METALS

CONSTRUCTION MATERIALS AND TESTING

GROUP 3

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 Course Outline
01 Wrought Iron, cast iron & steel

02 Non-ferrous metals

03 Steel frame construction

04 Testing of Metals
 Course Objectives
Explain the processes for mining and processing
01 iron ore and for producing steel (CO1)

Describe the different properties of ferrous metals

02 (CO2)

03 Identify the different types of testing metals (CO3)

 IRON
ONE OF THE MOST COMMON ELEMENTS OF THE EARTH
TYPES OF
IRON
•Wrought iron

•Cast Iron
Wrought
Iron
•It is one of two forms of iron which is
acquired through the process of smelting.

•It is a soft, ductile, and a fibrous that is

produced from iron that is covered with slag.

•It is much more superior to cast iron due to

its high carbon content.
Cast Iron
•An alloy of iron made out of metals such as
silicon and manganese alongside impurities
such as sulfur and and phosphorus.

•It is made with the use of a blast furnace.

•It can be also called as gray iron or white

iron
Iron

•PURE IRON IS A SOFT, GRAYISH – WHITE METAL

•IRON IS A COMMON ELEMENT, BUT PURE IRON IS

ALMOST NEVER FOUND IN NATURE, IT ONLY EXIST
ON FALLEN METEORITES
Ore Extraction & Refining Process

Extraction
• IRON ORES ARE EXTRACTED FROM OPEN PIT
MINING

Refining
• MINED ORES ARE CRUSHED TO REMOVE SAND
AND CLAY AWAY, THEN REFINED ORES ARE
TRANSPORTED TO BLAST FURNACE SITE.

Manufacturing
• ORES GOES TO THE BLAST FURNACE; CARBON
MONOXIDE REACTS WITH THE IRON ORE TO
FORM CARBON DIOXIDE AND PURE IRON. MELTED
IRON SINKS TO THE BOTTOM OF THE FURNACE.
Iron Mining Process
STEEL
•It is a product of iron and carbon in which the
• carbon content can only be at 2% maximum
otherwise when increased further it will be called
wrought iron.

•It is the most commonly used for construction of

infrastructures.
History of Steel
•Steel has been produced on a small scale for thousands of years.
The earliest known steel is about 4,000 years old and was
excavated in Turkey.

•The steel industry has grown from ancient times, when a few men
may have operated, periodically, a small furnace producing 10
kilograms, to the modern integrated iron- and steelworks, with
annual steel production of about 1 million tons.
Making of Steel

1. Basic oxygen furnace 2. Electric arc furnaces

Making of Steel

1. Basic oxygen furnace 2. Electric arc furnaces

•The most commonly applied process fo •The Electric arc furnace process, or mi
r steel-making is the integrated steel-ma ni-mill, does not involve iron-making. It
king process via the reuses existing steel, avoiding the need
Blast Furnace – Basic Oxygen Furnace. for raw materials and their processing.

•In the basic oxygen furnace, the iron is •The furnace is charged with steel scrap
combined with varying amounts of it can also include some direct reduced
steel scrap (less than 30%) and small a iron (DRI) or pig iron for chemical balan
mounts of flux. ce.

• Feed recycled steel scrap through use

high power electric arcs (temperatures
up to 1650°C) to melt the metal and con
vert it to high-quality steel.
Types of Steel
There numerous kinds of steel used in the industry; only the commonly used steel
are listed as follows:

Carbon Stainless
Tool Steel Alloy Steel
Steel Steel
Tool steel
•This kind of steel is used for production of tools that people use
domestically and commercially.

•It is very durable due to its purpose that it helps create other tools that
needs to be shaped or cut.

•It has a high resistance to heat.

Common examples of tool steel that can be seen domestically are
hammers, chisels, screwdrivers, and pliers.
Alloy Steel
•These are steels fabricated which contain varying alloying elements
stated in the design i.e. manganese, silicon, nickel, and titanium

•The alloying elements vary due to the use of the steel it may be used
in transformers, steel pipelines, transportation parts.
Carbon Steel
•This kind of steel only has traces of alloying elements and accounts
for 90% of total steel production

•This kind of steel can be classified into three groups due to their
carbon content, it as follows:
Low carbon steel/Mild Steel ( carbon content lower than 0.3%
)
Medium Carbon Steel ( carbon content 0.3%-0.6% )
High Carbon Steel ( carbon content higher than 0.6% )
Stainless Steel
•This kind of steel contains alloying elements but the majority of it
contains chromium which ranges up to 10% - 20% because of this it
has a high resistance to corrosion.

•It can be classified into three groups:

Austenitic - these are the common stainless steel that are

used commercially.

Ferritic - these are magnetic steel that are used for electronic
devices.

Martensitic - these are heat treatable steel that are used for
cutting such as knives, scissors and
surgical equipment.
STEEL
CASTING
STEEL
CASTING
•Is a process where in
molten steel is poured into
mold cavities in order to
produce different kinds of
steel used in the industry.

