Metals

A C A B O , G A L E O N , O N GE S T R A D A , I G D O N , J U A N I C O

METALS

INTRODUCTION

•an element, compound, or alloy that is a good conductor of both electricity and heat. •usually malleable, ductile and shiny, that is they reflect most of incident light.

•atoms readily lose electrons to form positive ions (cations). •The solid thus produced is held by electrostatic interactions between the ions and the electron cloud, which are called metallic bonds.

Iron and Steel

Dean Cris M. AcaboBS ChE – 5

ChE 61

Overview• Iron - An Overview- Physical Properties- Application• Steel- An Overview- Production- Application

Iron• a chemical element with the symbol Fe (from

Latin: ferrum) and atomic number 26.• Pure iron is soft (softer than aluminium), but is

unobtainable by smelting.• The material is significantly hardened and

strengthened by impurities from the smelting process, such as carbon.

Iron• Solid phase in normal conditions• Density: 7.874 grams/cm3

• Melting Point: 1811 Kelvin• Boiling Point: 3134 Kelvin• Heat of Fusion: 13.81 kJ/mol• Heat of Vaporization: 340 kJ/mol• Molar Heat Capacity: 25.10 J/(mol*K)• Thermal Expansion: (25 C) 11.8 m/(m*K)𝜇

IronWrought Iron• An easily welded and forged iron that is a

mechanical mixture of refined metallic iron with 1 to 3 percent siliceous slag

• tends to be more resistant to rusting than many other forms of iron

• outdoor seating, decorative fences, arbors, and trellises

IronCast Iron• A hard, brittle, nonmalleable iron-carbon alloy,

cast into shape, containing 2 to 4.5 percent carbon, 0.5 to 3 percent silicon, and lesser amounts of sulfur, manganese, and phosphorus.

• It is a perfect material for skillets, Dutch ovens, cake pans, cornbread trays and a number of other forms of cooking hollow ware.

Steel• a variety of iron intermediate in composition and

properties between wrought iron and cast iron• an alloy made by combining iron and other elements,

the most common of these being carbon.• when carbon is used, its content in the steel is

between 0.2% and 2.1% by weight, depending on the grade.

• its malleability decreases, and fusibility increases, with an increase in carbon.

• Density: 7,750kg/m3 to 8,050kg/m3

Steel• Iron is smelted from its ore by commercial

processes but it contains more carbon than the desirable amount.

• It is melted and reprocessed to reduce the carbon to the correct amount, at which point other elements can be added.

• Approximately 96% of steel is continuously cast, while only 4% is produced as cast steel ingots.

Steel• The ingots are then heated in a soaking pit

and hot rolled into slabs, blooms, or billets.• Slabs are hot or cold rolled into sheet metal or

plates.• Billets are hot or cold rolled into bars, rods,

and wire.• Blooms are hot or cold rolled into structural

steel, such as I-beams and rails.

Steel• It is widely applied in the construction of

roads, railways, other infrastructure, appliances, and buildings.

• Most large modern structures, such as stadiums and skyscrapers, bridges, and airports, are supported by a steel skeleton.

• In addition, it sees widespread use in major appliances and cars.

SteelLong Steel• As reinforcing bars and mesh in reinforced

concrete• Railroad tracks• Structural steel in modern buildings and

bridges• Wires• Input to reforging applications

SteelFlat Carbon Steel• Major appliances• Magnetic cores• The inside and outside body of automobiles,

trains, and ships.

SteelStainless Steel• Cutlery• Rulers• Surgical equipment• Wrist watches

SteelLow-background Steel• Geiger counters• Radioactive Shielding

R O S E M AY B . I G D O N

STAINLESS STEEL

MECHANICAL PROPERTIES

• Ductile • High Tensile Strength• High Yield Stress

COMPOSITION

•Steel alloy•Minimum of 10.5% to 11% chromium content by mass

CORROSION RESISTANCE:

• Stainless steel does not corrode, rust or stain with water as ordinary steel does, but despite the name it is not fully stain-proof, most notably under low oxygen, high salinity, or poor circulation environments. It is also called corrosion-resistant steel or CRES

CORROSION RESISTANCE:

• Corrosion-resistance can be adversely affected if the component is used in a non-oxygenated environment.• Similarly to steel, stainless steel is not a

very good conductor of electricity, with about a few percent of the electrical conductivity of copper.

INDUSTRIAL USAGE:

• Coils• Sheets• Plates• Bars• Wires• Tubing• Fittings• Storage Tanks

COPPER AND ITS ALLOYS

COPPER and its alloys constitute one 2of the major groups of commercial metals. They are widely used because of their excellent electrical and thermal conductivity, outstanding resistance to corrosion, and ease of fabrication, together with good strength and fatigue resistance. They are generally nonmagnetic.

