discusses the manufacturing process for orthodontic wires, including annealing, different heat treatments, and forms of steel like austenite and martensite.
Metallurgy is the process of extracting pure metals from their ores. Ores contain unwanted impurities and the required metal. The process involves both physical and chemical steps to separate the metal from impurities. One such process is the Parke's process for extracting silver, which involves heating an alloy of lead and silver to melt it, mixing it with molten zinc where the silver dissolves and separates from the lead due to different solubilities. Ellingham diagrams graphically show the thermodynamic stability of metal oxides and their variation with temperature, indicating the spontaneity of oxidation reactions. Iron is extracted from its ore, haematite, using a blast furnace where coke and limestone are added and hot
The Indian Dental Academy is the Leader in continuing dental education , training dentists in all aspects of dentistry and
offering a wide range of dental certified courses in different formats.for more details please visit
www.indiandentalacademy.com
Este documento presenta un resumen del proceso de piro metalurgia del cobre, incluyendo los principales pasos como la extracción del mineral, molienda, flotación, producción de concentrado de cobre, fusión, conversión y piro-refinación para producir ánodos de cobre. También incluye un diagrama de bloques del proceso general y enlaces a sitios web con más información sobre cada etapa.
The document discusses rate controlled sintering in advanced ceramic processes. It explains that sintering transforms ceramic powder compacts into dense materials through heating by reducing pores and growing grains. The driving force is lowering free energy. Sintering occurs in three stages and is affected by various factors. Rate controlled sintering controls the heating rate or temperature to control the sintering process for improved material properties. It provides examples demonstrating the effects of heating rate on microstructure.
This document provides an overview of basic metallurgy. It discusses the classification of materials, including metals and alloys, ceramics, polymers, and composites. The key metallurgy processes of casting, forming, welding, and powder metallurgy are described. Advanced materials like electronic materials, biomaterials, and nanomaterials are also introduced. The document is authored by K. Sevugarajan of Metz Lab Pvt. Ltd and provides their contact information.
Advantages of Liquid Liquid Extraction Systemkumarsachin3801
Common industrial application of Liquid Liquid Extraction include in areas like Bulk chemical industry, Petroleum industry, Fine chemical industry, Pharmaceutical industry, Biotech industry, Food industry, Hydrometallurgy
Injection metallurgy and ladle furnaces are used to refine molten steel. In injection metallurgy, desulfurizing reagents are injected into the ladle through a lance using argon gas as a carrier, which helps remove sulfur. Ladle furnaces are used to reheat, stir, and refine steel in a ladle. They allow for desulfurization, alloy additions, and inclusion removal. Both processes make use of slag and can reduce sulfur levels to 0.0002%, improving steel properties.
General principles and processes of isolation of elementsMukul Kumar
The document discusses the extraction and purification processes of various metals like aluminum, copper, zinc, and iron. It explains that metals are usually found in earth's crust in the form of ores and have to be extracted through various metallurgical processes. These include steps like concentration, roasting, reduction of metal oxides, electrolysis, zone refining etc. It also provides examples of the uses of these purified metals in various applications and industries.
Este documento describe los procesos pirometalúrgicos para obtener cobre metálico a partir de minerales y concentrados. Explica que la pirometalurgia consta de tres etapas: fusión, conversión y refinación. En la fusión se separan el eje rico en cobre y la escoria usando hornos como el reverbero o hornos de fusión flash. Luego la conversión convierte el eje en cobre blister usando un convertidor. Finalmente la refinación produce cobre electrolítico de alta pureza.
