Bello, Geleni Shalaine P.

2014-24685
MetE 11 TYZ

Cast Iron (Bollard)

Iron
Iron, the fourth most abundant element in the Earth's crust, is a silvery-white or
grayish metal which is known for its high ductility and malleability. It is also one
of only three naturally occurring magnetic elements, which include nickel and
cobalt. It also has a very high tensile strength which enables it to be stretched
without breaking. It is also easy to be formed into desired shape and thickness.
The melting point of pure iron is 1,536C (2,797F) and its boiling point is about
3,000C (5,400F). Its density is 7.87 grams per cubic centimeter. The melting
point, boiling point, and other physical properties of steel alloys may be quite
different from those of pure iron which makes it allotropic.
When it comes to its chemical properties, iron is a very active metal. It readily
combines with oxygen in moist air. The product of this reaction, iron oxide (

Fe2 O3 ), is known as rust. Iron also reacts with very hot water and steam to
produce hydrogen gas. It also dissolves in most acids and reacts with many other
elements.

Extraction of Iron
In the blast furnace process, the initial step is the production of pig iron
from iron ore. The composition of the ore and additions is accurately
adjusted to the final products.
Burdening
Burdening materials such as sinter, pellets, lump ore, alloys, and coke is
measured in exact quantities. The limestone removes impurities in the iron
ore. These are transported alternately via a belt conveyor to the blast
furnace head. Using a rotary chute, these are charged in layers via sluice
vessels into the furnace.
Cowper
The cowper supplies the blast furnace with a current of hot air ("blast"),
initiating the chemical reaction. Top gas produced in the blast furnace
heats the refractory checker bricks in the cowper. A temperature of over
1300 C will be reached by the blast, then flows through these hot bricks.

Blast furnace
A counterflow principle is followed by the blast furnace. This starts from
the stock column, made up of ore, coke and additions, slides down
towards its conversion, while the top gases rise and heat the stock
column.

3 Fe 2 O3 +CO 2 Fe 3 O4 +C O2
Fe3 O 4 +4 CO 3 Fe+ 4 C O2
Fe2 O3 +CO 2 FeO +C O2
At the bottom of the furnace the iron ore is chemically reduced. The blast
reacts with the coke; carbon dioxide and carbon monoxide are formed at
temperatures of up to 2000 C.

C O2 +C 2CO
3 FeO +C O2 Fe+ C O2
The carbon monoxide removes the oxygen from the iron ore resulting in
pig iron production. Slag is formed from the other ore components and the
additions.
Casting bay
Through the blast furnace tap hole, the hot metal is filled into torpedo
cars, launder lined with refractory material, and transported to the steel
plants. The silicon content of between 0.3 % and 0.5 % is already adjusted
to steel plant and rolling mill requirements. Escaping of dust is prevented
by a modern dust extractor during tapping. The slag floating on the top of
the hot metal in the lauder, which has low specific gravity, is separated
from the metal and poured into slag dumps where it solidifies or is
immediately granulated with high-pressure water. The solidified slag is
used as road building material, whereas the granulated material is
supplied to the cement industry.

Foundry Process
This is the production of near-net shape products by pouring molten
metal, produced from scrap, pig iron, ingots and alloys, into molds. This also
includes processes such as mold/core preparation and finishing of cast
components.

The Production of Cast Iron

The production of cast iron may be employed through traditional sand casting
techniques enhanced by modern materials and technology. There are four stages
in production; Design, Pattern Making, Mould Making and Casting.
Design:
In this stage, the ideas of the expected product are converted into solid
metal. This requires planning and taking into account the products
function and appearance. These factors include the stresses, conditions
under it operate, strength, durability and decorative embellishment.
Designs must be with detailed and precise dimensions, metal thickness.
Pattern Making:
The design is made into a pattern, normally in wood but sometimes using
fibreglass or plastics. These have to be exactly the shape of the finished
item and precise in their dimensions. Patterns can be re-used to make
more molds. A meticulous process must be done to prevent any
irregularity or mistake that might be reproduced in the casting. Patterns
must also allow metal shrinkage when it cools and provide channels and
runners to allow metal to flow into the mold. Risers must also be created
to allow gas escape.
Mold Making:
The next stage involves making a mold in sand into which the molten iron
can be poured. The sand is packed by chemically active binding
components or sometimes, with resin and clay. Molds are made in two
parts and held in boxes for the actual pouring. When these are placed
face to face, one on top of the other, a cavity is created into which the
molten iron can be poured and will take its shape of the final product.
In a special case, casting for bollards and columns has hollow centers or
cavities. To create a cavity the internal shape of the casting is formed by
making a sand core, which is then placed in the mold cavity. Precise metal
thickness and form is ensured. The molten iron runs round the core so that
when the casting is broken out of its mould the internal sand core remains.
It is then removed to leave a cavity.
When breaking out the casting the sand mould is destroyed, but of course
new moulds can be made from the pattern using the same sand after it
has been re-cycled.
Casting:
This is the final part of the process and the one associated with foundries.
Melting and pouring iron at 1,350 C is a potentially violent process.
Correct chemical characteristics for the prescribed grade of iron are
ensured as the iron is loaded in the furnace. It is then melted in the

furnace and poured off to go into the molds. After the iron has cooled in
the molds, it is broken out. All the excess iron from the process, the
runners, is cleaned off through fettling, which also includes grinding and
shot blasting, to produce a finished casting. Excess iron can then go back
to be melted down again.

Casting of a Bollard:

1. A wooden pattern is made, half a bollard, and placed in a

box for sand moulding. The inside of the pattern box is coated
with either micronized talcum powder or micronized
aluminium to ease mold release.

2.
Molds
are
around
the
When the sand
removed
from
mold
can
be
insides of the
the molten iron is poured in.

made using a sand and resin mix packed

pattern. The mold is made in two halves.
resin mix has compacted, the mold can be
the pattern box and the second half of the
made. A refractory paint is used to coat the
mold to protect the finished product when

3. A sand core is made that fits precisely within the mould

leaving a space between the core and the mould that will
produce a constant and exact metal thickness.

4. The top half and the bottom half are placed face to face.
Metal can now be poured into the mold.

5. When the molten iron has solidified and cooled down, the
sand mould is broken open, exposing the finished casting.

6. Any extraneous
the sand core.
is shot blasted

iron is removed at the fettling stage, as is

Once the fettling is complete, the casting
ready for painting and delivery.

7. The final product is produces and the mold is used again, if

applicable or is recycled to form more casting.

References:
(1) Foundry Process
http://www.castingstechnology.com/public/documents/000000000000129.
pdf (accessed May 15, 2016).
(2) Metal Casting Process
http://thelibraryofmanufacturing.com/metalcasting_basics.html (accessed
May 16, 2016).
(3) Cast Iron Production
http://www.hargreavesfoundry.co.uk/userfiles/attachments/pages/96/castir
onproduction.pdf (accessed May 15, 2016).
(4) Extraction Of Iron | What happens in the Blast Furnace & Reactions
http://byjus.com/chemistry/iron-extraction-blast-furnace-metallurgy/
(accessed May 17, 2016).
(5) Iron, Chemical Element - reaction, water, uses, elements, metal, gas,
number, name http://www.chemistryexplained.com/elements/C-K/Iron.html
(accessed May 18, 2016).