INTRODUCTION

Background of the Study

A Short History Of Metals:

Process metallurgy is one of the oldest applied sciences. It’s history can be

traced back to 6000 BC. Admittedly, it’s form at that time was rudimentary, but, to

gain a perspective in process metallurgy, it is worthwhile to spend a little time

studying the initiation of mankind's association with metals. Currently there are 86

known metals. Before the 19th century only 24 of these metals had been discovered

and, of these 24 metals, 12 were discovered in the 18th century. Therefore, from the

discovery of the first metals - gold and copper until the end of the 17th century, some

7700 years, only 12 metals were known. Four of these metals, arsenic, antimony, zinc

and bismuth were discovered in the thirteenth and fourteenth centuries, while

platinum was discovered in the 16th century. The other seven metals, known as the

Metals of Antiquity, were the metals upon which civilisation was based. These seven

metals were: (1) Gold (ca) 6000BC; (2) Copper, (ca) 4200BC; (3) Silver, (ca)

4000BC; (4) Lead, (ca) 3500BC ;(5) Tin, (ca) 1750BC; (6) Iron, (ca) 1500BC; (7)

Mercury, (ca) 750BC. These metals were known to the Mesopotamians, Egyptians,

Greeks and the Romans. Of the seven metals, five can be found in their native states,

e.g., gold, silver, copper, iron (from meteors) and mercury. However, the occurrence

of these metals was not abundant and the first two metals to be used widely were gold

and copper. And, of course, the history of metals is closely linked to that of coins and

gemstones.

Metallurgy weapons could be made from it, however, it needed the discovery

of tin to become the alloy of choice. Native Tin is not found in nature. The first tin
artifacts date back to 2000 B.C., however, it was not until 1800 B.C. that tin smelting

became common in western Asia. Tin was reduced by charcoal and at first was

thought to be a form of lead. The Romans referred to both tin and lead as plumbum

where lead was plumbum nigrum and tin was plumbum candidum. Tin was rarely

used on its own and was most commonly alloyed to copper to form bronze. The most

common form of tin ore is the oxide casserite. By 1400 BC. bronze was the

predominant metal alloy. Tin's symbol is Sn from the stannum. Tin is highly

malleable and ductile and has two allotropic forms which lead to tin initially having

its own disease (tin pest or blight) which was actually formation of alpha-tin below 13

C. As alpha-tin is a highly friable cubic structure with a greater specific volume than

beta-tin, during the phase change, which is kinetically limited, nodules of alpha-tin

become visible on the surface of beta-tin giving rise to early belief of sickness and the

first true doctors of metallurgy. Tin is highly crystalline and during deformation is

subject to mechanical twinning and an audible tin cry. Tin is also quite resistant to

corrosion. Tin is found as vein tin or stream tin. The tin ore is stannic oxide and is

generally found with quartz, feldspar or mica. The ore is a hard , heavy and inert

substance and is generally found as outcroppings as softer impurities are washed

away.

Aluminum or Steel

Aluminium is mostly used metal in construction, appliances and technologies,

it was first produced by Christian Oersted in 1825. However it was not until 20 years

later that significant quantities were produced. Wohler fused anhydrous aluminum

chloride with potassium to set free aluminum. Later Ste Claire Deville in 1854 put

together a production process using sodium instead of potassium. The current from

Galvanic cells were also used for electroplating. This was first practiced in the 1830's
when silver was deposited on baser metals. After silver plating, copper and nickel

plating was developed. In the middle of the 18th century it was found that metallic

separation could be carried out by the application of galvanic electricity. The current

was passed from an anode made of an impure , crude metal into a suitable electrolyte

and the pure material plated out onto a resistant cathode. Impurities present in the

crude cathode dropped to the bottom of the vessel and formed a sludge. From this

short review of metallurgical developments it can be seen that as the early

metallurgists became more sophisticated their ability to discover and separate all the

metals grew. However in all of their work it was necessary for all the basic steps to be

carried out e.g. the ore had to be identified, separated from gangue, sized,

concentrated and reduced in a manner which accomplished a phase separation.

