COPPER ALLOYS

• Beryllium Bronze

1.75% to 2.5% Be, 0.5 % Co, balance CuTreated at 800oC , quenched, cold worked if

needed, then precipitation hardened at 2750C for 1 hour.

Tensile strength 1300-1400N/mm2

(for hammers, chisels, hacksaw blades in gas, oil, mine, explosive fields)

• Al- Alloys,

• Cr-Cu alloys, Zr-Cu, Ti-Cu,

• K-Monel (Monel- Cu-Ni alloys), • Narcoloy (Al, Bronze- 7%Al, 0.5%Co, 0.25%Sn)

• Mg based alloys, • Zn based alloys for dies• (MAZAK)- excellent casting properties- for parts in

Washing machines, radios, Alarm Clocks, wiper motor casing, door handles,etc.

• Titanium Alloys

• Shutter blades, surgical implants,

Detailed tables on these shall be supplied.

ABOUT ALLOY STEELS

PLAIN CARBON STEELS-

with upto 1% Mn- due to deoxidation and desulphurisation processes

ALLOY STEELS- CONTAINS > 01% Mo/V

>0.3%W/Co/ Cr

>0.4%Ni

>2%Mn

To improve & extend the properties of PCS,

To introduce new properties

Thus are costly – (Ni, Cr, etc. much costlier than PCT)

PIG IRON PRODUCTION• Smelting of Iron Ore in Blast Furnace shaft type furnace >60 m high, output of 10000 tonnes /day

Refractory lining to last for several years

• Ore, coke, lime stone charged to furnace through top. preheated air blast through tuyeres near base at times fuel oil injected to reduce coke consumption& increase output

• At intervals, tap hole & slag hole at bottom opened.STEEL PRODUCTION BY BESSEMER PROCESS, L-D PROCESS BASIC OXYGEN STEEL MAKING (By Basic Oxygen Furnace)

• Reduction occurs in three stages-

Fe2O3

to Fe3O4, to FeO,

then to Fe

Reaction in upper part of furnace. Iron remains as a spongy mass

The earthy waste- GANGUE- combines with lime to produce a fluid slag.

Gangue- composed of silica, will not melt at blast furnace temp.

SPONGE IRON Sponge Iron is a metallic product formed by the reduction of iron ore at temperature just below the fusion point of iron. This product has derived the name "Sponge Iron" due to its porous nature. It is also called as Direct Reduced Iron (DRI).

A substitute of steel scrap for steel making through the secondary route Replaces ferrous scrap as a coolant in LD converter. The value of DRI is measured by comparing its cost and properties with those of scrap. It is free from elements like Copper, Zinc, Tin, Chromium, Tungsten and Molybdenum etc that are usually present in scrap. It has low Sulphur content. It has the ability to use low grade fuels and fuels that are unacceptable for conventional iron making. It is more suited for some special metallurgical processes than conventional iron & steel products e.g. Precipitation of copper from leaching solution during copper extraction. Production of metal objects by powder compaction

PARTICULARS OF SPONGE IRON LUMPS

• TOTAL IRON - 91.5% Min • METALLIC IRON - 80% Min • DEGREE OF METALLIZATION - 88% Min • CARBON - 0.2% Min • SULPHUR - LESS THAN 0.04% Min • PHOSPHOROUS - LESS THAN 0.45% • GANGUE- LESS THAN 5% • NON MAGNETIC MATLS. - LESS THAN 0.5%

• SIZE - 3 to 20 mm

• Ancor MH-100: sponge iron powder which is the P/M industry standard for producing low to medium density parts with good compressibility-

produced by the direct reduction of high grade magnetite iron ore. This process results in spongy particles

• Ancormet 101: sponge iron powder which was developed to supply the P/M industry with a powder grade that could be used for low to medium density parts with higher strength requirements

results in fast and uniform carbon pick-up during sintering and permits shorter sintering cycles. Dimensional change factors are lower especially in copper steels.