They can be readily brazed, and many coppers and copper alloys can be welded by various gas, arc and resistance methods. For decorative parts, standard alloys having specific colors are readily available. Copper alloys can be polished and buffed to almost any desired texture and luster. They can be plated, coated with organic substances or chemically colored to further extend the variety of available finishes.

MAIN PROPERTIES OF COPPER:

_ High electrical and thermal conductivity _ Good corrosion resistance, Machinability,

strength _ Ease of fabrication _ Non magnetic _ Has a pleasing colour _ Can be welded, brazed, and soldered _ Easily finished by plating and lacquering

Electrical conductors - 99.9% Cu and identified as Electrolytic Tough Pitch (ETP) copper or Oxygen Free High Conductivity (OFHC) copper.

Arsenical copper - ≈ 0.3% Arsenic – improved resistance to special corrosive conditions

Free cutting copper - ≈ 0.6% Tellurium – excellent machining properties

Silver bearing copper – 7 to 30 oz/ton silver – Silver raises the recrytallization of copper

TEMPER DESIGNATION: Cu and most of its alloys are homogeneous single phases, there are not susceptible to heat treatment and t heir strength may be altered only by cold working.

Two general classes of temper for non heat treatable wrought copper alloys: cold worked and soft or annealed. The different cold worked tempers are obtained by cold working the annealed material a definite amount.

COPPER ALLOYS:

BRASSES – ESSENTIALLY ALLOYS OF CU AND ZN.

Some of the alloys may contain small amounts of Pb, Sn, Al.

Variations in composition will result in desired colour, strength, ductility, machinability, corrosion resistance, or a combination of such properties.

Best combination of strength and ductility 70 Cu- 30 Zn.

COMMERCIAL BRASS:

Brasses for cold worked (Alpha brasses)

Brasses for hot working (Alpha Plus Beta Brasses)

A. ALPHA BRASSES

– containing up to 36% Zn

Relatively good corrosion resistance and good working properties.

YELLOW Α BRASSES – 20-36% ZN

Good strength with high ductility. Suitable for drastic cold working.

Admiralty metal (71Cu-28Zn-1Sn)- improved strength and corrosion resistance

  Aluminium brass (76 Cu-22Zn-2Al) - better

corrosion resistance form tenacious and self healing film

RED BRASSES – 5 TO 20 % ZN 

Better corrosion resistance than yellow brasses and not susceptible to stress corrosion cracking and dezincification.

Gliding metal (95Cu-5Zn), Commercial bronze (90Cu-10Zn), Red brass (85Cu-15Zn), Low brass (80 Cu-20 Zn)

ALPHA PLUS BETA BRASSES – 54 TO 62 % CU

Consist of two phases - α + β1 β1 harder and more brittle than α at room

temperature therefore more difficult to cold work.

At elevated temperatures- single phase β becomes very plastic, hence excellent hot working properties.

BRONZES – UP TO 12 % ALLOYING ELEMENTS.

Alloys of Cu and Sn, Al, Si, Be, in addition may contain P, Pb, Zn, or Ni

A. Tin bronzes (Phosphor bronzes) B. Silicon bronzes C. Aluminum bronzes D. Beryllium bronzes

Cupro-Nickels – Alloys of Copper and Nicke

Nickel Silvers - alloys of Copper, Nickel and Zinc

Jennifer A. Juanico

BS ChE - 5

*Nickel and its Alloys

-a hard malleable ductile silvery metallic element that is resistant to corrosion

Discovery: Axel Cronstedt 1751 (Sweden)

Origin: Germany; "Old Nick". :contaminated ores came to be

called Kupfer-nickel (devils copper.)

Properties

Limitations

Applications/ Uses

Turbine Blades

Aerospace flow bodies

Production of Nickel

There are three major types of nickel deposits (sources):

1.) Nickel – copper sulphide2.) Nickel silicates3.)Nickel laterites and serpentines

Classification of Nickel and its Alloys

1.) Commercially pure nickel2.) Nickel – copper alloys (Monels)3.) Nickel – chromium alloys4.) Nickel – base superalloys5.) Nickel – iron superalloys

*Commercially pure nickel

Properties

Applications

Some nickels of commercial importance include: Nickel 200, Nickel 201, Nickel 205, Nickel 270 and 290, Permanickel Alloy 300, Duranickel Alloy 301.

*Nickel – copper alloys (Monels)

Applications: pumps, marine fixtures and fasteners, chemical processing equipment and oil-well drill collars and instruments.

