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Production of Iron Manufacturing Processes

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Production of Iron Manufacturing Processes 23 December 2016 Overview of Metals Production of Iron INPUT Manufacturing Processes Iron ore: rocks and minerals from which metallic iron can be economically extracted Limestone: it gathers the impurities in the iron ore to it and forms a lighter liquid that floats on top of the molten iron Coke: it burns causing an intense heat which removes the oxygen from the iron ore thus allowing the molten metal to trickle to the bottom of the furnace OUTPUT Molten iron: it is poured into molds to form what is called “pig iron” billets Slag: it is basically metal oxides and non-iron impurities and it is removed from the top Blast Furnace Note: some slag remains and combines with the molten iron causing the presence of non-metallic inclusions in the pig iron billets. Pig iron is not used as is, it is melted again to Manufacturing Processes reduce its carbon content and it is combined with other elements (silicon, nickel, In general, manufacturing operations and manganese, chromium, molybdenum, etc.) processes can be categorized as: to give the desired material (Cast Iron, Steel, Carbon Steel, Stainless Steel, Alloy steel, etc.) Casting Processes Pig iron billets After pig iron is molten again Bulk Forming Processes and other alloying elements are added it is poured into relatively SheetSheet--MetalMetal Forming Processes large molds to form INGOTS Material Removal Processes An ingot is a material, Joining Processes usually metal, that is cast into a shape suitable for further Heat Treatment Processes processing Aluminum Stainless Steel INGOTS INGOTS Metal Plating Processes Introduction to Non-Destructive Testing Techniques Instructor: Dr. Ala Hijazi 1 23 December 2016 Casting Bulk Forming: Forging Casting is the first process required to reach to any Forging is the shaping of metal type of products (ingots are produced by casting then using localized compressive they are further processed) forces and usually it is done at Casting is also used to produce some high temperatures products in their final (or near final) shape Pig iron is melted with other alloying elements and poured into molds of the OpenOpen--diedie forging desired shape (ingots of the desired material ClosedClosed--diedie forging can also be used) Permanent molds (made of metal) Expendable molds (sand, shell-mold, plaster-mold, etc.) Bulk Forming: Rolling Bulk Forming: Extrusion Rolling is a metal forming process in which metal stock is passed Extrusion is a process used to create long objects of a fixed cross- through a pair of rolls to give it a desired smaller cross-sectional sectional profile by pushing the material through a die of the dimensions (rolling is usually done at several stages) desired cross-section According to temperature, rolling is classified into: Depending on the desired shape, extrusion .Hot rolling (above crystallization temperature) can be done at hot or cold temperatures .Cold rolling (below crystallization temperature) (usually hot) Rolling is usually used for producing: The two basic types of extrusion are: Plates & Sheets Direct extrusion Bars (material is pushed thru the die) Indirect extrusion (material and container move while the die is stationary) Introduction to Non-Destructive Testing Techniques Instructor: Dr. Ala Hijazi 2 23 December 2016 Bulk Forming: Drawing SheetSheet--MetalMetal Forming Drawing is a process used for long products of small cross- Sheet metal is simply metal formed into thin flat sectional area where they are usually pulled through a die, pieces and thus it can be cut, bent, stretched rather than pushed as in extrusion and formed into a variety of different shapes Drawing is used when the desired reduction in area is not that large Roll forming is used for long and it is usually done at cold parts with constant complex temperatures cross-sections Stretch forming is used for It is usually used for large parts with shallow producing wirers and contours sometimes for plates Deep drawing is used mostly for deep parts with relatively simple shapes SheetSheet--MetalMetal Forming SheetSheet--MetalMetal Forming Stamping includes a variety of operations such as punchingpunching, Spinning is used for small blankingblanking, bendingbending, flangingflanging, or large axisymmetric parts embossingembossing, etc. It is used for simple or complex shapes Explosive forming is used formed at high production rates for very large sheets with relatively complex shapes (explosive charge is used to generate a pressure which forms the sheet-metal in the die) Introduction to Non-Destructive Testing Techniques Instructor: Dr. Ala Hijazi 3 23 December 2016 Material Removal: Material Removal: Machining Machining Machining is the term used to The three principal types of describe a variety of material machining operations are: removal processes in which a Turning sharp cutting tool is used to (A turning tool moves axially, along the side of remove unwanted material from a rotating workpiece) workpiece to achieve a desired Milling geometry (A rotating cutting tool with sharp teeth In general, machining translates along the surface of the workpiece) operations are relatively slow and usually a cutting fluid is Drilling used to reduce friction and (A rotating drill bit enters the workpiece remove excess heat axially and cuts a hole with a diameter equal to that of the tool) Material Removal Material Joining: Welding Welding is a process in which the Grinding is a finishing process used to improve pieces to be joined are melted at the surface finish where an joining interface (usually a filler material abrasive material rubs is added) then allowed to solidify to against the part surface become a strong joint removing tiny pieces of Grinding is usually done at very The most commonly used welding process is Arc Welding high speeds and thus generates where a power supply is used to create and maintain an material very high temperatures electric arc between an electrode and the base material to melt metals at the welding point Polishing is the process of Other types of welding include: creating a smooth and shiny Gas welding surface by rubbing it using Resistance welding very fine abrasive particles EnergyEnergy--beambeam welding (or using a chemical action) Solid state welding Introduction to Non-Destructive Testing Techniques Instructor: Dr. Ala Hijazi 4 23 December 2016 Material Joining Material Joining Soldering is a process in Fastening is mechanically which metal parts are joined joining or affixing two or more together by melting and objects together, usually using flowing a filler metal (solder) bolts and nuts into the joint (the filler metal having a lower melting point Bolted joints can be easily than the workpiece) Soldering differs from welding disassembled when needed in that soldering does not involve melting the work pieces Riveting is a permanent joining Brazing is a process in which method where a rivet is inserted a filler metal is heated above into a hole then the end of the melting point and introduced rivet is physically deformed such between close-fitting surfaces that it can not come out Riveting is widely used in the by capillary action construction of airplanes Heat Treatment Heat Treatment Heat treatment refers to time & temperature- Quenching is a process in which controlled process that is used to modify the material is made to be very hard material properties (strength and ductility) (strength is increased and material Heat treatment is one of the final steps in the manufacturing becomes brittle) process where it removes the internal stresses in the material During quenching the material is heated to a resulting from other manufacturing operations temperature above the crystallization temperature then it is cooled at a very fast rate using water or oil Annealing is a process in which the material is softened (strength is reduced Tempering is done after quenching and ductility is increased) and it is used to reduce the hardness of the material (increase ductility) During annealing the material is heated to a temperature above the crystallization temperature and is held at this temperature During tempering the material is heated to for a sufficient time then it is allowed to cool-down slowly some temperature below the crystallization temperature then it is cooled in still air Introduction to Non-Destructive Testing Techniques Instructor: Dr. Ala Hijazi 5 23 December 2016 Metal Plating Plating is a process in which a thin For More Information on layer of metal is deposited on the surface of a conductive material Manufacturing Processes Plating is used to give the surface some desirable appearance or characteristic such as: http://www.custompartnet.com/ corrosion resistance, improve solderability, increase hardness, reduce friction, improve http://www.efunda.com/processes/ paint adhesion, alter conductivity, etc. The most widely used plating method is electroplating where the part to be plated (the cathode) and the plating material (the anode) are immersed in a solution (called an electrolyte) which allows metal ions to move by the electric field to coat the cathode Introduction to Non-Destructive Testing Techniques Instructor: Dr. Ala Hijazi 6.
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