Ferrous and Non Ferrous Metals:

Ferrous Metals:
These metals contain iron as their main constituent and are obtained from IRON ORES which consists of
compounds of iron, non metallic elements and impurities such as carbon, manganese, phosphorous,
silicon and sulphur.
• Cast iron (2.5 to 5 % Carbon)
• Wrought iron (Not more than 0.5% carbon)
• Steel (Between 0.4 to 1.5 % carbon)
Non-Ferrous Metals:
These metals do not contain iron as their main constituent. Some of the non ferrous metals are:
• Aluminum
• Copper
• Lead
• Zinc
• Nickel

Various terminologies used:

• Brittle: Can be broken into pieces.
• Ductile: can be drawn into wires.
• Malleable: Can be beaten into thin sheets.
• Hard: Can not be cut by a sharp tools.
• Soft: Can be easily cut by sharp tools.
• Tough: Does not break easily under a hammer.

Properties of Pig Iron :

1.It can be hardened but not tempered.
2. It cannot be magnetised.
3. It cannot be welded or riveted.
4. It does not rust.
5. It is difficult to bend.
6. It is hard and brittle.
7. It is neither ductile nor malleable.
8. It melts easily and its fusion temperature is 1200 C.
9. It possesses high compression strength. But it is weak in tension and shear.
Ferrous Metals:
Cast Iron:
It is manufactured by refining pig iron in a cupola furnace. Old castings or scrap iron is sometimes added
to improve the quality of the cast iron.
it contains about 2 to 4 percent of carbon. In addition, it contains various impurities such as
manganese, phosphorus, silicon and sulphur.
Cast irons are generally classified into three main varieties, namely
a) Gray cast iron
b) White cast iron
c) Malleable cast iron.
d) Alloy Cast Iron
e) Ductile Cast iron
f) Mottled Cast iron
Properties of cast iron:
• Carbon content varies from 1.7 to 4.5 percent.
• It is strong in compression and weak in tension.
• It is brittle and does not absorb shocks.
• It can not be welded easily, forged or rolled.
• It can not be punched or riveted like steel but it can be easily melted, and cast into various
shapes.
• Its melting point is about 2000 0 F
• It can be hardened by heating and sudden cooling.
• It shrink on cooling.
• It becomes soft in contact with salt water.
• It rapidly corrode in salt water, for which regular Painting as a preservative is must.
• it can not be magnetized.
Uses of cast iron:
For making decorative columns.
• Water and sewage pipes.
• Wheels
• Spiral staircases.
• Manhole covers
• Rain water pipes
• Sanitary fittings

Wrought Iron
It is the purest form of iron with low carbon content,less than 0.15 %. It is made from white pig iron by
removing most of the carbon, manganese, silicon phosphorous and sulphur, by the process of ‘Puddling’
in a reverberatory furnace.
Properties of Wrought Iron:
• It is tough, ductile, and malleable.
• it can be easily welded at a temperature of 9000 c by a hammer but not by fusion as its melting
point is above 15000c
• It can be bent, or twisted when either hot or cold but it can not be cast into moulds.
• Wrought iron rusts more quickly than cast iron but stands salt water better.
• Its compressive strength is about 2000kg/cm2 and tensile strength is about 4000kg/cm2
• It is heavy and costly.
Uses of Wrought Iron:
It is used for making spikes, nails, bolts and nuts, chains. Handrails, ornamental gates, pipes , stairs etc.

Steel:
Steel is an alloy or compound of carbon and iron in the form of carbide of iron.
It is manufactured mostly by removing portion of carbon from pig iron and refining it.
There are three grades of steel in accordance with the percentage of carbon.
Three grades of steel are:
1. Low carbon steel or mild steel (Carbon content<0.25)
2. Medium carbon steel or hard steel (Carbon content, 0.25 to 0.7)
3. High carbon steel (carbon content, 0.7 to 1.5)
Properties of Mild Steel:
1. It can be magnetised permanently.
2. It can be readily forged and welded.
3. It can’t be easily hardened and tempered.
4. It has fibrous structure.
5. It is malleable and ductile.
6. It is not easily attacked by salt water.
7. It is tougher and more elastic than wrought iron.
8. It is used for all types of structural work.
9. It rusts easily and rapidly.
10. Its melting point is 1400 c
11. Its specific gravity is 7.80
Properties of hard Steel:
1. It can be magnetised permanently.
2. It can’t be readily forged and welded.
3. It can be easily hardened and tempered.
4. It has granular structure.
5. It is malleable and ductile.
6. It is not easily attacked by salt water.
7. It is tougher and more elastic than mild steel.
8. It is used for finest cutlery, edge tools and for parts which are to be subjected to shocks and
vibrations.
 9. It rusts easily and rapidly.
10. Its melting point is 1300 c
11. Its specific gravity is 7.90
12. Uses of Steel:
13. Mild Steel : Sections, Bars, Sheet Metal, Tin Plate
14. Medium Carbon Steel : Hammers, Structural Steel
15. High Carbon Steel: Stone Mason Tools, Axes, Drills, Knives, Wood Working Tools.
16. Market Forms of Steel:
17. Angle Sections, Channel Sections, Corrugated Sheets, Flat bars, I sections, round bars, square
bars, T- sections.
18. I Section Junior beams(I.S.J.B) , light beams( I.S L.B.) , medium beams ( I.S.M.B.) , wide-flange
beams (I.S..W.B.) and heavy beams (I.S.H.B.) are available in market.

