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1 Classification and Selection of Materials 1. INTRODUCTION Materials science and engineering plays a vital role in this modern age of science and technology. Various kinds of materials are used in industry, housing, agriculture, transportation, etc., to meet the plant and individual requirements. The rapid developments in the field of quantum theory of solids have opened vast opportunities for better understanding and utilisation of various materials. The spectacular success in the field of space is primarily due to the rapid advances in high-temperature and high-strength materials. The term materials science and engineering combines both materials science and materials engineering. Materials science is at the basic knowledge end of the materials knowledge spectrum and materials engineering is at the applied knowledge end, and there is no demarcation line between the two (Fig. 1.1). Materials may be defined as substances of which something is composed or made. Mankind, materials and engineering have evolved over the passage of time and are continuing to do so. Figure 1.2 shows a three-stage diagram that indicates the relationship among the basic sciences (and mathematics), materials science and engineering, and the other engineering disciplines. The basic sciences are located within the first stage or core of the diagram, while the various engineering disciplines (mechanical, electrical, civil, chemical, etc.) are located in the outermost third stage. The applied sciences, metallurgy, ceramics and polymer science are located in the middle or second stage. Materials Materials science Materials science and engineering Materials engineering Basic knowledge of materials Resultant knowledge of the structure, properties, processing, and performance of engineering materials Applied knowledge of materials Fig. 1.1 Materials knowledge spectrum. Using the combined knowledge of materials from materials science and engineering engineers convert materials into the useful products 1 2 MATERIAL SCIENCE Engineering Applied sciences Medicine Basic sciences Life sciences Mechanics Physics Chemistry Math Earth sciences Mechanical Chemical Civil Metallurgy ceramics Materials science and engineering Polymers Electrical Mining, mineral and geological engineering Nuclear Aerospace Fig. 1.2 Materials science and engineering form a bridge of knowledge between the basic sciences and engineering disciplines science and engineering is shown to form a bridge of materials knowledge from the basic sciences (and mathematics) to the engineering disciplines. The selection of a specific material for a particular use is a very complex process. However, one can simplify the choice if the details about (i) operating parameters, (ii) manufacturing processes, (iii) functional requirements and (iv) cost considerations are known. Factors affecting the selection of materials are given in Table 1.1. Table 1.1 Factors affecting the selection of materials Manufacturing processes l l l l l l l l l (i) Plasticity Malleability Ductility Machinability Casting properties Weldability Heat Tooling Surface finish Functional requirements Cost considerations (ii) l l l l l l l l l Strength Hardness Rigidity Toughness Thermal conductivity Fatigue Electrical treatment Creep Aesthetic look l l l l l l l l l (iii) Raw material Processing Storage Manpower Special treatment Inspection Packaging properties Inventory Taxes and custom duty Operating parameters l l l l l l l l l (iv) Pressure Temperature Flow Type of material Corrosion requirements Environment Protection from fire Weathering Biological effects There are thousands and thousands of materials available and it is very difficult for an engineer to possess a detailed knowledge of all the materials. However, a good grasp of the fundamental CLASSIFICATION AND SELECTION OF MATERIALS 3 principles which control the properties of various materials help one to make the optimum selection of material. In this respect, materials science and engineering draw heavily from the engineering branches, e.g., metallurgy, ceramics and polymer science. The subject of material science is very vast and unlimited. Broadly speaking, one can sub-divide the field of study into following four branches: (i) Science of metals, (ii) Mechanical behaviour of metals (iii) Engineering metallurgy and (iv) Engineering materials. We shall discuss them in subsequent chapters. 