Ferrous metals

Task 1. Make a list of the ferrous metals and compare it with your partner.

Task 2. You are going to read about ferrous metals. Seven sentences have been removed from the text. Choose from the sentences (A-H) the one which fits each gap (1-7). There is one extra sentence which you do not need to use. There is an example at the beginning (1).

A It is very cheap, in fact, it is the cheapest of all the engineering metals used in machine-building.

B But very much carbon makes steel brittle, which reduces its strength.

C Various grades of copper are used for engineering purposes.

D Carbon is the most important of all elements to be presented in ferrous alloys.

E Cast iron is a general term applied to iron-carbon alloys containing more than 1.7 per cent of carbon.

F However, in comparison with other metals grey iron is weak.

G This process is known as casting.

H It has high resistance to corrosion.

To produce ferrous metals one must combine iron with carbon, silicon, other elements. 1) ___D____ Ferrous metals are used in industry in two general forms: steel and cast iron, which differ in the quantity of carbon content. These two ferrous alloys are derived from pig iron which is produced in a blast furnace in form of pigs. Metals are usually melted and poured into a form which is called a "mould". 2) _______ The cast metal is shaped in the mould where it cools and solidifies. Thus one can cast different objects known as castings. The shop where metals are cast is called a "foundry". Castings are used to produce different types of machinery.

Steel is a ferrous material with a carbon content from 0.1% to 1.0%, which makes it much stronger than iron and is therefore widely used in machine building. 3) ______ Therefore the carbon content in steel is confined to certain limits. Semisteel is a name to a metal made by melting 20 to 40% of steel scrap with cast iron in the cupola. Steel castings are more expensive but stronger and tougher.

Cast steel normally contains about 0.5% of carbon, and is used to replace cast iron when castings of considerable strength are required.

Forged steel is steel that has been hammered, drawn, pressed or rolled in the process of manufacturing of a particular part.

Alloy steels are those in which some alloying element in addition to the carbon is present in some appreciable quantity. The principal alloying elements used in steel are nickel, chromium, vanadium, molybdenum, manga­nese, and to lesser extent, copper, tungsten, cobalt, beryl­lium and boron.

Cast iron contains a higher percentage of carbon than steel does (more than 2.0 %). 4) _______ Cast iron without the addition of alloying elements is weak in tension and shear, strong in compression and has low resistance to impact. It is obtained from the cupola furnace where pig iron is remelted in contact with coke.

Grey cast iron has the carbon present in the free or graphite state and is soft, easily machined, and only moderately brittle.

White cast iron has most of the carbon in the combined state and is therefore hard and brittle.

Malleable cast iron is made by heating white iron castings for a period of several days in airtight pots filled with an oxide of iron. 5) _______

Grey iron foundries are the most numerous because grey iron can be cast into almost any conceivable shape and size. Grey iron is also adapted to a great variety of castings, such as automobile, gas, steam, and hydraulic engine cylinders, bed plates for machines, car wheels, agricultural machinery parts, furnace and stove parts, water pipes, gears, etc. The nature of the metal used for grey iron castings is such that castings can be made so hard that ordinary tool steel will not cut them or, on the other hand, so soft that they can be readily-machined. 6) _______ The alloy of grey castings is composed of iron, carbon, silicon, phosphorus, manganese, and sulphur. These elements are used in different proportions depending on the grade of castings.

There is one more kind of ferrous materials - wrought iron. It is quite ductile and can be easily rolled, drawn, forged and welded. 7) _______ The carbon content is generally less than 0.1% and the material must contain not less than 1% slag.

Task 3. Find in the text equivalents to the following words and expressions:

кількість, вміст вуглецю, чушки, мульда, затвердівати, цех, крихкий, ливарний цех, обмежувати, вагранка, межа міцності, легована сталь, кокс, сплав, колізія, сірий чавун, дешевий, необхідні форма та розмір, опорні плити, труба, шестерня

Task 4. Translate into Ukrainian the following words and word combinations:

ferrous alloys, the quantity of carbon content, a blast furnace, melted and poured into, to cool and solidify, casting, brittle, weak in tension and shear, easily machined, airtight pots, stove parts, water pipes, soft, grade of castings, to be rolled, drawn, forged and welded

Task 5. Match the words in column A with their meaning from column B.

	A		B
1	casting	a)	вуглець
2	gear	b)	вагранка
3	cast iron	c)	машинне обладнання
4	cupola	d)	шестерня
5	semisteel	e)	ливарна форма
6	stove	f)	ливарний цех
7	mould	g)	виливок
8	machinery	h)	піч
9	carbon	i)	чавун
10	foundry	j)	напівсталь

Task 6. Fill in the gaps with the verbs given below used in the proper tense form:

to consist, to form, to have, to restrict

1. The cast metal _______ in the mould where it cools and solidifies.

2. The carbon content in steel _______ to certain limits.

3. Cast steel normally ______ about 0.5% of carbon.

4. The alloy of grey castings ________ of iron, carbon, silicon, phosphorus, manganese, and sulphur.

Task 7. Translate next sentences into English:

1. Вміст вуглецю допомагає визначити чорний метал.

