S T E E L Steel, the world's foremost construction material, is an alloy of iron , containing between 0.2% and 2% carbon (by weight). H I S T O R Y : The advent of commercial steel production in the late 19th century was a result of Sir Henry Bessemer's creation of an efficient way to lower the carbon content in cast iron . By lowering the amount of carbon in iron to about 2%, the harder and more malleable steel is produced. The development of steel can be traced back 4000 years to the beginning of the Iron Age . Proving to be harder and stronger than bronze, which had previously been the most widely used metal, iron began to displace bronze in weaponry and tools. For the following few thousand years, however, the quality of iron produced would depend as much on the ores available as on the production methods. By the 17th century, iron's properties were well understood, but increasing urbanization in Europe demanded a more versatile structural metal. And by the 19th century, the amount of iron being consumed by expanding railroads provided metallurgists with financial incentive to find a solution to iron's brittleness and inefficient production processes. A major breakthrough came in 1856 when Henry Bessemer developed an effective way to use oxygen to reduce the carbon content in iron. The modern steel industry was born. P R O D U C T I O N :
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S T E E LSteel, the world's foremost construction material, is an alloy of iron, containing between 0.2% and 2% carbon (by weight).
H I S T O R Y :
The advent of commercial steel production in the late 19th century was a result of Sir Henry Bessemer's creation of an efficient way to lower the carbon content in cast iron. By lowering the amount of carbon in iron to about 2%, the harder and more malleable steel is produced.
The development of steel can be traced back 4000 years to the beginning of the Iron Age. Proving to be harder and stronger than bronze, which had previously been the most widely used metal, iron began to displace bronze in weaponry and tools.
For the following few thousand years, however, the quality of iron produced would depend as much on the ores available as on the production methods.
By the 17th century, iron's properties were well understood, but increasing urbanization in Europe demanded a more versatile structural metal. And by the 19th century, the amount of iron being consumed by expanding railroads provided metallurgists with financial incentive to find a solution to iron's brittleness and inefficient production processes.
A major breakthrough came in 1856 when Henry Bessemer developed an effective way to use oxygen to reduce the carbon content in iron. The modern steel industry was born.
P R O D U C T I O N :
Today, most steel is produced by basic oxygen methods (also known as basic oxygen steelmaking or BOS). BOS is so-named because it requires oxygen to be blown into large vessels containing molten iron and scrap steel.
Although BOS accounts for the largest share of global steel production, the use of electric arc furnaces (EAF) has been growing since the early 20th century and now accounts for about one-third of all steel production.
Over 3,500 different grades of steel exist. Commercial steel is generally classified into four groups depending on their metal alloy content and end-use applications:
1. Carbon Steels (including low carbon, medium carbon and high carbon steels)2. Alloy Steels (common alloy metals; manganese, silicon, nickel and chromium)3. Stainless Steels (contain about 10% chromium and classified as austenitic, ferritic and
martensitic)4. Tool Steels (alloyed with high temperature and hard metals, such as molybdenum and
tungsten)
According to the World Steel Association, there are over 3,500 different grades of steel, encompassing unique physical, chemical and environmental properties.
In essence, steel is composed of iron and carbon, although it is the amount of carbon, as well as the level of impurities and additional alloying elements that determines the properties of each steel grade.
The carbon content in steel can range from 0.1-1.5%, but the most widely used grades of steel contain only 0.1-0.25% carbon. Elements such as manganese, phosphorus and sulphur are found in all grades of steel, but, whereas manganese provides beneficial effects, phosphorus and sulphur are deleterious to steel's strength and durability.
Different types of steel are produced according to the properties required for their application, and various grading systems are used to distinguish steels based on these properties. According to the American Iron and Steel Institute (AISI), steels can be broadly categorized into four groups based on their chemical compositions:
A steel whose properties are determined primarily by the amount of carbon present. Apart from iron and carbon, manganese up to 1.5% may be present as well as residual amounts of alloying elements such as nickel, chromium, molybdenum, etc. It is when one or more alloying elements are added in sufficient amount that it is classed as an alloy steel.
Carbon steels contain trace amounts of alloying elements and account for 90% of total steel production. Carbon steels can be further categorized into three groups depending on their carbon content:
Low Carbon Steels/Mild Steels contain up to 0.3% carbon
Although not usually considered as an alloying element, is the most important constituent of steel. It raises tensile strength, hardness and resistance to wear and abrasion. It lowers ductility, toughness and machinability.