2. ENGINEERING REQUIREMENTS While selecting materials for engineering purposes, properties such as impact strength, tensile strength, hardness indicate the suitability for selection but the design engineer will have to make sure that the radiography and other properties of the material are as per the specifications. One can dictate the method of production of the component, service life, cost etc. However, due to the varied demands made metallic materials, one may require special surface treatment, e.g., hardening, normalising to cope with the service requires. Besides, chemical properties of materials, e.g., structure, bonding energy, resistance to environmental degradation also effect the selection of materials for engineering purposes. In recent years polymeric materials or plastics have gained considerable popularity as engineering materials. Though inferior to most metallic materials in strength and temperature resistance, these are being used not only in corrosive environment but also in the places where minimum wear is required, e.g., small gear wheels, originally produced from hardened steels, are now manufactured from nylon or teflon. These materials perform satisfactorily, are quiet and do not require lubrication. Thus, before selecting a material or designing a component, it is essential for one to understand the requirements of the process thoroughly, operating limitations like hazardous or non-hazardous conditions, continuous or non-continuous operation, availability of raw materials as well as spares, availability of alternate materials vis-a-vis life span of the instrument/equipment, cost etc. Different materials possess different properties to meet the various requirement for engineering purposes. The properties of materials which dictate the selection are as follows: 2.1 Mechanical Properties The important mechanical properties affecting the selection of a material are: (i) Tensile Strength: This enables the material to resist the application of a tensile force. To withstand the tensile force, the internal structure of the material provides the internal resistance. (ii) Hardness: It is the degree of resistance to indentation or scratching, abrasion and wear. Alloying techniques and heat treatment help to achieve the same. (iii) Ductility: This is the property of a metal by virtue of which it can be drawn into wires or elongated before rupture takes place. It depends upon the grain size of the metal crystals. (iv) Impact Strength: It is the energy required per unit cross-sectional area to fracture a specimen, i.e., it is a measure of the response of a material to shock loading. (v) Wear Resistance: The ability of a material to resist friction wear under particular conditions, i.e., to maintain its physical dimensions when in sliding or rolling contact with a second member. (vi) Corrosion Resistance: Those metals and alloys which can withstand the corrosive action of a medium, i.e., corrosion processes proceed in them at a relatively low rate are termed corrosionresistant. (vii) Density: This is an important factor of a material where weight and thus the mass is critical, i.e., aircraft components. 4 MATERIAL SCIENCE 2.2 Thermal Properties The characteristics of a material, which are functions of the temperature, are termed its thermal properties. One can predict the performance of machine components during normal operation, if he has the knowledge of thermal properties. Specific heat, latent heat, thermal conductivity, thermal expansion, thermal stresses, thermal fatigue, etc., are few important thermal properties of materials. These properties play a vital role in selection of material for engineering applications, e.g., when materials are considered for high temperature service. Now, we briefly discuss few of these properties: (i) Specific Heat (c): It is the heat capacity of a unit mass of a homogeneous substance. For a homogeneous body, c = C/M, where C is the heat capacity and M is the mass of the body. One can also define it as the quantity of heat required to raise the temperature of a unit mass of the substance through 1°C. Its units are cal/g/°C. (ii) Thermal Conductivity (K): This represents the amount of heat conducted per unit time through a unit area perpendicular to the direction of heat conduction when the temperature gradient across the heat conducting element is one unit. Truely speaking the capability of the material to transmit heat through it is termed as the thermal conductivity. Higher the value of thermal conductivity, the greater is the rate at which heat will be transferred through a piece of given size. Copper and aluminium are good conductors of heat and therefore extensively used whenever transfer of heat is desired. Bakelite is a poor conductor of heat and hence used as heat insulator. The heat flow through an area A which is perpendicular to the direction of flow is directly proportional to the area (A) and thermal gradient (dt/dx). Thermal conductivity (K) is given by K= Qx A ( T1 T2 ) t kcal/m/°C/s or J/m/s/k or W/m/k ...(1.1) where Q ® flow of heat (kcal), A ® face area (m2), t ® time (second), q1 and q2 are temperatures of hot and cold side of the material (°C) and x is the distance between the two faces (m). The thermal conductivity of a metal can be expressed as 2 K= ne2 O S2 È k Ø T 3 Ê eÚ 2 m v0 ...(1.2) where l ® mean free path, k ® Boltzmann Constant, m ® electron mass, e ® electronic charge, v0 ® initial velocity of the electron. We must note that similar expression is used for electrical conductivity. The ratio of heat and electrical conductivity (k and s respectively) is given by 2 K S2 È k Ø T ...