•The flowchart represents the

simplified steel casting
process.
Steel Casting Process (Simplified )
•Patternmaking - A replica that has the exterior of the cast. This
pattern can be made out of wood, metal, plastic, or plaster. This is
very important due to the calculated design for the pieces in order for
them to work together.

•Coremaking - If a casting is hollow another material must be inside

of the hollow cast that can be removed before pouring the molten
steel. This core can be made out of sand or metal.

•Molding - Making the mold for the individual/mass production of the

part that is needed when the molten steel will be poured on.
Steel Casting Process (Simplified )
•Melting and Pouring - This the step wherein molten steel is poured
on the pattern and mold. After pouring the molten steel it is left for the
solidify.

•Cleaning - This is the final step of the casting wherein impurities are
removed and rough edges are grinded to meet the proper design of
the pattern.
NON-FERROUS
METALS
- Metals that do not have iron,
not magnetic and do not rust.
ALUMINUM
•Lightweight, but strong

•Usually used in aircraft and

automobile industries.

•Can change easily into many

shapes

•Inexpensive
MERCURY
•Toxic if ingested, that is why
extreme care is needed.

•Low melting point

•Heavy metal, denser than other

common metals

•Usually used in thermometers and

barometers.
ZINC
•Bluish-white metallic element

•Ordinary temperature = Brittle

Slightly heated = Ductile

•Used in alloys as a protective

coating in galvanizing iron and
steel.
COPPER
•Soft, malleable and ductile metal
with very high thermal and
electricity conductivity.

•Usually used in making wires and

coins

•Used as a conductor of heat and

electricity
BRONZE
•Yellowish-brown metal which is a
mixture if copper and tin.

•Between 4000 and 3000 B.C in

which bronze was the hardest
metal in widespread use is known
as the Bronze Age.

•Other name(s): phosphor bronze,

aluminum bronze, or silicon
bronze”
BRASS
•Used for decoration, for its bright
gold-like look

•An alloy of copper and zinc

•Used for doors, windows, railings,

trim, grilles and for finish hardware
 “
STEEL FRAME CONSTRUCTION
Steel frame Construction
Steel frame is typically consisting of vertical
column and horizontal beams which are riveted,
bolted or welded together in a rectilinear grid. Steel
beams are horizontal structural members that resist
loads applied laterally to their axis. Columns are
vertical structural members that transfer compressive
loads. It can be used to form the skeleton of a
building.
Types of Steel Frame
Construction
•Conventional Steel Fabrication

•Bolted Steel Construction

•Light Gauge Steel Construction

Conventional
Steel Fabrication
This involves cutting steel members
to the correct length and welding them to
build the final structure.
 Bolted Steel
Construction

“ In this technique, all structural

steel members are fabricated
and painted off-site, then
delivered to the construction
site, and finally bolted in place.
 Light
Gauge Steel
Construction
Light gauge steel is a
thin sheet (commonly
range between 1-3mm)
of steel which has
been bent into shape
to form C-sections or
Z-sections..
Types of Structural Steel Framing
Systems for Buildings

•Skeleton steel framing

•Wall bearing steel framing
•Long span steel framing
 Skeleton steel
Framing

“ is composed of steel beams and

columns which are connected
using proper connection. Steel
beams around perimeter of the
structure is termed as spandrel
beams on which masonry walls
are placed.
Wall bearing steel
framing
In a wall bearing steel framing
structure, building wall whether it is
interior or exterior is used to carry the
end of structural members that
support floor or roof loads.
Wall bearing should be adequately
strong to not only be able to carry
vertical reactions but also to resist
any imposed horizontal loads.
Long Span Steel Framing

Long span steel framing is considered

when large clearance is required and such long
spanning cannot be realized using steel beams
and columns.
Long span steel framing options can be
categorized into different types, for instance,
girders, trusses, rigid frames, arches and
cantilever suspension spans.
TESTING OF
METALS
Metal Tests
There are tons of metals tests and can be classified into two groups which are Destructive
and Non-destructive tests.

Destructive Tests Non-destructive Tests

1.Bend Test 1.Liquid Penetrant

2. Impact Test 2. Testing
3. Hardness Test 3. Magnetic Particle
4. Tensile Test 4. Inspection
5. Fatigue Test 5. Hydrostatic Pressure
6. Corrosion Test 6. Ultrasonic testing
7. X-ray Inspection
 Destructive Test:
Bending Test

“ Bend tests deform the test material at

the midpoint causing a concave
surface or a bend to form without the
occurrence of fracture and are typically
performed to determine the ductility or
resistance to fracture of that material. It
is commonly performed on pipe, plates
and component products.
Destructive Test:
Impact Test
Impact testing of metals is
performed to determine the impact
resistance or toughness of materials by
calculating the amount of energy
absorbed during fracture. It is
performed at various temperatures to
uncover any effects on impact energy.

