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    L9. Metals - 1 (CE2330-2024) AKM

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    L9. Metals - 1 (CE2330-2024) AKM

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    ce23b068
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    Copyright:

    © All Rights Reserved
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    Download as pdf or txt
    2 views29 pages

    L9. Metals - 1 (CE2330-2024) AKM

    Uploaded by

    ce23b068

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 29

    Metals - 1

    Repair and Maintenance of Concrete Structures

    (Iron, Iron products,


    Embedded and Steel)
    Metal Corrosion

    Aslam Kunhi Mohamed


    Radhakrishna G. Pillai
    Department of Civil Engineering
    Indian Institute of Technology Madras
    Chennai, India

    CE 2330

    Courtesy: Some images are sourced from the internet for demonstration purposes.
    Outline

    • Iron, iron products and steel This lecture

    • Steel reinforcing bars (rebars)


    used in concrete structures

    • Structural steel
    Various iron products include

    • Pig iron
    • Cast, ductile, and wrought iron
    • Steel reinforcement
    • Structural steel
    Iron ore is used to manufacture/extract iron

    • India contributes about 5% to the world’s iron ore


    output

    https://tradingandironore.weebly.com/iron-ore-exports.html
    https://mobile.abc.net.au/cm/lb/6515982/data/shares-of-world-iron-ore-output-data.jpg
    Iron is melted in a blast furnace

    • Typical Blast furnace


    – 30 to 60 m high
    Processes inside a blast furnace

    • Stack of raw materials


    • Hot air blast
    • Temperature variations
    • Reduction of iron ore
    • Limestone decomposes
    and molten slag forms
    • Molten iron forms

    Pig iron

    https://ukcsma.co.uk/mpa-cms/wp-content/uploads/2016/08/csma-Blast-Furnace-Diagram-white.jpg
    Old pig iron casting moulds
    Modern pig iron casting moulds
    - with conveyor belts
    Composition and key properties of pig iron

    • 90–95 % Iron, 3–4 % Carbon, and


    traces of other elements such as
    silicon, manganese, and
    phosphorus
    – Not well-controlled manufacturing
    – Poured into the pigs/moulds
    • Harder than 100 % pure iron
    • Lower strength
    – Porous
    – Not good for most applications
    Cast iron products used in construction

    Complex
    shapes
    Manufacturing of cast iron

    • Better casting moulds than the pigs


    – Foundry sand
    • Clean and uniformly sized silica sand
    • Cohesive

    Foundry
    sand

    Molten Fe+C being poured into a mould View of a sand mould

    Example of
    a cast iron
    products
    Applications of cast iron
    Composition and key properties of cast iron

    • Iron plus upto ≈4% carbon


    • High strength
    • Corrosion resistant
    • Highly brittle

    https://www.scientific.net/MSF.649.511.pdf
    Ductile iron is more preferred now-a-days for
    similar applications
    • Ductile iron is more ductile than grey cast iron
    – spherical inclusions of graphite particles

    Flaky graphite Spherical graphite

    http://www.iron-foundry.com/blog.files/cast%20iron%20microstructure.jpg
    Ductile iron pipe

    • From outside, DI look similar to CI


    Wrought iron

    • Cast iron has 2 to 4% carbon


    • Wrought iron has less than 1% carbon and 1 to 2%
    fibrous slag inclusions (silicon, phosphorus and
    sulfur)
    – "grain" structure
    • Heated and then worked or “wrought”

    https://ascelibrary.org/cms/asset/a8261a29-cdca-4f94-ba4e-ac1ad2c5ae0f/8.jpg
    Wrought iron properties and products

    • Stronger and Lighter than cast iron


    • Less hard than cast iron
    • Metal fence and other complex cast shapes
    Cast, Ductile, and Wrought iron

    Flaky graphite Globular graphite Grain structure

    https://www.chegg.com/homework-help/questions-and-answers/3-iron-samples-identify-cast-iron-wrought-iron-ductile-iron-explain-difference-micro-struc-q17120521
    Iron-Carbon Equilibrium Phase
    Diagram

    Young et al.
    How is steel manufactured? Why it corrodes?

    2O2 + 4 H 2O + 4 Fe ® 4 Fe(OH )2

    4Fe(OH )2 + O2 + 2H 2O ® 4Fe(OH )3

    Iron Ore Rolling/ other manufacturing


    (Fe2O3) Blast Furnace Molten material processes

    “Dust to dust . . . back to its lowest energy state”

    3. 4Fe(OH )3 ® 2Fe2O3 + 6H 2O

    2. 4Fe(OH )2 + O2 + 2H 2O ® 4Fe(OH )3

    1. 2O2 + 4H 2O + 4Fe ® 4Fe(OH )2


    Exposure conditions
    Steel manufacturing process
    Steel classification

    https://image.slidesharecdn.com/alloysteel-170629095156/95/alloy-steel-8-638.jpg?cb=1498729990
    Effect of carbon content on properties of
    plain carbon steel

    http://www.engineersgallery.com/wp-content/uploads/2015/12/Effect-of-carbon-on-properties-of-steel.jpg
    Uses of steel in construction

    • Reinforcing steel
    – Rebar for concrete
    • Structural steel
    – Plates, bars, pipes, structural shapes, etc.
    • Cold-formed steel
    – Studs, truss, roofing, cladding
    • Fastening products
    – Bolts, nuts, washers
    • Miscellaneous
    – Forms, hardware, etc.
    Types of Reinforcing Bars/strands

    1. Plain and ribbed (hot rolled) mild steel bars

    2. Cold twisted deformed (CTD) steel bars


    3. Thermo-mechanically treated (TMT) or
    Quenched and self-tempered (QST) steel bars
    4. Corrosion-resistant steel (CRS) bars

    5. Stainless steel bars

    6. Prestressing steel strands

    7. Galvanized steel bars

    8. Fusion-bonded-epoxy coated (FBEC) steel bars

    9. Cement-polymer-composite coated (CPCC) steel bars

    10. Fiber reinforced polymer (FRP) bars


    Commonly used structural steel shapes
    Properties of iron products and steel

    • Ultimate strength
    • Modulus of elasticity
    • Yield strength
    • Brittleness/ductility
    • Corrosion resistance

    Cast iron… here

    http://www.billavista.com/tech/Articles/Steel_and_Materials_Strength_Bible/index.html
    "Engineer to Win". Carroll Smith; Motorbooks International, 1985 p.41
    Summary

    • Cast iron
    • Ductile iron
    • Wrought iron
    • Steel

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