Production Of Metals

Question 1

Ingredients in a blast furnace

Answer 1

Iron ore, coke, limestone

Question 2

Coke is….

Answer 2

Refined coal.

Question 3

Blows oxygen rich air to remove carbon as CO2 that bubbles out (blast furnace)

Answer 3

Tuyeres

Question 4

Pig iron

Answer 4

4-5 percent carbon
Raw ingredient

Question 5

Cupola furnace

Answer 5

Charged with pig iron and scrap cast iron. (Makes cast iron)

Question 6

Main hardening agent in steel

Answer 6

Carbon

Question 7

Induction furnace

Answer 7

Makes cast iron
Uses electricity instead of fire

Question 8

Basic oxygen steel making furnace (bos)

Answer 8

Loaded with 70-80 percent scrap steel and molten pig iron

Question 9

Electric arc furnace

Answer 9

Graphite electrodes
Controlled environment
Highest quality steel and alloys
Carefully selected scraps

Question 10

Tundish

Answer 10

A reservoir with a drain
(Continuous casting process)

Question 11

Hot rolled steel

Answer 11

Formed while hot
Mill scale
Rounded corners
Greater ductility
Less exact dimensions

Question 12

Cold rolled

Answer 12

Formed below lower critical temp
Shiny and smooth
Sharp corners
Greater strength
Precise dimensions

Question 13

Carbon content in
Pig iron…..
Cast iron….
Steel…

Answer 13

Pig iron: 4-5 %
Cast iron: 2-4.5%
Steel max: 2%

Question 14

Grey cast iron

Answer 14

2.5-4%
Brittle
Extreme hardness
Absorbs vibration
Excellent wear resistance

Question 15

White cast iron

Answer 15

Grey cast iron poured into a chilled mold
Harder and more brittle than grey
Better wear resistance than grey cast

Question 16

Malleable cast iron

Answer 16

Annealed white cast iron
Has a small amount of ductility
(Plumbing fittings)

Question 17

Ductile cast iron

Answer 17

Highest strength and ductility of cast irons
Alloyed with rare earth elements and manganese
(Valves and crankshafts)

Question 18

0.05 - 0.30 carbon content

Answer 18

Low carbon

Question 19

0.30 - 0.45 carbon content

Answer 19

Medium carbon

Question 20

0.45. - 0.75 carbon content

Answer 20

High carbon

Question 21

0.75 - 1.50 carbon content

Answer 21

Very high carbon

Question 22

Killed steel

Answer 22

Fully deoxidized
Highest quality

Question 23

Semi killed

Answer 23

Some deoxidizers added
Medium quality

Question 24

Rimmed

Answer 24

No deoxidizers added
Lowest quality

Question 25

Capped

Answer 25

No deoxidizers added Cap added to slow cooling Slightly better than rimmed

Question 26

With the basic oxygen steel making process what is the purpose of blowing in oxygen

Answer 26

To combine with the carbon

Question 27

What is the continuous casting process

Answer 27

Where molten metal is solidified into billets, blooms, blanks, rounds or slabs From a ladle to a tundish then to continuous casting

Question 28

What is the carbon content for cast irons

Answer 28

2 - 4.5%

Question 29

Highest strength and ductility Crankshafts and valves Alloyed with rare earth elements and manganese (which cast iron)

Answer 29

Ductile or nodular cast iron

Question 30

Used as a flux in the blast furnace to help remove impurities

Answer 30

Limestone

Question 31

Pig iron is refined to produce either …

Answer 31

Cast iron or steel

Question 32

Process where molten steel is solidified into billets, blooms, blanks, rounds or slabs…

Answer 32

Continuous casting (Improve yield, quality, productivity and cost efficiency)

Question 33

Based on the deoxidization process, what are the four classes of steel

Answer 33

1. Rimmed 2. Capped 3. Semi killed 4. Killed

Question 34

Which metal leaves the steel making furnace and is poured into a mould that is in the shape of the final product

Answer 34

Cast iron

Question 35

4 types of cast iron

Answer 35

1. Grey 2. White 3. Malleable 4. Ductile or nodular

Question 36

Why is limestone added to the blast furnace

Answer 36

To act as a flux to remove impurities

Question 37

Engine blocks, tools, machinery and fly wheels are made from which cast iron

Answer 37

Grey

Question 38

Two main ing in steel are

Answer 38

Iron and carbon

Question 39

Level of quality in deoxidization process

Answer 39

1. Killed - fully deoxidized 2. Semi killed - some deoxidizers added 3. Capped - no deoxidizers added cap added to slow cooling 4. Rimmed - no deoxidizers

Question 40

Which cast iron is crushing and grinding equipment

Answer 40

White cast iron Better wear resistant more brittle than gray, rapidly cooled not weldable

Question 41

Which cast iron is annealed, rounded carbon particles, greater ductility ex plumbing fittings

Answer 41

Malleable cast iron

Question 42

Which steel making process is commonly used for making high quality alloy and tool steels

Answer 42

An electric arc furnace

Question 43

The first step in separating the iron from the oxygen in the naturally occurring iron ore

Answer 43

Blast furnace

Question 44

Carbon content in coke

Answer 44

98 %

Question 45

Molten metal starts to cool and gets a thin shell of solidified metal in outside the middle is still molten and is now called

Answer 45

A strand

Question 46

Why is continuous casting preferred to stationary moulds

Answer 46

Increase control through automation Lower cost Improve yield Quality productivity

Question 47

5 types of moulds

Answer 47

Billets Blooms Blanks Rounds Slabs

Question 48

Which type of cast iron has extreme hardness due to rapid cooling

Answer 48

White cast iron

Question 49

Which type of cast iron has the highest strength and can be used for making valves

Answer 49

Ductile or nodular cast iron

Question 50

Which type of cast iron undergoes an annealing process

Answer 50

Malleable cast iron

Question 51

What is the carbon content range for steels

Answer 51

Less than 2 %

Question 52

What is rimmed steel used for

Answer 52

Core wire, electrodes, bar stock, plate and some structural steel