Solution Mining; Technology of the Salt Production; Rock salt (NaCl); Sylvinite; Solution mining of carnallitite with; two wells; selective dissolution; hot leaching; Methods to control the size of the caverns; INTRODUCTION; TECHNOLOGY OF SOLUTION MINING; FRASCH PROCESS-SULFUR PRODUCTION; TECHNOLOGY OF THE SALT PRODUCTION; What is Rock salt ?; Evaporite deposits ; Rock salt; Sylvinite; Carnallite; HEAP LEACHING; Heap leach production model; Important parameters during metallurgical testing; Staged Approach to Heap Leach Testwork and Design; Uranium Heap Leaching; Uranium Ore Minerals; Basic Geochemistry of Uranium Minerals; Copper Heap Leaching; Layout of copper bio-heap pilot plant; Laterite heap leaching; Nickel Laterite Deposits; Proposed counter-current heap leach arrangement; Neutralizing potential of laterites in 6 meter column; Advantages and Problems of Solution Mining
This presentation describes about evolution of nitinol (NiTi), its properties, manufacturing, metallurgy and various rotary systems in the field of endodontics.
This document discusses various mechanical properties of metals including ductility, malleability, elasticity, plasticity, toughness, hardness, strength, and heat treatment processes. It defines each property and provides examples. Ductility refers to a metal's ability to be drawn out without breaking, while malleability allows it to be hammered or rolled without cracking. Elasticity is the ability to return to original shape after deformation, whereas plasticity involves permanent deformation. Toughness and hardness relate to a material's resistance to fracture or deformation. Strength properties include tensile, compressive, and shear strengths. Heat treatment can be used to alter a metal's internal structure and properties by heating and cooling.
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El documento describe las etapas del proceso pirometalúrgico para la obtención de cobre a partir de minerales sulfurados, el cual incluye concentración, tostación, fundición, conversión y refinación. El objetivo es transformar el cobre contenido en los minerales en cobre metálico puro a través de reacciones químicas mediadas por el calor y la oxidación.
The document discusses various materials used in industrial design and manufacturing including composites, metals, ceramics, polymers, and their properties. Composites combine materials for desired properties like strength and weight. Aluminum and fiber-reinforced polymers are increasingly used in place of steel for car bodies due to their lighter weight. Ceramics can withstand high temperatures and acids but are brittle. Metals, ceramics, and polymers each have distinct strengths and weaknesses for different applications. Fatigue and creep are material failure modes that must be considered.
The document discusses extractive metallurgy processes for zinc extraction. It describes the major zinc ores and details several pyrometallurgical and hydrometallurgical extraction processes. The key processes are roasting to produce zinc oxide from zinc sulfide ores, followed by leaching and electrolysis to recover zinc. Approximately 80% of zinc is produced via hydrometallurgical routes like roast-leach-electrowinning.
This document discusses various methods for testing metals, including non-destructive testing methods like dye penetrant, magnetic crack detection, X-ray, and ultrasonic testing. It also describes tensile testing, which involves applying loads to a test piece to determine its elastic limit, yield point, ultimate tensile strength, and breaking point. Other tests discussed include proof testing, creep testing, hardness testing, and brittle fracture testing to evaluate metals at different temperatures.
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The document discusses the extraction of metals from their ores. It begins by describing where metals are found in nature based on their reactivity. Very reactive metals like calcium are found in the sea, while less reactive metals like aluminum and zinc are found as oxides and sulfides. The least reactive metals like gold and silver are found as free elements.
It then provides examples of metal ores found in Tanzania like copper, tin, iron, gold and uranium. The extraction process involves purifying the ore through processes like dressing, calcination and roasting. Metals are then extracted through electrolysis or chemical reduction. Common extraction methods for sodium, aluminum and iron are described. Finally, the document outlines some physical and chemical
The document discusses metal reactivity and extraction methods. It provides a metal reactivity series from most reactive to least reactive. More reactive metals can displace hydrogen from acids and form hydroxides, while less reactive metals can only do so from acids or cannot displace hydrogen at all. Extraction methods include electrolysis of molten compounds, smelting, reduction, and physical extraction depending on the reactivity of the metal. Ores contain metal minerals mixed with impurities and most metals must be extracted from their ores through processes like concentration, roasting, calcination, and reduction.
Metals and non-metals class 10th presentation. For all those who have been given an assignment just like me to make a ppt, this might help.