Aluminium or steel can be recycled by melting it down and recasting into new

products. Currently, 60% of steel 39% of aluminium is recycled worldwide. However,

while recycling is a greener alternative to manufacturing new materials, it has high

energy costs which could be avoided if the metals were reused in their original form.

In this extensive analysis, the researchers gathered information on steel and

aluminium reuse from academic and industry literature, drawing on 200 sources, and

conducted 17 interviews with industry experts. They identified which products use

these materials, the key design requirements for components, and the fraction of end-

of-life components that could be technically reused, considering available strategies

and the physical barriers to the reuse of the remaining components. From this, they

concluded that up to 27% of steel and 33% of aluminium ‘end-of-life’ components

could potentially be reused. At present, there is little reuse of either material.

Information from the interviews revealed that two key factors determine the type of

steel or aluminium component that can be reused and the way in which it is reused:
condition and market demand. If the condition is good and demand is high,

components can be simply ‘relocated’, i.e. transferred to similar product, with little

need for amendment. For example, aluminium car wheels can be transferred to

another vehicle. If the condition is poor and demand is low, the component can be

‘cascaded’ to a different type of product with less demanding use, for example, metals

once used to clad buildings can be reused on agricultural sheds. Alternatively, they

can be ‘reformed’ (or reshaped), as when ship plates are reformed to a reinforcing bar.

High demand but poor quality calls for ‘remanufacturing’, which involves further

disassembly and refurbishment. For steel, the main areas for reuse are the relocation

of building components and the reforming of ship plates and line pipes. For

aluminium, the main areas of reuse are in buildings and car wheels. These areas of

opportunity, if carried out to their full potential, could allow reuse of 180 megatonnes

(Mt) of steel (18% of all steel) and 5.5 Mt of aluminium (12% of all aluminium) per

year. Policymakers seeking to maximise aluminium and steel reuse should prioritise

opportunities to relocate metal, according to the researchers. Their analysis indicates

that the greatest barrier to reuse is component incompatibility, i.e. different models of

domestic appliances and car parts using different components, followed by

degradation, i.e. metal corrosion. Approximately one-fifth of all global steel is used to

reinforce concrete (210 Mt in 2008), which also presents a major challenge for reuse,

as it is difficult to recover the steel bars without damaging them.

Reuse describes the spectrum of activities to bring discarded metal back into use

without melting. Reuse of end of life products is currently dominated by large

constructions or components. Processing is required to disassemble, recondition and

re-assemble products for reuse in similar applications, but much with the original

shape and functionality is retained. Reuse in manufacturing scrap occurs in much

which it can be reused, either by trimming to shape or by joining small pieces to

larger ones. Reuse is not a new concept before the industrial revolution, metal reuse

was normal practice. Barriers to reuse are associated with the reasons why a product

reaches its end of life. Fridges may become aesthetically undesirable, cars may be

scrapped because of unacceptable repair costs; ships may be broken due to changes in

legislation. However the bulk of the metal in this scrapped products is still fit for

purpose; reuse is not limited by any degradation of the metal’s technical

characteristics. This suggests that new design approaches to facilitate reuse could

have significant potential to reduce total carbon emissions in delivering steel and

aluminum goods.

Lampshade is a fixture that covers the lightbulb on a lamp to diffuse the light emits.

Lampshades can be made out of a wide variety of material and one of them is the

reuse metal scraps. Beyond its practical purpose, significant emphasis is also usually

given to decorative and aesthetic features. A lampshade also serves to shade human

eyes form the direct glare of the light bulbs use to illuminate the lamp.
Statement of the Problem

1. What are possible metal scraps that can be reuse in making a lampshade?

2. How to make a lampshade and what are possible designs that will come out after

reusing metal?

3. What are the possible effect of reusing metal scraps to our environment?

Objective of the study

General Objective

This study aims to lessen metal scraps by turning or reusing them as material

in making a decorative lampshade.