NON FERROUS METALS:

Aluminium
Cobalt
Copper
Lead
Magnesium
Nickel
Tin
Zinc
1. Aluminium:The aluminium occurs in abundance on the surface of earth. It is available in various
forms such as oxides, sulphates, silicates and phosphates etc.
Properties of Aluminium:
1. It is very good conductor of heat and electricity.
2. It is silvery white metal and it exhibits bright luster on a freshly broken surface.
3. It is non-magnetic metal
4. It is rarely attacked by nitric acid, organic acid, or water.
5. It is highly resistant to corrosion.
6. It is light in weight, malleable and ductile.
7. It is very soft.
8. It melts at 6600C and its boiling point is 20560C
9. It possesses great toughness and tensile strength.
10. It readily dissolves in Hydrochloric acid.
11. Its specific gravity is about 2.70
12. Uses of Aluminium
13. Making parts of aero planes, utensils,electric wires, window frames, glazing bars, corrugated
sheets, structural members, foils, posts, panels etc.
14. Used as reducing agent for making steel.
15. Used for making aluminium alloys, automobile bodies, engine parts, and surgical instruments.
 16. For casting of steel.
17. Manufacture of paints in powder forms.
18. Al is used as a source of light in flash bulbs used for this purpose.
19. The heat reflecting property of Al. is made used in building insulation. It has low conductivity
and it reflects as much as 90 to 95 % of the radiant heat. Hence al alone or coupled with glass-
wool, foam glass etc. is used for heat insulation.
Telescope Mirrors: for this purpose capacity of Al. to reflect ultra-violet rays is utilized. Therefore
it is used in Astronomical Mirrors
Importance of Aluminium in building industry:
1. Appearance:
The finished aluminium is generally smooth, having bright finish.
2. Air tightness:
a well designed aluminium door, window is perfectly airtight and sealed for dust and rain water,
when closed. This is a very high functional advantage in a modern fully air conditioned building.
3. Ease in fabrication and assembly:
it is comparatively soft and ductile metal, the fabrication of doors, windows etc.
The al. alloys can be cast, forged, extruded rolled and welded with relatively ease.
The al. corrugated sheets do not break or crack during or after erection because al. is not brittle. An al.
structure can easily be dismantled, transported and re-erected.
Handling and transportation:
It is very light weight material so the cost of handling and transportation is easy.
High Corrosion Resistance:
It has excellent corrosion resistance and it can resist weathering conditions very well. It can also
withstand humid and hot dry conditions.
High reflectivity:
As al. posses good reflectivity, it does not absorb radiant heat and low absorption of heat helps in
maintaining the surrounding area cool during summer and warm in winter.
High strength to weight ratio:
As al. posses very high strength to weight ratio, the overall weight of building is considerably reduced.
This helps in speed of construction and in the decrease of load on the foundation of building.
Maintenance:
Due to high corrosion resistance of al. the maintenance cost is negligible. Properly treated al. sections
can withstand both sea-coast and industrial atmosphere for more than 25 to 30 years without any
maintenance.
High scrap value:
The scrap value of al. is very high as it hardly deteriorates, it gets high resale value.
COMPARISSION WITH OTHER MATERIALS:
Aluminium is comparatively expensive material in the initial cost. But it proves to be economical in long
run.
Asbestos cement corrugated sheets:
These sheets are cheaper than al. sheets. But they are about 7 times heavier than aluminium sheets. The
asbestos being a fragile material is liable to breakages. It creates serious health hazards so it has been
banned in several industries.
Corrugated galvanized iron sheets:
These sheets are costly as compared to the al. corrugated sheets. As it is light in weight it requires light
structural supports and offer ease of erection at any height.
Steel:
Only limited standard sections are available in steel. Heavy.the al. offers limitless possibilities of
different shapes and profiles.
Timber:
As compared to timber, the initial cost of al. is less. And with practically no maintenance cost.
Copper:
Aluminium is a good conductor of electricity. The electrical conductivity of Al. is about 70% more than
that of Cu wire of same size and density if 1/3 of that of Cu. Therefore, Al is a better conductor of
electricity than Cu and is much cheaper than Cu and hence it is used in high tension cables.
Al. has lower tensile strength than Cu but this drawback has not affected its use. This drawback has
removed by making central core of iron wire surrounded by Al. wires. Such cables are used for long
distance power transmission.
Commercial Forms of Aluminium:
1. Casting Based
2. Extrusion Based
3. Foil and powder based
4. Sheet based
Casting Based:
a) Baluster-heads
b) Hardware and fittings
c) Security and decorative grills
Extrusion Based:
a) Door and window frames
