UNIT I

METALS

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A metal is a material that, when freshly prepared, polished, or
fractured, shows a lustrous appearance, and conducts electricity
and heat relatively well.

Approximately three-quarters of all known chemical elements are

metals. The most abundant varieties in the Earth’s crust
are aluminum, iron, calcium, sodium, potassium, and magnesium.
The vast majority of metals are found in ores (mineral-bearing
substances), but a few such as copper, gold, platinum,
and silver frequently occur in the free state because they do not
readily react with other elements.

Extraction of Metals: Ores and Minerals

The process of extracting metal ores buried deep underground is
called mining. The metal ores are found in the earth’s crust in
varying abundance. The extraction of metals from ores is what
allows us to use the minerals in the ground. The ores are very
different from the finished metals that we see in buildings and
bridges. Ores consist of the desired metal compound and the
impurities and earthly substances called gangue.

An ORE is a type of rock that contains MINERALS with important

elements including metals. Once mined, metals must be extracted
usually by chemical or electrolytic reduction.

PYROMETALLURGY
uses high temperatures to convert ore into raw materials

HYDROMETALLURGY
employs aqueous chemistry for the same purpose.
PHYSICAL PROPERTIES OF METALS
1. Metals can be malleable
(hammered into thin sheets).
1. Metals are ductile
(turn into thin wires).
1. Metal are the best conductor of
electricity and heat.
2. Metals are lustrous, meaning they have
a shiny appearance.
3. Metals have high tensile strength
4. Metals are sonorous.
5. Metals are hard.

CHEMICAL PROPERTIES OF METALS

Metals react with oxygen, water, dilute
acids, and other salts.

(1) They form positive ions.

(2) They form basic oxides and hydroxides.

(3) They react with oxygen present in atmosphere to form oxides

and iron corrodes.

(4) They form metallic bonds.

(5) They react with water to produce hydrogen gas.

CLASSIFICATION OF METALS

FERROUS
1. Contains Iron
2. Magnetic in nature
3. Gives little resistance to corrosion

NON FERROUS
1. Does not contain iron
2. Non magnetic
3. Gives more resistance to corrosion than ferrous metals

FERROUS METALS
I. Cast Iron
a. Grey Cast iron
b. White Cast Iron
c. Malleable Cast Iron

Properties:
Cast Iron is strong in compression and weak in tension. It is brittle
and does not absorb shock. When subjected to shocks or fire, it fails
suddenly without giving any warning. It cannot be welded easily,
forged or rolled. It cannot be punched or riveted like steel but can
be easily melted and cast into various shapes and machined. It
offers excellent resistance to corrosion as compared with many
other ferrous metals and rusts slowly, but corrodes in sea water
Uses:
Cast Iron is used for making building columns, caps and bases of
Columns, brackets, sewage and water pipes, wheels, spiral -
staircases, manhole covers, rain water pipes, gutters, sanitary
fittings etc
II. Wrought Iron
It is the purest form of Iron with low carbon content, less than
0.15 percent.

Properties:
It possess the qualities of toughness, ductility, and malleability. It
can be bent, twisted when hot or cold but cannot be cast into
moulds and can neither be hardened nor tempered like steel but
can be case hardened. Some grades of iron are more rust – resisting
than steel and are at times used for hydraulic and marine structures.

Uses:
Wrought Iron is replaced at present to a great extent by Mild Steel.
It is therefore produced to a very small extent. It is used for making
tough materials such as nails, spikes, bolts and nuts, chains, sheets,
plates, handrails, ornamental gates, straps for timber roof trusses,
pipes and tubing. It is also used as raw material for crucible steel.
III. Steel
Steel is an alloy or compound of iron and carbon in the form of
carbide of iron. This percentage of carbon is limited to 1.5. There are
three grades of steel in this accordance with the percentage of
carbon three grades of steel in accordance with the percentage of
carbon. The smaller the amount of carbon steel contains, the nearer
will be its properties resemble those of wrought iron and greater
the amount of carbon it possesses, nearer it will be
approaching in properties to that of cast iron. The three grades of
steel are:
(i) Low carbon steel or mild steel (carbon percent <0.25).
(ii) Medium carbon steel or hard steel (carbon percent, 0.25 to 0.7).
(iii) High carbon steel (carbon percent, 0.7 to 1.5).

