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Copper & its alloys

(Properties and Uses)

Dr. Muhammad Riaz Bhatti

12/14/2011

Introduction - Nonferrous metals and alloys

These materials technology.

have

assumed

important

roles

in

modem

Because of their number and properties, they provide an almost limitless range of properties for the design engineer. costly than iron or steel, but often possess certain properties or combinations of properties that are not available in the ferrous metals, such as:

Resistance to corrosion
Ease of fabrication High electrical and thermal conductivity Light weight

Strength at elevated temperatures


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Non-Ferrous Alloys
Brass : Zn is subst. impurity -lower : 2.7g/cm 3 (costume jewelry , coins, -Cu, M g, Si, M n, Zn additions corrosion resistant) -solid sol. or p recip . Bronze : Sn, Al, Si, Ni are strengthened (struct. subst. impurity aircraft p arts (bushings, landing & p ackaging) gear) NonFerrous Mg Alloys Cu-Be : -very low : 1.7g/cm 3 Alloys p recip . hardened -ignites easily for strength -aircraft, missles

Cu Alloys

Al Alloys

Ti Alloys

-lower : 4.5g/cm 3 vs 7.9 for steel -reactive at high T -sp ace ap plic.
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Refractory metals
-Ag, Au, Pt -oxid./corr. resistant

Noble metals

-high melting T -Nb, M o, W, Ta

General properties and characteristics of copper

The first uses - decorative (jewelry) because of its attractiveness and malleability. an important engineering metal for over 6000 years. As a pure - backbone of the electrical industry.

Because of its excellent conductivity, about one third of all copper produced is used in some form of

electrical application, such as the, commutators.


It is also the base metal of alloys, known as brasses and bronzes.

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Useful Properties of Copper

a good electrical conductor a good thermal conductor corrosion resistant Antibacterial easily joined Ductile tough

non magnetic Non-sparking attractive colour easy to alloy Recyclable catalytic

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Uses / Application of copper


Motors, pumps, domestic appliances (washing machines, dishwashers, fridges, vacuum cleaners, electric bells),

cars (starter motors, windscreen wipers, computers, disc drives, fans),


entertainment systems (walkman, video player, CD and DVD players).

Transformers mains adaptors, electricity substations, power stations.


plumbing, heating, air conditioning.

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Uses / Applications of copper

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Properties of Copper & its alloys vs other Engineering Materials

Compared to other engineering materials, copper and copper alloys offer

three important properties:

high electrical and thermal conductivity, useful strength with high ductility, and corrosion resistance to a wide range of media..

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Alloying

Although copper has excellent electrical and thermal properties, it


needs to be hardened and strengthened for many industrial applications

Copper can be combined with other metals to make alloys. copper alloys are: brass: copper + zinc bronze: copper + tin cupro nickel: copper + nickel

Some

The alloys are harder, stronger and tougher than pure copper. They can be made even harder by hammering them - a process called work
hardening.
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Cu-Zn Phase Diagram

and are terminal solid solutions , , , and are terminal solid solutions10

Copper Alloys: Brasses

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Copper Alloys: Brasses

Zinc is the most popular alloying element and the resulting alloys are known as brasses. Developed to overcome softness, low strength and high casting temp of Cu. Two types:

Alpha () Brasses (Zn upto 36 %), single phase with FCC structure, quite ductile and formable, with both strength and ductility increasing with the zinc content up to about 36%. can be strengthened significantly by cold working and are commercially available in various degrees of cold-worked strength and hardness.
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Copper Alloys: Brasses

Cartridge brass, (70% Cu-30% Zn), offers the best overall combination of strength and ductility & has become a

popular material for sheet-forming


operations like deep drawing.

Brasses with 20-36% Zn are subject to

dezincification.

Add 0.1 % As to prevent this & add 2 % Al for better resistance to Corrosion.
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Copper Alloys: Brasses



Beta () Brasses ( 36% Zn) BCC structure, two-phase region, hard & brittle, High thermo-ductility With 36% zinc, the Cu+Zn alloys enter a two-phase region involving a brittle, Zn-rich phase and its ductility drops markedly. cold-working properties are poor for these high-zinc brasses, deformation can be performed easily at elevated temperature. Brasses with 15% zinc often experience season cracking or stresscorrosion cracking (due to the presence of stress and corrosive media) cold-worked brass is stress relieved (to remove the residual stresses) before storing or putting into service

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Copper Alloys: Brasses

Leaded brass: When high machinability is required, 2 to 3 % lead can be added to the brass to ensure the formation of free-breaking chips. Brass casting alloys are quite popular for use in plumbing fixtures and fittings, low-pressure valves, and a variety of decorative hardware. They have good fluidity during pouring and attractive low melting points. An alloy containing between 50 and 55% copper and the remainder zinc is often used as a filler metal in brazing. obtained by welding.
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Copper Alloys: Cupro nickel


Cupro nickel: Cu + Ni (2-30%) Copper and nickel exhibit complete solubility. Key features include:

high thermal conductivity, high-temperature strength, resistance to stresscorrosion cracking and corrosion resistance to a range of materials, including seawater.

Uses include: heat exchangers, cookware, desalination apparatus and a wide variety of coinage. Nickel silvers contain no silver, but 10 to 30% nickel and at least 5% zinc. used for ornamental applications and musical instruments.
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Bronzes

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Copper Alloys: Bronzes

Bronze, an alloy of Cu & Sn (<12 % Sn)

Strength continues to increase as tin is added up to about 20%, but the high-tin alloys tend to be brittle.
Tin bronzes offer good strength, toughness, wear resistance, and corrosion resistance.

used for bearings, gears, and fittings that are subjected to heavy compressive load
when the Cu-Sn are used for bearing applications, up to 10% lead is added.

Gunmetal containing 10% tin and 2 % Zn, has very good resistance to seawater corrosion and is used on ships for pipe fittings, gears, pump parts, bushings, and bearings.
Phosphor bronze (0.1 to 0.5%) increases hardness as does addition of Zn, used for springs, instruments & for bearing bushes (in cast condition). 12/14/2011

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Copper Alloys: Aluminum Bronzes


Aluminum-Bronze (93 % Cu, 7 % Al) are best known for their combination of high strength and excellent corrosion resistance. often considered to be cost-effective alternatives to stainless steel and nickel-based alloys. With < 8% Al, the alloys are very ductile. When Al exceeds 9%, however, the ductility drops and the hardness approaches that of steel. Still higher aluminum contents result in brittle, but wear-resistant materials.

used in marine hardware, power shafts, sleeve, bearings, and pump and valve components for handling seawater and various industrial fluids.
6% Al alloy has fine gold colour & used for imitation jewellery & decorative purpose
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Thanks

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