Enjoy 10th grade. In this presentation, we unravel the fundamental differences between these two categories of elements. Explore the conductivity of metals and learn how they play a vital role in electrical systems and technology. Delve into the world of non-metals and uncover their diverse applications, from supporting life as essential components of organic compounds to their roles in various industrial processes.
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Metals can be extracted from their ore through various processes depending on the reactivity of the metal. Less reactive metals can be manually separated from crushed ore, while more reactive metals require more energy-intensive processes like electrolysis or extraction in a blast furnace. In a blast furnace, ore, limestone flux and coke fuel are continuously fed into the top while hot air is blown into the bottom, allowing extraction of the metal in molten form from the bottom. Roasting is also used as a preliminary step, where sulfide ores are heated in air to transform the metal into an oxide and release sulfur dioxide gas. These processes can release toxic fumes and pollutants if not properly controlled.
The document discusses the extraction of three important metals - iron, aluminum, and copper. It describes how these metals are commonly found as ores and the multi-step processes required to extract the pure metals. Iron is extracted from its ore, hematite, using a blast furnace. Aluminum is extracted via electrolysis of aluminum oxide in molten cryolite. Copper is extracted through concentration, roasting, smelting and refining processes including bessemerization to produce blister copper from chalcopyrite ore.
This document discusses the physical and chemical properties of metals and non-metals. It describes how metals are generally solid, malleable, and good conductors, while non-metals can be solid, liquid, or gas and are not malleable. It also explains how metals react with oxygen, water, and acids, forming ionic compounds. Common extraction methods are outlined, such as electrolysis for reactive metals and roasting/reduction for others. The document concludes by discussing corrosion prevention through methods like galvanization and alloying.
The document provides an overview of metallurgy and metal extraction processes. It discusses:
1) Different methods of metal extraction including pyrometallurgy (using heat), hydrometallurgy (using water), and electrometallurgy (using electricity).
2) Properties and applications of cast iron, which has 2-4.5% carbon content and is strong in compression.
3) The process of extracting iron from iron ore in a blast furnace, producing pig iron which can then be further processed to make wrought iron or steel.
This document discusses the physical and chemical properties of metals and non-metals. It describes how metals react with oxygen, water, and acids. A reactivity series of metals is provided. The document also discusses how ionic compounds form and their properties. The extraction of metals from ores and the refining process is explained. Corrosion of metals and methods to prevent it are covered. Alloys are defined as homogeneous mixtures of metals or metals with non-metals.
1. The document discusses the physical and chemical properties of metals and non-metals. It describes how metals react with oxygen, water, acids and metal salt solutions.
2. A reactivity series of metals is presented, ranking them from most reactive (potassium) to least reactive (gold). The extraction processes for obtaining metals from their ores is also outlined.
3. Metals are extracted via concentration, reduction, and refining steps. Extraction methods depend on the reactivity of the metal, involving processes like roasting, calcination, or electrolysis of molten ores.
This document provides information on the physical and chemical properties of metals and non-metals. It discusses how metals react with oxygen, water, and acids. A reactivity series of metals is presented from most reactive to least reactive. The document also describes how ionic compounds form and their properties. Extraction and refining of metals from their ores is outlined, including concentration, reduction, and electrolytic processes. Corrosion of metals and methods to prevent it are also summarized.
This document summarizes the physical and chemical properties of metals and non-metals. It discusses how metals react with oxygen, water, and acids. It also describes the reactivity series of metals, how ionic compounds form, and how metals are extracted from their ores. Key points include:
- Metals are malleable and conductive while non-metals vary in state and are not usually malleable.
- Metals react with oxygen to form metal oxides, with water to form hydroxides and hydrogen, and with acids to form salts and hydrogen.
- The reactivity series arranges metals from most reactive (e.g. potassium) to least reactive (e.g. gold
The document discusses the physical and chemical properties of metals and non-metals. It describes how metals are generally solids, malleable, good conductors of heat and electricity, and react with oxygen, water, acids, and displace less reactive metals. It also discusses how non-metals can be solids, liquids or gases, are not malleable, and are generally poor conductors. The document then explains the extraction of metals from ores through concentration, reduction, and refining processes.