(1.3) V 3 Ê eÚ Obviously, the thermal conductivity (K) and electrical conductivity (s) vary in the same fashion 2 from one material to another. The ratio S2 È k Ø is known as Wridemann—Franz ratio. Thermal 3 Ê eÚ conductivity for some of the materials is given in Table 1.1. (iii) Thermal Expansion: All solids expand on heating and contract on cooling. Thermal expansion may take place either as linear, circumferential or cubical. A solid which expands equally in three mutually orthogonal directions is termed as thermally isotropic. The increase in any linear dimension of a solid, e.g., length, width, height on heating is termed as linear expansion. The coefficient of linear expansion is the increase in length per unit length per degree rise in temperature. The CLASSIFICATION AND SELECTION OF MATERIALS 5 increase in volume of a solid on heating is called cubical expansion. The thermal expansion of solids has its origin in the lattice vibration and lattice vibrations increases with the rise in temperature. Table 1.2 Thermal conductivity for some materials Type of the material Material (i) Metals Thermal conductivity (K) (W/m/k) Copper Aluminium Cast iron Mild steel Stainless steel Alumina Titanium carbide Glass Bakelite (ii) Ceramics (iii) Polymers (iv) Composites Concrete Wood 380 230 52 54 16 2.0 3.0 1.0 0.23 0.0019 1.4 0.14 (iv) Thermal Resistance (RT): It is the resistance offered by the conductor when heat flow due to temperature difference between two points of a conductor. It is given by T1 T2 second – °C/Kcal RT = H where H ® rate of heat flow and q1 and q2 are temperatures at two points (°C). (v) Thermal Diffusivity (h): It is given by Thermal conductivity ( K ) cm 3 /s h = Heat capacity ( C p ) density ( U ) = K represent heat requirement per unit volume Cp U A material having high heat requirement per unit volume possesses a low thermal diffusivity because more heat must be added to or removed from the material for effecting a temperature change. (vi) Thermal Fatigue: This is the mechanical effect of repeated thermal stresses caused by repeated heating and cooling. The thermal stresses can be very large, involving considerable plastic flow. We can see that fatigue failures can occur after relatively few cycles. The effect of the high part of the temperature cycle on the strength of material plays an important factor in reducing its life under thermal fatigue. 2.3 Electrical Properties Conductivity, resistivity, dielectric strength are few important electrical properties of a material. A material which offers little resistance to the passage of an electric current is said to be a good conductor of electricity. The electrical resistance of a material depends on its dimensions and is given by Resistance = Resistivity ´ Length Cross-section area 6 MATERIAL SCIENCE Usually resistivity of a material is quoted in the literature. Unit of resistivity is Ohm-metre. On the basis of electrical resistivity materials are divided as: (i) Conductors (ii) Semiconductors and (iii) Insulators. In general metals are good conductors. Insulators have very high resistivity. Ceramic insulators are most common examples and are used on automobile spark plugs. Bakelite handles for electric iron, plastic coverings on cables in domestic wiring. When a large number of metals and alloys are sufficiently cooled below transition temperature, Tc, enter the state of superconductivity in which the dc resistivity goes to zero. The estimates of the resistivity in the super-conducting phase place it at less than 4 ´ 10–25 W-m, which is essentially zero for all practical purposes. The highest value of Tc up to 133 K has been reached for mercury cuprate. 2.4 Magnetic Properties Materials in which a state of magnetism can be induced are termed magnetic materials. There are five classes into which magnetic materials may be grouped: (i) diamagnetic (ii) paramagnetic (iii) ferromagnetic (iv) antiferromagnetic and (v) ferrimagnetic. Iron, Cobalt, Nickel and some of their alloys and compounds possess spontaneous magnetization. Magnetic oxides like ferrites and garnets could be used at high frequencies. Because of their excellent magnetic properties along with their high electrical resistivity these materials today find use in a variety of applications like magnetic recording tapes, inductors and transformers, memory elements, microwave devices, bubble domain devices, recording hard cores, etc. Hysteresis, permeability and coercive forces are some of the magnetic properties of magnetic substances which are to be considered for the manufacture of transformers and other electronic components. 2.5 Chemical Properties These properties includes atomic weight, molecular weight, atomic number, valency, chemical composition, acidity, alkalinity, etc. These properties govern the selection of materials particularly in chemical plant. 2.6 Optical Properties The optical properties of materials, e.g., refractive index, reflectivity and absorption coefficient etc., affect the light reflection and transmission. 