Some nickel-copper alloys of commercial importance include: Alloy 400 (66% Ni, 33% Cu), Alloy R-405, Alloy K-500.

*Nickel – chromium alloys

Properties

Applications

*Nickel – chromium alloys

Some high-temperature variants include:

*Alloy 601.

*Alloy X750.

*Alloy 718.

*Alloy X (48Ni-22Cr-18Fe-9Mo + W).

*Waspaloy (60Ni-19Cr-4Mo-3Ti-1.3Al).

*Nickel – chromium alloysSome corrosion-resistant variants in the Ni-Cr-Fe system

include:

*Alloy 625.

*Alloy G3/G30 (Ni-22Cr-19Fe-7Mo-2Cu).

*Alloy C-22 (Ni-22Cr-6Fe-14Mo-4W).

*Alloy C-276 (17% Mo plus 3.7W)

*Alloy 690 (27% Cr addition).

*Nickel – base superalloys

*Nickel – iron superalloys

* Electrical Resistance Alloys

Types of resistance alloys containing nickel include:

*Cu-Ni alloys containing 2 to 45% Ni

*Ni-Cr-Al alloys containing 35 to 95% Ni

*Ni-Cr-Fe alloys containing 35 to 60% Ni

*Ni-Cr-Si alloys containing 70 to 80% Ni

Types of resistance heating alloys con-taining nickel include:

*Ni-Cr alloys containing 65 to 80% Ni with 1.5% Si

*Ni-Cr-Fe alloys containing 35 to 70% Ni with 1.5% Si + l% Nb

AluminumAluminum

Description- chemical symbol: Al- a shiny, silvery white colored metal- light in weight* and strong**- atomic number: 13- atomic mass: 26.98- density: 2.7 g/mL (will sink in water, but is still relatively light)

* weight is about 1/3 of the weight of steel, brass or copper of equal volume.** can stand heavy pressures and loads. When it is alloyed properly, it can have the

strength of steel.

Aluminum

Corrosion Resistance

- has natural corrosion resistance.- aluminum oxide* forms a protective and not

destructive layer (unlike that of iron)

* resists attack by acids but not by alkalies (that can remove the oxide)

Aluminum

Mechanical PropertiesYoungs Modulus: 70 GPa (in alloys)

Aluminum alloys in general have higher modulus of elasticity due to pinned dislocations in their structure.

Ductility* & Malleability**: High

- both very malleable, and very ductile. - the 2nd most malleable metal- the 6th most ductile metal

*malleable - possible to roll it into sheets**ductile - can be drawn into wires

Aluminum

Mechanical Properties

Hardness: 420 MPa- relatively low due to its low density- easier to scratch than other metals like steel

Melting Point: 660.32 °C and Boiling Point: 2519 °C - relatively low thermal points help aluminum to be reshaped, and welding quite easily.

Aluminum

Cost

Data is for primary aluminum. London Metal Exchange(LME) price shown is for aluminium of 99.7% purity or more. Year 2012 (http://www.steelonthenet.com/charts.html).

Aluminum

Cost: 1800 to 2650 US Dollars per tonne.

- Relatively quite cheaper and economical than other metals (i.e., cost-effective).

Availability

Aluminum

- among the world's most abundant elements (behind only oxygen and silicon).

- reserves are thought to be plentiful enough to maintain supplies of aluminum for some centuries to come.

Industrial Applications

Aluminum

• Packaging - one of the most common uses of aluminum.

(ex. drink cans, bottle caps, foils, trays)

• Construction- ex. aluminum scrap, casting, fabricating, pipes, sheets,

tubing, tanks, bars, wire, stampings, windows, pins, doors, rods, railings, ladders, shutters, building bridges, skylights

• Industrial appliances - ex. aluminium heat exchangers.

AluminumLead

Description

- chemical symbol: Pb- a bluish-white lustrous metal.- atomic number: 82- atomic mass: 207.2

Lead

Corrosion Resistance- Excellent corrosion resistance caused by the formation of

protective surface coatings*.

* Coating- highly insoluble lead salts,(such as sulfate, carbonate, or phosphate):

good corrosion resistance

- soluble salt (such as nitrate, acetate, or chloride): little protection

- Good resistance to sulfuric acid and phosphoric acid- Susceptible to attack by acetic acid and nitric acid.

Lead

Mechanical Properties

Ductility- very ductile or malleable- can be plastically deformed*

*can be stretched, bent etc. and do not return to their original shape when the load is released.), and large deformations are possible before the material breaks.

