Product and Industrial Designe MET 28-10-11

8/3/2019 Product and Industrial Designe MET 28-10-11

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PRODUCT AND

INDUSTRIAL

DESIGNE

INRODUCTION TO THEINDUSTRIAL DSIGNE


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Materials Technology III Classification and properties of various alloys, (a) Plain carbon steel (b) Low alloy steels (c) Stainless steels (d) Aluminum alloys

(e)Copper alloys (f) Mg, Ti and Ni alloys. Uses of the alloys in following fields of engineering (1)surgical industry, (2) aerospace industry and other

industries Material selection for design of various products using

metallic materials Comparison of metallic materials with other materials


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MANUFACTURING OF PIG IRON

Blast furnace is used for the manufacturing of pig iron from iron ore. Smelting of iron oretakes place for this purpose. It runs for 5-7years continuously having daily capacity of 600 -1000 tons of pig iron per 24 hours. It has30 m height and 6m in dia.


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1. Hot blast from stoves2. Melting zone ( bosh )3. Reduction zone of ferrousoxide ( barrel )4. Reduction zone of ferric oxide(stack )5. Pre-heating zone ( throat )

6. Feed of ore, limestone, andcoke7. Exhaust gases8. Column of ore, coke andlimestone9. Removal of slag10. Tapping of molten pig iron11. Collection of waste gases
http://en.wikipedia.org/wiki/File:VysokaPec.jpg


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Fe2O3 + 3CO 2Fe +

3CO2

CO2 + C 2CO


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Blast furnace placed in an installation 1. Iron ore + limestone sinter

2. Coke3. Elevator4. Feedstock inlet5. Layer of coke6. Layer of sinter pellets of ore and limestone7. Hot blast (around 1200C)8. Removal of slag9. Tapping of molten pig iron10. Slag pot11. Torpedo car for pig iron12. Dust cyclone for separation of solid particles13. Cowper stoves for hot blast14. Smoke outlet (can be redirected to carboncapture & storage (CCS) tank)15: Feed air for Cowper stoves (air pre-heaters)16. Powdered coal17. Coke oven18. Coke19. Blast furnace gas downcomer


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Iron and its alloys

Iron ore. Processing of iron ore in blast furnace.

It leads to the production of PIG iron. Pig iron is further treated to produce

a) Cast Iron b) steel


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Cast Irongrey cast iron

White cast iron

Malleable cast IronAlloy Cast Iron

Ductile Cast Iron

Chilled cast IronMeehanite Cast Iron


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Steel Steel is an alloy that consists mostly of iron

and has a carbon content between 0.2% and2.1% by weight, depending on the grade.

Carbon is the most common alloying materialfor iron, but various other alloying elementsare used, such as

manganese, chromium, vanadium, and


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Steel Tungsten. Carbon and other elements act as a

hardening agent, Varying the amount of alloyingelements and the form of their presence in thesteel controls qualities such as the

hardness, ductility, and tensile strength of the resulting steel.

Steel with increased carbon content can be madeharder and stronger than iron, but such steel isalso less ductile than iron.


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Steel

Types of steels The carbon steel may be divided into two groups

a) Free cutting steel b) Plain carbon steelFree Cutting Steel Free cutting steel, these consists of B1111, B1112 and

B1113 they differ in S content. High S content in

theses grades promotes machineability. High S and Pcontent leads to some problems.


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Free Cutting Steel Poor properties

1. Poor welding2. Low conductivity3. Low malleability

4. Poor fatigue5. Brittle under impact load.

Good Things1. High machineability2. High quality surface finish in machining3. Tool life is 2-2.5 times greater than when carbon steels of the

same carbon content are machined4. These steels are more susceptible to corrosion


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Plain Carbon Steel It consists of basic open hearth steel from

C1006 to C1095 These are cheaper than alloy steels but

adequate in properties These are of higher purity, and perfect for Heavy rails, structural shapes for building and

bridges, boiler plates, axels, gears etc.