Specific Objective

1. To enumerate the list of sources of metal scraps to reuse as material in making a

lampshade.

2. To provide some designs as a basis in designing a well reuse metal scrap.

3. To lessen the metal scraps and turning them into something useful.
Significance of the Study

This study is significant to all students, lampshade designers, environmentalist

and future researchers. It can serve as a basis on how to reuse the metal scraps in

forming a lampshade. In connection to this study, it is beneficial to the following:

Students. This study will help the students to get ideas for future research

with regards on mitigating the excess metal scraps that comes from factories,

junkshop and construction sites.

Lampshade Designers. This study will help the designers to have knowledge

on how to use metal scraps in making their own designs. It’s an introduction to them

how to use resources like reusable metal scraps.

Environmentalist. This study will help environmentalist to propose projects

how to reuse metal scraps to help the surroundings and environment. It will help them

get ideas how to solve excess metal scraps in environment.

The Future Researchers. This proposed study will be a tool and guide for the

future researcher. It can be use as their source of information pertaining to their study

that is related to our topic.

This chapter provides a background review of related literature pertaining

to the study entitled The Feasibility of Using Metal Scraps as a Material in making a

lampshade. In addition, information related to this study was gathered from internet

services, articles and books.

According to Jonathan M. Cullen many products’ use-phase energy

requirements are decreasing. The relative importance of the embodied impacts from

initial production is therefore growing and the prominence of reuse as an abatement

strategy is likely to increase in the future. Many examples are found in the literature

of beneficial reuse of standardized, unpowered products and components, and

repairing an item is always found to be less energy intensive than new production.

However, reusing a product does not guarantee an environmental benefit. Attention

must be paid to restoring and upgrading old product efficiencies, minimizing

overspecification in the new application, and considering whether more efficient, new

products exist that would be more suitable. Cheap, reused goods can allow many

consumers access to products they would otherwise have been unable to afford.

Though socially valuable, these sales, which may help minimize landfill in the short

term, can represent additional consumption rather than a net environmental benefit

compared to the status quo.

Daniel R. Cooper and Timothy G. Gutowski also said that, introduction

Reuse has become one of the well-known 3Rs—“reduce, reuse, recycle”—promoted

greater reuse in the future, it is essential that the environmental impacts of reuse be

better understood.

According to Julian M. Allwood, reuse covers a range of activities from

informal product exchanges between acquaintances, to the semiformal structure of

car-boot sales and internet exchanges such as eBay, to industrial reuse of products and

components, often called remanufacturing. A broad definition is employed that covers

most of the activities branded as reuse in the literature: It is a nondestructive process

that finds a second or further use for end-of-first-life solid materials (products or

components) without a change of state, excluding melting for metals, plastics and

glasses, and pulping for paper. The further use of a product may be considered as

product life extension. The spectrum from reuse to product life extension overlaps

with the activity of product resale.

Reeta Maila said that global warming is a big issue today. The issue is

complex because it simultaneously concerns everybody and nobody. Sustainable

development should be considered in everyday activities, but to be an

environmentally conscious consumer requires a lot of time and effort which can

reduce the amount of actual sustainable consumer activities or habits. As a designer it

is particularly important to consider sustainable development when it comes to

industrially manufactured products. In theory there exists the possibility that the

designer’s decisions and judgments during the design process cause more positive or

negative environmental impacts than can be caused as a single consumer. Instead of

concentrating on repairing the damage and pollution caused in the production process,
it is more important to focus on preventing environmental damage in the first place.

Designers have to carry the responsibility of the consequences of their design

decisions instead of disregarding designers’ ethical responsibility.