2) A L L O Y S T E E L S :
A steel to which one or more alloying elements other than carbon have been deliberately added (e.g. chromium, nickel, molybdenum) to achieve a particular physical property.
Alloy steels contain alloying elements (e.g. manganese, silicon, nickel, titanium, copper, chromium and aluminum) in varying proportions in order to manipulate the steel's properties, such as its hardenability, corrosion resistance, strength, formability, weldability or ductility. Applications for alloys steel include pipelines, auto parts, transformers, power generators and electric motors.
M A N G A N E S E
Manganese is a key component in the production of steel. Although classified as a minor metal, the quantity of manganese produced worldwide each year falls behind only iron, aluminum, copper and zinc.
Properties:
Atomic Symbol: Mn Atomic Number: 25
Element Category: Transition Metal Density: 7.21 g/cm³ Melting Point: 2274.8°F (1246°C) Boiling Point: 3741.8° F (2061 °C) Mohs Hardness: 6
Characteristics:
Manganese is an extremely brittle and hard, silvery-grey metal. The twelfth most abundant element in the earth's crust, manganese increases strength, hardness and wear resistance when alloyed in steel.
It is manganese’s ability to readily combine with sulphur and oxygen, which make it critical in the production of steel. Manganese's proclivity to oxidize helps to remove oxygen impurities, while also improving the workability of steel at high temperatures by combining with sulphur to form a high melting sulphide.
Nickel is a strong, lustrous, silvery-white metal that was not isolated by scientists until the mid-18th century, but is now a staple of our daily lives and can be found in everything from the batteries that power our television remotes to the stainless steel that is used to make our kitchen sinks.
Properties:
Atomic Symbol: Ni Atomic Number: 28 Element Category: Transition metal Density: 8.908 g/cm3
Pure nickel reacts with oxygen and, therefore, is seldom found on the earth's surface, despite being the fifth most abundant element on (and in) our planet. In combination with iron, nickel is extremely stable, which explains both its occurrence in iron containing ores and its effective use in combination with iron to make stainless steel.
Nickel is very strong and resistant to corrosion, making it excellent for strengthening metal alloys. It is also very ductile and malleable, properties that allow its many alloys to be shaped into wire, rods, tubes and sheets.
Ni-Steel It contains 2% to 4% Ni. Uses: Gear, shaft, cable.
C H R O M I U M
Chromium metal is most widely recognized for its use in chromium plating (which is often referred to simply as 'chrome'), but its largest use is as an ingredient in stainless steels. Both applications benefit from chromium's hardness, resistance to corrosion and ability to be polished for a lustrous appearance.
Element Category: Transition Metal Density: 7.19g/cm3 at 20°C Melting Point: 3465°F (1907°C) Boiling Point: 4840°F (2671°C) Moh’s Hardness: 5.5
Characteristics
Chromium is a hard, grey metal that is valued for its incredible resistance to corrosion. Pure chromium is magnetic and brittle, but when alloyed can be made malleable and polished to a bright, silvery finish.
Chromium derives its name from khrōma, a Greek word meaning color, due to its ability to produce vivid, colourful compounds, such as chrome oxide.
T I T A N I U M
Titanium is a strong and lightweight refractory metal. Alloys of titanium are critical to the aerospace industry but, due to their numerous unique properties, are also used in medical, chemical and military applications, as well as in sporting goods.
Properties:
Atomic Symbol: Ti Atomic Number: 22 Element Category: Transition Metal Density: 4.506/cm3 Melting Point: 3034°F (1668°C) Boiling Point: 5949°F (3287°C) Moh's Hardness: 6
Characteristics:
Alloys containing titanium are known for their high strength, light weight and exceptional corrosion resistance.
Despite being as strong as steel, titanium is about 40% lighter in weight, which, along with its resistance to cavitation and erosion, makes it an essential structural metal for aerospace engineers.
Titanium is also formidable in its resistance to corrosion by both water and chemical media. It does this by forming a thin layer of titanium dioxide (TiO2) on its surface that is extremely difficult for these materials to penetrate.
Having a low modulus of elasticity means that titanium is not also very flexible, but returns to its original shape after bending, resulting in its importance to shape memory alloys.
Titanium is non-magnetic and biocompatible (non-toxic, non-allergenic), which has led to its increasing use in the medical field.
C O P P E R
Copper (Cu) is one of the best electrical conductors of all the metals, and its abundance helped it become the material that tied the world together in telecommunications. Light red in color and easily oxidized to a gritty green hue, copper can be drawn and formed to serve many purposes from architecture and jewelry to water pipes and circuit boards.
