2. Ferrous Acft Metal

FERROUS AIRCRAFTMETAL

FERROUS AIRCRAFT METALS

Ferrous Aircraft Metal are group of metals having iron as thier principal contents or base metal

Ferrous metals are those metals that contain Iron.The steel production process might be divided into three phases:

Reduction of iron to pig ironRefining pig iron to steelForming the steel into product

STEEL PROCESSSTEEL PROCESS

Heating stove and blast furnance

• Iron is extracted from iron ores such as Hematite (Fe2O3) and Magnetite (Fe3O4)

• The iron ores contain 25% to 70% metallic iron. Sulfur, phosphorous, silica and clay are the principal impurities.

• Materials used to produce pig iron are coke, limestone and iron ore.

• Iron ore, coke and limestone are heated together at high temperatures in blast furnaces for the extraction process of iron.

IRONIRON

Pure iron is a soft metal having a structure of iron crystals. In metallurgy, pure iron is called “Ferrite”Coke → provides the heat & supplies carbon (C) to extract iron

C + O2 → CO2

CO2 + C → 2CO3CO + Fe2O3 → 2Fe + 3CO2Limestone is used to reduce the

impurities.Ordinary pig iron as produced by blast furnaces contains iron, about 92 percent; carbon, 3 or 4 percent; silicon, 0.5 to 3 percent; manganese, 0.25 to 2.5 percent; phosphorus, 0.04 to 2 percent; and a trace of sulfur.

CAST IRONCAST IRONWhen pig iron is further processed by remelting to eliminate some of the carbon, cast iron (having a carbon content of about 1.5 to 4%) is produced. The remelting process is usually performed in a cupola (a smaller version of blast furnace).During the remelting operation in the cupola, no particular chemical change in the iron is ecpected. Some of the impurities may be eliminated and a more uniform product is obtained.

STEELSTEEL

Steel is also produced from pig iron by removing the impurities and by decreasing the carbon content.Pig iron is again heated and the excess carbon is removed as CO2 gas and the oxides of other impurities form a slag on top of the molten steel.

STEEL AND STEEL ALLOY DESIGNATION

A numerical index, sponsored by Society of Automotive Engineers (SAE) and The American Iron and Steel Institute (AISI) is used to identify the chemical composition of the structural steel.In this system a four numerical series is used to designate Steel and Steel Alloy

STEEL AND STEEL ALLOY

(SAE) XXXX

First digit indicates Type of Steel.

Second digit indicates Major Alloying Element.

Last two digit indicates hundread of one percent carbont content in the steel.

Example• SERIES CODE STEEL TYPE• 1XXX Plain carbon (non alloy) steel

13XX Manganese steel 2XXX Nickel alloy steels 23XX 3.5% Nickel 25XX 5.0% Nickel 3XXX Nickel/Chrome steels 4XXX Molybdenum steels 40XX Carbon/Moly 41XX Chrome/Moly 43XX Chrome/Moly/Nickel 46XX or 48XX Moly/Nickel 5XXX Chromium alloy steels 51XX Low Chromium content 52XX Medium Chromium content 53XX High Chromium content 6XXX Chromium/Vanadium alloy steels 86XX or 87XX Nickel/Chromium/Moly alloy steels 92XX Manganese/Silicon alloy steels

•

example

• 1020 = plain carbon steel

• 3135 = nickel chromium steel

• 4130 = chromium molybdenum steel

• 10105 =carbon steel,1,05% carbon

• 51420 =chromium steel, 14% chromium

TYPE , CHARACTERISTIC AND USES STEEL ALLOY

Carbon Steel

Devided into three group based on percentage carbon content.

• Low Carbon Steel • Medium Carbon Steel• High Carbon Steel


Low Carbon SteelSteel containing carbon in perecentage range 0.10 to 0.30 percent. The equivalent SAE number 1010 to 1030. Used for making safety wire, nuts, cable bushing, or threaded rod ends.

Medium Carbon SteelSteel containing carbon in perecentage range 0.30 to 0.50 percent. SAE number 1035. Used for making rod ends and light forging .


High Carbon SteelSteel containing carbon in perecentage range 0.50 to 1.05 percent. SAE number 1095. Used for making flat spring and coil spring.


Nickel Steel

Steel containing Nickel in perecentage range 3 to 3.75 percent. SAE number 2330. Used for making bolts, terminal, keys, clevises, and pins. Nickel incrases the hardness, tensile strength, and elastic limits.


Chromium Steel

Used for making balls and rollers of antifriction bearing.

Nickel incrases the hardness, strength, and corrosion resistant roperties.


Chromium Nickel Steel

Known as stainless steel, corrision resistant steel and 18 – 8. Its contents 18 percents chromium and 8 percents nickel Used for making exhaust collector, stack and manifolds, structural and machined part, spring, casting, tie rod and control cable.


Chromium Vanadium Steel

Its contents 18 percents vanadium and 1 percents chromium. SAE 6150 used for making spring and SAE 6195 used for ball and roller bearing.


Chromium Molybdenum Steel

Used for making fuselage tubing, engine mounts, landing gears, ant other structural parts. SAE number 4130. Containing 0.25 to 0.55 percent carbon, 0.15 to 0.25 percent molydenum and 0.50 to 1.10 percent chromium.


Inconel

Is Nickel Chromium Steel alloy. Closely resembling stainless steel. Its contents greater than 50 percents nickel. Used for making exhaust collector, stack and manifolds, structural and machined part, spring, casting, tie rod and control cable.Tensile strength 100,000 psi annealed and 125,000 psi when hard rolled and withstand temperature as a high 1,600 0F

2. Ferrous Acft Metal

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