[PPT]Ferrous and Non-ferrous Metals - Springburn Academy · Web viewTitle Ferrous and Non-ferrous...

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Product Design Ferrous and Non-Ferrous Metals


Learning objectives


Lear

ning

obj

ectiv

es To understand where metals come from and how they are prepared for use.

To look at examples of ferrous metals, non-ferrous metals and alloys, and to know the properties of different metals.

To understand how heat treatment can change the properties of metals.

To be able to use hand tools to work with metals.

To be familiar with the industrial processes used to manufacture metal goods.


Metals are common in manufacturing today. From building and construction work to vehicles and leisure products, they are a vital material for product designers and engineers.

The elements of all metals are found naturally in the earth. However, they need to be extracted and processed before they can be used for manufacturing purposes.

Because metals in their most basic form are natural resources, designers and manufacturers need to be careful and socially responsible about how much they use, and reuse or recycle metals where possible.

Background on metals


Metals form part of the earth’s crust as metal ore. To obtain useful metals, the metal ore is mined and washed to remove other minerals and unwanted materials.

Iron ore is the basis for most steels. To extract pure iron the iron ore is heated in a furnace in a process known as smelting.

Where do metals come from?


Primary processes – rolling


Primary processes – extrusion


Metals are available in several raw forms. Each form is suitable for different manufacturing processes depending on the type of equipment used, the cost of the metal, the scale of production and the properties of the finished product.

Stock forms of metals

octagonal

hexagonal

square

round rod

sheet

flat stripround tube

square tube

angle

channel


Metals can be broken down into these main categories:

Non-ferrous metals

Ferrous metals

Alloys

Alloys

Pure m

etals

Pure metals do not contain any other metals or elements.

Categories of metals


Ferrous metals are obtained from iron ore. You might recognize the letters ‘Fe’ from the periodic table, where they represent iron.

Iron replaced bronze as the principal metal by 1000 BC.Early pots and pans made from iron poisoned the users!Early steels were made by adding carbon to iron as it was melted over a charcoal fire.

Ferrous metals

Ferrous metals:contain ironwill corrode unless protectedare attracted by a magnetare strong, rigid and cheap.

Ferrous facts


A closer look at ferrous metals


Non-ferrous metals do not contain iron. These are pure metals used by designers, manufacturers and engineers in a wide variety of applications.

Aluminium is the most common non-ferrous metal, found in abundance in bauxite ore.Non-ferrous metals are not magnetic.

Non-ferrous metals

Non-ferrous metals:

contain no ironare not attracted by a magnet.

Non-ferrous facts


A closer look at non-ferrous metals


Sometimes ferrous and non-ferrous metals require different properties in order to function better in specific situations. Alloying metals involves mixing two or more metals and other elements to improve their properties.

Alloys

Alloying metals can:lower the melting pointalter thermal and electrical propertiesmake a material harder for cutting purposesimprove resistance to corrosionhelp metal to flow better into a cast.


A closer look at alloys


Random alloy generator


Metals and their properties


Changing the properties of metals


Heat treatment – hardening steel


Heat treatment – tempering


Heat treatment – annealing


Working with metals – hand tools


Milling machines are used to remove thin layers from a billet (block of material) which is clamped to the bed (base) of the machine. The material is fed past a cutting tool which has many sharp teeth and can remove material quickly.

Industrial processes

When manufacturers want to make cylindrical products, they use a centre lathe. Metals and plastics can be used on this machine. The work is held in a chuck and a cutting tool is moved towards the work while being held in a tool holder, mounted on the tool post.


Several surface finishing techniques can be used on metals. The most common ones are detailed below:

Paint

Plastic Coating

Lacquering

Enamelling

Surface must be smooth andde-greasedPrimer requiredHammerite is a good one-coat metal paint.

Suitable for most metalsObject is heated and dipped in a tank of powder paintObject is returned to oven to ensure a smooth, glossy finish.

Helps to prevent corrosion after polishingA layer of cellulose or varnish is appliedOften used on jewellery.

Powdered glass is melted onto the metal surfaceProvides a hard (but brittle) finish with different colours and textures.

Finishing techniques


Key points


Key

poi

nts

Metals are extracted from the earth’s crust and then prepared into standard shapes before being sold to manufacturers.

Ferrous metals are obtained from iron ore and include cast iron and steel. Non-ferrous metals include aluminium, copper and tin.

Alloys, such as brass and stainless steel, are formed from two or more metals and other elements. Different elements alter the properties of metals.

Heating metals also alters their properties.

Metals can be worked with hand and machine tools, including milling machines and centre lathes.

[PPT]Ferrous and Non-ferrous Metals - Springburn Academy · Web viewTitle Ferrous and Non-ferrous...

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