Dr. Jim Bowyer said that in an era in which waste recovery, recycling, and

recycled content are high on society’s agenda, improvement of recycling performance

is on the radar screens of almost every product manufacturer. Increased impetus for

more extensive recycling is the focus of an emerging environmental initiative to

decouple increasing consumption from needs for additional resource extraction. A

central goal is to reduce environmental impacts of consumption. To achieve

improvement in recycling rates first requires an understanding of what recycling

statistics mean and current recovery and recycling rates. In this report we examine

recycling rates for steel, the metal used in 8-9 times greater quantity than all other

metals combined. We found that commonly used definitions of recycling serve to

obscure actual recovery and recycling performance, that there are considerable losses

of material with each use cycle, and that the often cited claim that steel is

continuously recyclable without loss of quality is not true. We also found a much

greater potential for steel recovery and recycling than is currently being realized.

According to A. Javaid, the recycling cycle is well established for the steel

industry, and there has been a significant increase in the use of recycled scrap. This

trend is expected to continue and grow because of the increased availability of cheap

automotive scrap. Steel is the world’s, as well as North America’s, most recycled

material. The North American steel industry annually recycles millions of tons of

steel scrap from recycled cans, automobiles, appliances, construction materials and

other steel products. It has had an average recycling rate in excess of 50% since

World War II and over 60% since 19702 . In fact, the industry’s overall recycling rate
is nearly 68%. In 2002, over 72 million tons of steel and iron was recycled in steel

mills and foundries in the United States, while over 15 million tons were recycled in

Canada2,3. Steel is the engine that drives the recycling of many consumer goods, as

can be seen with the virtual 100% recycling rate of automobiles, the nearly 80%

recycling rate of appliances, and the almost 60% recycling rate of steel packaging2 .

Additionally, millions of tons of steel and iron from demolition projects are diverted

from the waste stream to the recycling stream. This results from steel’s magnetic

properties, which make it the easiest material to separate from the solid waste stream.
 RESULTS AND DISCUSSIONS

This chapter presents the feasibility of using metal scraps as a material in

making a lampshade. It includes possible metal scraps and procedures on how to

make a metal lampshade. It also includes the possible effects of reusing metal on

making a lampshade to environment.

1. List of Possible Metal Scraps to be Use.

Sources Of Steel Scrap

The iron and steel industry recycles three types of scrap: “home”, “new”,

and “old” scrap.

Home scrap is internally generated in the steel production process when

steel mills and foundries manufacture new steel products. This form of scrap rarely

leaves the steel-making production area. Instead, it is returned to the furnace on site

and melted again. Technological advancements have significantly reduced the

generation of home scrap which accounts for approximately 29% of total scrap4 .

New scrap (also called prompt or industrial scrap) is generated in steel-

product manufacturing plants and includes such items as turnings, clippings and

stampings leftover when a part is made during manufacturing processes. This material

is typically sold to the scrap metal industry that processes it for sale to steel mills and

foundries. It accounts for approximately 23% of total steel scrap.

Old scrap or post-consumer scrap results when industrial and consumer

steel products (such as, automobiles, appliances, buildings, bridges, ships, cans,

railroad cars, etc.) have served their useful life. Old or post-consumer scrap accounts
for approximately 48% of total scraps . A major challenge in recycling scrap is to

maintain the quality of steel products and minimize contamination with other metals.

Potential residual element contamination may come from the recycling of automobiles

and municipal scrap. Ferrous scrap metal from old automobiles in North America

amounts to about 10 million tons per year. Use of recycled scrap steel in steelmaking

processes has been increasing, and this trend is expected to continue and grow

because of the increased availability of cheap automotive scrap. As a result, levels of

residual impurity elements entering the steel-making process from scrap feed are

increasing with increased scrap use and repeated recycling. The ability to control the

detrimental effects of these residual elements, and the need for more efficient refining

technologies to recycle future scrap feed, are major concerns. Close to 52 million cars

are manufactured each year and, considering their relatively short service time

(between nine and thirteen years), their disposal has a significant impact on the

environment6 . As it did with the development of the 3-L sub-compact car,

government pressure has led to dramatic changes in this aspect of the automotive

industry. For example, the British government recently signed an agreement with the

Society of Motor Manufactures and Traders, the Motor Vehicle Dismantlers and the

British Metals Federation, among others, to increase automobile recycling to 85% of

the average vehicle weight by 20057 . In order to achieve this goal, separation of

automobile component materials must be improved to minimize contamination of the

metal streams during recycling. Clean, well-sorted scrap is crucial to costefficient

recycling.