2.7 Structure of Materials The properties of engineering materials mainly depends on the internal arrangement of the atoms on molecules. We must note that in the selection of materials, the awareness regarding differences and similarities between materials is extremely important. Metals of a single type atom are named pure metals. Metals in actual commercial use are almost exclusively alloys, and not pure metals, since it is possible for the designer to realize an infinite variety of physical properties in the product by varying the metallic composition of the alloy. Alloys are prepared from mixed types of atoms. Alloys are classified as binary alloys, composed of two components, as ternary alloys, composed of three components or as multi component alloys. Most commercial alloys are multicomponent. The composition of an alloy is described by giving the percentage (either by weight or by atoms) of each element in it. The basic atomic arrangement or pattern is not apparent in the final component, e.g., a shaft or a pulley but the properties of the individual crystals within the metallic component, which are controlled by the atomic arrangement, are mainly responsible for their application in industry. CLASSIFICATION AND SELECTION OF MATERIALS 7 One can determine the strength of a piece of metal by its ability to withstand external loading. The structure of metal or alloy responds internally to the applied load by trying to counteract the magnitude of the applied load and thus tries to keep the constituent atoms in their ordered positions if however the load is higher than the force which holds the atoms in place, the metallic bond becomes ineffective and atoms in the metal are then forced into new displaced positions. The movement of atoms from their original positions in the metal is termed as slip. The ease with which atoms move or slip in a metal is an indication of hardness. We must note that the relative movement of atoms or slip within a material has a direct bearing on the mechanical properties of the material. 3. CLASSIFICATION OF ENGINEERING MATERIALS The factors which form the basis of various systems of classifications of materials in material science and engineering are: (i) the chemical composition of the material, (ii) the mode of the occurrence of the material in the nature, (iii) the refining and the manufacturing process to which the material is subjected prior it acquires the required properties, (iv) the atomic and crystalline structure of material and (v) the industrial and technical use of the material. Common engineering materials that falls within the scope of material science and engineering may be classified into one of the following seven groups: (i) (ii) (iii) (iv) (v) (vi) (vii) Metals (ferrous and non-ferrous) and alloys Ceramics Polymeric (plastic) materials Composites Electronic materials (Semiconductors) Biomaterials Advanced materials. 3.1 Metals All the elements are broadly divided into metals and non-metals according to their properties. Metals are element substances which readily give up electrons to form metallic bonds and conduct electricity. Some of the important basic properties of metals are: (a) metals are usually good electrical and thermal conductors, (b) at ordinary temperature metals are usually solid, (c) to some extent metals are malleable and ductile, (d) the freshly cut surfaces of metals are lustrous, (e) when struck metal produce typical sound and (f) most of the metals form alloys. When two or more pure metals are melted together to form a new metal whose properties are quite different from those of original metals, it is called an alloy. Metallic materials possess specific properties like plasticity and strength. Few favourable characteristics of metallic materials are high lustre, hardness, resistance to corrosion, good thermal and electrical conductivity, malleability, stiffness, the property of magnetism, etc. Metals may be magnetic, non-magnetic in nature. These properties of metallic materials are due to: (i) the atoms of which these metallic materials are composed and (ii) the way in which these atoms are arranged in the space lattice. Metallic materials are typically classified according to their use in engineering as under: (i) Pure Metals: Generally it is very difficult to obtain pure metal. Usually, they are obtained by refining the ore. Mostly, pure metals are not of any use to the engineers. However, by specialised and very expensive techniques, one can obtain pure metals (purity ~ 99.99%), e.g., aluminium, copper etc. 8 MATERIAL SCIENCE (ii) Alloyed Metals: Alloys can be formed by blending two or more metals or at least one being metal. The properties of an alloy can be totally different from its constituent substances, e.g., 18-8 stainless steel, which contains 18% chromium and 8% nickle, in low carbon steel, carbon is less than 0.15% and this is extremely tough, exceedingly ductile and highly resistant to corrosion. We must note that these properties are quite different from the behaviour of original carbon steel. (iii) Ferrous Metals: Iron is the principal constituent of these ferrous metals. Ferrous alloys contain significant amount of non-ferrous metals. Ferrous alloys are extremely important for engineering purposes. On the basis of the percentage of carbon and their alloying elements present, these can be classified into following groups: (a) Mild Steels: The percentage of carbon in these materials range from 0.15% to 0.25%. These are moderately strong and have good weldability. The production cost of these materials is also low. (b) Medium Carbon Steels: These contains carbon between 0.3% to 0.6%. The strength of these materials is