Steel Inferno
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Steel is an alloy made up of iron with added carbon to improve its
strength Strength may refer to: Physical strength *Physical strength, as in people or animals *Hysterical strength, extreme strength occurring when people are in life-and-death situations *Superhuman strength, great physical strength far above human ca ...
and fracture resistance compared to other forms of iron. Many other elements may be present or added. Stainless steels that are corrosion- and oxidation-resistant typically need an additional 11%
chromium Chromium is a chemical element with the symbol Cr and atomic number 24. It is the first element in group 6. It is a steely-grey, lustrous, hard, and brittle transition metal. Chromium metal is valued for its high corrosion resistance and hardne ...
. Because of its high tensile strength and low cost, steel is used in buildings,
infrastructure Infrastructure is the set of facilities and systems that serve a country, city, or other area, and encompasses the services and facilities necessary for its economy, households and firms to function. Infrastructure is composed of public and priv ...
, tools, ships, trains,
car A car or automobile is a motor vehicle with wheels. Most definitions of ''cars'' say that they run primarily on roads, seat one to eight people, have four wheels, and mainly transport people instead of goods. The year 1886 is regarded as ...
s,
machine A machine is a physical system using Power (physics), power to apply Force, forces and control Motion, movement to perform an action. The term is commonly applied to artificial devices, such as those employing engines or motors, but also to na ...
s, electrical appliances, weapons, and rockets. Iron is the base metal of steel. Depending on the temperature, it can take two crystalline forms (allotropic forms): body-centred cubic and face-centred cubic. The interaction of the
allotropes of iron At atmospheric pressure, three allotropic forms of iron exist, depending on temperature: alpha iron (α-Fe), gamma iron (γ-Fe), and delta iron (δ-Fe). At very high pressure, a fourth form exists, called epsilon iron (ε-Fe). Some controvers ...
with the alloying elements, primarily carbon, gives steel and cast iron their range of unique properties. In pure iron, the crystal structure has relatively little resistance to the iron atoms slipping past one another, and so pure iron is quite ductile, or soft and easily formed. In steel, small amounts of carbon, other elements, and inclusions within the iron act as hardening agents that prevent the movement of dislocations. The carbon in typical steel alloys may contribute up to 2.14% of its weight. Varying the amount of carbon and many other alloying elements, as well as controlling their chemical and physical makeup in the final steel (either as solute elements, or as precipitated phases), impedes the movement of the dislocations that make pure iron ductile, and thus controls and enhances its qualities. These qualities include the hardness, quenching behaviour, need for annealing, tempering behaviour, yield strength, and tensile strength of the resulting steel. The increase in steel's strength compared to pure iron is possible only by reducing iron's ductility. Steel was produced in
bloomery A bloomery is a type of metallurgical furnace once used widely for smelting iron from its oxides. The bloomery was the earliest form of smelter capable of smelting iron. Bloomeries produce a porous mass of iron and slag called a ''bloom ...
furnaces for thousands of years, but its large-scale, industrial use began only after more efficient production methods were devised in the 17th century, with the introduction of the
blast furnace A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals, generally pig iron, but also others such as lead or copper. ''Blast'' refers to the combustion air being "forced" or supplied above atmospheric ...
and production of crucible steel. This was followed by the open-hearth furnace and then the Bessemer process in England in the mid-19th century. With the invention of the Bessemer process, a new era of mass-produced steel began.
Mild steel Carbon steel is a steel with carbon content from about 0.05 up to 2.1 percent by weight. The definition of carbon steel from the American Iron and Steel Institute (AISI) states: * no minimum content is specified or required for chromium, cobalt ...
replaced wrought iron. The German states saw major steel prowess over Europe in the 19th century. Further refinements in the process, such as basic oxygen steelmaking (BOS), largely replaced earlier methods by further lowering the cost of production and increasing the quality of the final product. Today, steel is one of the most commonly manufactured materials in the world, with more than 1.6 billion tons produced annually. Modern steel is generally identified by various grades defined by assorted
standards organisations A standards organization, standards body, standards developing organization (SDO), or standards setting organization (SSO) is an organization whose primary function is developing, coordinating, promulgating, revising, amending, reissuing, interpr ...
. The modern steel industry is one of the largest manufacturing industries in the world, but is one of the most energy and greenhouse gas emission intense industries, contributing 8% of global emissions. However, steel is also very reusable: it is one of the world's most-recycled materials, with a recycling rate of over 60% globally.


