Nonferrous Metals and Their

Properties
Introduction

Nonferrous Metals, Their Specifications and Uses

Making of Nonferrous Metals

 Introduction
Aluminum
Magnesium
Titanium
Beryllium
Copper
Zinc
Tin
Nickel
Lead
•Base Metals
Aluminum, Nickel, Copper, Zinc, Tin, Lead.
•Precious Metals
Rhodium, Palladium, Silver, Osmium, Iridium, Ruthenium,
Platinum, Gold.
•Noble Metals
Vanadium, Chromium, Niobium, Molybdenum, Tantalum,
Tungsten.
•Minor Metals
Magnesium, Silicon, Titanium, Manganese, Cobalt, Germanium,
Strontium, Zirconium, Cadmium, Antimony, Mercury.
•Rare Earth Metals
Scandium, Yttrium, Lanthanum, Cerium, Praseodymium,
Samarium, Europium, Cesium.
Aluminum
Bauxite Aluminum
 Aluminum

Most used metal after steel and iron

Light, great strength, highly resistant to corrosion

High degree of workability, conductivity, pleasing appearance

Alloy Number
Pure aluminum 1xxx
Copper 2xxx
Manganese 3xxx
Silicon 4xxx
Magnesium 5xxx
Magnesium & silicon 6xxx
Zinc 7xxx
Other elements 8xxx
 Magnesium
From dolomite or canallite and seawater

Alloying aluminum, die cast magnesium components,

desulphurization of steel.
 Magnesium

Specified with a 5 alphanumeric acronym

AM60B

Aluminum 5.6 to 6.4%

Manganese .26 to .50%
Zinc
 Zinc

Galvanizing steel, brass, zinc based alloys

Zinc alloys often die cast

ASTM B240, B286

 Zinc Corrosion Protection
Galvanizing
 Tin

From the mineral cassiterite (SnO2)

Smelted above 1200º C

Iron removed by blowing steam into liquid metal
Arsenic & antimony removed by addition of aluminum

Alloyed with other metals such as lead

Pewter and bronze are alloys of tin

Tin
 Titanium
From the element rutile (Titanium dioxide) and ilmenite
(iron-titanium oxide)

Three basic structural groups:

Alpha Non-heat treatable, very weldable

Hexagonal close packed
Excellent mechanical properties @ cryogenic
temperatures
Excellent high temperature creep strengths
 Titanium (continued)
Alpha-Beta
Heat treatable most are weldable
Medium to high strength
Creep strength not as good as Alpha

Beta Readily heat treatable, generally weldable

High strength and good creep resistance at
intermediate temperatures
BCC
Used for heavy sections, fasteners and springs
 Beryllium

Extracted from Be3Al2(SiO3) by electrolysis

Used as an alloy of bronze (2 to 3%)

Most transparent metal to X-rays

Used as windows in X-Ray equipment

Copper
Copper
Standard Chemical Composition Limits
The composition limits in this listing of Standard Designations for Copper and
Copper Alloys are presented according to the following numerical convention,
wherever practicable.
CONSTITUENTCONVENTION FOR
EXPRESSING
COMPOSITION LIMITS

Copper Nos. C10000 - C15999 (wrought) and C80000 - C81199 (cast):

CopperXX.XX
Alloying elements and impurities
1/10 and over.XX
1/100 and less than 1/10.0XX
1/1000 and less than 1/100.00X
less than 1/1000.000X
Copper Alloy Nos. C16000 - C79999 (wrought) and C81300 - C99999 (cast):
CopperXX.X
Alloying elements and impurities
6/10 and over.X
1/10 and less than 6/10.XX
1/100 and less than 1/10.0X
1/1000 and less than 1/100.00X
less than 1/1000.000X
 Copper Alloys

High copper alloys (between 94 and 99% copper)

Brasses (contain zinc as the principle alloy)
Bronzes (alloys of copper in which zinc or nickel is not the
principle alloy)
Copper-Nickels (nickel is the principle alloy)
Nickel Silvers (nickel and zinc are the principle alloys)
Leaded Coppers (cast alloys with 20% or more lead)
Special Alloys (other alloys not included in above)
Nickel
 Nickel
From Sulphide or laterite ores