Physical Properties
Strength : Copper is a weak metal with a tensile strength about half that of mild carbon steel. This explains why copper is easily formed by hand, but is not a good choice for structures.
Toughness : Copper may not be strong, but it is not easy to break due to its high toughness. This property comes in handy for piping and tube applications, where a rupture can be dangerous and expensive.
Ductility : Copper is very ductile and also very malleable. The electrical and jewelry industries benefit from the ductility of copper.
Conductivity: Second only to silver, copper is not only an excellent conductor of electricity, but also of heat. As a result, copper serves well in applications such as cookware, where it quickly draws heat to the food inside.
A L U M I N U M
Aluminum (also known as aluminium) is the most abundant metal element in the earth's crust. And it's a good thing too, because we use a lot of it. About 41 million tons are smelted each year and employed in a wide arrange of applications. From auto bodies to beer cans, and from electrical cables to aircraft skins, aluminum is a very big part of our everyday lives.
Properties:
Atomic Symbol: Al Atomic Number: 13 Element Category: Post-transition metal Density: 2.70 g/cm3
Aluminum is a lightweight, highly conductive, reflective and non-toxic metal that can be easily machined. The metal's durability and numerous advantageous properties makes it an ideal material for many industrial applications.
3) S T A I N L E S S S T E E L S :
Can be defined as a group of corrosion resisting steels containing a minimum 10% chromium and in which varying amounts of nickel, molybdenum, titanium, niobium as well as other elements may be present. An Englishman, Harry Brearley, is generally acknowledged to be the pioneer who developed stainless steels for commercial use.
Stainless steels generally contain between 10-20% chromium as the main alloying element and are valued for high corrosion resistance. With over 11% chromium, steel is about 200 times more resistant to corrosion than mild steel. These steels can be divided into three groups based on their crystalline structure:
Austenitic: Austenitic steels are non-magnetic and non heat-treatable, and generally contain 18% chromium, 8% nickel and less than 0.8% carbon. Austenitic steels form the largest portion of the global stainless steel market and are often used in food processing equipment, kitchen utensils and piping.
Ferritic: Ferritic steels contain trace amounts of nickel, 12-17% chromium, less than 0.1% carbon, along with other alloying elements, such as molybdenum, aluminum or titanium. These magnetic steels cannot be hardened with heat treatment, but can be strengthened by cold works.
Martensitic: Martensitic steels contain 11-17% chromium, less than 0.4% nickel and up to 1.2% carbon. These magnetic and heat-treatable steels are used in knives, cutting tools, as well as dental and surgical equipment.
4) T O O L S T E E L S :
A generic term applied to a wide range of steels, both plain carbon and alloy. It includes steels suitable for various types of cutting tools, press tools, hot and cold heading dies, moulds for plastics and die- casting, extrusion tools, hand tools, etc.
Tool steels contain tungsten, molybdenum, cobalt and vanadium in varying quantities to increase heat resistance and durability, making them ideal for cutting and drilling equipment.
Steel products can also be divided by their shapes and related applications:
Long/Tubular Products include bars and rods, rails, wires, angles, pipes, and shapes and sections. These products are commonly used in the automotive and construction sectors.
Flat Products include plates, sheets, coils and strips. These materials are mainly used in automotive parts, appliances, packaging, shipbuilding, and construction.
Other Products include valves, fittings, and flanges and are mainly used as piping materials.
M O L Y B D E N U M
Molybdenum (often referred to as 'Moly') is valued as an alloying agent in structural and stainless steels because of its strength, corrosion resistance and ability to hold shape and operate at high temperatures.
Properties:
Atomic Symbol: Mo Atomic Number: 42 Element Category: Transition metal Density: 10.28 g/cm3 Melting Point: 4753 °F (2623 °C) Boiling Point: 8382 °F (4639 °C) Moh’s Hardness: 5.5
Characteristics:
Like other refractory metals, molybdenum has a high density and melting point, and is resistant to heat and wear. At 2,623 °C (4,753 °F), molybdenum has one of the highest melting points of all metal elements, while its coefficient of thermal expansion is one of the lowest of all engineering materials. Moly also has a low toxicity.
In steels, molybdenum reduces brittleness as well as enhances strength, hardenability, weldability and corrosion resistance.
T U N G S T E N
Tungsten is a dull silver-colored metal with the highest melting point of any pure metal.
Also known as wolfram, from which the element takes its symbol, W, tungsten is more resistant to fracturing than diamond and is much harder than steel. It is the refractory metal's unique properties - its strength and ability to withstand high temperatures - that make it ideal for many commercial and industrial applications.