Properties of Steel:
Steels are highly elastic, ductile, malleable, forgeable and weldable.
Steels have much higher tensile and compressive strengths than
wrought iron and also stand wear and tear much better.

Generally, a soft and malleable steel is required for rolling into thin
sheets, and a very hard and brittle steel is required for making tools,
and a steel containing carbon 0.3 percent is required for high
strength and structural purposes.
Uses:
Steels are generally used for the following purposes:

(i) As structural material in trusses, stanchions, beams and light

frames in the form of various sections,
(ii) As non-structural components for grills, stair balustrades,
windows and doors,
(iii) Mechanical services in the form of steel pipes, tubes, tanks,
ducts, etc.
(iv) Sanitary and sewer fittings,
(v) Expanded metal and metal lath,
(vi) Rain water goods, and
(vii) Corrugated sheets.
Non-Ferrous Metals
These are the metals which do not contain iron as their main
constituent. Non-ferrous metals are of several types such as
aluminium, lead, copper, magnesium, nickel, tin, zinc, etc. Only first
three of these metals are important for use in building industry and
hence will be discussed here:
1. Aluminium
• Properties:
• It is a bluish silvery white
lustrous metal obtained from
‘Bauxite’ ore.
• Pure aluminium is very soft
and ductile and therefore, it is
alloyed
• (mixed) with other metals like copper, magnesium, silicon,
• manganese, etc. which increases it's tensile strength and
hardness
• while retaining its characteristics of lightness and durability.
• Aluminium is highly resistant to corrosion, and very good
conductor
• of heat and electricity.
Uses:
(i) Frame work as channels, beading, and structural support
systems

(ii) As lightweight fasteners ex nuts & bolts, screws etc

(iii) Corrugated Aluminium sheets for roofing,

(iv) Window-frames and sub-frames,

(v) Posts, panels and balustrades, and

(vi) General purposes such as glazing bars, foils, wires, bars, rods,
as a pigment in paints, etc.
2. Zinc
Zinc is an abundant metal,
found in the Earth’s crust, with
a myriad of industrial and
biological uses. At room
temperature, zinc is brittle and
blue-white in color, but it can
be polished to a bright finish.

Properties:
i. Strength: Zinc is a weak metal with less than half the tensile
strength of mild carbon steel. It is generally not used in load-
bearing applications, although inexpensive mechanical parts
can be die cast from zinc.

ii. Toughness: Pure zinc has low toughness and is generally brittle,
but zinc alloys generally have high impact strength compared to
other die casting alloys.

iii. Ductility: Between 212 and 302 degrees Fahrenheit, zinc

becomes ductile and malleable, but at elevated temperatures, it
reverts to a brittle state. Zinc alloys greatly improve on this
property over the pure metal, allowing more complex fabrication
methods to be used.