Definitions and related materials

The noun ''steel'' originates from the Proto-Germanic adjective ''stahliją'' or ''stakhlijan'' 'made of steel', which is related to ''stahlaz'' or ''stahliją'' 'standing firm'. The carbon content of steel is between 0.002% and 2.14% by weight for plain carbon steel ( iron- carbon alloys). Too little carbon content leaves (pure) iron quite soft, ductile, and weak. Carbon contents higher than those of steel make a brittle alloy commonly called
pig iron Pig iron, also known as crude iron, is an intermediate product of the iron industry in the production of steel which is obtained by smelting iron ore in a blast furnace. Pig iron has a high carbon content, typically 3.8–4.7%, along with silic ...
. Alloy steel is steel to which other alloying elements have been intentionally added to modify the characteristics of steel. Common alloying elements include: manganese, nickel,
chromium Chromium is a chemical element with the symbol Cr and atomic number 24. It is the first element in group 6. It is a steely-grey, lustrous, hard, and brittle transition metal. Chromium metal is valued for its high corrosion resistance and hardne ...
,
molybdenum Molybdenum is a chemical element with the symbol Mo and atomic number 42 which is located in period 5 and group 6. The name is from Neo-Latin ''molybdaenum'', which is based on Ancient Greek ', meaning lead, since its ores were confused with lea ...
,
boron Boron is a chemical element with the symbol B and atomic number 5. In its crystalline form it is a brittle, dark, lustrous metalloid; in its amorphous form it is a brown powder. As the lightest element of the ''boron group'' it has th ...
, titanium,
vanadium Vanadium is a chemical element with the symbol V and atomic number 23. It is a hard, silvery-grey, malleable transition metal. The elemental metal is rarely found in nature, but once isolated artificially, the formation of an oxide layer ( pas ...
, tungsten, cobalt, and
niobium Niobium is a chemical element with chemical symbol Nb (formerly columbium, Cb) and atomic number 41. It is a light grey, crystalline, and ductile transition metal. Pure niobium has a Mohs hardness rating similar to pure titanium, and it has sim ...
. Additional elements, most frequently considered undesirable, are also important in steel: phosphorus,
sulfur Sulfur (or sulphur in British English) is a chemical element with the symbol S and atomic number 16. It is abundant, multivalent and nonmetallic. Under normal conditions, sulfur atoms form cyclic octatomic molecules with a chemical formula ...
, silicon, and traces of oxygen, nitrogen, and copper. Plain carbon-iron alloys with a higher than 2.1% carbon content are known as cast iron. With modern steelmaking techniques such as powder metal forming, it is possible to make very high-carbon (and other alloy material) steels, but such are not common. Cast iron is not malleable even when hot, but it can be formed by casting as it has a lower melting point than steel and good castability properties. Certain compositions of cast iron, while retaining the economies of melting and casting, can be heat treated after casting to make
malleable iron Malleable iron is cast as white iron, the structure being a metastable carbide in a pearlitic matrix. Through an annealing heat treatment, the brittle structure as first cast is transformed into the malleable form. Carbon agglomerates into small ...
or ductile iron objects. Steel is distinguishable from wrought iron (now largely obsolete), which may contain a small amount of carbon but large amounts of
slag Slag is a by-product of smelting (pyrometallurgical) ores and used metals. Broadly, it can be classified as ferrous (by-products of processing iron and steel), ferroalloy (by-product of ferroalloy production) or non-ferrous/base metals (by-prod ...
.


Material properties


Origins and production

Iron is commonly found in the Earth's crust in the form of an ore, usually an iron oxide, such as magnetite or
hematite Hematite (), also spelled as haematite, is a common iron oxide compound with the formula, Fe2O3 and is widely found in rocks and soils. Hematite crystals belong to the rhombohedral lattice system which is designated the alpha polymorph of . ...
. Iron is extracted from
iron ore Iron ores are rocks and minerals from which metallic iron can be economically extracted. The ores are usually rich in iron oxides and vary in color from dark grey, bright yellow, or deep purple to rusty red. The iron is usually found in the fo ...
by removing the oxygen through its combination with a preferred chemical partner such as carbon which is then lost to the atmosphere as carbon dioxide. This process, known as smelting, was first applied to metals with lower melting points, such as tin, which melts at about , and copper, which melts at about , and the combination, bronze, which has a melting point lower than . In comparison, cast iron melts at about . Small quantities of iron were smelted in ancient times, in the solid-state, by heating the ore in a
charcoal Charcoal is a lightweight black carbon residue produced by strongly heating wood (or other animal and plant materials) in minimal oxygen to remove all water and volatile constituents. In the traditional version of this pyrolysis process, cal ...
fire and then welding the clumps together with a hammer and in the process squeezing out the impurities. With care, the carbon content could be controlled by moving it around in the fire. Unlike copper and tin, liquid or solid iron dissolves carbon quite readily. All of these temperatures could be reached with ancient methods used since the Bronze Age. Since the oxidation rate of iron increases rapidly beyond , it is important that smelting take place in a low-oxygen environment. Smelting, using carbon to reduce iron oxides, results in an alloy (
pig iron Pig iron, also known as crude iron, is an intermediate product of the iron industry in the production of steel which is obtained by smelting iron ore in a blast furnace. Pig iron has a high carbon content, typically 3.8–4.7%, along with silic ...
) that retains too much carbon to be called steel. The excess carbon and other impurities are removed in a subsequent step. Other materials are often added to the iron/carbon mixture to produce steel with the desired properties. Nickel and manganese in steel add to its tensile strength and make the austenite form of the iron-carbon solution more stable,
chromium Chromium is a chemical element with the symbol Cr and atomic number 24. It is the first element in group 6. It is a steely-grey, lustrous, hard, and brittle transition metal. Chromium metal is valued for its high corrosion resistance and hardne ...
increases hardness and melting temperature, and
vanadium Vanadium is a chemical element with the symbol V and atomic number 23. It is a hard, silvery-grey, malleable transition metal. The elemental metal is rarely found in nature, but once isolated artificially, the formation of an oxide layer ( pas ...
also increases hardness while making it less prone to metal fatigue. To inhibit corrosion, at least 11% chromium can be added to steel so that a hard
oxide An oxide () is a chemical compound that contains at least one oxygen atom and one other element in its chemical formula. "Oxide" itself is the dianion of oxygen, an O2– (molecular) ion. with oxygen in the oxidation state of −2. Most of the E ...
forms on the metal surface; this is known as
stainless steel Stainless steel is an alloy of iron that is resistant to rusting and corrosion. It contains at least 11% chromium and may contain elements such as carbon, other nonmetals and metals to obtain other desired properties. Stainless steel's corros ...
. Tungsten slows the formation of cementite, keeping carbon in the iron matrix and allowing martensite to preferentially form at slower quench rates, resulting in high-speed steel. The addition of lead and
sulfur Sulfur (or sulphur in British English) is a chemical element with the symbol S and atomic number 16. It is abundant, multivalent and nonmetallic. Under normal conditions, sulfur atoms form cyclic octatomic molecules with a chemical formula ...
decrease grain size, thereby making the steel easier to
turn Turn may refer to: Arts and entertainment Dance and sports * Turn (dance and gymnastics), rotation of the body * Turn (swimming), reversing direction at the end of a pool * Turn (professional wrestling), a transition between face and heel * Turn, ...
, but also more brittle and prone to corrosion. Such alloys are nevertheless frequently used for components such as nuts, bolts, and washers in applications where toughness and corrosion resistance are not paramount. For the most part, however,
p-block A block of the periodic table is a set of elements unified by the atomic orbitals their valence electrons or vacancies lie in. The term appears to have been first used by Charles Janet. Each block is named after its characteristic orbital: s-blo ...
elements such as sulfur, nitrogen, phosphorus, and lead are considered contaminants that make steel more brittle and are therefore removed from the steel melt during processing.