Properties:
Atomic Symbol: W Atomic Number: 74 Element Category: Transition Metal Density: 19.24g/cm3
Tungsten is primarily extracted from two types of minerals, wolframite and scheelite. However, tungsten recycling also accounts for about 30% of the global supply. China is the world's largest producer of the metal, providing over 80% of the world supply.
Once tungsten ore has been processed and separated, the chemical form, ammonium paratungstate (APT), is produced. APT can be heated with hydrogen to form tungsten oxide or will react with carbon at temperatures above 1925°F (1050°C) to produce tungsten metal.
Applications:
Tungsten's primary application for over 100 years has been as the filament in incandescent light bulbs. Doped with small amounts of potassium-aluminum silicate, tungsten powder is sintered at high temperature to produce the wire filament that is in the center of light bulbs that light millions of homes around the world.
Due to tungsten's ability to keep its shape at high temperatures, tungsten filaments are now also used in a variety of household applications, including lamps, floodlights, heating elements in electrical furnaces, microwave ovens, x-ray tubes and cathode-ray tubes (CRTs) in computer monitors and television sets. The metal's tolerance to intense heat also makes it ideal for thermocouples and electrical contacts in electric arc furnaces and welding equipment. Applications that require a concentrated mass, or weight, such as counterweights, fishing sinkers and darts often use tungsten because of its density.
Tungsten Carbide:
Tungsten carbide is produced either by bonding one tungsten atom with a single carbon atom (represented by the chemical symbol WC) or two tungsten atoms with a single carbon atom (W2C). This is done by heating tungsten powder with carbon at temperatures of 2550°F to 2900°F (1400°C to 1600°C) in a stream of hydrogen gas.
According to Moh's hardness scale (a measure of one material's ability to scratch another), tungsten carbide has a hardness of 9.5, only slightly lower than diamond. For this reason, this hard compound is sintered, a process that requires pressing and heating the powder form at high temperatures, to make products used in machining and cutting. The result are materials that can operate in conditions of high temperature and stress, such as drill bits, lathe tolls, milling cutters and armor piercing ammunition.
Cemented carbide is produced using a combination of tungsten carbide and cobalt powder, and is used to manufacture wear-resistant tools, such as those used in the mining industry. The tunnel-boring machine that was used to dig the Channel Tunnel linking Britain to Europe was, in fact, outfitted with almost 100 cemented carbide tips.
Tungsten Alloys:
Tungsten metal can be combined with other metals to increase their strength and resistance to wear and corrosion. Steel alloys often contain tungsten for these beneficial properties. Many high speed steels - those used in cutting and machining tools like saw blades - contain around 18 percent tungsten.
Tungsten-steel alloys are also used in the production of rocket engine nozzles, which must have high heat resistant properties. Other tungsten alloys include Stellite (cobalt, chromium and tungsten), which is used in bearing and pistons due to its durability and resistance to wear, and Hevimet, which is made by sintering a tungsten alloy powder and is used in ammunition, dart barrels and golf clubs. Superalloys made of cobalt, iron or nickel, along with tungsten, can be used to produce turbine blades for aircrafts.
C O B A L T
Cobalt is a shiny, brittle metal that is used to produce strong, corrosion and heat resistant alloys, permanent magnets and hard metals.
Properties
Atomic Symbol: Co Atomic Number: 27 Atomic Mass: 58.93g/mol Element Category: Transition metal Density: 8.86g/cm3 at 20°C Melting Point: 2723°F (1495°C) Boiling Point: 5301°F (2927°C) Moh's Hardness: 5
Characteristics
Silver-colored cobalt metal is brittle, has a high melting point and is valued for its wear resistance and ability to retain its strength at high temperatures.
It is one of the three naturally occurring magnetic metals (iron and nickel being the other two) and retains its magnetism at a higher temperature (2012°F, 1100°C) than any other metal. In other words, cobalt has the highest Curie Point of all metals. Cobalt also has valuable catalytic properties
P R O P E R T I E S O F S T E E L
H A R D E N A B I L I T Y
The property that determines the depth and distribution of hardness when steel is heated to a given temperature and then quenched (more precisely it may be defined as an inverse measure of the severity of cooling conditions necessary to produce on continuous cooling a martensitic structure in a previously austenitized steel i.e. to avoid transformations in the pearlitic and bainitic ranges). The lower the cooling rate to avoid these transformations, the greater the hardenability. The critical cooling rate is largely a function of the composition of the steel. In general the higher the carbon content, the greater the hardenability, whilst alloying elements such as nickel, chromium, manganese and molybdenum increase the depth of hardening for a given ruling section.