2. Сталь та чавун виготовляються в доменних печах.

3. Метал плавиться та заливається в мульду, де він охолоджується та затвердіває.

4. Виливки виготовляються в ливарному цеху, а потім використовуються в різних видах машинного обладнання.

5. Сталь широко використовується в машинобудування оскільки вона міцніша за залізо.

6. Легована сталь містить в собі, окрім вуглецю, ще деякі легуючі елементи.

7. Чавун виготовляється в мартенівських печах з заліза в чушках.

8. Автомобільні колеса, газові та парові двигуни, труби та шестерні виготовляються з сірого чавуну.

Task 8. Find in the text antonyms to the following words:

brittle, to heat, weaker, cooling, scanty

Task 9. Fill in the table using the information from the texts:

metal	composition	usage

Task 10. Memorize the following words and word combinations:

1.	alloy steel	легована сталь
2.	airtight pots	герметичні резервуари
3.	bed plate	фундаментальна (базова) плита
4.	brittle	крихкий
5.	casting	лиття; виливок
6.	cast steel	лита сталь
7.	coke	кокс
8.	ductile	пластичний, ковкий
9.	to draw	витягувати
10.	ferrous metals	чорні метали
11.	forged steel	кована сталь
12.	foundry	ливарний цех, ливарне виробництво
13.	machinery	обладнання
14.	malleable cast iron	ковкий чавун
15.	mould	мульда, ливарна форма
16.	pigs	чушки
17.	resistance to impact	ударна міцність
18.	semisteel	напівсталь
19.	shop	цех
20.	to solidify	затвердів ати
21.	steam engine	паровий двигун
22.	strength	міцність
23.	tough	тугий, пружний, гнучкий
24.	wheel	колесо
25.	wrought iron	коване залізо

Lesson 8.

NON-FERROUS METALS

Task 1. Make a list of the non-ferrous metals and compare it with your partner.

Task 2. You are going to read about non-ferrous metals. Seven sentences have been removed from the text. Choose from the sentences (A-H) the one which fits each gap (1-7). There is one extra sentence which you do not need to use. There is an example at the beginning (1).

A These characteristics are: high electrical and thermal conductivity, high corrosion resistance, non-magnetic qualities, light weight, etc.

B It has high corrosion-resistant qualities and is used for plating other metals such as iron or brass.

C Aluminium is a soft, silvery white metal.

D On account of its low electrical resistance, aluminium is used in certain cases in wires and cables as conductors.

E It was replaced for these purposes by iron and steel.

F Aluminium is the most abundant of the metals and the most widely distributed.

G It is quite ductile and can be easily rolled, drawn, forged and welded.

H Metallurgists propose copper to be used for making electrical contacts, wires, water heaters, etc.

Non-ferrous metals are more expensive than ferrous metals and are used only when some characteristic not possessed by iron or steel is essential or desirable in application. 1) A .

The metals most frequently used to make non-ferrous metal castings are copper, tin, zinc, nickel, gold, aluminium and lead. Some of the basic non-ferrous metals and their characteristics are described below.

Copper was used in prehistoric times for making weapons and tools and later was alloyed with tin to form bronze, which was the most important metal of the Greeks and Romans. 2) __________ Various grades of copper are used for engineering purposes. The great development of the electric industries has resulted in such extensive uses of the metal that it now ranks next to iron in importance.

We know copper to be a reddish-brown tough metal. Among non-ferrous metals copper is the most important. Because of its high electric conductivity about 60 % of all the copper produced is used in electrical work. It has high corrosion-resistant qualities. 3) _________

The copper alloys are more widely employed. The alloying of copper with other elements increases the strength of the metal in some cases and improves the anticorrosive and anti-friction properties in others.

Aluminium is the typical metal in the third group in the periodic clas­sification of the elements. 4) ________ It is found in feldspars, micas, kaolin, clay, bauxite, cryolite, alunite, corundum and certain gems. Compounds of aluminium have been known for many years and they were recognised as being derived from a metal that had not been isolated. 5) ___________ It is light in weight, has high corrosion-resistant qualities. Scientists suggest aluminium to be used for automobile and airplane parts. It can be used also for making different light-weight objects used in everyday life such as: frames, cooking utensils, chairs.

