Question 1:
Continuous casting accounts
Continuous casting invented in 1865 by Sir Henry Bessemer one of the original founders of modern steelmaking, this invention used and developed to produce 750 million tons of steel, 20 million tons of aluminum, and many tons of other alloys produced in the world every year.
Continuous casting is process whereby molten steel is solidified into a "semi finished" billet, bloom, or slab for subsequent rolling in the finishing mills.
Process Description:
Continuous casting process starts by molten steel flows from a ladle through a tundish into the molder.
The concept in continuous casting is the use of an open ended mold to cast an indefinite length of the desired cross-sectional shape. The molten steel solidifies from the outer cooled surfaces inward during the casting process, the finally a fully solid slab, bloom or billet is produced which can then either be processed in a secondary rolling mill or shipped as a semi-finished steel product.
The importance of continuous casting:
The process of continues casting is preferred now in the world by many reasons and become powerful method to produce high quality products with less expenses beside other ways there are some reason made continuous casting such an important :
Energy savings:
The energy saving in continuous made by using the elimination of soaking pits,
Reheating furnaces and primary rolling mills so that can reduce consumption of power in process
Less scrap produced:
The complete process of continues casting leads to this result because the high efficiency of the whole process and reduced exposure of hot steel to air also reason to reduce scrap production
Improved labor productivity:
The labor productivity increase in contin...
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...ections in a car’s body in white (BIW). Sheet steel blanks are inserted into a press, the outer edge of the sheet is clamped and the sheet stamped between a male and a female die. To obtain a deep section requires extra metal, which is pulled from the clamped region; the part is then described as ‘drawn’. Very deep shapes, such as door inners or spare-wheel wells, are ‘deep drawn’ and require the most formable grades of steel. The higher-strength steel used in modern cars requires presses with higher press forces. Press Hardening, also known as die-quenching, is similar to press forming, but in the press-hardening process the steel is first heated to 9500 C and simultaneously pressed and quenched in the die to produce a very strong martensitic steel. Roll forming is a process where sheet metal is progressively folded to shape through a series of rollers.
This new form was called hydraulic die-forming. Hydraulic stems from the Greek word hydro meaning water and aulos meaning tube (McCreight, 2004). In today’s society, hydraulic pressing and stamping of dies are used for everything from making small pots and pans to the more extravagant automobile body models. Another use that has recently developed is the more artistic use of, producing form in silver and gold. In order to achieve this smaller, cheaper scale of die-forming experiment were conducted by Richard Thomas and Ruth Girard, which eventually led to the development of the pourable epoxy steel...
In 1886 an electrolytic process by which aluminum could be produced in commercial quantities was invented almost simultaneously by Paul Heroult in France and C.
Bronzes are made by making two molds (one larger than the other), pouring melted bronze in...
Nucor is the second largest steel producer (2nd in assets, 1st in profits) in the United States. Its profits of $123 million have made it one of the most efficient firms in the steel industry. Nucor achieved that position by focusing on the manufacturing segment known as mini-mills - the relatively small, electrically-powered mills that melt down scrap steel to manufacture products. This process saves on costly labor, raw materials, and the capital-intensive machinery necessary to produce steel from iron ore. A major concern of mini-mill steel manufacturers is maintaining quality, since their raw material consists of scrap steel of varying quality, containing a variety of alloys and impurities. Another concern it the recent rising price of scrap steel.
-Developed and implemented strip casting overseas to eliminate a step in the steel making process
In the 1870s Carnegie's new company built the first steel plants in the United States to use the new Bessemer steel-making process, borrowed from Britain.
One of the major effects of the Technological Revolution was the increased production of steel among the four European powers(Russia, France, Germany, and Britain). In 1911, for example, Russia was outputting nearly 600 times the amount of steel than they had in 1871. This surge in production was mainly caused by British metallurgist Henry Bessemer's method for obtaining the desired amount of carbon in the steel. The use of these Bessemer blast furnaces was widely adopted by industrial countries that needed to construct railroads, heavy artillery, and warships. Steel eventually replaced iron as the main metal used in housing, because it was stronger,cheaper to produce, and less corrosive. This allowed for more durable buildings, giving architects more freedom to design. (Hause, Maltby 756)
My Senior project is welding and welding is a manufacture or sculptural process that joins materials, most often metals or thermoplastics, by causing fusion, which is joined from lower moderation of heat metal fusion techniques such as brass and soldering, which do not fuse the base metal. In addition to melting the base bullion, a filler material is typically added to the joined to form a pile of molten material that cools to form a joint that is ordinarily stronger than the degraded material. Pressure may also be used in conjunction with heat, or by itself, to produce a weld. Welding also has a way to protect the filler metals or melted metals from being contaminated.
Four brass wedges were tested. Two were cold rolled to a thickness of 5.0 mm and two were cold rolled to a thickness of 2.5 mm. One wedge of each thickness was then annealed for 1 hour at 350 °C. Because the wedges varied in thickness across the length, multiple cold work values were able to be recorded. Hardness and thickness measurements were taken before and after the cold rolling and after the annealing as shown in Figure 1. Generally, as cold work increased, hardness increased.
Industrialization was wide spread during the early 19th century largely due to the advancement of the railroad system. A system put into place that allowed businesses to transport their goods throughout the countryside. Unfortunately, the wrought iron that was used for the rails couldn’t hold up long enough under those extreme conditions. For this reason, another alternative was needed to keep everything functioning as it should. Andrew Carnegie, an immigrant from Scotland who started in the textile industry couldn’t let that opportunity slip by and with the use of the Bessemer process he was able to make a stronger metal out of pig iron.
Relatively new injection molding (first machine was built in 1930s) is often used in mass-production and prototyping.
Manufacturing and machining processes such as –Press working and forging, Sheet metal fabrication, Milling and drilling type operations and assembly lines.
A typical injection-molding production process involves blending of viscosity or plasticity adjusting agents, auxiliary and active(s) ingredients with the melted polyethylene glycol base. The melt is then extruded into precision-machined multicavity molds followed by rapid solidification.
During the middle ages welding was very common. Early Egyptians learned the art of welding. Several of their tools were made by welding. A set of specialized workmen called blacksmiths created tools by melting the metal, then hammering them together. This method did not change much until the dawn of the 19th century which held major breakthroughs in welding. An open flame (acetylene) was very important to the history of welding. It allowed manufactures to make metal tools and equipment. In 1836 a man named Edmund Davy discovered acetylene which was soon utilized in the welding industries. Coated metal electrodes were first introduced in the 1900s. A coating of lime covered the electrode and made the weld much more stable. A number of other welding processes were also invented, such as seam welding, spot welding, flash butt welding, and projection welding. Stick welding also became popular around this time too. In the 1920s automatic welding was first introduced by P.O. Nobel. Automatic welding integrated the use of arc voltage and bare wire. It was mainly used for fixing old, molding metals. Several types of electrodes were also developed during this decade. A new type of welding was developed in the 1940s by Meredith. This became known as Heliarc Welding. Gas shielded arc welding or GTAW was another significant milestone in the welding history. Several advancements in the welding field were made in the 1960s. Dual shield, inner shield, and electro slag were some of the more important kinds developed. Plasma arc was also invented and was mainly used for metal spraying. Even now more techniques are being made. For example, laser welding was developed by the Russians and is being used more and more every day (“Welcome to
This study is intended to investigate the effects of heat treatment particularly quenching on the mechanical properties of mild steel especially on its strength using different quenching medium.