b) Panels and curtain walls
c) Space frames and grids
d) Partitions and space dividers
Foils and Powder Based:
a) Decorative laminates
b) Paints
c) Insulating foils
Sheet Based:
a) Roofing sheets
b) False ceiling
c) Cable tray
d) Prefabricated houses
e) Properties of Copper:
Following are the important properties of Copper:
1. It has a peculiar reddish brown colour.
2. It becomes brittle just below melting point.
3. It can be worked in hot or cold conditions, but cannot be welded.it can be joined by rivets,
soldering or brazing.
4. It is a good conductor of heat and electricity.
5. It is not attacked by dry air, but moist air gives a green coating to the copper surface.
6. It is not attacked by water at any temperature.
7. It is malleable, ductile, extremely soft but it can not be casted well.
8. It melts at 1083 0 C and its boiling point is 2300 0 C
9. Its specific gravity is 8.92
10. Uses of Copper:
11. Sheets, tubes and wires are made.
12. Electrical Conductivity: Copper is next to silver so far as electrical conductivity is concern. It is
used as a conductor in electric power transmission lines, electric wiring for domestic purposes,
motor generators and fittings etc.
13. Heat conductivity: Cu is good thermal conductor. Its thermal conductivity is twice that of Al. and
nine times that of steel. Because of this it is used for making utensils, automobiles radiators,
condensers, boilers, evaporator coils and hot water tanks.
14. Copper in plumbing: its light weight, sufficient strength to resist pressure, are properties which
are used in plumbing. Pipes and tubes can quickly be soldered and they do not sag between
points of support. Copper plumbing once installed lasts for the entire life of the building.
15. Copper can be electro plated and forms a thin uniform film on the metallic surface. It protects
against corrosion.
16. Lead:
17. The lead occurs occasionally in free state in nature. In combined form it occurs as sulphide.
18. Properties of Lead:
Following are the important properties of Lead:
1. It can be cut with a knife
2. It makes impression on paper.
3. It melts at 327.5 0 C and its boiling point is 1620 0 C
4. It is a lustrous metal with bluish gray colour.
5. It is not attacked by dry air, but moist air takes away its bright metallic luster and a dark
protective film is produced on the surface of metal.
6. It possess little tenacity.
7. It is readily dissolved in dilute nitric acid.
8. It is very soft but does not posses elasticity at all.
9. Its specific gravity is 11.36
10. Uses of Lead:
11. Lead for laboratory tables: it is used for covering tables for chemistry lab. Insoluble chlorides
and sulphates formed by action of HCL and H2So4 respectively on the metal form a protective
film on the metal and protect it from further action.
 12. Lead for Plumbing: it is very soft, easily bent and easily installed. Its parts can be joined by soft
soldering or welding and the metal is inert to chemicals. Therefore lead is used for drains in
chemical plants and laboratory.
13. Lead for sheathing: it is flexible and corrosion resistant it is used for sheathing electric and
telephone cables which may be under ground or overhead. Now a days it is almost replaced by
the plastics.
14. Lead for storage batteries: it is resistant to the attack of corrosive acids therefore it is used for
accumulators and storage batteries.
15. Lead has the property of absorbing radiation. Therefore it is used as a protective shield for X-Ray
equipments, nuclear equipments and as a castings to store and transport radioactive materials.
16. It is used for making shots, bullets alloys etc.
17. Alloy:
18. An alloy is a substance possessing metallic properties and is composed of two or more elements
one of which must be a metal.
19. Alloying elements contribute useful properties.
20. e.g. Cu makes gold less ductile and malleable, in addition it hardens gold.
21. Chromium Makes steel corrosion resistant (Stainless Steel).
22. Brass:
23. Brass is an alloy of copper and zinc. Normally it contains 60-70 % copper and remaining zinc.
24. Properties of Brass:
25. It is corrosion resistant.
26. Readily machinable.
27. It is hard.
28. Its tensile strength increases with increase in percentage of zinc, but at the same time their
ductility decreases.
29. It is resistant to sea water.
30. It is light reddish yellow in colour.
31. Uses of Brass:
32. It is used for manufacturing evaporators in sugar and salt industry.
33. Used for making cartridges, condensers, tubes, sheets etc.
34. Because of their pleasing reddish colour, they are used for ornamental and decorative purposes.
35. Making screws, nuts, rivets, pins and wires.
36. It is used in marine and engineering castings.
37. It is used for making condensers.
38. Making sanitary fittings.
39. Bronze:
40. Bronze is an alloy of copper and tin.
41. The ordinary bronze consists of 88-96% of copper and 4-12% tin. The percentage of tin varies
from 4-12%, but the commonly used bronze contains 5-10% tin.
42. It is used in making coins, ornaments, and statues.