high but their weldability is comparatively less. (c) High Carbon Steels: These contains carbon varying from 0.65% to 1.5%. These materials get hard and tough by heat treatment and their weldability is poor. The steel formed in which carbon content is up to 1.5%, silica up to 0.5%, and manganese up to 1.5% along with traces of other elements is called plain carbon steel. (d) Cast Irons: The carbon content in these substances vary between 2% to 4%. The cost of production of these substances is quite low and these are used as ferrous casting alloys. (iv) Non-Ferrous Metals: These substances are composed of metals other than iron. However, these may contain iron in small proportion. Out of several non-ferrous metals only seven are available in sufficient quantity reasonably at low cost and used as common engineering metals. These are aluminium, tin, copper, nickle, zinc and magnesium. Some other non-ferrous metals, about fourteen in number, are produced in relatively small quantities but these are of vital importance in modern industry. These includes, chromium, mercury, cobalt, tungsten, vanadium, molybdenum, antimony, cadmium, zirconium, beryllium, niobium, titanium, tantalum and manganese. (v) Sintered Metals: These materials possess very different properties and structures as compared to the metals from which these substances have been cast. Powder metallurgy technique is used to produce sintered metals. The metals to be sintered are first obtained in powered form and then mixed in right calculated proportions. After mixing properly, they are put in the die of desired shape and then processed with certain pressure. Finally, one gets them sintered in the furnace. We must note that the mixture so produced is not the true alloy but it possesses some of the properties of typical alloys. (vi) Clad Metals: A ‘sandwich’ of two materials is prepared in order to avail the advantage of the properties of both the materials. This technique is termed as cladding. Using this technique stainless steel is mostly embedded with a thick layer of mild steel, by rolling the two metals together while they are red hot. This technique will not allow corrosion of one surface. Another example of the use of this technique is cladding of duralium with thin sheets of pure aluminium. The surface layers, i.e., outside layers of aluminium resist corrosion, whereas inner layer of duralumin imparts high strength. This technique is relatively cheap to manufacture. 4. POLYMERIC (PLASTIC) MATERIALS Most polymeric materials consist of organic (carbon-containing) long molecular chains or networks. Structurally, most polymeric materials are noncrystalline, but some consist of mixtures of crystalline and noncrystalline regions. The strength and ductility of polymeric materials vary greatly. Because of the nature of their internal structure, most polymeric materials are poor conductors of electricity. Some of CLASSIFICATION AND SELECTION OF MATERIALS 9 these materials are good insulators and are used for electrical insulative applications. One of the more recent applications of polymeric materials has been in manufacture of digital video disks. In general, polymeric materials have low densities and relatively low softening or decomposition temperatures. 4.1 Organic, Inorganic and Biological Materials Organic materials are carbon compounds and their derivatives. They are solids composed of long molecular chains. The study of organic compounds is very important because all biological systems are composed of carbon compounds. There are also some materials of biological origin which do not possess organic composition, e.g., limestone. 4.2 Organic Materials These materials are carbon compounds in which carbon is chemically bonded with hydrogen, oxygen and other non-metallic substances. The structure of these compounds is complex. Common organic materials are plastics and synthetic rubbers which are termed as organic polymers. Other examples of organic materials are wood, many types of waxes and petroleum derivatives. Organic polymers are prepared by polymerisation reactions, in which simple molecules are chemically combined into long chain molecules or three-dimensional structures. Organic polymers are solids composed of long molecular chains. These materials have low specific gravity and good strength. The two important classes of organic polymers are: (a) Thermoplastics: On heating, these materials become soft and hardened again upon cooling, e.g., nylon, polythene, etc. (b) Thermosetting plastics: These materials cannot be resoftened after polymerisation, e.g., ureaformaldehyde, phenol formaldehyde, etc. Due to cross-linking, these materials are hard, tough, nonswelling and brittle. These materials are ideal for moulding and casting into components. They have good corrosion resistance. The excellent resistance to corrosion, ease of fabrication into desired shape and size, fine lusture, light weight, strength, rigidity have established the polymeric materials and these materials are fast replacing many metallic components. PVC (Polyvinyl Chloride) and polycarbonate polymers are widely used for glazing, roofing and cladding of buildings. Plastics are also used for reducing