Aluminium has a very low density, 2.7; it is used in construction when a metal is required and weight is important. It is ductile, malleable, and can be rolled. Its tensile strength is low in comparison with that of iron; it cannot be machined and polished readily and does not yield good castings. These defects can be overcome by alloying it with other metals. The metals which alloy freely with aluminium are copper, zinc, and iron. Usually where aluminium alloys are made, aluminium predominates. 6) _________

Zinc is a hard, brittle, bluish-white metal that is employed in the pure form as sheet zinc.

Lead is a very heavy bluish-grey metal which is very soft. We know lead to be supported by a core to strengthen it. Lead is used for lining pipes, acid tanks and coating electrical cables.

Tin is a silvery, corrosion-resistant metal. We suggest tin to be used as an alloying element. Tin is hardly used in pure form.

Nickel is a hard, tough, silvery metal. 7) _________

There are many applications of non-ferrous metals in the unalloyed state, but in most cases, some alloying element is added.

Task 3. Find in the text equivalents to the following words and expressions:

електро- та термо-провідність, корозійностійкий, олово, свинець, зброя, польовий шпат, слюда, глина, м’який, вага, межа міцності на розтягнення, у порівнянні з золотом, легко сплавляється, дроти, провідник, чиста форма, труби, міцний

Task 4. Translate into Ukrainian the following words and word combinations:

more expensive, desirable in application, non-magnetic qualities, light weight, most frequently used, metal castings, making weapons and tools, engineering purposes, extensive uses, the anticorrosive and anti-friction properties, the most abundant of the metals, the most widely distributed, automobile and airplane parts, ductile, malleable, unalloyed state

Task 5. Match the words in column A with their meaning from column B.

	A		B
1	feldspar	a)	свинець
2	alloying element	b)	межа міцності на розрив
3	expensive	c)	бак для кислоти
4	mica	d)	жорсткий
5	lead	e)	олово
6	corrosion resistance	f)	слюда
7	tin	g)	легуючий елемент
8	tough	h)	польовий шпат
9	acid tank	i)	стійкість до корозії
10	tensile strength	j)	дорогий

Task 6. Fill in the gaps with the verbs given below used in the proper tense form: to show, to possess, to give rise to, to beat

1. Copper _____ high corrosion-resistant qualities

2. These defects _______ by alloying it with other metals.

3. Some of the basic non-ferrous metals and their characteristics _____ below.

4. The great development of the electric industries _______ such extensive uses of the metal that it now ranks next to iron in importance.

Task 7. Translate next sentences into English:

1. Кольорові метали використовуються через їх фізичні властивості, такі як: стійкість до корозії, тепло та електропровідність та інші.

2. Люди сплавили мідь з оловом, щоб утворити бронзу.

3. Мідь використовується для дротів, електричних контактів, нагрівачів води, і т.п.

4. В автомобільній та повітряній промисловостях конструктори використовують алюміній через його легку вагу та антикорозійні властивості.

5. Олово найчастіше використовується як легуючий елемент.

6. Кольорові метали дуже рідко використовуються в чистому виді, дуже часто додається який-небудь легуючий елемент.

Task 8. Put the verbs in brackets into Passive Voice and translate the following sentences into Ukrainian:

1. Iron, like most metals, (to find) in the Earth's crust in an elemental state.

2. If a piece of copper (to heat) it quickly becomes coated in black copper oxide.

3. Tensile strength (to measure) in units of force per unit area.

4. A malleable metal easily (to deform), especially by hammering or rolling, without cracking.

5. Hardness (to measure) on the Mohs scale or various other scales.

6. Blast furnaces (to use) for non-ferrous smelting processes, particularly in the production of lead.

Task 9. Fill in the table using the information from the texts:

metal	composition	usage

Task 10. Memorize the following words and word combinations:

1.	acid tank	бак для кислоти
2.	anti-friction properties	анти-зношувальні властивості
3.	coating electrical cables	покриття електрокабелів
4.	cooking utensil	кухонне начиння
5.	core	осердя, ядро
6.	corrosion resistance	стійкість до корозії
7.	corundum	корунд, наждак
8.	to derive	отримувати, добувати
9.	feldspar	польовий шпат
10.	frame	рама
11.	electrical contacts	електричні контакти
12.	to employ	використовувати, застосовувати
13.	expensive	коштовний, дорогий
14.	gem	дорогоцінне каміння
15.	grades of copper	сорт міді
16.	mica	слюда
17.	pipe	труба
18.	plating	покриття
19.	pure form	чиста форма
20.	sheet zinc	листовий цинк
21.	tensile strength	межа міцності на розрив
22.	thermal conductivity	термопровідність
23.	unalloyed state	несплавлений стан
24.	water heater	водневий нагрівач
25.	wire	дріт

Lesson 9.