Properties

The density of steel varies based on the alloying constituents but usually ranges between , or . Even in a narrow range of concentrations of mixtures of carbon and iron that make steel, several different metallurgical structures, with very different properties can form. Understanding such properties is essential to making quality steel. At
room temperature Colloquially, "room temperature" is a range of air temperatures that most people prefer for indoor settings. It feels comfortable to a person when they are wearing typical indoor clothing. Human comfort can extend beyond this range depending on ...
, the most stable form of pure iron is the body-centred cubic (BCC) structure called alpha iron or α-iron. It is a fairly soft metal that can dissolve only a small concentration of carbon, no more than 0.005% at and 0.021 wt% at . The inclusion of carbon in alpha iron is called ferrite. At 910 °C, pure iron transforms into a face-centred cubic (FCC) structure, called gamma iron or γ-iron. The inclusion of carbon in gamma iron is called austenite. The more open FCC structure of austenite can dissolve considerably more carbon, as much as 2.1%, (38 times that of ferrite) carbon at , which reflects the upper carbon content of steel, beyond which is cast iron. When carbon moves out of solution with iron, it forms a very hard, but brittle material called cementite (Fe3C). When steels with exactly 0.8% carbon (known as a eutectoid steel), are cooled, the austenitic phase (FCC) of the mixture attempts to revert to the ferrite phase (BCC). The carbon no longer fits within the FCC austenite structure, resulting in an excess of carbon. One way for carbon to leave the austenite is for it to precipitate out of solution as cementite, leaving behind a surrounding phase of BCC iron called ferrite with a small percentage of carbon in solution. The two, ferrite and cementite, precipitate simultaneously producing a layered structure called pearlite, named for its resemblance to mother of pearl. In a hypereutectoid composition (greater than 0.8% carbon), the carbon will first precipitate out as large inclusions of cementite at the austenite grain boundaries until the percentage of carbon in the grains has decreased to the eutectoid composition (0.8% carbon), at which point the pearlite structure forms. For steels that have less than 0.8% carbon (hypoeutectoid), ferrite will first form within the grains until the remaining composition rises to 0.8% of carbon, at which point the pearlite structure will form. No large inclusions of cementite will form at the boundaries in hypoeuctoid steel. The above assumes that the cooling process is very slow, allowing enough time for the carbon to migrate. As the rate of cooling is increased the carbon will have less time to migrate to form carbide at the grain boundaries but will have increasingly large amounts of pearlite of a finer and finer structure within the grains; hence the carbide is more widely dispersed and acts to prevent slip of defects within those grains, resulting in hardening of the steel. At the very high cooling rates produced by quenching, the carbon has no time to migrate but is locked within the face-centred austenite and forms martensite. Martensite is a highly strained and stressed, supersaturated form of carbon and iron and is exceedingly hard but brittle. Depending on the carbon content, the martensitic phase takes different forms. Below 0.2% carbon, it takes on a ferrite BCC crystal form, but at higher carbon content it takes a
body-centred tetragonal In crystallography, the tetragonal crystal system is one of the 7 crystal systems. Tetragonal crystal lattices result from stretching a cubic lattice along one of its lattice vectors, so that the cube becomes a rectangular prism with a squa ...
(BCT) structure. There is no thermal activation energy for the transformation from austenite to martensite. There is no compositional change so the atoms generally retain their same neighbors.. Martensite has a lower density (it expands during the cooling) than does austenite, so that the transformation between them results in a change of volume. In this case, expansion occurs. Internal stresses from this expansion generally take the form of compression on the crystals of martensite and tension on the remaining ferrite, with a fair amount of
shear Shear may refer to: Textile production *Animal shearing, the collection of wool from various species **Sheep shearing *The removal of nap during wool cloth production Science and technology Engineering *Shear strength (soil), the shear strength ...
on both constituents. If quenching is done improperly, the internal stresses can cause a part to shatter as it cools. At the very least, they cause internal work hardening and other microscopic imperfections. It is common for quench cracks to form when steel is water quenched, although they may not always be visible.


Heat treatment

There are many types of heat treating processes available to steel. The most common are annealing, quenching, and tempering. Annealing is the process of heating the steel to a sufficiently high temperature to relieve local internal stresses. It does not create a general softening of the product but only locally relieves strains and stresses locked up within the material. Annealing goes through three phases:
recovery Recovery or Recover may refer to: Arts and entertainment Books * Recovery (novel), ''Recovery'' (novel), a Star Wars e-book * Recovery Version, a translation of the Bible with footnotes published by Living Stream Ministry Film and television * R ...
, recrystallization, and grain growth. The temperature required to anneal a particular steel depends on the type of annealing to be achieved and the alloying constituents. Quenching involves heating the steel to create the austenite phase then quenching it in water or oil. This rapid cooling results in a hard but brittle martensitic structure. The steel is then tempered, which is just a specialized type of annealing, to reduce brittleness. In this application the annealing (tempering) process transforms some of the martensite into cementite, or
spheroidite Carbon steel is a steel with carbon content from about 0.05 up to 2.1 percent by weight. The definition of carbon steel from the American Iron and Steel Institute (AISI) states: * no minimum content is specified or required for chromium, coba ...
and hence it reduces the internal stresses and defects. The result is a more ductile and fracture-resistant steel.


