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steeluniversity.org | Steel Processing | Steel Processing Overview
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Steel Processing Overview
The production of steel from raw materials involves several stages.
Ironmaking
Iron ore, coke and lime are the raw materials fed into the blast furnace to produce liquid iron (often called 'hot metal'). The iron that emerges from the blast furnace contains 4-4.5 wt% carbon and other impurities which makes the metal too brittle for most engineering applications.
Steelmaking
The Basic Oxygen Steelmaking (BOS) process takes this liquid iron plus recycled scrap steel, and reduces the carbon content to between 0 and 1.5% by blowing oxygen through the metal in a converter to produce molten steel. Alternatively, the Electric Arc Furnace (EAF) is used to remelt scrap iron and steel.
Secondary steelmaking processes are then applied to make fine adjustments to the steel composition, temperature and cleanness.
Casting
The steel is then continuously cast into solid slabs, blooms or billets. Continuous casting has largely replaced traditional ingot casting.
Primary Forming
Primary forming operations, such as hot rolling are those which are applied to continuous cast slabs, blooms and billets (and to traditional ingots). The main purpose is usually to achieve large shape changes, rather than to develop the steel properties, although these too can be significantly altered.
Manufacturing, Fabrication & Finishing
A wide variety of "secondary" forming operations are applied to give the steel component its final shape and properties. These can be sub-divided into the following general processes:
a.. shaping (e.g. cold rolling)
b.. machining (e.g. drilling)
c.. joining (e.g. welding)
d.. coating (e.g. galvanizing)
e.. heat treatment (e.g. tempering)
f.. surface treatment (e.g. carburizing)
For more information, simulations and interactive exercises, check out the SteelMATTER site.
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