Lead

Mechanical Properties Tensile Strength: 12-17 Mpa

- very much lower than that of the other common metals mild steel is about 15 times stronger; copper (“as cast”) 10 times stronger; aluminium (“as cast”) about 6 times stronger. even less strong materials (soft pine, plastics) have slightly higher strengths

- strength can be considerably improved by small additions of alloying elements (antimony, tin and copper)

Lead

Mechanical Properties

Fatigue- subject to fatigue. - Fatigue resistance can be improved by certain alloying

additions, most importantly copper.

Lead

Costs

Pure lead cost: $2.45 per 100g Bulk cost: $0.02 per 100g.

Lead

http://www.chemicool.com/elements/lead.html

Availability

• Abundance in the earth’s crust:– 14 ppm by weight– 1 ppm by moles.

• rarely occurs naturally in nature • can be found in ores, mainly with copper, zinc and silver.• approximately 240 mines in more than 40 countries produce

lead. • Leading producers: China, Australia, the United States, and

Peru, in descending order of output.

Lead

Industrial Applications- one of the most used metals in industry (being just

surpassed by other metals as iron, copper, zinc and aluminum)

- main application: electrical batteries for vehicles.- Industry:

– Lead alloys*addition of a small percentage of arsenic, or antimony, to the lead, increases its hardness and mechanical resistance, protecting it from abrasion. The calcium-lead and the tin-lead alloys are used in coating certain electrical cables.

Lead

Industrial Applications

Lead

Industry Usage

Fillers Conductive Fillers in Plastics

Heat Transferring Agents Liquid Metal Heat-transfer Media

Lubricants and Additives Metals/Inorganics - Solid Lubricants

Paints Drying agents

By: Paolo Gabriel Ong

TITANIUM AND SILVER

Titanium was discovered in Cornwall, Great Britain, by William Gregor in 1791 and named by Martin Heinrich Klaproth for the Titans of Greek mythology. The element occurs within a number of mineral deposits, principally rutile and ilmenite, which are widely distributed in the Earth's crust and lithosphere, and it is found in almost all living things, rocks, water bodies, and soils.

TITANIUM

Characteristics of titaniumHigh strength to weight ratio Low densityParamagnetic (low thermal and electrical conductivity)

TITANIUM

Classification: Transtition metalColor: silvery-whiteAtomic weight: 47.87State: SolidMelting point: 1941 KBoiling point: 3560 KDensity @ 20 C: 4.50 g/cm3

Atomic volume: 10.64 cm3/mol

TITANIUM

Uses of titaniumused as an alloying agent with metals used in aerospace, aircraft and engines titanium is used for hulls of ships, propeller shafts and other structures exposed to the sea

used in joint replacement implantsWelded titanium pipe and process equipment

TITANIUM

Corrosion Resistance of Titaniuma very reactive metal that shows remarkable corrosion resistance in oxidizing acid environments by virtue of a passive oxide film

not immune to seawater corrosion if the temperature is greater than about 110oC

TITANIUM

Abundance of Titaniumthe ninth-most abundant element in the Earth's crust (0.63% by mass)

the seventh-most abundant metalpresent in most igneous rocksSignificant titanium-bearing ilmenite deposits exist in western Australia, Canada, China, India, Mozambique, New Zealand, Norway, Ukraine and South Africa

TITANIUM

Processing of titanium Reduction of ore into sponge

Melting of sponge

Conversion into finished product

Secondary fabrication

TITANIUM

Characteristics of SilverSoft, white and lustrous transition metal

Highest electrical conductivity of any element

Highest thermal conductivity of any metal

SILVER

SILVER

Phase: SolidDensity: 10.49g/cm3

Melting pt: 1234.3 KBoiling pt: 2435 KHeat of fusion: 11.28 kJ/molMolar heat capacity: 25.350 J/mol K

SILVER

Uses of SilverWas used in making coins (700 BC)

Jewelry and Silver ware (alloyed with copper)

Used in dentistry to make amalgams (alloyed with other metals)

SILVER

Electronics industryCatalyst

production of formaldehyde from methanol and air by means of silver screens or crystallites containing a minimum 99.95 weight-percent silver

conversion of ethylene to ethylene oxide

SILVER

Corrosion Resistance of Silver

quite resistant to corrosion and does not oxidize easily, although it readily forms a surface tarnish of silver sulfide

SILVER

The principal sources of silver are the ores of copper, copper-nickel, lead, and lead-zinc obtained from Peru, Bolivia, Mexico, China, Australia, Chile, Poland and Serbia.

SILVER

Processing of SilverElectrolytic refiningParks process

SILVER