Production

When iron is smelted from its ore, it contains more carbon than is desirable. To become steel, it must be reprocessed to reduce the carbon to the correct amount, at which point other elements can be added. In the past, steel facilities would cast the raw steel product into ingots which would be stored until use in further refinement processes that resulted in the finished product. In modern facilities, the initial product is close to the final composition and is continuously cast into long slabs, cut and shaped into bars and extrusions and heat treated to produce a final product. Today, approximately 96% of steel is continuously cast, while only 4% is produced as ingots. The ingots are then heated in a soaking pit and
hot rolled In metalworking, rolling is a metal forming process in which metal stock is passed through one or more pairs of rolls to reduce the thickness, to make the thickness uniform, and/or to impart a desired mechanical property. The concept is simil ...
into slabs,
billets A billet is a living-quarters to which a soldier is assigned to sleep. Historically, a billet was a private dwelling that was required to accept the soldier. Soldiers are generally billeted in barracks or garrisons when not on combat duty, alth ...
, or blooms. Slabs are hot or cold rolled into sheet metal or plates. Billets are hot or cold rolled into bars, rods, and wire. Blooms are hot or cold rolled into
structural steel Structural steel is a category of steel used for making construction materials in a variety of shapes. Many structural steel shapes take the form of an elongated beam having a profile of a specific cross section. Structural steel shapes, sizes, ...
, such as I-beams and rails. In modern steel mills these processes often occur in one assembly line, with ore coming in and finished steel products coming out. Sometimes after a steel's final rolling, it is heat treated for strength; however, this is relatively rare.


History


Ancient

Steel was known in antiquity and was produced in
bloomeries A bloomery is a type of metallurgical furnace once used widely for smelting iron from its oxides. The bloomery was the earliest form of smelter capable of smelting iron. Bloomeries produce a porous mass of iron and slag called a ''bloom''. ...
and crucibles. The earliest known production of steel is seen in pieces of ironware excavated from an archaeological site in Anatolia (
Kaman-Kalehöyük Kaman-Kalehöyük is a multi-period archaeological site in Kırşehir Province, Turkey, around 100 km south east of Ankara, 6 km east of the town center of Kaman. It is a tell or mound site that was occupied during the Bronze Age, Iron ...
) and are nearly 4,000 years old, dating from 1800 BC.
Horace Quintus Horatius Flaccus (; 8 December 65 – 27 November 8 BC), known in the English-speaking world as Horace (), was the leading Roman lyric poet during the time of Augustus (also known as Octavian). The rhetorician Quintilian regarded his ' ...
identifies steel weapons such as the '' falcata'' in the Iberian Peninsula, while Noric steel was used by the Roman military. The reputation of ''Seric iron'' of India (wootz steel) grew considerably in the rest of the world. Metal production sites in
Sri Lanka Sri Lanka (, ; si, ශ්‍රී ලංකා, Śrī Laṅkā, translit-std=ISO (); ta, இலங்கை, Ilaṅkai, translit-std=ISO ()), formerly known as Ceylon and officially the Democratic Socialist Republic of Sri Lanka, is an ...
employed wind furnaces driven by the monsoon winds, capable of producing high-carbon steel. Large-scale Wootz steel production in India using crucibles occurred by the sixth century BC, the pioneering precursor to modern steel production and metallurgy. The
Chinese Chinese can refer to: * Something related to China * Chinese people, people of Chinese nationality, citizenship, and/or ethnicity **''Zhonghua minzu'', the supra-ethnic concept of the Chinese nation ** List of ethnic groups in China, people of va ...
of the Warring States period (403–221 BC) had quench-hardened steel, while Chinese of the Han dynasty (202 BC—AD 220) created steel by melting together wrought iron with cast iron, thus producing a carbon-intermediate steel by the 1st century AD.Gernet, Jacques (1982). ''A History of Chinese Civilization''. Cambridge: Cambridge University Press. p. 69. . There is evidence that
carbon steel Carbon steel is a steel with carbon content from about 0.05 up to 2.1 percent by weight. The definition of carbon steel from the American Iron and Steel Institute (AISI) states: * no minimum content is specified or required for chromium, cobalt ...
was made in Western Tanzania by the ancestors of the Haya people as early as 2,000 years ago by a complex process of "pre-heating" allowing temperatures inside a furnace to reach 1300 to 1400 °C.


Wootz and Damascus

Evidence of the earliest production of high carbon steel in India are found in
Kodumanal Kodumanal is a village located in the Erode district in the southern Indian state of Tamil Nadu. It was once a flourishing ancient trade city known as Kodumanam, as inscribed in ''Patittrupathu'' of Sangam Literature. The place is an important ...
in Tamil Nadu, the
Golconda Fort (Telugu: గోల్కొండ, romanized: ''Gōlkōnḍa'') is a historic fortress and ruined city located in Hyderabad, Telangana, India. It was originally called Mankal. The fort was originally built by Kakatiya ruler Pratāparu ...
area in Andhra Pradesh and Karnataka, and in the Samanalawewa, Dehigaha Alakanda, areas of
Sri Lanka Sri Lanka (, ; si, ශ්‍රී ලංකා, Śrī Laṅkā, translit-std=ISO (); ta, இலங்கை, Ilaṅkai, translit-std=ISO ()), formerly known as Ceylon and officially the Democratic Socialist Republic of Sri Lanka, is an ...
. This came to be known as Wootz steel, produced in South India by about the sixth century BC and exported globally. The steel technology existed prior to 326 BC in the region as they are mentioned in literature of Sangam Tamil, Arabic, and Latin as the finest steel in the world exported to the Romans, Egyptian, Chinese and Arab worlds at that time – what they called ''Seric Iron''. A 200 BC Tamil trade guild in Tissamaharama, in the South East of Sri Lanka, brought with them some of the oldest iron and steel artifacts and production processes to the island from the classical period. The Chinese and locals in Anuradhapura, Sri Lanka had also adopted the production methods of creating Wootz steel from the Chera Dynasty Tamils of South India by the 5th century AD. In Sri Lanka, this early steel-making method employed a unique wind furnace, driven by the monsoon winds, capable of producing high-carbon steel.Coghlan, Herbert Henery. (1977). ''Notes on prehistoric and early iron in the Old World''. Oxprint. pp. 99–100 Since the technology was acquired from the Tamilians from South India, the origin of steel technology in India can be conservatively estimated at 400–500 BC. The manufacture of what came to be called Wootz, or Damascus steel, famous for its durability and ability to hold an edge, may have been taken by the Arabs from Persia, who took it from India. It was originally created from several different materials including various trace elements, apparently ultimately from the writings of Zosimos of Panopolis. In 327 BC, Alexander the Great was rewarded by the defeated King Porus, not with gold or silver but with 30 pounds of steel. A recent study has speculated that carbon nanotubes were included in its structure, which might explain some of its legendary qualities, though, given the technology of that time, such qualities were produced by chance rather than by design. Natural wind was used where the soil containing iron was heated by the use of wood. The
ancient Sinhalese Sinhalese people ( si, සිංහල ජනතාව, Sinhala Janathāva) are an Indo-Aryan ethnolinguistic group native to the island of Sri Lanka. They were historically known as Hela people ( si, හෙළ). They constitute about 75% of ...
managed to extract a ton of steel for every 2 tons of soil, a remarkable feat at the time. One such furnace was found in Samanalawewa and archaeologists were able to produce steel as the ancients did. Crucible steel, formed by slowly heating and cooling pure iron and carbon (typically in the form of charcoal) in a crucible, was produced in Merv by the 9th to 10th century AD. In the 11th century, there is evidence of the production of steel in
Song China The Song dynasty (; ; 960–1279) was an imperial dynasty of China that began in 960 and lasted until 1279. The dynasty was founded by Emperor Taizu of Song following his usurpation of the throne of the Later Zhou. The Song conquered the rest ...
using two techniques: a "berganesque" method that produced inferior, inhomogeneous steel, and a precursor to the modern Bessemer process that used partial decarbonization via repeated forging under a cold blast.