Two types:
•Charpy test
•Drop weight test
Destructive Test: Hardness Test

•Hardness Testing is generally performed using test

machines equipped with an indenter that is forced into
the test material over a certain amount of time. The
shape of the indentor varies by type of hardness test
and includes cone, ball and pyramid shapes. Each test
machine also uses a different force or load application
system and records an indentation hardness value in
kilograms-force according to their individual hardness
scales.
Destructive Test: Hardness Test

Types:
•Brinell Hardness Test
•Rockwell Hardness Test
•Knoop Hardness Test
•Vickers Hardness Test
Destructive Tests:
Tensile Test
Tensile test is a destructive test
process that provides information about
the tensile strength, yield strength and
ductility of the material.
Destructive Tests:
Tensile Test
Destructive Test: Fatigue Test
A fatigue test helps determine a material’s ability to withstand cyclic
fatigue loading conditions. Low cycle fatigue and high cycle fatigue test
processes measure the ability of materials to withstand the application of
repeated load cycles. Both high and low-cycle fatigue testing use cyclic
loading to evaluate the lifespan of materials that are subjected to conditions
of fluctuating strain and stress, which may result in cracking or fracture.

Two types:
•High Cycle Fatigue Test
•Low Cycle Fatigue Test
Destructive Test: Corrosion Test
Corrosion Testing determines the resistance of materials to
corrosion under certain environmental conditions, including temperature,
humidity and salt water.
Non-destructive Test:
Liquid Penetrant Testing
Also known as Liquid
Penetrant Inspection (LPI) or Dye
Penetrant Testing, is reliable for
detecting surface-breaking flaws in
materials with a non-porous surface
such as metals, plastics, glass and
ceramics.
Non-destructive Test:
Liquid Penetrant Testing
Also known as Liquid
Penetrant Inspection (LPI) or Dye
Penetrant Testing, is reliable for
detecting surface-breaking flaws in
materials with a non-porous surface
such as metals, plastics, glass and
ceramics.
Non-destructive Test:
Magnetic Particle Inspection

also called Magnetic Particle Testing

(MT), MPI Inspection or Magnaflux Testing, is
a very sensitive test method used to identify
defects on the surface of ferromagnetic
materials. This nondestructive MPI test is
commonly used on forgings, castings,
weldments, fasteners and machined or
stamped parts.
Non-destructive Test:
Hydrostatic Pressure

also known as Hydrostatic Testing or

a Leak Test, provides a method for finding
leaks or verifying performance and durability
in pressure vessels. It is classified as one of
our nondestructive testing techniques,
meaning the sample is typically not harmed
during the test. The hydro test can be
completed with pressure up to 10,000 PSI.
Non-destructive Test:
Ultrasonic Testing
Also known as UT Testing, Ultrasonic
Non Destructive Testing and Ultrasonic NDT,
can locate surface and internal defects in raw
materials and parts without causing damage
during inspection. In addition, ultrasonic
testing services can measure the wall
thickness of tubing and pipe.
Non-destructive Test: X-ray
Inspection
Industrial X-ray Inspection of solid materials
and products, also called Industrial
Radiography or Radiographic Testing (RT), is
a very effective method of uncovering
subsurface defects. X-ray inspection can
reveal hidden voids and defects in a variety
of solid materials, including metal, plastic,
composites, silicone and rubber.
References
* Wrought Iron
The Britannica - https://www.britannica.com/technology/wrought-
iron
* The 3 Most Commonly Used Types Of Steel
https://www.indmetalstrap.com/3-commonly-used-types-steel
* Home
https://www.labtesting.com/services/materials-testing
* Home
https://www.testresources.net/applications/test-types
* The Metal Casting Process Explained
Kinematics - https://www.generalkinematics.com/blog/metal-
casting-process-explained* Cast Iron
The Britannica -https://www.britannica.com/technology/cast-iron
* Steel
Jack Nutting-E.F. Wondris-Edward Wente -
https://www.britannica.com/technology/steel
* What Are the Different Types Of Steel?
Terence Bell - https://www.thebalance.com/steel-grades-2340174
* The Metal Casting Process Explained
Kinematics - https://www.generalkinematics.com/blog/metal-
casting-process-explained
• http://www.issp.ac.ru/ebooks/books/open/Alloy_Steel_-
_Properties_and_Use.pdf
• https://www.gunt.de/images/download/Mechanical-materials-
testing-methods-basic-knowledge_english.pdf
Activity
1. Types of Iron (2pts)
2. This kind of steel is very durable and can
shape, or cut other steel. (1pt)
3. Give two examples of non-ferrous metals
(2pts)
4. This involves cutting steel members to the
correct length and welding them to build the final
structure. (1pt)
5. Give 4 examples of Testing of Metals (4pts)
Thank you
CONSTRUCTION MATERIALS AND TESTING
GROUP 3