Nickel–copper
Nickel-molybdenum
Nickel-chromium
Illium alloys (containing Ni-Cr-Mo-Cu)
D Nickel (95% Ni, 4.5% Mn)
Duranickel (94% Ni-4.5% Al)
Monel (67% Ni, 30% Cu)
Inconnel (76% Ni, 16% Cr, 8% Fe)
Hastelloy B (62% Ni, 28% Mo, 5% Fe)
 Lead
Batteries
Lead Uses
Cable Sheathing

Rolled and
Extruded
Shot/Ammunition

Alloys

Compounds

Gasoline
Additives
Miscellaneous
 Lead

From galena ores

Alloys
Solder typical: 38% lead, 62% tin
5.0 Plastics and Composite
Materials

5.1 Introduction

5.2 Classifications

5.3 Manufacture of Plastic Components

 5.1 Introduction
From the Greek word “plastikos” meaning fit for molding.

More than 50 families of plastics

Much less dense than metals

Plastics: .9 to 2.2 gm/cm3
Steel: 7.85 gm/cm3
Monomers
Thermo & Thermosetting
Plastics
 Thermo Plastics

Polyethylene
Polyvinyl chloride
Polypropylene
Polystyrene
Polyethylene Terephthalate
Acrylonitrile Butadiene Styrene
Polymethyl Methacrylate
Polyamide
 Polyethylene
High and low density

LDPE (low density polyethylene)

Inexpensive, flexible and tough
Bottles, frozen food packages and toys

HDPE (High density polyethylene)

Grocery bags, fuel tanks, piping
 Polyvinyl Chloride

Polyvinyl chloride (PVC)

Most widely used amorphous plastic
Compact disks casings and piping
Used in its softened state for packaging, shoe
soles and floor tiles
 Polypropylene
Polypropylene
Highly aligned molecular structure

Rope, fibre, carpet

 Polystyrene

Polystyrene
Amorphous, transparent, somewhat brittle

Flotation devices and styrofoam

 Polyethylene Terephthalate
Polyethylene Terephthalate (PET)
Highly aligned molecular structure

Gears, pulleys and food trays

 Acrylonitrile Butadiene
Styrene
Acrylonitrile Butadiene Styrene (ABS)
Superior hardness, gloss toughness,
electrical resistance
Electrical conduit, helmets, washing machine agitators
 Polymethyl Methacrylate
Polymethyl Methacrylate (PMMA)
Hard, extremely clear

Aircraft windshields, skylights, signs

Also known by trade names: Lucite and Plexiglass

 Polyamide
Polyamide
Known by trade name nylon

Low coefficient of friction

Tensile strength comparable to soft aluminum

Textiles, rope, fishing line, brushes

 Thermosetting Plastics

Polyurethane
Phenolics
Melamine-Formaldehyde and Urea-Formaldehyde
Unsaturated Polyester
Epoxy
 Polyurethane

Thermosetting polyurethane
Soft and hard forms

Soft: cushions, mattresses, packing

Hard: Insulation for homes and refrigerators

 Phenolics
Phenolics
Date back to 1810

Excellent electrical resistance

Circuit boards, electrical switches

 Epoxy
Epoxy
Excellent chemical and electrical resistance

Coatings, adhesives, composites

Used in making wings for F-18 and F-22 fighter jets

 Composites
Cloth, fibres, strands or other materials in a polymer
bonding agent

Creates strengths greater than any of the individual

components

Boeing 777, tennis rackets, jet skis and golf clubs

Composites
Composites
 Advanced Composites
Fibre reinforced matrix of ceramics or metals

Multiple bonded layers or different materials

Combinations of both (laminated matrix)

High temperature high strength applications

Mechanical Properties
 5.3 Manufacture of Thermo
Plastic Components
Calendaring

A finishing process by which the

plastic is passed between rolls to
Achieve shape and surface finish
 Manufacture of Thermo
Plastic Components

Injection Molding

The process of forcing heated

plastic into a mold.