weight of mobile objects, e.g., cars, aircrafts and rockets. Polypropylenes and polyethylene are used in pipes and manufacturing of tanks. Thermoplastic films are widely used as lining to avoid seepage of water in canals and lagoons. To protect metal structure from corrosion, plastics are used as surface coatings. Plastics are also used as main ingredients of adhesives. The lower hardness of plastic materials compared with other materials makes them subjective to attack by insects and rodents. Because of the presence of carbon, plastics are combustible. The maximum service temperature is of the order of 100°C. These materials are used as thermal insulators because of lower thermal conductivity. Plastic materials have low modulus of rigidity, which can be improved by addition of filters, e.g., glass fibres. Natural rubber, which is an organic material of biological origin, is an thermoplastic material. It is prepared from a fluid, provided by the rubber trees. Rubber materials are widely used for tyres of automobiles, insulation of metal components, toys and other rubber products. 4.3 Inorganic Materials These materials include metals, clays, sand rocks, gravels, minerals and ceramics and have mineral origin. These materials are formed due to natural growth and development of living organisms and are not biological materials. 10 MATERIAL SCIENCE Rocks are the units which form the crust of the earth. The three major groups of rocks are: (i) Igneous Rocks: These rocks are formed by the consolidation of semi-liquid of liquid material (magma) and are called Plutonic if their consolidation takes place deep within the earth and volcanic if lava or magma solidifies on the earth’s surface. Basalt is igneous volcanic where as granite is igneous plutonic. (ii) Sedimentary Rocks: When broken down remains of existing rocks are consolidated under pressure, then the rocks so formed are named as sedimentary rocks, e.g., shale and sandstone rocks. The required pressure for the formation of sedimentary rocks is supplied by the overlying rocky material. (iii) Metamorphic Rocks: These rocks are basically sedimentary rocks which are changed into new rocks by intense heat and pressure, e.g., marble and slates. The structure of these rocks is in between igneous rocks and sedimentary rocks. Rock materials are widely used for the construction of buildings, houses, bridges, monuments, arches, tombs, etc. The slate, which has got great hardness is still used as roofing material. Basalt, dolerite and rhyolite are crushed into stones and used as concrete aggregate and road construction material. Another type of materials, i.e., Pozzolanics, are of particular interest to engineers because they are naturally occurring or synthetic silicious materials which hydrate to form cement. Volcanic ash, blast furnace slag, some shales and fly ash are examples of pozzolanic materials. When the cement contains 10-20% ground blast furnace slag, then it is called pozzolans-portland cement, which sets more slowly than ordinary portland cement and has greater resistance to sulphate solutions and sea water. Rocks, stone, wood, copper, silver, gold etc., are the naturally occurring materials exist in nature in the form in which they are to be used. However, naturally occurring materials are not many in number. Nowadays, most of the materials are manufactured as per requirements. Obviously, the study of engineering materials is also related with the manufacturing process by which the materials are produced to acquire the properties as per requirement. Copper, silver, gold, etc., metals, which occur in nature, in their free state are mostly chemically inert and highly malleable and ductile as well as extremely corrosion resistant. Alloys of these metals are harder than the basic metals. Carbonates, sulphates and sulphide ores are more reactive metals. 4.4 Biological Materials Leather, limestone, bone, horn, wax, wood etc., are biological materials. Wood is fibrous composition of hydrocarbon, cellulose and lignin and is used for many purposes. Apart from these components a small amount of gum, starch, resins, wax and organic acids are also present in wood. One can classify wood as soft wood and hard wood. Fresh wood contains high percentage of water and to dry out it, seasoning is done. If proper seasoning is not done, defects such as cracks, twist, wrap etc., may occur. Leather is obtained from the skin of animals after cleaning and tanning operations. Nowadays, it is used for making belts, boxes, shoes, purses etc. To preserve the leather, tanning is used. Following two tanning techniques are widely used: (a) Vegetable Tanning: It consists of soaking the skin in tanning liquor for several days and then dried to optimum conditions of leather. (b) Chrome Tanning: This technique involves pickling the skin in acid solution and then revolving in a drum which contains chromium salt solution. After that the leather is dried and rolled. Limestone is an important material which is not organic but has biological origin. It mainly consist of calcium carbonate and limestone. It is widely used to manufacture cement. In Iron and Steel Industries, limestone in pure form is used as flux.