The document discusses metals, minerals, ores, and metallurgy. It describes how metals are found naturally, either in their free elemental state or combined as minerals and ores. Metallurgy is the process of extracting metals from ores and purifying them. Metals are categorized based on their reactivity, and extracted using different methods like electrolysis or heating with carbon or in air. The document also discusses alloying, corrosion, and methods to prevent corrosion like coating and alloying with other metals.
1. The document discusses various properties and reactions involving metals and non-metals. It describes the structure of alloys and how they are stronger than pure metals.
2. Key extraction methods are related to a metal's position in the reactivity series, such as electrolysis of reactive metals and blast furnaces for less reactive metals.
3. Common uses of metals such as aluminum, zinc, and iron alloys are explained in terms of the metals' properties including strength, corrosion resistance, and galvanization.
The document discusses various topics related to metals and metallurgy. It begins by defining metals and metallurgical principles, then discusses alkali metals, alkaline earth metals, and their compounds. It also covers minerals, ores, concentration processes, smelting, electrolytic reduction, and refining of metals. Key concentration methods described are magnetic separation, gravity separation, froth flotation, and leaching. The document also differentiates between minerals and ores, discusses alloys, amalgams, and existence of metals. It provides an overview of metallurgy and the steps involved in the metallurgical process.
This document discusses the physical and chemical properties of metals and non-metals. It describes how metals react with oxygen, water, and acids. A reactivity series of metals is provided from most reactive to least. The document explains how ionic compounds form and their properties. The extraction of metals from ores is summarized including concentration, reduction, and refining steps. Common extraction methods are outlined for metals of high, medium, and low reactivity in the series.
Metals are highly valuable materials used in hundreds of products. They have played a vital role in human civilization. Metals are usually solid at room temperature and have properties like conductivity, strength, and malleability due to their metallic bonding structure. Most metals are found combined with other elements in ores and must be extracted through processes like electrolysis or using carbon before they can be used. Alloys are mixtures of metals that can have very different properties than the pure metals.
Metal-and-Non-metal-10 BEST FOR CBSE STUDENTS.pptxravisharma1308
This document discusses the physical and chemical properties of metals and non-metals. It describes how metals are generally solid, malleable, good conductors of heat and electricity, and react with oxygen, water, and acids. Non-metals can be solid, liquid, or gas, are not malleable, conduct heat and electricity poorly, and do not react the same as metals. The reactivity of different metals is explained through the activity series. Common extraction methods include concentration, reduction, and refining. Corrosion and prevention methods are also outlined.
This document discusses the extraction of metals from ores. It begins by stating that most metals are found in nature combined with other elements in compounds like oxides, sulfides, and carbonates. It then explains different extraction methods including heating alone, heating with carbon or carbon monoxide, and electrolysis. As an example, it describes the extraction of iron from iron ore in a blast furnace. The document also briefly discusses alloys and their important uses.
Similar to Metallurgy and its proospect BBA DU Finance (20)
2. Name ID
MD. Ubidullah Khokan 19-003
MD. Ashadul Islam 19-141
MD. Mahedy Hasan 19-272
Sudev Chakma 19-251
Zubayer Ahmed 19-257
Bijoy Dripto Acharjya 19-261
Submitted To-
Dr. Md. Zahangir Alam
Associate Professor
Department of Applied Chemistry &
Chemical Engineering
University of Dhaka
Submitted By-
4. METALLURGY
art and science of extracting metals from
their ores and modifying the metals for
use.
Study of the chemical, physical, and
atomic properties and structures of
metals and the principles whereby metals
are combined to form alloys.
5. HISTORY OF METALLURGY
A magic material
The first known metal was gold.
Gold is bright, incorruptible, malleable,
and appears in pure form in the beds of
streams.
The earliest surviving gold jewelry is from
Egypt in about 3000 BC.
