2nd ESO technology

Metals

1.- WHAT ARE METALS? Metals account for about two thirds of all the elements and for about 24% of the mass of the planet. They are all around us in such forms as steel structures, copper wires, aluminium foil and gold jewellery. Metals are widely used (transportation, aerospace, computers, satellites, construction, biomechanical applications, farming, household conveniences ) because of their properties: strength, ductility, high melting point, thermal and electrical conductivity, and toughness. Therefore, most metals are malleable and ductile and are, in general, denser than other elemental substances. 2.- TYPES OF METALS Metals are classified as either ferrous or non-ferrous metals. Ferrous metals contain iron. Non-ferrous metals do not contain iron. In general ferrous metals tend to corrode and therefore need some form of protection against corrosion. Nonferrous metals do not tend to corrode in the same way. Metals can also be divided into 3 categories: base metals (a metal that oxidises and corrodes relatively easily, e.g.: iron, nickel, lead and zinc), noble metals (metals that are resistant to corrosion or oxidation, e.g.: tantalum, platinum and rhodium) and precious metals (they are rare metallic chemical elements of high

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Metals

economic value; they are less reactive than most elements, have high lustre and high electrical conductivity; examples are gold, silver, platinum and palladium). Metals are available in pure or alloy form. Pure metals, such as pure aluminium or pure copper, contain only one type of metal. They are not mixed with any other metal. Alloys are homogeneous mixtures of two or more metals or elements. Alloys tend to have better strength properties than pure metals. Alloys and pure metals often have special physical properties. For example, pure copper is used where electrical conductivity is required; tin and copper alloy is used for making bronze objects. 2.1. PURE METALS The most important pure metals are the following: Aluminium, non-ferrous metal Tin, non-ferrous metal Zinc, non-ferrous metal Copper, non-ferrous metal Lead, non-ferrous metal Iron, ferrous metal

2.2. ALLOYS The presence of other elements in a metal can also change its properties, sometimes drastically. The arrangement and kind of bonding in metals permits the addition of other elements into the structure, forming mixtures of metals called alloys. Even if the added elements are non-metals, alloys may still have metallic properties. Alloys are homogeneous mixtures and their percentage composition can vary. This is useful, because the properties of alloys can be manipulated by varying their composition. For example, electricians need a solder with different properties to the one used by plumbers. Electrical solder hardens very quickly producing an almost immediate connection. This would not be practical for plumbers who need some time to set the joint. Electrical solder contains about 60% tin, whereas plumbers solder contains about 30%. The most common alloys are the following: Brass (Llaut): Copper and Zinc Bronze (Bronze): Copper, Zinc and Tin Cast iron (Fosa): Iron, Carbon, Manganese and Silicon.

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Metals

Steel (Acer): Iron and Carbon (plus small amounts of alloying elements).

3.- FERROUS METALS: Iron was available to the ancients in small amounts from meteors. This iron is easily distinguishable because it contains 6-8% nickel. There is some indication that man-made iron was available as early as 2500 B.C., however, iron making did not become an everyday process until 1200 B.C. Hematite, an oxide of iron, was widely used by the ancients for beads and ornaments and it was 5 times more expensive than gold. Iron weapons revolutionized warfare and iron implements did the same for farming. Iron and steel was the building block for civilization. Interestingly, an iron pillar dating to 400 A.D. remains standing today in Delhi, India. Corrosion to the pillar has been minimal, a skill lost to current ironworkers. Iron is rarely found in its native state, the only known source is Greenland where the iron occurs as nodules in basalt that erupted through beds of coal and two very rare nickel-iron alloys. Irons symbol is Fe from the Latin ferrum. 3.1. CLASIFICATION Ferrous metals include: Wrought iron (ferro forjat): it is a high purity iron. Wrought iron is quite soft and easily worked on and has little structural strength. It was once used to make decorative gates and railings, but these days mild steel is normally used instead. Steel: it is one of the most common alloys available, being a mixture of iron and carbon. Iron is soft and ductile, while carbon is hard and brittle. By adjusting the amount of carbon used, steels with different hardness can be produced. It contains less than 1.76% of carbon. It is white-grey and its properties are: ductility; malleability; high strength; can be soldered and forged; and good electricity conductivity. We can vary its properties mixing it with other materials or with thermal/heat treatments. Plain carbon steels: they are alloys of iron and carbon. The carbon content varies from 0.01% up to about 1.5%. They can be divided up into three main groups: mild steel (0.15-0.35% carbon), medium steel (0.35-0.7% carbon) and high carbon steel (0.8-1.5% carbon). Increasing the carbon content in the steel increases its hardness and toughness but reduces its ability to be cold-worked.

2nd ESO technology

Metals

Tool steels: they are special steels, which are alloys of iron and carbon but with other additions such as tungsten. This helps to increase their wear resistance.

Stainless steels (acer inoxidable): they do not corrode. Stainless steels are alloys of iron and carbon but also contain chromium and nickel. These additions give it its anti-corrosive properties. They are used for applications such as sinks and kitchen utensils.

Cast irons (ferro colat o fosa): they are alloys of iron containing around 3.54.5% carbon. They are dark-grey; more resistant to rusting; transmit heat easily and absorb vibration. They are generally used in sand-cast products. 3.2. USES AND PROPERTIES

3.3. IRON AND STEEL OBTAINING PROCESS About 1400 B.C. an Armenian tribe began to make steel. So began the named Iron Age, during this age its use was generalised. The obtaining process consisted in heating and hitting some iron object on a coal fire. So the iron surface absorbed carbon particles and so turning into steel (so the iron won better mechanical resistance properties).

