The Steel Rose Project

The Steel Rose is made from mild steel.
Mild Steel was chosen to make the Steel Rose by year 9 students in the academy because of its very favourable working properties.
Mild Steel is a ferrous metal which contains approximately 0.05–0.25% carbon making it malleable and ductile.
Ferrous metals are metals that contain Iron and are magnetic.
The other two classifications of metal are Non-Ferrous metals and Alloys.
Non-Ferrous Metals, for example Aluminium and Copper,  do not contain carbon and are not magnetic.
Alloys, for example Brass and Bronze, are mixtures of two or more metals or elements.
Mild Steel has a low tensile strength compared to other metals.
It is relatively inexpensive and can be cut, shaped and formed quite easily in the academy workshop.
Tensile Strength refers to the property of a material that makes it able to retain its strength whilst it is being stretched.

How Steel is Made

As we have mentioned above, there are two types of metals, ferrous & non-ferrous. Ferrous comes from, or contains iron, while Non-Ferrous does not contain iron.
Examples of ferrous metals would be mild steel, cast iron, high strength steel, and tool steels.
To make steel you need the ingredients iron ore, coal and limestone.
You also need a Blast Furnace in which you can mix all of the ingredients of steel together in the correct proportions.
You will also a lot of heat, up to to 2000 Degrees Centigrade, and a blast of Oxygen.
The super hot liquid is transported to a processing plant where the impurities are removed to create pure steel.
The video opposite explains to children how a Biscuit Tin is made.
A very simple definition of steel is "iron alloyed with carbon, usually less than 1%."

Cold and Hot Working of Steel

Cold working of steel is done when the metal is at room temperature.
We will use a Ball Pein Hammer to cold work the Steel Petals into a Bowl Shape.
Cold working of the steel will make the steel harden and become brittle.
To achieve the fine organic details of the rose petals, the metal is hot worked.
The mild steel is heated to red heat which increases  ductility and malleability of the mild steel.
Long nosed pliers are used to shape and form the petals. You can see this done in the video
Take care with hot metal!

Using Heat to shape and form the Rose Petals

Being Safe when working with Mild Steel

Great care must be taken when working with mild Steel.
  • When using metal snips to shear the metal, you will produce very sharp edges.
  • Great care must be taken to ensure you protect yourself from these edges.
  • Any sharp pieces of  metal must be collected and put into the workshop Metal Bin.
  • Sharp metal should not be left in a bench vice or discarded onto the workshop floor.
  • A dust pan and brush, Gloves  or even a Magnet can be used to pick up small sharp pieces of mild steel.
Drilling Holes in Mild Steel
  • YOU MUST NEVER HOLD METAL IN YOUR HAND WHEN YOU ARE CARRYING OUT A DRILLING OPERATION, THIS IS VERY DANGEROUS.
  • Mild steel must be secured in a hand vice or Machine Vice 
  • A centre punch must be used to mark the position of the hole prior to drilling; this will stop the drill from wandering and ultimately snapping.
Working with Hot Metal
You will be given the opportunity to work with red hot steel.
  • You must never hold the hot metal in your hand
  • Ensure that the metal is secured in a Vice
  • Allow the metal to cool before removing from the Vice
  • The Metal can be cooled in water, although this can create rust spots in the completed product.
  • Your teacher will be with you to guide you

Drilling Safely in the workshop

The Tools and Equipment You will use To make your steel rose

The workshop tools, equipment and extra materials that you will use to make the steel Rose are:
Metal snips, Ball pein hammer, Cold chisel, Centre punch, Pillar Drill, Machine vice, Engineers Bench Vice, Hand Vice, Diameter 6mm metal threaded rod ( studding) , M6 Nut, Pillar Drill, Brazing Hearth, Anvil, Long Nosed Pliers, M6.5 Twist Drill.
Can you identify all of the above in the image opposite?

Stage By Stage making of the Steel Rose