Assignment 3

Cornelius Erick (1106069872)

Figure 2 shows cast iron fence. A. Explain how is the processing of the fence. B. Predict the microstructure of the fence. C. If you hit the tip of the fence by a hammer, what do you think will happen? Why? Please elaborate your answer.

Answer:
A.

1. First we use Blast Furnace method for processing of the fence

Source: (http://www.jirvine.co.uk/Chemistry_GCSE/C1A/c1al9.htm)

Fe2O3 that has been purified put into blast furnace with coke and limestone. Coke that contains C will react with hot air that is O2. 2C + O2 2CO Then, iron ore reacts with CO gas that has been formed. Fe2O3 (iron ore) + 3CO Fe3O4 + CO2 Fe3O4 is formed will react again with CO gas produces FeO. Fe3O4 + CO FeO + CO2 FeO will react again with CO gas and eventually obtained Fe. FeO + CO Fe + CO2 CO2 that has been formed will react with C produces CO. CO2 + C CO If we look at the reaction or the previous equation it appears that the reducing CO gas produced from the reaction between coal and hot air. Thus, the reducing gas is not inserted directly into the blast furnace, but generated from within the blast furnace process. Therefore, this process is known as an indirect reduction process. CO reductant gas and then gradually reduce the iron ore so that the Fe (iron) in the liquid state, because the reaction is exothermic. CO2-reduction reaction resulting from this iron-ore will react back with coal to CO gas. Limestone is added to react with impurities in the iron ore to form slag, which will float on the molten iron because its density is lower. Materials produced from blast furnace molten iron, which is often referred to as pig iron at temperatures 1.530oC. For each ton of molten iron, typically there are slag, which when cooled can be destroyed and the materials used in cement mixers, liquid iron containing 3-4% carbon, which is then poured into a torpedo car, and immediately experienced hot metal pre-treatment process for reduce levels of

phosphorus (dephosphorization) and sent to steel impurities process, for reduced levels of carbon. Limestone that is added is used to bind impurities ( Si, P, S, Mn ) that exist in the form of iron ore and formed slag. This slag will float and will be taken with a spoon. Slag can be used as cement. The material obtained is molten iron called pig iron. 2. Second we will use method of Gray Casting Iron A method of casting parts with gray iron includes the steps of providing molten gray iron metal with controlled carbon, silicon (Si), phosphorous (P), sulfur (S), manganese (Mn) and chromium content; alloying said molten gray iron metal, prior to pouring, with tin to a total tin content of about 0.05% to about 0.10%; inoculating said molten tin-alloyed gray iron metal, prior to pouring, with a gray iron inoculant to an additional silicon addition of from about 0.10% to about 0.12%; and casting the gray iron part from said molten, tin-alloyed inoculated gray iron metal as son as possible after said inoculation. Gray Casting Iron Molten iron will go through the casting process. Cast iron is processed again into grey cast iron. Grey cast iron is molten iron containing carbon from 2.5 to 4.0-wt% and silica containing 1.0 to 3.0-wt%. Then the molten iron will be processed again to obtain the content. Grey cast iron can be identified through the presence of graphite in the form of flakes. This grey cast iron is the material of fence. 3. Third steps we will use Cutting process In this step after result of gray casting iron when it is solid form we will cut that. We must pass this step because make easy when it will pass the welding's step, we will cut that as we want be a needed form for next step.

4. Fourth we will use method of Welding Method of installing fence with welding, gray cast iron will be welded, but welding is typically at a relatively high preheat applicable to prevent the formation of white cast iron. After that because the fence isnt good enough to used for standards fence of applied, it will go through the process of smoothing called aching. The fence will paint with spray method or traditional methods with a brush.

B. Microstructure of cast iron consists of shaped graphite flakes surrounded by

graphites layer and ferrite. Here is the picture.

Source: (www.nrc.ca/irc/ircpubs - Failure modes and mechanisms in gray cast iron pipe.pdf)

C. When I hit the tip of the fence by a hammer, the fence will damp vibrations and
will be broken due to the microstructure of graphite in the form of flakes. This form of flakes is sharp so it is brittle, but for this case in my opinion if the pressure of my hit by a hammer less than toughnesss limits nothing will happen even toughnesss limit of the hammer less than the fence, the hammer will broken.

References: - http://www.nrc.ca/irc/ircpubs - Failure modes and mechanisms in gray cast iron pipe.pdf - http://www.fence-depot.com/fence-guide/installing-fence/ - http://www.jirvine.co.uk/Chemistry_GCSE/C1A/c1al9.htm - http://osdir.com/patents/Metal-founding/Method-manufacture-gray-cast-ironcrankcases-cylinder-heads-06973954.html -Smith, William F. 2004. Foundations of Materials Science and Engineering, Third Edition. New York: Mc. Graw Hill International Edition -Sofyan, T. Bondan. 2010. Pengantar Material Teknik. Jakarta: Salemba Teknika