1. Learning Intention: Show a working knowledge of various metals

2. Metal Ores
Ores are naturally occurring rocks that contain metal or metal compounds.
Ores are naturally occurring rocks that contain metal or metal compounds in sufficient amounts to make it worthwhile extracting them. For example, iron ore is used to make iron and steel. Copper is easily extracted, but ores rich in copper are becoming more difficult to find.
Methods of extracting metals
The method used to extract a metal from its ore depends upon the stability of its compound in the ore, which in turn depends upon the reactivity of the metal:
The oxides of very reactive metals, such as aluminium, form stable oxides and other compounds. A lot of energy is needed to reduce them to extract the metal.
The oxides of less unreactive metals, such as iron, form less stable oxides and other compounds. Relatively little energy is needed to reduce them to extract the metal.

3. Pure metals and Alloys
Metals are rarely used in their pure form. They are usually mixed with other metals to improve their properties. This is called an alloy
The simplest steels are iron (Fe) alloyed with carbon (C) (about 0.1% to 1%, depending on type). However, the term "alloy steel" is the standard term referring to steels with other alloying elements added deliberately in addition to the carbon.
The common pure metals are:-aluminium, copper, iron, lead, zinc, tin,silver and gold. An alloy is a mixture of two or more metals. When a material is needed which requires certain properties and this does not exist in a pure metal we combine metals . Pure white aluminium is very soft and ductile
aluminium, copper, iron, lead, zinc, tin,silver and gold

4. Ferrous and Non-ferrous Metals
Non-Ferrous Metals do not contain Iron, are not magnetic and are usually more resistant to corrosion than ferrous metals

5. Ferrous Metals Name Properties Typical Uses Cast Iron
Hard skin, softer underneath, but brittle, corrodes by rusting but better resistance than steel
Parts with complex shapes which can be made by casting
Cast iron is very brittle (it cracks easily) but it has a greater resistance to corrosion (see rusting) than either pure iron or steel. Cast iron is used for manhole covers on roads and pavements and as engine blocks for petrol and diesel engines
Although cast-iron blocks and cylinder heads still dominate, aluminum is increasingly being used by designers to reduce weight and improve fuel efficiency.

6. Ferrous Metals Name Properties Typical Uses Mild Steel Tough, ductile,
malleable, good tensile strength, poor resistance to corrosion
General structural work for example girders, nuts, bolts, screws, car body panels and non-cutting tools
Carbon steel is a metal alloy that is formed as a result of combining iron and carbon. Steel typically is considered to be carbon steel when the proportions of other trace elements in it do not exceed certain percentages. The maximum percentages typically are 1.65 percent for manganeseand 0.6 percent for copper and silicon. The copper percentage must be at least 0.4 percent. Steel that also contains higher or specified quantities of other elements, such as nickel, chromium orvanadium, is called alloy steel.
Manufacturers add carbon to iron to solidify the structures in it and strengthen the resulting metal. It’s one of the most cost-effective alloying materials, and altering the amount of carbon changes the properties of the steel. Carbon steels can be classified as low-carbon steels, medium-carbon steels, high-carbon steels and ultrahigh-carbon steels.
Steels with very low amounts of carbon, about 0.05 percent to 0.3 percent, are called low-carbon steels and are similar to iron. They are very ductile, which makes them hard to machine. They are used to make flat-rolled sheets or steel strips that are utilized to create ships, wire products, car bodies, domestic appliances, tin plates and more. Low-carbon steels are cheaper, but they cannot be altered by heat treatment, which is why they generally are used for fabrication and paneling purposes.
There are four types of carbon steel based on the amount of carbon present in the alloy. Lower carbon steels are softer and more easily formed, and steels with a higher carbon content are harder and stronger, but less ductile, and they become more difficult to machine and weld. Below are the properties of the grades of carbon steel:
Low Carbon Steel – Composition of 0.05%-0.25% carbon and up to 0.4% manganese. Also known as mild steel, it is a low-cost material that is easy to shape. While not as hard as higher-carbon steels, carburizing can increase its surface hardness.
Medium Carbon Steel – Composition of 0.29%-0.54% carbon, with 0.60%-1.65% manganese. Medium carbon steel is ductile and strong, with long-wearing properties.
High Carbon Steel – Composition of 0.55%-0.95% carbon, with 0.30%-0.90% manganese. It is very strong and holds shape memory well, making it ideal for springs and wire.
Very High Carbon Steel - Composition of 0.96%-2.1% carbon. Its high carbon content makes it an extremely strong material. Due to its brittleness, this grade requires special handling.