2nd ESO technology

Metals

Nowadays the separation of iron from its mineral is done in a blast furnace. The common ores of iron are two iron oxides (haematite, Fe2O3, and magnetite, Fe3O4), and these can be reduced to iron by heating them with carbon in the form of coke. Coke is produced by heating coal in the absence of air. Coke is cheap and provides both the reducing agent for the reaction and also the heat source.

The Blast Furnace:

The industry that obtains iron and steels is called iron and steel industry (siderrgia, in Catalan). These industries used to be installed near the ports where ships docked; this was to make the transport of the raw material easier and cheaper. 4.- NON-FERROUS METALS: These metals contain no iron and therefore do not rust. 4.1. THE MOST IMPORTANT NON-FERROUS METALS

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Metals

4.2. NON-FERROUS ALLOYS

5.- HEAT TREATMENT PROCESSES The properties of some metals can be altered by heat treatments. Heat treatment processes may be used to improve the properties of a metal. They are also used to help soften the metal for use in processes such as cold rolling, cold extrusion and wire drawing of metals. During heat treatment the metal is heated and cooled in a controlled way to give it the required properties. The main heat treatment processes are: The annealing of non-ferrous and ferrous metals to make them less brittle. The normalising of medium carbon steels to make them more stable. Normalising is an industrial process used to improve the strength and toughness of products when they have been forged or rolled. Normalising improves the internal structure of the metal and reduces the internal stresses that have been produced by hot working. The temperature at which the steel is heated depends upon the carbon content of the steel. After heating the steel is cooled in air. The hardening and tempering of steels above 0.4% carbon content to improve toughness on impact. The case-hardening of mild steels to improve strength.

2nd ESO technology 6.- METALS HISTORICAL GUIDELINE

Metals

Process metallurgy is one of the oldest applied sciences. Its history can be traced back to 6000 B.C. There are seven metals known as the Metals of Antiquity, these were the metals upon which civilisation was based. These seven metals are Gold (6000 B.C.), Copper (4200 B.C.), Silver (4000 B.C.), Lead (3500 B.C.), Tin (1750 B.C.), Smelted Iron (1500 B.C.) and Mercury (750 B.C.). These metals were known to the Mesopotamians, Egyptians, Greeks and Romans. Five of these metals can be found in their native states (gold, silver, copper, iron from meteors- and mercury). However the occurrence of these metals was not abundant and the first two metals to be widely used were gold and copper. You must also consider, of course, the history of metals is closely linked to that of coins and gemstones. Currently there are 86 known metals.

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Metals

2nd ESO technology 7.- FUTURE TRENDS

Metals

In the future, we will continue to depend heavily on metals. Lightweight aluminium alloys will be utilized more in automobiles to increase fuel efficiency. Also, heat resistant superalloys will be developed so that engines can operate at higher, more efficient temperatures. Similarly, ceramic coatings will be used more to protect metals from high temperatures, and to increase the lifetime of tools. New, radiation-resistant alloys will allow nuclear power plants to operate longer, and thus lower the cost of nuclear energy. Steel will continue to be the most commonly used metal for many years to come, due to its very low cost and the ability to customize its properties by adding different alloying elements. Finally, as easily-mined, high grade ores are depleted, recycling will become more important. Already, half of all aluminium, copper and steels are being recycled. Why is metal recycling important? Because if you recycle metals you can contribute to: save raw materials and energy by not having to first extract the iron from the ore; avoid the pollution problems in the extraction of iron from the ore; not having to find space to dump the unwanted iron if when it

is not recycled.

2nd ESO technology EXERCISES:

Metals

1.- Which are the most common non-ferrous metals? 2.- Most of the molten iron from a Blast Furnace is used to make one of a number of types of steel. a) As you know, there isnt just one substance called steel. Steel is a family of alloys of iron containing carbon and sometimes different metals. Explain which they are. b) What is a Blast Furnace? 3.- Why is it important to recycle metals? 4.- Are metals raw materials? 5.- What are heat treatment processes? 6.- State four properties of metals. 7.- What is an alloy? Name 4 alloys and specify the metals they are made of. 8.- Set some examples of applications of metals. 9.- Which were the seven metals known as Metals of Antiquity? 10.- How many metals are currently known? 11.- Complete the blank spaces with the appropriate word: Metals can be classified in ______ metals and _______ metals, depending if they contains _______ or they dont contain it. Metals are available in _______ or ______ form. An _______ is an __________ mixture of a pure metal with another _________, Alloys can be formed by _____ or more metals, while pure metals, such as __________ or ________, contain only _____ type of metal. (one, ferrous, iron, pure aluminium, non ferrous, pure copper, alloy, metal, pure, alloy, homogeneous, two) 12.- Write the name of a metal with the following properties: i) Good electrical conductor and corrosion resistant. ii) Good electrical and heat conductor, heavy and expensive. iii) High corrosion resistance, ductile, malleable and low melting point. iv) Easily joined, good electrical and heat conductor, malleable and ductile. 13.- Set some examples of the uses of the following metals: metal copper cast steel brass bronze aluminium uses tin stainless steel duralumin mild steel lead metal uses

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