6. HISTORY OF METALLURGY
The age of copper: from 7000 BC
From about 7000 BC a few neolithic
communities begin hammering copper
into crude knives and sickles.
azurite and malachite, two ores of
copper were found.
two significant steps in the development
of metallurgy:
- the casting of metal, by pouring it into
prepared moulds
- the smelting of mineral ores to extract
metal.
7. HISTORY OF METALLURGY
The age of bronze: from 2800 BC
The cast alloy of copper and tin is bronze
The technology of bronze is first developed in
the Middle East
The age of iron: from 1500 BC
A few iron objects dating from before 2000
BC have been found (beads, a ring, some
blades), but it is not until about 1500 BC that
the working of iron is done anywhere on a
regular basis.
The Hittites are the first people to work iron, in
Anatolia from about 1500 BC
8. HISTORY OF METALLURGY
The discovery of steel: 11th century BC
By the 11th century BC it has been discovered that iron can be much
improved. If it is reheated in a furnace with charcoal (containing carbon),
some of the carbon is transferred to the iron.
A new material- steel is produced
Cast iron in the east: 513 BC
The melting point of iron (1528°C) is too high for primitive furnaces.
The Chinese develop a furnace hot enough to melt iron, enabling them to
produce the world's first cast iron
9. HISTORY OF METALLURGY
Ironmasters of Coalbrookdale: 18th century
In 1709 Abraham Darby, an ironmaster
with a furnace at Coalbrookdale on the
river Severn, discovers that coke can be
used instead of charcoal for the smelting
of pig iron.
Iron bridge: 1779
in 1779 the world's first iron bridge, with a
single span of over 100 feet, is created
over the Severn just downstream from
Coalbrookdale.
10. HISTORY OF METALLURGY
Pudding and rolling: 1783-1784
Henry Cort invented a furnace which shakes the molten iron so that air
mingles with it. The technique which becomes known as pudding. Oxygen
combines with carbon in the metallic compound, leaving almost pure iron.
In the previous year he invented machine for drawing out red-hot lumps of
purified metal between grooved rollers, turning them into manageable bar.
His device is the origin of the rolling mills.
11. HISTORY OF METALLURGY
The 19th century
The large-scale production of
cheap steel.
The development of the open-hearth
furnace by William and Friedrich Siemens
in Britain and by Pierre and Émile Martin in
France.
The separation from their ores, on a
substantial scale, of aluminum and
magnesium.
Development of electrolytic cell for
producing cheaper sodium in 1886.
12. HISTORY OF METALLURGY
The 20th century
the introduction of fusion welding
The first practical oxyacetylene torch was
produced in 1901.
Striking an arc from a coated metal
electrode, which melts into the join, was
introduced in 1910.
In extractive metallurgy, the application of
chemical thermodynamics, kinetics, and
chemical engineering are introduced.
In physical metallurgy, the study of
relationships between macrostructure,
atomic structure and physical and
mechanical properties are developed.
14. EXTRACTIVE METALLURGY
Extractive metallurgy is the art of obtaining valuable metals from an ore or
metallic concentrate and refining the initial products into a purer form.
Metals can be found on the earth in several chemical forms such as natives
(gold, copper), oxides, sulphides, sulphates, carbonates, nitrates, and others.
The compound must be converted into a type that can be more readily
treated. Common practice is to convert metallic sulfides to oxides, sulfates,
or chlorides; oxides to sulfates or chlorides; and carbonates to oxides.
16. EXTRACTIVE METALLURGY
Mineral processing
Mineral processing involves crushing,
grinding, and concentration.
Pyrometallurgy
Pyrometallurgy involves the treatment of
ores at high temperature to convert ore
minerals to raw metals, or intermediate
compounds for further refining.
17. EXTRACTIVE METALLURGY
The processes of Pyrometallurgy are-
Roasting- in which compounds are converted at temperatures just below
their melting points.
smelting- All the constituents of an ore or concentrate are completely
melted and separated into two liquid layers, one containing the valuable
metals and the other the waste rock.
Refining- The final procedure for removing the last small amounts of impurities
left after the major extraction steps have been completed.