Modern

Since the 17th century, the first step in European steel production has been the smelting of iron ore into
pig iron Pig iron, also known as crude iron, is an intermediate product of the iron industry in the production of steel which is obtained by smelting iron ore in a blast furnace. Pig iron has a high carbon content, typically 3.8–4.7%, along with silic ...
in a
blast furnace A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals, generally pig iron, but also others such as lead or copper. ''Blast'' refers to the combustion air being "forced" or supplied above atmospheric ...
.Tylecote, R.F. (1992) ''A history of metallurgy'' 2nd ed., Institute of Materials, London. pp. 95–99 and 102–105. . Originally employing charcoal, modern methods use coke, which has proven more economical.


Processes starting from bar iron

In these processes pig iron was refined (fined) in a finery forge to produce bar iron, which was then used in steel-making. The production of steel by the
cementation process The cementation process is an obsolete technology for making steel by carburization of iron. Unlike modern steelmaking, it increased the amount of carbon in the iron. It was apparently developed before the 17th century. Derwentcote Steel F ...
was described in a treatise published in Prague in 1574 and was in use in Nuremberg from 1601. A similar process for case hardening armor and files was described in a book published in Naples in 1589. The process was introduced to England in about 1614 and used to produce such steel by Sir Basil Brooke at Coalbrookdale during the 1610s. The raw material for this process were bars of iron. During the 17th century, it was realized that the best steel came from
oregrounds iron Oregrounds iron was a grade of iron that was regarded as the best grade available in 18th century England. The term was derived from the small Swedish city of Öregrund, the port from which the bar iron was shipped. It was produced using the Wal ...
of a region north of
Stockholm Stockholm () is the Capital city, capital and List of urban areas in Sweden by population, largest city of Sweden as well as the List of urban areas in the Nordic countries, largest urban area in Scandinavia. Approximately 980,000 people liv ...
, Sweden. This was still the usual raw material source in the 19th century, almost as long as the process was used. Crucible steel is steel that has been melted in a crucible rather than having been forged, with the result that it is more homogeneous. Most previous furnaces could not reach high enough temperatures to melt the steel. The early modern crucible steel industry resulted from the invention of Benjamin Huntsman in the 1740s. Blister steel (made as above) was melted in a crucible or in a furnace, and cast (usually) into ingots.


Processes starting from pig iron

The modern era in steelmaking began with the introduction of
Henry Bessemer Sir Henry Bessemer (19 January 1813 – 15 March 1898) was an English inventor, whose steel-making process would become the most important technique for making steel in the nineteenth century for almost one hundred years from 1856 to 1950. He ...
's process in 1855, the raw material for which was pig iron. His method let him produce steel in large quantities cheaply, thus
mild steel Carbon steel is a steel with carbon content from about 0.05 up to 2.1 percent by weight. The definition of carbon steel from the American Iron and Steel Institute (AISI) states: * no minimum content is specified or required for chromium, cobalt ...
came to be used for most purposes for which wrought iron was formerly used. The Gilchrist-Thomas process (or ''basic Bessemer process'') was an improvement to the Bessemer process, made by lining the converter with a
basic BASIC (Beginners' All-purpose Symbolic Instruction Code) is a family of general-purpose, high-level programming languages designed for ease of use. The original version was created by John G. Kemeny and Thomas E. Kurtz at Dartmouth College ...
material to remove phosphorus. Another 19th-century steelmaking process was the
Siemens-Martin process An open-hearth furnace or open hearth furnace is any of several kinds of industrial furnace in which excess carbon and other impurities are burnt out of pig iron to produce steel. Because steel is difficult to manufacture owing to its high melt ...
, which complemented the Bessemer process. It consisted of co-melting bar iron (or steel scrap) with pig iron. These methods of steel production were rendered obsolete by the Linz-Donawitz process of basic oxygen steelmaking (BOS), developed in 1952, and other oxygen steel making methods. Basic oxygen steelmaking is superior to previous steelmaking methods because the oxygen pumped into the furnace limited impurities, primarily nitrogen, that previously had entered from the air used, and because, with respect to the open hearth process, the same quantity of steel from a BOS process is manufactured in one-twelfth the time. Today, electric arc furnaces (EAF) are a common method of reprocessing scrap metal to create new steel. They can also be used for converting pig iron to steel, but they use a lot of electrical energy (about 440 kWh per metric ton), and are thus generally only economical when there is a plentiful supply of cheap electricity.