C O R R O S I O N R E S I S T A N C E
Corrosion is the chemical or electrochemical reaction between a material, usually a metal, and its environment that produces a deterioration of the material and its properties.
S T R E N G T H
Strength is a measure of how well a material can resist being deformed from its original shape. Typically, metals are specified for their tensile strength, or their resistance to being pulled apart, but compressive strength is also a legitimate material property describing resistance to being squeezed. Strength is measured in units of pressure, and is typically reported in units of ksi, or "thousands of pounds per square inch."
F O R M A B I L I T Y
The relative ease with which a metal can be shaped through plastic deformation.
W E L D A B I L I T Y
The feasibility of welding a particular metal or alloy. A number of factors affect weldability including chemistry, surface finish, heat-treating tendencies, etc.
D U C T I L I T Y
The property of metal which permits it to be reduced in cross sectional area without fracture. In a tensile test, ductile metals show considerable elongation eventually failing by necking, with consequent rapid increase in local stresses.
P R O C E S S E S
H E A T T R E A T M E N T
Heat treatment is the process of heating and cooling metals to achieve desired physical and mechanical properties through modification of their crystalline structure. The temperature, length of time, and rate of cooling after heat treatment will all impact properties dramatically. The most common reasons to heat treat include increasing strength or hardness, increasing toughness, improving ductility and maximizing corrosion resistance.
C O L D W O R K I N G
Altering the shape or size of a metal by plastic deformation. Processes include rolling, drawing, pressing, spinning, extruding and heading, it is carried out below the recrystallisation point usually at room temperature. Hardness and tensile strength are increased with the degree of cold work whilst ductility and impact values are lowered. The cold rolling and cold drawing of steel significantly improves surface finish.
G E N E R A L P R O P E R T I E S O F S T E E L S
Different types of steel are produced according to the properties required for their application, and various grading systems are used to distinguish steels based on these properties. According to the American Iron and Steel Institute (AISI), steels can be broadly categorized into four groups based on their chemical compositions:
The following advantages in general may be credited to steel as a structural design material:
1. High strength/weight ratio. Steel has a high strength/weight ratio. Thus, the dead weight of steel structures is relatively small. This property makes steel a very attractive structural material for
a. High-rise buildingsb. Long-span bridgesc. Structures located on soft groundd. Structures located in highly seismic areas where forces acting on the structure due to an earthquake are in general proportional to the weight of the structure.2. Ductility. As discussed in the previous section, steel can undergo large plastic deformation before failure, thus providing a large reserve strength. This property is referred to as ductility. Properly designed steel structures can have high ductility, which is an important characteristic for resisting shock loading such as blasts or earthquakes. A ductile structure has energy-absorbing capacity and will not incur sudden failure. It usually shows large visible deflections before failure or collapse.
3. Predictable material properties. Properties of steel can be predicted with a high degree of certainty. Steel in fact shows elastic behavior up to a relatively high and usually well-defined stress level. Also, in contrast to reinforced concrete, steel properties do not change considerably with time.
4. Speed of erection. Steel structures can be erected quite rapidly. This normally results in quicker economic payoff.
5. Quality of construction. Steel structures can be built with high-quality workmanship and narrow tolerances.
6. Ease of repair. Steel structures in general can be repaired quickly and easily.
7. Adaptation of prefabrication. Steel is highly suitable for prefabrication and mass production.
8. Repetitive use. Steel can be reused after a structure is disassembled.
9. Expanding existing structures. Steel buildings can be easily expanded by adding new bays or wings. Steel bridges may be widened.
10. Fatigue strength. Steel structures have relatively good fatigue strength.
D I S A D V A N T A G E S O F S T E E LThe following may be considered as disadvantages of steel in certain cases:
1. General cost. Steel structures may be more costly than other types of structures.
2. Fireproofing. The strength of steel is reduced substantially when heated at temperatures commonly observed in building fires. Also, steel conducts and transmits heat from a burning portion of the building quite fast. Consequently, steel frames in buildings must have adequate fireproofing.
3. Maintenance. Steel structures exposed to air and water, such as bridges, are susceptible to corrosion and should be painted regularly. Application of weathering and corrosion-resistant steels may eliminate this problem.
4. Susceptibility to buckling. Due to high strength/weight ratio, steel compression members are in general more slender and consequently more susceptible to buckling than, say, reinforced concrete compression members. As a result, considerable materials may have to be used just to improve the buckling resistance of slender steel compression members.