Stainless Steel (Steel Alloy) :
• Adding chromium to low carbon steel gives it stain resistance.
 • It is produced by adding over 12 per cent of chromium to low carbon
steel.
• It has corrosion resistant property and this can be hardened by suitable
heat treatment.
• In general stainless steel contains 18 to 20 per cent of chromium and 8 to 10 per cent of nickel.
• It can be cast, pressed and machined.
• It is not affected by acids.
• It is widely used for household utensils, vessels to store acids, dairy plant equipments etc.
• Corrosion and rusting of iron:
• Corrosion of iron is an ‘Electrochemical process’
• Rusting of iron in presence of oxygen and moisture is rapid and far reaching. Once rusting is
initiated, it gradually increases and corrodes iron.
• Mild steel corrodes or rusts less than iron, steel rust usually rubs off as fine dust.
• The corrosion of wrought iron is mainly due to the galvanic action set up between the iron and
the uncombined carbon present in iron.
• Local corrosion sometimes occurs from air bubbles entrapped in iron. Unevenness in physical
condition also effects corrosion.
• Preservation of Iron and Steel:
There are several methods of preservation of iron and steel from the effect of corrosion and rusting.
1. Galvanising
2. Tin plating
3. Enamelling
4. Painting
5. Coal taring
6. Galvanising:
7. It is a process by which iron is coated with a thin film of zinc, so that the iron surface does not
come in contact with air and water.
8. The iron piece to be galvanised is cleaned properly by removing scales and rusts by pickling it in
dilute HCL. It is then placed in molten bath of zinc, which is covered with a layer of Sal-ammonic.
This serves as a flux and induces a coating of iron by zinc.
9. Tin Plating:
10. It is done to cover the surface of iron with a film of tin instead of zinc. The iron piece to be
coated is washed with hydrochloric acid to remove dust and scales and washed well for removal
of acids. The piece of iron to be coated is immersed in molten bath of tin. For perfect coating,
the iron piece is to be passed through successive baths of molten tin. The coated iron is then
finished passing through rollers in grease bath to squeeze off the excess tin.
11. Enamelling:
12. It is the process of putting preliminary glaze to iron.
13. This is achieved by cleaning the iron piece properly first. Then by melting a flux on the surface in
a muffle furnace and then coating it with a second layer of more fusible glaze.
14. The first layer contains borax with cobalt or nickel oxide and small quantity of hydrated ferric
oxide.
15. The second coat essentially is of glass, stannic oxide, bone ash, and other metallic oxides to give
desired colour.
16. For transparent enameling, a typical mixture of three parts of siliceous sand, three parts of
crystal borax, one part of chalk, one part of antimony and one fourth part of nitrate of potash is
used.
17. Painting:
18. Painting is one of the effective methods for preservation of iron and steel. Red lead paint seems
to be the best for painting iron and steel.
19. Before painting the surface is made free from rust and scales and cleaned well.
20. The paining should preferably be done in dry weather, when the humidity is low. the adherence
of paint increases, if the surface to be painted is preheated.
21. Coal Tarring:
22. It is laid hot on the iron surface and it protects from atmospheric actions. It is usually done on
iron which is used below ground.
23. Electroplating:
24. It is process of coating iron or steel by metal, which protects it from acid, moisture and air. The
principle of electrolysis is used for the process. The iron to be coated is made cathode and
chromium, nickel, or zinc is used as anode. When electric current passes through a solution
between two electrodes, the solution breaks into ions, which deposit on the cathode and thus
iron is electroplated.
25. Metal Spraying:
26. In this technique molten metal is sprayed through a spray pistol on the surface of iron to
produce a thin and uniform film over it.
27. Plastic Spraying:
28. It is done with the help of spray gun. Urea resin or a suitable plastic in a hot thin liquid state is
spread over the surface.
29. Powder coating:
30. It is a type of coating that is applied as a free-flowing, dry powder. The main difference between
a conventional liquid paint and a powder coating is that the powder coating does not require a
solvent to keep the binder and filler parts in a liquid suspension form. The coating is typically
applied electrostatically and is then cured under heat to allow it to flow and form a "skin". The
powder may be a thermoplastic or a thermoset polymer. It is usually used to create a hard finish
that is tougher than conventional paint. Powder coating is mainly used for coating of metals,
such as household appliances, aluminium extrusions, drum hardware, and automobile and
bicycle parts. Newer technologies allow other materials, such as MDF (medium-density
fibreboard), to be powder coated using different methods.