Industry

The steel industry is often considered an indicator of economic progress, because of the critical role played by steel in infrastructural and overall economic development. In 1980, there were more than 500,000 U.S. steelworkers. By 2000, the number of steelworkers had fallen to 224,000. The economic boom in China and India caused a massive increase in the demand for steel. Between 2000 and 2005, world steel demand increased by 6%. Since 2000, several Indian and Chinese steel firms have risen to prominence, such as
Tata Steel Tata Steel Limited is an Indian multinational steel-making company, based in Jamshedpur, Jharkhand and headquartered in Mumbai, Maharashtra. It is a part of the Tata Group. Formerly known as Tata Iron and Steel Company Limited (TISCO), Tata ...
(which bought
Corus Group Corus may refer to: Places *Çörüş, Gazipaşa, a village in Antalya Province, Turkey Facilities and structures * Corus Quay, Toronto, Ontario, Canada; an office tower Fictional locations * Corus, a fictional world that is the setting for the ...
in 2007), Baosteel Group and
Shagang Group Jiangsu Shagang Group Company Limited, Jiangsu Shagang Group, Shagang Group or Shasteel is located in Zhangjiagang, Jiangsu, China, an Economic Development Zone of the Yangtze River. According to a 2008 survey conducted by the All-China Federatio ...
. , though, ArcelorMittal is the world's largest steel producer. In 2005, the
British Geological Survey The British Geological Survey (BGS) is a partly publicly funded body which aims to advance geoscientific knowledge of the United Kingdom landmass and its continental shelf by means of systematic surveying, monitoring and research. The BGS h ...
stated China was the top steel producer with about one-third of the world share; Japan, Russia, and the US followed respectively. The large production capacity of steel results also in a significant amount of carbon dioxide emissions inherent related to the main production route. In 2021, it was estimated that around 7% of the global greenhouse gas emissions resulted from the steel industry. Reduction of these emissions are expected to come from a shift in the main production route using cokes, more recycling of steel and the application of carbon capture and storage or carbon capture and utilization technology. In 2008, steel began trading as a commodity on the London Metal Exchange. At the end of 2008, the steel industry faced a sharp downturn that led to many cut-backs.


Recycling

Steel is one of the world's most-recycled materials, with a recycling rate of over 60% globally; in the United States alone, over were recycled in the year 2008, for an overall recycling rate of 83%. As more steel is produced than is scrapped, the amount of recycled raw materials is about 40% of the total of steel produced - in 2016, of crude steel was produced globally, with recycled.


Contemporary


Carbon

Modern steels are made with varying combinations of alloy metals to fulfill many purposes.
Carbon steel Carbon steel is a steel with carbon content from about 0.05 up to 2.1 percent by weight. The definition of carbon steel from the American Iron and Steel Institute (AISI) states: * no minimum content is specified or required for chromium, cobalt ...
, composed simply of iron and carbon, accounts for 90% of steel production. Low alloy steel is alloyed with other elements, usually
molybdenum Molybdenum is a chemical element with the symbol Mo and atomic number 42 which is located in period 5 and group 6. The name is from Neo-Latin ''molybdaenum'', which is based on Ancient Greek ', meaning lead, since its ores were confused with lea ...
, manganese, chromium, or nickel, in amounts of up to 10% by weight to improve the hardenability of thick sections. High strength low alloy steel has small additions (usually < 2% by weight) of other elements, typically 1.5% manganese, to provide additional strength for a modest price increase. Recent Corporate Average Fuel Economy (CAFE) regulations have given rise to a new variety of steel known as Advanced High Strength Steel (AHSS). This material is both strong and ductile so that vehicle structures can maintain their current safety levels while using less material. There are several commercially available grades of AHSS, such as
dual-phase steel Dual-phase steel (DP steel) is a high-strength steel that has a ferritic–martensitic microstructure. DP steels are produced from low or medium carbon steels that are quenched from a temperature above A1 but below A3 determined from continuous co ...
, which is heat treated to contain both a ferritic and martensitic microstructure to produce a formable, high strength steel. Transformation Induced Plasticity (TRIP) steel involves special alloying and heat treatments to stabilize amounts of austenite at room temperature in normally austenite-free low-alloy ferritic steels. By applying strain, the austenite undergoes a phase transition to martensite without the addition of heat. Twinning Induced Plasticity (TWIP) steel uses a specific type of strain to increase the effectiveness of work hardening on the alloy. Carbon Steels are often galvanized, through hot-dip or electroplating in zinc for protection against rust.