iv. Conductivity: Zinc’s conductivity is moderate for a metal. Its

strong electrochemical properties, however, serve well in
alkaline batteries and during the galvanizing process.
Uses:
(i) One of the biggest uses of zinc is in making protective
coatings for steel.
(ii) In architectural applications Zinc is used for
rainwater systems, cladding and roofing, and alloyed
with copper and titanium. This combination of metals
maximises tensile strength, malleability and
load bearing capacity. Zinc panels can last up to 50 years
under the right conditions.
(iii) Another growth area is that of zinc castings, which is based
on new alloys and new technology.
3. Copper
Properties:
Copper is extracted by smelting ‘copper pyrites’ which is an ore of
copper. Pure copper is of lustrous red colour and is extensively used
for engineering purposes. It is a light, tough, strong, ductile and
malleable metal with good properties of resistance to corrosion in dry
air. It can be forged, rolled or otherwise worked hot or
cold and drawn into wires. It is attacked by acids but stands well
against sea water. It is a good conductor of heat and electricity.
Uses:
Copper is used for several purposes, viz.,
(i) Electric wires and cables,
(ii) light gauge tubing for hot and cold water supply,
gas and sanitation services,
(iii) General purposes such as alloying with brass and others,
protective coatings for other metals, electroplating, etc.
(iv) Dowels in stone masonry, and
(v) Sheets for roofing
4. Tin
The mineral cassiterite is the source of the soft,
silver-blue metal known as tin. It is a base metal
frequently used to make alloys with other metals.

Properties:
i. It is a soft, malleable metal with a bluish-white colour tint
ii. Water and oxygen have little impact on the tin at room
temperature. Additionally, it is corrosion-resistant. It is used as a
coating for other metals because of this.
iii. When the metal reacts with oxygen and water at higher
temperatures, it produces its oxide.

Uses:
i. Tin is used in the soldering of steel.
ii. It is also employed in producing other alloys, including copper
and bronze.
iii. Glass, ceramics, and sensors employ it as a reducing and
colouring agent.
iv. Most tin is utilised as an alloy with other metals like lead or zinc
or as a protective coating.
v. Tin is used in glass production, bearing alloys, coatings for steel
containers, solders for connecting pipes or electrical/electronic
circuits, and other tin chemical use.
5.Lead
Properties:
It is bluish grey in colour with silvery
lustre when freshly cut. It occurs in
free state and is also obtained from
sulphide ore of lead, i.e., galena. Lead is a very soft, highly ductile
malleable, plastic, non—corrodible metal with low fusion point and
very low strength. The metal is extremely resistant to atmospheric
corrosion and is not affected by soil and sewage effluents or
industrial wastes.
Uses:
Lead is used for several purposes, viz.
(i) Lead sheets for roofing,
(ii) Gutters, flashings and cistern linings,
(iii) Damp-proof courses,
(iv) Cable coverings,
(v) Lead wool and solders for plumbing,
(vi) Cast lead for ornamental lead work, and
(vii) General purposes such as lead oxides for paints, making bullets,
alloys, storage cells, etc.
Various Alloys
An alloy is an intimate mixture of two or more metals. It should be
noted in this regard that it is not merely a mechanical mixture but as
a matter of fact, the properties of an alloy are entirely different from
those of its constituents. The alloys are of several types but only
copper alloys namely brass and bronze, which are used in building
industry, are discussed here.
1. Brass
Properties:
Brass in an alloy of copper and zinc. But various alloys are produced
by varying the proportions of these metals and even adding minor
proportions of other metals. Properties of brasses vary considerably
by changing these proportions. Most commercial wrought ' brasses
contain 65% copper and 35% zinc. Brasses are ductile and malleable
at ordinary temperatures and can be rolled into sheets, turned into
tubes, drawn into wires or cast into moulds. Brass resists corrosion
well. Although colour is bright yellow when fresh but requires
regular cleaning.
Uses:
Brass is used for various purposes, viz.,
(i) Fittings for doors and windows;
(ii) Stop cocks and valves in water works;
(iii) Stair treads, grills, protective sheets, and finished hardware in
buildings;
(iv) Bearings for machinery; and
(v) Household utensils, name and
number plates, etc.
2. Bronze

Properties:
Bronze is an alloy of copper, zinc and tin and contains about 80%
copper. Bronzes are hardened copper. They are stronger and
superior to brasses for corrosion-resisting properties. It is difficult to
work with bronzes and also are more expensive
Uses:
Bronze is largely used in building industry for various purposes such
as door, window sash, frames, grills, balconies, balustrades, screens,
hardware and for many decorative purposes.
THE END