7. Ferrous Metals Name Properties Typical Uses High carbon steel
(tool steel)
Even harder than medium carbon steel and more brittle, can be heat-treated to make it harder and tougher
Steel is an alloy of metals that consists primarily of iron and contains 0.2 to 2.1 percent carbon. All steel contains carbon, but the term “carbon steel” applies specifically to steel that contains carbon as the main alloying constituent. Medium carbon steel is carbon steel that contains between 0.30 and 0.60 percent carbon. It also has a manganese content between 0.6 and 1.65 percent. This type of steel provides a good balance between strength and ductility, and it is common in many types of steel parts.
Iron consists of a crystal lattice of iron atoms that allow the atoms to slide past each other, making pure iron relatively soft. The carbon in steel reduces this tendency, making medium carbon steel harder than iron. Additional elements such as chromium, manganese, tungsten and vanadium can also act as hardening agents in steel. The precise proportion of these elements determines the specific properties of the steel.
Additional carbon makes the steel harder but also more brittle, so manufacturing carbon steel requires a balance between hardness and ductility. The most common uses of medium carbon steel are in heavy machinery, such as axles, crankshafts, couplings and gears. Steel with a carbon content between 0.4 and 0.6 percent is commonly used in the railroad industry to make axles, rails and wheels.

8. Ferrous Metals Name Properties Typical Uses Stainless steel
Hard and tough, resistant to wear and corrosion
It is the addition of a minimum of 12% chromium to the steel that makes it resist rust, or stain 'less' than other types of steel. The chromium in the steel combines with oxygen in the atmosphere to form a thin, invisible layer of chrome-containing oxide, called the passive film.

9. Non-ferrous Metals Non-ferrous metals do not contain iron
Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter and tinbased alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.

10. Non-ferrous Metals Name Properties Typical Uses Aluminium
(pure metal is rarely used) Main alloy is Duralumin
Good strength-to-weight ratio. Strong. Malleable. Good conductor of electricity. Resistant to corrosion. Can be highly reflective. and  

11. Non-ferrous Metals Name Properties Typical Uses
Copper
Excellent conductor of heat & electricity
Malleable
Resistant to corrosion

12. Non-ferrous Metals Name Properties Brass (copper + zinc)
Harder and cheaper than copper. Corrosion resistant
Brass is an alloy of copper (70%) and zinc (30%).

13. Non-ferrous Metals Name Properties Typical Uses
Bronze
Copper (zinc) + tin
Harder than brass – resistant to salt water corrosion
Bronze, on the other hand, has been used in boat and ship fittings because of its resistance to salt water corrosion.
While both bronze and brass are resistant to the corrosive effects of water, bronze has a stronger threshold than brass. Bronze is also much harder than brass, and is more difficult to manipulate into different forms, whereas brass has a reputation for malleability. Brass has strong acoustic properties, making it the metal of choice for musical instruments like the tuba, trumpet, saxophone, and French horn.

14. Non-ferrous Metals
Name
Properties
Typical Uses
Tin (pure)
Soft, weak, malleable, ductile and resistant to corrosion
Soft solder. Coating steel to form tin-plate
Tinplate,  thin steel sheet with a coating of tin applied either by dipping in molten metal or by electrolytic deposition; almost all tinplate is now produced by the latter process. Tinplate made by this process is essentially a sandwich in which the central core is strip steel. This core is cleaned in a pickling solution and then fed through tanks containing electrolyte, where tin is deposited on both sides. As the strip passes between high-frequency electric induction coils, it is heated so that the tin coating melts and flows to form a lustrous coat

15. Non-ferrous Metals
Name
Properties
Typical Uses
Lead (pure)
Soft, weak, malleable, ductile and resistant to corrosion
Alloyed with tin to produce soft solder
Tinplate,  thin steel sheet with a coating of tin applied either by dipping in molten metal or by electrolytic deposition; almost all tinplate is now produced by the latter process. Tinplate made by this process is essentially a sandwich in which the central core is strip steel. This core is cleaned in a pickling solution and then fed through tanks containing electrolyte, where tin is deposited on both sides. As the strip passes between high-frequency electric induction coils, it is heated so that the tin coating melts and flows to form a lustrous coat

16. Test Yourself

17. What are metals with iron in them called?
Ferrous

18. What are metals that do not have iron in them called?
Non-ferrous

19. What are metals that are mixed with other metals called?
Alloys

20. What are pure metals called?

21. What metal would be used?
Cast Iron

22. What metals could be used?
Cast Iron and Aluminium alloy

23. What metal could be used?
Copper

24. Bronze is an alloy of what 2 sometimes 3 metals?
Copper, Tin and sometimes Zinc

25. What is Bronze used for and why?
Resistant to salt water – and it’s very hard

26. What metal is used and why?
Mild steel – cheap, readily available, malleable, tough.

27. What metal is this and what properties does it have?
Hard and tough, resistant to wear and corrosion

28. What is it? What metal is it made from? What main property does it have? What needs to be done for it to be less brittle?
Dot / centre punch. High carbon steel. V. Hard needs to be heat-treated to make it less brittle

29. What metal would these be made from and why?
Light weight but strong. Malleable and corrosion resistant in the case of the can

30. What metal would be used and why? What other uses?
Brass – excellent conductor of electricity. Taps, brass instruments, (brass) screws

31. What metal would these mild steel cans be coated in and why
Tin – corrosion resistant

32. What else is tin used for?
Alloyed with lead to make solder