Alloy

Stainless steels Stainless steel is an alloy of iron that is resistant to rusting and corrosion. It contains at least 11% chromium and may contain elements such as carbon, other nonmetals and metals to obtain other desired properties. Stainless steel's res ...
contain a minimum of 11% chromium, often combined with nickel, to resist corrosion. Some stainless steels, such as the
ferritic A ferrite is a ceramic material made by mixing and firing large proportions of iron(III) oxide (Fe2O3, rust) blended with small proportions of one or more additional metallic elements, such as strontium, barium, manganese, nickel, and zinc. Th ...
stainless steels are
magnetic Magnetism is the class of physical attributes that are mediated by a magnetic field, which refers to the capacity to induce attractive and repulsive phenomena in other entities. Electric currents and the magnetic moments of elementary particle ...
, while others, such as the austenitic, are nonmagnetic. Corrosion-resistant steels are abbreviated as CRES. Alloy steels are plain-carbon steels in which small amounts of alloying elements like chromium and vanadium have been added. Some more modern steels include tool steels, which are alloyed with large amounts of tungsten and cobalt or other elements to maximize
solution hardening Hardening is a metallurgical metalworking process used to increase the hardness of a metal. The hardness of a metal is directly proportional to the uniaxial yield stress at the location of the imposed strain. A harder metal will have a higher r ...
. This also allows the use of precipitation hardening and improves the alloy's temperature resistance. Tool steel is generally used in axes, drills, and other devices that need a sharp, long-lasting cutting edge. Other special-purpose alloys include weathering steels such as Cor-ten, which weather by acquiring a stable, rusted surface, and so can be used un-painted. Maraging steel is alloyed with nickel and other elements, but unlike most steel contains little carbon (0.01%). This creates a very strong but still malleable steel. Eglin steel uses a combination of over a dozen different elements in varying amounts to create a relatively low-cost steel for use in bunker buster weapons. Hadfield steel (after Sir
Robert Hadfield Sir Robert Abbott Hadfield, 1st Baronet FRS (28 November 1858 in Sheffield – 30 September 1940 in Surrey) was an English metallurgist, noted for his 1882 discovery of manganese steel, one of the first steel alloys. He also invented silicon s ...
) or manganese steel contains 12–14% manganese which when abraded strain-hardens to form a very hard skin which resists wearing. Examples include tank tracks,
bulldozer blade A bulldozer or dozer (also called a crawler) is a large, motorized machine equipped with a metal blade to the front for pushing material: soil, sand, snow, rubble, or rock during construction work. It travels most commonly on continuous tracks, ...
edges, and cutting blades on the
jaws of life Hydraulic rescue tools, also known as jaws of life, are used by emergency rescue personnel to assist in the extrication of victims involved in vehicle accidents, as well as other rescues in small spaces. These tools include cutters, spreaders, ...
.


Standards

Most of the more commonly used steel alloys are categorized into various grades by standards organizations. For example, the Society of Automotive Engineers has a series of
grades Grade most commonly refers to: * Grade (education), a measurement of a student's performance * Grade, the number of the year a student has reached in a given educational stage * Grade (slope), the steepness of a slope Grade or grading may also r ...
defining many types of steel. The
American Society for Testing and Materials ASTM International, formerly known as American Society for Testing and Materials, is an international standards organization that develops and publishes voluntary consensus technical standards for a wide range of materials, products, systems, an ...
has a separate set of standards, which define alloys such as A36 steel, the most commonly used structural steel in the United States. The JIS also defines a series of steel grades that are being used extensively in Japan as well as in developing countries.


Uses

Iron and steel are used widely in the construction of roads, railways, other infrastructure, appliances, and buildings. Most large modern structures, such as stadiums and skyscrapers, bridges, and airports, are supported by a steel skeleton. Even those with a concrete structure employ steel for reinforcing. It sees widespread use in
major appliances A major appliance, also known as a large domestic appliance or large electric appliance or simply a large appliance, large domestic, or large electric, is a non-portable or semi-portable machine used for routine housekeeping tasks such as cook ...
and cars. Despite the growth in usage of aluminium, steel is still the main material for car bodies. Steel is used in a variety of other construction materials, such as bolts, nails and screws and other household products and cooking utensils. Other common applications include shipbuilding, pipelines, mining, offshore construction, aerospace,
white goods A major appliance, also known as a large domestic appliance or large electric appliance or simply a large appliance, large domestic, or large electric, is a non-portable or semi-portable machine used for routine housekeeping tasks such as cookin ...
(e.g. washing machines),
heavy equipment Heavy equipment or heavy machinery refers to heavy-duty vehicles specially designed to execute construction tasks, most frequently involving earthwork operations or other large construction tasks. ''Heavy equipment'' usually comprises five e ...
such as bulldozers, office furniture,
steel wool Steel wool, also known as iron wool, wire wool or wire sponge, is a bundle of very fine and flexible sharp-edged steel filaments. It was described as a new product in 1896.''Iron Age'', Vol. LVII, p.871, cited by ''Journal of the Iron and Steel ...
, tool, and
armour Armour (British English) or armor (American English; see spelling differences) is a covering used to protect an object, individual, or vehicle from physical injury or damage, especially direct contact weapons or projectiles during combat, or fr ...
in the form of personal vests or vehicle armour (better known as rolled homogeneous armour in this role).


Historical

Before the introduction of the Bessemer process and other modern production techniques, steel was expensive and was only used where no cheaper alternative existed, particularly for the cutting edge of knives, razors,
sword A sword is an edged, bladed weapon intended for manual cutting or thrusting. Its blade, longer than a knife or dagger, is attached to a hilt and can be straight or curved. A thrusting sword tends to have a straighter blade with a pointed ti ...
s, and other items where a hard, sharp edge was needed. It was also used for springs, including those used in clocks and watches. With the advent of speedier and thriftier production methods, steel has become easier to obtain and much cheaper. It has replaced wrought iron for a multitude of purposes. However, the availability of plastics in the latter part of the 20th century allowed these materials to replace steel in some applications due to their lower fabrication cost and weight. Carbon fiber is replacing steel in some cost insensitive applications such as sports equipment and high-end automobiles.


Long

* As reinforcing bars and mesh in
reinforced concrete Reinforced concrete (RC), also called reinforced cement concrete (RCC) and ferroconcrete, is a composite material in which concrete's relatively low tensile strength and ductility are compensated for by the inclusion of reinforcement having hig ...
* Railroad tracks *
Structural steel Structural steel is a category of steel used for making construction materials in a variety of shapes. Many structural steel shapes take the form of an elongated beam having a profile of a specific cross section. Structural steel shapes, sizes, ...
in modern buildings and bridges * Wires * Input to reforging applications


Flat carbon

* Major appliances *
Magnetic core A magnetic core is a piece of magnetic material with a high magnetic permeability used to confine and guide magnetic fields in electrical, electromechanical and magnetic devices such as electromagnets, transformers, electric motors, generators, in ...
s * The inside and outside body of automobiles, trains, and ships.