19. EXTRACTIVE METALLURGY
Conversion-
Because not all ores and concentrates are found naturally in a form that is
satisfactory for leaching, they must often be subjected to preliminary
operations. For example, sulfide ores, which are relatively insoluble in sulfuric
acid, can be converted to quite soluble forms by oxidizing or sulfatizing
roasts.
A second popular treatment for converting sulfides is pressure oxidation, in
which the sulfides are oxidized to a porous structure.
20. EXTRACTIVE METALLURGY
Leaching
Dissolution of the valuable metals into the aqueous solution.
Oxides are leached with a sulfuric acid or sodium carbonate solvent.
sulfates can be leached with water or sulfuric acid.
Ammonium hydroxide [NH4OH] is used for native ores, carbonates, and
sulfides, and sodium hydroxide [NaOH] is used for oxides. Cyanide solutions
are a solvent for the precious metals, while a sodium chloride solution
dissolves some chlorides.
Two methods of leaching:
simple leaching
pressure leaching
21. EXTRACTIVE METALLURGY
Recovery
the solution from leaching operations is treated in a variety of ways to
precipitate the dissolved metal values and recover them in solid form.
These include-
electrolytic deposition- Insoluble anodes, and cathodes are inserted into a
tank containing leach solution. As current is passed, the solution dissociates,
and metal ions deposit at the cathode. This common method is used for
copper, zinc, nickel, and cobalt.
22. EXTRACTIVE METALLURGY
Recovery continue….
chemical precipitation- a displacement reaction takes place in which a
more active metal replaces a less active metal in solution. For example, in
copper cementation iron replaces copper ions in solution.
changing the acidity of a solution is a common method of precipitation.
24. PHYSICAL METALLURGY
Physical metallurgy is the science of making useful products out of metals.
Metal parts can be made in a variety of ways, depending on the shape,
properties, and cost desired in the finished product.
The cost of a finished part is often determined more by its ease of
manufacture than by the cost of the material.
Usually a metal part has the same properties throughout.
25. PHYSICAL METALLURGY
Structures and properties of metals
Metallic crystal structures-
Metals are used in engineering structures (e.g., automobiles, bridges, pressure
vessels) because, in contrast to glass or ceramic, they can undergo appreciable
plastic deformation before breaking.
This plasticity stems from the crystalline structure of metal and the nondirectional
nature of the bond between the atoms.
In the most ductile metals, atoms are arranged in a close-packed manner.
aluminum, copper, nickel, gamma iron, gold, and silver are face-centred cubic
structured.
alpha iron, tungsten, chromium, and beta titanium are body-centred cubic
structured.
26. PHYSICAL METALLURGY
Physical Property
Good electrical conductors and heat
conductors.
Dense – Most metals have high density.
Malleable - can be beaten into thin
sheets.
Ductile - can be stretched into wire.
Solid at room temperature (except Hg).
Sonorous – Metals make a ringing sound
when they are struck.
Possess metallic luster.
Have high melting and boiling point.
Opaque as thin sheet.
27. PHYSICAL METALLURGY
Chemical Property
Usually have 1-3 electrons in their outer shell.
Lose their valence electrons easily.
Almost any metal will oxidize in air, the only exception is gold.
Are good reducing agents.
Have lower electronegativities.
28. PHYSICAL METALLURGY
Alloy
Almost all metals are used as alloy.
Alloy is the solid solution of tow or more metals.
Alloys have properties superior to pure metal.
29. PHYSICAL METALLURGY
Reasons for making Alloy
To improve the strength and hardness of metals.
To improve the appearance of metals.
To improve the resistance of metal against corrosion and rusting.
To lower the melting point of metal.
31. PHYSICAL METALLURGY
Casting
Casting consists of pouring molten metal
into a mold, where it solidifies into the
shape of the mold.
The process was well established in the
Bronze Age (beginning. 3000 BC)
It is particularly valuable for the
economical production of complex
shapes, ranging from mass-produced
parts for automobiles to production of
statues, jewelry, or massive machinery.