Injection pressures typically between

5000 and 20,000 psi
 Manufacture of Thermo
Plastic Components
Extrusion
Molten plastic is forced through a die resulting in a
continuous line of shaped plastic
 Manufacture of Thermo
Plastic Components
Thermoforming
Vacuum forming
Pressure forming
Twin sheet forming
 Manufacture of Thermo
Plastic Components
Blow Molding
A molten tube is formed of thermoplastic material

Compressed air is used to blow up the tube to form

and chill the interior

Extrusion blow molding

Injection blow molding
Injection stretch blow molding
 Manufacture of Thermosetting
Plastic Components
Compression Molding
Most common method for thermosetting plastics
Not usually used for thermo plastics

Plastic molding powder and filler is put into heated

mold and compressed to fill the mold. A
chemical reaction takes place. The component
solidifies and is removed.
 6.0 Determining Material
Properties
6.1 Definitions

6.2 Common Test Methods, Specifications

 6.1 Definitions
Nondestructive testing is the utilization of a particular form
of energy to gain some specific knowledge about a part or
system of parts with out affecting its usefulness.

Test is a procedure in which the performance of a product

is measured under various conditions

Proof Test is a specified stress being applied to a material

or structure in order to assess its ability to support service
loads
 Definitions
Indication is a response or evidence of a response that
requires interpretation to determine its significance.

Discontinuity is any interruption in the normal physical

structure of a part.

Defect is a discontinuity whose size shape, orientation

make it detrimental to the useful service of the part.
 Tensile Tests

Some units mechanical screw &

others hydraulic

Extensometer
Tensile Tests Specimens
After

Before
 Stress vs. Strain

No work hardening
.2% Offset Method
Well Defined Yield Point
 Elongation & Reduction of
Area
% Elongation = Lf - Lo x 100%

Lo

% Reduction of Area = Ao – Af x 100%

Ao

Where A = Area, L = Length, o for original, f for final

 Hardness Tests

Three groups:

 Elastic hardness

 Resistance to cutting or abrasion

 Resistance to penetration
 Elastic Hardness Devices
Scleroscope

Indicates the height of rebound of a

small diamond tipped hammer

ASTM E448
 Elastic Hardness Devices
LEEB Principle

Impact device is forced towards the

surface in a guide tube by a spring.
A magnet in the impact device
generates a signal in an encircling
coil, after rebound it generates a
second signal. The signals are
compared to compensate for orientation
and calculate hardness.

ASTM E956
 Resistance to Scratching
Mohs Hardness

Friedrich Mohs devised the method in 1812.

No significant engineering use.

It has values from 1 to 10.

Talc the softest material is assigned 1

Diamonds the hardest material is assigned 10.

 Resistance to Penetration
Brinell Hardness Test

A hard steel ball or carbide sphere is

forced into the surface under a specified
load.

Diameter is measured to determine Brinell

Hardness

BHN = Brinell Hardness Number

 Resistance to Penetration
Rockwell Hardness Method
Measures the net increase in depth of the
impression after a minor load is applied
and after the major load is applied

14 different scales

C, A & D are the most common scales

15-N, 30-N & 45-N are the most common

Superficial scales
 Resistance to Penetration
Vickers Hardness Test

Considered a micro hardness method

Uses a square based diamond pyramid

The surface dimensions of the indent are

measured and converted to hardness

Used for measuring case hardening and

heat affected zones of welds

VHN = Vickers Hardness Number

 Resistance to Penetration
Tukon Hardness Method

Micro hardness technique

Employs a diamond indenter

Usually combined with a Vickers unit

 Resistance to Penetration
Knoop Hardness Method

Micro hardness technique

KHN = Knoop Hardness Number

 Impact Tests
Measures the decrease in
fracture resistance caused by
sudden loading in the
presence of a notch

Methods:

Charpy

Izod

Units: foot pounds of joules

Charpy Impact Tests
CVN = Charpy V-Notch
Izod Impact Tests
 Transition Temperature
Impact test results must include temperature

Most materials exhibit a change from notch tough to notch

brittle over a very narrow temperature range called the
transition temperature

Transition temperature is determined by conducting impact

tests at different temperatures until an abrupt change in
energy required to break the specimen is noted
 Bend Tests
The most common method for evaluating weld procedures
and welder performance

Weld bend tests:

Root bend
Face bend
Side bend

Used for testing many other types of structures

 Fatigue Tests
Used to evaluate performance of a part or material to
repeating load

Results are usually plotted as stress to number of cycles to

failure, S/N curve

Endurance limit is defined as the stress below which the part

can with stand infinite number of cycles