Metals - Ferrous, Non-Ferrous, Alloys – A Level Design and Technology Edexcel Revision

Metals - Ferrous, Non-Ferrous, Alloys

Ferrous metals are primarily composed of iron and small amounts of other elements or metals.
They are known for their strength and durability, making them ideal for structural and load-bearing applications.
Carbon steel, a common type of ferrous metal, can be categorised into low, medium, or high carbon steel depending on the carbon content. The higher the carbon content, the harder, but also more brittle the steel becomes.
Cast Iron, another ferrous metal, has excellent castability and machinability, making it suitable for engine blocks, pipes, and machinery.
Ferrous metals are magnetic, which can be advantageous in certain applications, such as electronics and motors.
A drawback of many ferrous metals is their tendency to rust, unless treated or alloyed to prevent oxidation.

Non-ferrous metals do not contain significant iron. They are usually more corrosion-resistant and lighter than ferrous metals.
Aluminium is a commonly used non-ferrous metal, valued for its lightweight, strength, conductivity, and resistance to corrosion. It is used in applications ranging from aircraft structures to beverage cans.
Copper is another significant non-ferrous metal known for its excellent electrical and heat conductivity. It is commonly used in wiring, plumbing, roofing, and electronics.
Other non-ferrous metals include zinc, tin, lead, and precious metals like gold and silver. Each has unique properties making them useful in various applications.

Alloys are a mixture of two or more metals, designed to have properties that improve upon those of the individual components.
Stainless steel is an alloy composed mainly of iron, carbon, and chromium. The addition of chromium provides a protective layer against rust and corrosion.
Brass, an alloy of copper and zinc, has superior machinability, *corrosion resistance/, and acoustic properties, making it popular in musical instruments, fittings, and decorative items.
Bronze, composed primarily of copper and tin, is valued for its hardness and resistance to wear and corrosion. It is commonly used to make bearings, springs, and sculptures.

Various processes including casting, forging, extrusion, and welding can be used to form and join metal parts.
Heat treatments like annealing, quenching, and tempering can alter the physical properties of metals, improving their hardness, ductility, or resistance to wear and corrosion.
Safety precautions are essential when working with metals, given the risk associated with high temperatures, sharp edges, and potentially harmful fumes.