Weathering (COR-TEN)

* Intermodal containers * Outdoor sculptures * Architecture *
Highliner The Highliner is a bilevel Electric Multiple Unit railcar. The original series of railcars were built in 1971 by the St. Louis Car Company for commuter service on the Illinois Central Railroad, in south Chicago, Illinois, with an additional batc ...
train cars


Stainless

*
Cutlery Cutlery (also referred to as silverware, flatware, or tableware), includes any hand implement used in preparing, serving, and especially eating food in Western culture. A person who makes or sells cutlery is called a cutler. The city of Sheffie ...
* Rulers * Surgical instruments * Watches * Guns * Rail passenger vehicles * Tablets *
Trash Cans A waste container, also known as a dustbin, garbage can, and trash can is a type of container that is usually made out of metal or plastic. The words "rubbish", "basket" and "bin" are more common in British English usage; "trash" and "can" a ...
*
Body piercing jewellery Body piercing jewelry is jewelry manufactured specifically for use in body piercing. The jewelry involved in the art of body piercing comes in a wide variety of shapes and sizes in order to best fit the pierced site. Jewelry may be worn for fashio ...
* Inexpensive rings * Components of spacecraft and
space station A space station is a spacecraft capable of supporting a human crew in orbit for an extended period of time, and is therefore a type of space habitat. It lacks major propulsion or landing systems. An orbital station or an orbital space station i ...
s


Low-background

Steel manufactured after World War II became contaminated with
radionuclide A radionuclide (radioactive nuclide, radioisotope or radioactive isotope) is a nuclide that has excess nuclear energy, making it unstable. This excess energy can be used in one of three ways: emitted from the nucleus as gamma radiation; transfer ...
s by nuclear weapons testing. Low-background steel, steel manufactured prior to 1945, is used for certain radiation-sensitive applications such as
Geiger counter A Geiger counter (also known as a Geiger–Müller counter) is an electronic instrument used for detecting and measuring ionizing radiation. It is widely used in applications such as radiation dosimetry, radiological protection, experimental ph ...
s and radiation shielding.


See also

* Bulat steel *
Carbon steel Carbon steel is a steel with carbon content from about 0.05 up to 2.1 percent by weight. The definition of carbon steel from the American Iron and Steel Institute (AISI) states: * no minimum content is specified or required for chromium, cobalt ...
* Damascus steel *
Galvanising Galvanization or galvanizing ( also spelled galvanisation or galvanising) is the process of applying a protective zinc coating to steel or iron, to prevent rusting. The most common method is hot-dip galvanizing, in which the parts are submerg ...
*
Global steel industry trends Global means of or referring to a globe and may also refer to: Entertainment * ''Global'' (Paul van Dyk album), 2003 * ''Global'' (Bunji Garlin album), 2007 * ''Global'' (Humanoid album), 1989 * ''Global'' (Todd Rundgren album), 2015 * Bruno ...
*
Iron in folklore Iron has a long and varied tradition in the mythology and folklore of the world. While iron is now the name of a chemical element, the traditional meaning of the word "iron" is what is now called wrought iron. In East Asia, cast iron was also ...
*
Knife metal Blade materials are materials used to make the blade of a knife or other simple edged hand tool or weapon, such as a hatchet or sword. Blades can be made from a variety of materials. The most common being carbon steel, stainless steel, tool s ...
* Machinability * Noric steel *
Pelletizing Pelletizing is the process of compressing or molding a material into the shape of a pellet. A wide range of different materials are pelletized including chemicals, iron ore, animal compound feed, plastics, waste materials, and more. The process ...
* Rolling * Rolling mill * Rust Belt * Second Industrial Revolution * Silicon steel *
Steel abrasive Steel abrasives are steel particles that are used as abrasive or peening media. They are usually available in two different shapes (shot and grit) that address different industrial applications. Steel shot refers to spherical grains made of molt ...
*
Steel mill A steel mill or steelworks is an industrial plant for the manufacture of steel. It may be an integrated steel works carrying out all steps of steelmaking from smelting iron ore to rolled product, but may also be a plant where steel semi-finish ...
* Tamahagane, used in Japanese swords * Tinplate * Toledo steel * Wootz steel


References


Bibliography

* * * * * * * Verein Deutscher Eisenhüttenleute (Ed.). ''Steel – A Handbook for Materials Research and Engineering, Volume 1: Fundamentals''. Springer-Verlag Berlin, Heidelberg and Verlag Stahleisen, Düsseldorf 1992, 737 p. . * Verein Deutscher Eisenhüttenleute (Ed.). ''Steel – A Handbook for Materials Research and Engineering, Volume 2: Applications''. Springer-Verlag Berlin, Heidelberg and Verlag Stahleisen, Düsseldorf 1993, 839 pages, . *


Further reading

* Mark Reutter,
Making Steel: Sparrows Point and the Rise and Ruin of American Industrial Might
'. University of Illinois Press, 2005. * Duncan Burn,
The Economic History of Steelmaking, 1867–1939: A Study in Competition
'. Cambridge University Press, 1961. * Harukiyu Hasegawa,
The Steel Industry in Japan: A Comparison with Britain
'. Routledge, 1996. * J.C. Carr and W. Taplin,
History of the British Steel Industry
'. Harvard University Press, 1962. * H. Lee Scamehorn,
Mill & Mine: The Cf&I in the Twentieth Century
'. University of Nebraska Press, 1992. * Warren, Kenneth,
Big Steel: The First Century of the United States Steel Corporation, 1901–2001
'. University of Pittsburgh Press, 2001.


External links


Official website
of the World Steel Association (worldsteel) *
steeluniversity.org
Online steel education resources, an initiative of World Steel Association
Metallurgy for the Non-Metallurgist
from the
American Society for Metals ASM International, formerly known as the American Society for Metals, is an association of materials-centric engineers and scientists. ASM provides several information resources, including technical books, various digital databases, and ASM Han ...

MATDAT Database of Properties of Unalloyed, Low-Alloy and High-Alloy Steels
– obtained from published results of material testing {{Authority control 2nd-millennium BC introductions Building materials Roofing materials