CONTENTS SECTION 1 Introduction to Metallurgy Chapter 1 History of Metallurgy . . . . . . . . . . 4 1.1 The Bronze Age. . . . . . . . . . . 6 1.2 The Iron Age . . . . . . . . . . . . 7 1.3 Industrial Revolution . . . . . . . . 9 1.4 Twenty-First-Century Developments . . . . . . . . . . 12 Chapter 2 Metallurgists and Careers in Metals Industries. . . . . . . . . . . 16 2.1 The Structure, Properties, and Processing of Metals . . . . . . . . . 17 2.2 Practical Examples of Metallurgy. . . . 20 2.3 People Who Work with Metals. . . . 25 2.4 Advancing Metallurgy. . . . . . . . . 26 Chapter 3 Metallurgy Safety Practices. . . . . . . . 30 3.1 OSHA (Occupational Safety and Health Administration). . . . . . 31 3.2 Fire Safety . . . . . . . . . . . . . . . 32 3.3 Safety in Manufacturing. . . . . . . . 33 3.4 Safety in Metallurgy Labs. . . . . . . 37 3.5 Eff ects of an Accident . . . . . . . . 37 SECTION 2 Chemistry and Mechanics of Metals Chapter 4 Basic Structure of Metals. . . . . . . . . 44 4.1 Measurement Scales. . . . . . . . . 46 4.2 Atomic Elements . . . . . . . . . . 49 4.3 Compounds . . . . . . . . . . . . 51 4.4 Formation of Metals. . . . . . . . . . 52 4.5 Crystal Structures . . . . . . . . . . . 54 4.6 Chemical Reactions in the Production and Use of Metals. . . . . 57 Chapter 5 Physical and Chemical Properties of Metals . . . . . . . . . . . . . . . 66 5.1 Microstructure of Metals . . . . . . 68 5.2 Physical Properties of Metals . . . . 76 5.3 Chemical Properties of Metals . . . 85 Chapter 6 Mechanical Properties of Metals . . . . 92 6.1 Strength and the Elastic Region. . . . 94 6.2 Strength and the Plastic Region. . . . 99 6.3 Other Important Strength-Related Properties. . . . . . . . . . . . . 104 6.4 Fracture and Failure Modes in Metals . . . . . . . . . . . . . . 107 SECTION 3 Ferrous Metallurgy Chapter 7 Production of Steel by Hot-Rolling. . . . 122 7.1 Extraction, Refi nement, and Recovery of Iron. . . . . . . . 124 7.2 Recovery of Steel from Scrap . . . . 128 7.3 Production of Steel. . . . . . . . . 130 7.4 Alloy Elements and Numbering Systems . . . . . . . . 132 7.5 Production of Rolled and Other Semifi nished Steel . . . . . . . . . 135 Chapter 8 Production of Steel by Casting, Forging, Extrusion, and Powder Metallurgy . . . . . . . . . . . . . . .148 8.1 Production of Steel Castings. . . . 150 8.2 Production of Hot Forgings. . . . . 155 8.3 Production of Extrusions. . . . . . 160 8.4 Production of Powder Metal (PM) Parts . . . . . . . . . . . . . . . . 161 8.5 Additive Manufacturing . . . . . . 165 viii