32. PHYSICAL METALLURGY
Casting Process
Sand-casting
Sand-casting is widely used for making cast-iron and steel parts of medium
to large size
sand combined with a binder such as water and clay is packed around a
pattern to form the mold.
Metal molds
molds are made from metal.
33. PHYSICAL METALLURGY
Casting Process Continued….
Investment casting
In investment casting a mold is made by drying a refractory slurry on a
pattern made of wax or plastic.
A series of layers is applied and dried to make a ceramic shell, and the
pattern is then melted or burned out to provide the mold.
This process allows the mass production of parts with more complex shapes
and finer surface
Centrifugal casting
Centrifugal casting forces the metal into a mold by spinning it.
It is used for the casting of small precious-metal objects
34. PHYSICAL METALLURGY
MetalWorking
Metalworking is the process of working with metals to create individual parts,
assemblies, or large-scale structures.
- these can be divided into five broad groups:
1) Rolling
Rolling is a metal forming process in which metal stock is passed through
one or more pairs of rolls to reduce the thickness and to make the thickness
uniform.
- More than 90 percent of the aluminum, steel, and copper produced is rolled
at least once in the course of production.
35. PHYSICAL METALLURGY
2) Extrusion
Extrusion is the process by which long straight metal parts can be produced.
The cross-sections that can be produced vary from solid round, rectangular, to L
shapes, T shapes.
Extrusion is done by squeezing metal in a closed cavity through a tool, known as a
die using either a mechanical or hydraulic press.
3) Drawing
Drawing consists of pulling metal through a die.
4) sheet metal forming
5) Forging
Forging is the shaping of a piece of metal by pushing with open or closed dies.
37. POWDER METALLURGY
Powder metallurgy (P/M) consists of making solid parts out of metal powders
and and using them to make finished or semi-finished products.
Used when
• melting point is too high .
• reaction occurs at melting .
• too hard to machine.
• very large quantity.
39. POWDER METALLURGY
Powder production
The most common method of producing
metal powders is atomization of a liquid.
Here a stream of molten metal is broken
up into small droplets with a jet of water,
air, or inert gas such as nitrogen or argon.
Different shapes produced Will affect
compaction process significantly
40. POWDER METALLURGY
Blending or mixing
Blending means mixing powder of the same chemical composition but different
sizes.
Mixing means combining powders of different chemistries.
Except for powders, some other ingredients are usually added:
Lubricants: to reduce the particles-die friction
Binders: to achieve enough strength before sintering
Deflocculants: to improve the flow characteristics during feeding
Elemental or pre-alloyed metal powders are first mixed with lubricants or other alloy
to produce a homogeneous mixture of ingredients
Blending and mixing are accomplished by mechanical means.
42. POWDER METALLURGY
Powder compaction
Pressing process
Blended powders are pressed in dies under high pressure to form them into
the required shape.
Produces a “Green” compact
Size and shape of finished part (almost)
Not as strong as finished part – handling concern
44. POWDER METALLURGY
Sintering
Green compacts are heated in a controlled-atmosphere furnace to allow
packed metal powders to bond together
Transforms compacted mechanical bonds to much stronger metal bonds.
45. POWDER METALLURGY
Finishing Operations
to improve properties, finishing processes are needed:
• Cold restriking, resintering, and heat treatment.
• Impregnation of heated oil.
• Infiltration with metal (e.g., Cu for ferrous parts).
• Machining to tighter tolerance.
Plating, Painting
47. APPLICATION POWDER METALLURGY
Electrical Contact materials
Sliding Electrical Contacts
Heavy-duty Friction materials
Self-Lubricating Porous bearings
Carbide, Alumina, Diamond cutting tools
Structural parts
Cermets
Hard and Wear Resistant Tools
Refractory Material Products
THESE COMPONENTS ARE
USED IN AIR & SPACE
CRAFTS, HEAVY
MACHINERY, COMPUTERS,
AUTOMOBILES, etc…