Types of Metal Scraps

There are numerous types of basic metal and almost thousands when you get down to

the nitty-gritty classifications. When you know the types of scrap metal you are
dealing with, it’s easier to know what you can and what you can’t do with it, where

it’s commonly found, and what could it bring to the table.

Aluminum is one of the most commonly reused scrap metal. You can find

aluminum in soda cans, food wrap foils, screen door frames, or storm windows and

etc.

Figure 1. Example picture of Aluminum

Brass is a common metal to find in and around your home. You can find it

in places such as your doorknobs, brass plated crockery and old bed frames.

Figure 2. Example picture of Brass

Carbide can be found in the tool bits or drill bits. So if you get a new tool set for

father’s day or just replacing the broken pieces, remember that you can recycle them

instead of tossing them in the trash.

Copper in the third most used metal in construction and manufacturing.

Copper is highly valuable and sought after. This metal is commonly found in your

household plumbing, living room decor, appliances, kitchen sinks, pots, and

electronic wiring.

Figure 4. Example picture of Copper

Iron is common household items such as cast iron pots and pans,

lawnmowers, swings in your backyard and iron railings are perfectly acceptable as

scrap metal. A lot of outdoor furniture is also commonly made of iron.

Figure 5. Example picture of Iron

Lead requires so much energy to mine that manufacturers prefer

purchasing recycled lead because it saves time and money. It is also highly toxic

metal, so be sure to protect yourself and your surroundings when handling it. Many

older houses were made with lead water pipes which need to be replaced as soon as

possible as these are dangerous to your health.

Titanium is used in just about everything from jewelry to airplanes, and

that’s why it’s so valuable. When you have a metal that is so versatile you can use it

on a number of projects. It’s also very durable and resistant to corrosion.

Figure 7. Example picture of Titanium

2. Steps on how to make a lampshade out from metal scraps and sample photos

of design.

To make a reuse metal lampshade, we need the following materials.

 Decorative or reusable metal scraps that can be found in our home.

 Gloves

 Clear epoxy

 Clamps

 Black spray paint and primer in one – you can choose any color that fits your

home decor.

 Cloth rag

 Wire

 Hanging lamp light cord with socket

 Bulb
 2.1. Assemble the reuse and decorative metal scraps found in your home.

Wearing gloves for protection of your hand. You will want the metal lampshade look

beautiful that’s why be creative in assembling the scraps to make a stand. You’ll also

need metal sheets to be big enough so that they will wrap around in a cylinder to

create the lampshade of your desired size. Use tape measure to determine your

dimensions.

2.2. Secure the sides of the lampshade. Wrap the metal sheets into a

cylinder and secure the sides together using clear epoxy. Clamp in place and

following manufacturer’s recommendations on drying time.

2.3. Paint the lampshade. Wipe the lampshade down with a rag to ensure it

is dirt and dust free. In a well ventilated area, spray paint the metal and allow to dry

thoroughly. You can select any color you want to match with your home décor.

2.4. Finish the lamp. Secure the metal scrap lampshade around its place and

make sure to stand still. Make sure that the lamp light cord is installed properly and

insert the bulb.

Sample image of metal scrap lampshade

Figure 8
 Figure 9

3. Possible effect of reusing metal scraps in making a lampshade to our

environment.

3.1. To prevent solid waste from entering the landfill, improve our

communities and increase the material, educational and occupational wellbeing of our

citizens by taking useful products such as metals which discarded by those who no

longer want them and providing them to those who want to reuse them and turn those

materials into something useful. In many cases, reuse supports local community and

social programs while providing donating businesses with tax benefits and reduced

disposal fees.

3.2. Reuse metals scraps provides an excellent, environmentally preferred

alternative to other waste management methods because it reduces water and landfill

pollution, it limits the need for new natural resources such as timber, petroleum, fibers

and other materials.