WACHEMO UNIVERSITY








College of Engineering and Technology
Department of Electro-Mechanical Engineering
Material Science and Engineering

Compiled by Dagim Asegid ([Link]. MEng.), Sept. 2023

Chapter Three

Production of Iron, Steel and Alloy Steels

 Chapter Three
3.1. Production of steel
 The production of steel at an integrated iron and steel plant is accomplished using several interrelated processes.
The major operations are:
Coke production
Sinter production
Iron production
Iron preparation
Steel production
 Chapter Three
3.1. Production of steel
Coke production
 Chapter Three
3.1. Production of steel
 Chapter Three
3.1. Production of steel
 Chapter Three
3.1. Production of steel
 Chapter Three
3.1. Production of steel
Sinter production
 The sintering process converts fine-sized raw materials, including iron ore, coke breeze, limestone, mill scale, and
flue dust, into an agglomerated product, sinter, of suitable size for charging into the blast furnace.
 The raw materials are sometimes mixed with water to provide a cohesive matrix, and then placed on a continuous,
travelling grate called the sinter strand.
 Chapter Three
3.1. Production of steel
 Chapter Three
3.1. Production of steel
 Chapter Three
3.1. Production of steel
 Chapter Three
3.1. Production of steel
 Chapter Three
3.2. Introduction to steel
Steel
 Steels are iron–carbon alloys that may contain appreciable concentrations of other alloying elements.
 The mechanical properties are sensitive to the content of carbon, which is normally less than 1.0 wt.%
 Chapter Three
3.2. Introduction to steel
i. Steel
 Some of the more common steels are classified according to carbon concentration namely;
 Low-carbon steel,
 Medium-carbon steel, and
 High-carbon steel
 Chapter Three
3.3. Classification of carbon steel
i. Steel
 Subclasses also exist within each group according to the concentration of other alloying elements.
 Plain carbon steels contain only residual concentrations of impurities other than carbon and a
little manganese.
 For alloy steels, more alloying elements are intentionally added in specific concentrations.
 Chapter Three
3.3. Classification of carbon steel
Steel
 Chapter Three
3.3. Classification of carbon steel
Steel
a) Low carbon steel
Contain less than 0.25 wt.% of C.
Strengthened by cold work.
Consist ferrite and perlite microstructure
Relatively sof t and weak
 Chapter Three
3.3. Classification of carbon steel
Steel
a) Low carbon steel
Outstanding ductility and toughness
Machinable and weldable
Least expensive to produce
 Chapter Three
3.3. Classification of carbon steel
Steel
a) Low carbon steel
Application ;
Automobile body components
Structural shapes (I beams, channels and angle iron)
Sheets for pipes, buildings and tin cans, nut and bolt.
 Chapter Three
3.3. Classification of carbon steel
Steel
b) Medium carbon steel
Contain carbon between 0.25 wt.% and 0.60 wt.%
Strengthened by heat treatment
Utilized in tempered condition
Addition of Cr, Ni, and Mo improve the heat treatment capacity
Stronger than low carbon steel at a sacrifice of ductility and toughness
 Chapter Three
3.3. Classification of carbon steel
Steel
b) Medium carbon steel
Application;
Railways wheels and tracks
Gears, crank shaf ts
Structural components for a combination of strength and wear resistance
 Chapter Three
3.3. Classification of carbon steel
Steel
c) High carbon steel
Carbon content between 0.60 and 1.4 wt.%
Hardest, strongest and yet least ductile of the carbon steels.
Strengthen by heat treatment.
Used in hardened and tempered conditions
Especially wear resistant and capable of holding a sharp cutting edge.
 Chapter Three
3.3. Classification of carbon steel
Steel
c) High carbon steel
Application;
Tool and die steels
Sharp cutting tools such as:
Knives, razors, and
Hack saw blades
 Chapter Three
3.4. Ef fects of alloying elements
 Chapter Three
3.4. Ef fects of alloying elements
 Chapter Three
3.4. Ef fects of alloying elements
Steel
 Ef fects of increasing carbon content in steel are;
Increase in hardness and strength
Decrease in weldability
Decrease in ductility
Decreased machinability
 Chapter Three
3.5. Classification of alloy steel
Steel
 Stainless steels
Highly resistant to corrosion (rusting)
Cr < 11 wt.% is a predominant alloying element
Addition of Mo and Ni enhance corrosion resistance
 Chapter Three
3.5. Classification of alloy steel
Steel
 Stainless steels
Based on predominant phase constituent of the microstructure they can be classified as;
Martensitic stainless steel
Ferritic stainless steel
Austenitic stainless steel
 Chapter Three
3.5. Classification of alloy steel
Steel
a) Martensitic stainless steel
Capable of being heat treated
Martensite is there primary phase constituent
Have magnetic properties
 Chapter Three
3.5. Classification of alloy steel
Steel
b) Ferritic stainless steel
Not heat treatable
Hardened and strengthen by cold working
Have magnetic properties
 Chapter Three
3.5. Classification of alloy steel
Steel
c) Austenitic stainless steel
Not heat treatable
Hardened and strengthen by cold working
The most corrosion resistance due to high content of Ni and Cr
Produced in the largest quantities
They are not magnetic
Chapter One

End Of Chapter Three

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