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Plain Carbon Steel

Plain carbon steels are classified according totheir carbon content

Low carbon steel or mild steels ( .15 - .30 %) Medium Carbon steel ( C= .3 - .8 % ) High carbon steels ( C= .8 1.5 % )


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Types of Steel according to De-Oxidation Practice

Killed Steel : These are strongly deoxidized characterized by high composition

and property uniformity. Forging steels are killed steel andcontain .25 % C

Semi Killed Steel : C % .15 to .25 and in semi killed steel the aim is to produce

metal free from surface holes. Surface should have sound skin of considerable thickness

Rimmed steel: Partially deoxidized and less than .15 % C, aim is to produce

clean surface in low carbon steel. It is good for deep drawing.These steels are ideal for rolling . The good cold formingcharacteristics


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MANUFACTURING OF STEELThe different grades of steel are manufactured by the following processes

a) Cementation Processb) Crucible processc) Bessemer Processd) Open Hearth Processe) Electric Steel Making Processf) L D Processg) Duplex processh) Kaldo process


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BOS OR LD PROCESS The basic oxygen furnace or LD converter (originating from

the Linz-Donawitz process started in 1956) is based onoxygen injection by a lance into the melt of hot metal.Scrap and lime are charged into the converter to cool themelt and remove phosphorus, silicon and manganese.

The converter is lined with dolomite or magnesiterefractory which best resists erosion by slag and heatduring oxygen blowing. The life of a converter lining isabout 800 to 1400 heats.

The oxygen burns out the carbon as carbon monoxide COand carbon dioxide CO 2 gas which is collected in the

chimney stack and cleaned of its dust (Fe 203, and limeparticles, etc.). The elements Mn, Si and P are oxidized andcombine with lime (CaO) and FeO formed by the oxidationof Fe to form a molten slag.


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BOS OR LD PROCESS As these oxidation reactions are highly exothermic, the

process needs cooling in order to control thetemperature of the melt. This cooling is done bycharging scrap (recycled plant and mill scrap) and byadding iron ore during the blowing process.

The oxygen blowing takes 15 to 20 minutes, regardlessof the size of the converter (70 to 400 t) because theoxygen flow rate of the lance is adjusted to the meltweight. The charging and discharging of steel and slag,including sampling for temperature and analysis of themelt, extends the tap to tap time of a converter to 40 -60 minutes. The process is characterized by highproductivity and steel of low impurity content.


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BOS OR LD PROCESS The steel is tapped to the ladle through a taphole

by tilting the furnace. During this operation ferro-alloys for control of the steel composition areadded to the ladle.

A major development in the oxygen lanceblowing technique, known as Lance BubblingEquilibrium (LBE) was developed in the mid-seventies and has been widely adopted. Neutralgas, typically argon, is injected throughpermeable elements in the bottom of theconverter, stirring the melt and slag.


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BOC


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Electric Steel Making Process In the electric arc furnace process, the cold metallic

charge, mainly scrap, is melted by the energy of electric arcs generated between the tips of graphiteelectrodes and the conductive metallic charge.

The three electrodes and the furnace roof are raised

and swung away from the furnace shell to allow thecharging of scrap. The electrodes maintain the arc inaccordance with the voltage and current level selectedto produce the desired power input at the desired arc

length for melting and refining. As the noise generatedby the arcs is high during the melt-in-period, specialprotection is provided to the operators cabin and thefurnace has a special enclosure.


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Electric Steel Making Process

The three phase AC current is supplied by the lowvoltage side (300 - 700V) of a high power transformer.The nominal transformer rating, expressed as KVA/t,extends from 300 to 500 KVA/t for high power furnaces

and from 500 KVA/t upwards for Ultra High Power(UHP) furnaces. These furnaces have an inner diameterof 6 to 9 metres with a capacity of 100 to 200 tons of steel. The tap-to-tap time for these furnaces is 90 to110 minutes.

The traditional role of the EAF process is producingalloy, tool and carbon steels, and it has been extendedby the UHP furnace to mass steel production. Thus, theconcept of the Mini-Mill was born.


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Documents

Product and Industrial Designe MET 28-10-11