UNIT - III

Non-ferrous Metals and Alloys

 Introduction
• Metals broadly divided into two
– Ferrous metals
– Non ferrous metals

Non ferrous metals:

These are costlier than the ferrous metals because of its specialproperties.
– Copper or aluminium cannot be replaced in electricalconductors.
– Aeroplane never been developed to its present state without aluminium.
– Some stringent requirements like high strength, corrosion and
oxidation resistance at high temperatures, to be used in jet engines,
gasturbines, etc.,
 Metal Symbol Density,gm/CC Melting point,°C
Aluminium Al 2.7 660
Antimony Sb 6.69 630
Bismuth Bi 9.8 271
Cadmium Cd 8.65 321
Chromium Cr 7.2 1900
Copper Cu 8.9 1083
Gold Au 19.3 1064
Lead Pb 11.35 327
Magnesium Mg 1.7 650
Manganese Mn 7.2 1250
Nickle Ni 8.9 1453
Silver Ag 10.5 961
Tin Sn 7.29 232
Titanium Ti 4.5 1671
Zinc Zn 7.14 419
 Aluminium and its alloys
General properties of aluminium
• Symbol - Al
• Atomic number - 13
• Density - 2.7 g/cm3
• Melting point - 660 °C
• Crystal structure - Face-centered cubic
• Young's modulus - 70 GPa
• Poisson ratio - 0.35
 Advantages of aluminium
• Light weight
Aluminium is light with a density one third that of steel, 2.7 g/cm3
• Good machinability
Aluminium is easily worked using most machining methods – milling, drilling,
cutting, punching, bending, etc. Furthermore, the energy input during
machining is low
• High conductivity
Aluminium is an excellent conductor of heat and electricity. An aluminium
conductor weighs approximately half as much as a copper conductor having
the same conductivity
• High Corrosion resistance
Aluminium reacts with the oxygen in the air to form an extremely thin layer of
oxide that provides excellent corrosion protection. The layer is self-repairing if
damaged.
• Non-magnetic material
• Zero toxicity
 Advantages of aluminium
• Aluminum is the3rd most abundant element
in the Earth'scrust.
• Low cost

• Easy to recycle
 Classification of aluminium alloys

Aluminum alloys are normally classified into

three groups:
1. Wrought non-heat treatable alloys
2. Wrought heat treatable alloys
3. Casting alloys
Heat treatments in aluminium alloys
Precipitation Hardening or Agehardening:
• Age hardening requires a decrease in solid solubility ofthe
alloying elements with decreasingtemperature.
Heat treatment usually involves the three following stages:
1. Solution treatment at relatively high temperature to
dissolve the alloying elements.
2. Rapid cooling or quenching usually to room temperature to
obtain supersaturated solid solution (SSSS)of these
elements in aluminium.
3. Controlled decomposition of the SSSSto form a finely
dispersed precipitates, normally accompanied with ageing
at appropriate temperatures.
Precipitation Hardening of an Aluminum-Copper Alloy

Step -1

Step -2
Step -3
Step-3 Aging Curve for Aluminum Alloys
Designation for Aluminum WroughtAlloys
International Alloy Designation System
(IADS)

 The first digit designates the major alloy

The second digit designates the purity of the aluminum and mill control
The third and fourth digits have two meanings.
If the aluminum is 1xxx then the last two digits designate the amount of aluminum above 99%. For example 1025
signifies a non alloyed aluminum that is 99.25% pure aluminum with the remaining 0.75% uncontrolled impurities
 If the aluminum is any other than 1xxx the last two digits are registered with IADS
Treating

F-asfabricated H - Strain Hardening

W- solution heat treated T - Thermally treated
O- Annealed
 Designation of cast aluminium alloys
United States Aluminium Association system

 The first digit designates the major alloy

 The second and third digits have two meanings
second and third digits in 1xx.0 indicate the minimum percentage of Al, Ex: 150.x 99.50%
Al.
other than 1xx.0 second and third digits have no numerical significance only to identify
individual alloy
 Fourth digit that is right of the decimal point indicates product forms
0 = casting, 1 = ingot
 Classification of aluminium alloys

Aluminum alloys are normally classified into three

groups:
1. Wrought non-heat treatable alloys:
1xxx, 3xxx, 5xxx, 8xxx
2. Wrought heat treatable alloys:
2xxx, 6xxx, 7xxx
3. Casting alloys:
1xx.x, 2xx.x, 3xx.x, 4xx.x, 5xx.x, 6xx.x,
7xx.x, 8xx.x, 9xx.x
 British Standard Designation of aluminium
alloys
Designation of cast Al alloy in British system is covered by the British
Standard 1490.
 M -As-cast

 TB -Solution treated and naturally aged

 TB7- Solution treated andstabilised

 TE-Artificially aged after casting

 TF-Solution treated and artificial aged

 TF7- Solution treated, artificially aged andstabilised

 TS-Thermally stress-relieved

BS specifications for aeronautical use (designated as the Lseries)

 Important Aluminium alloys
1. Al-Si and Al-Si-Cu alloys:
 LM 6 is 88% Al-12% Si alloy, the molten metal of this
alloy has high fluidity and less shrinkage during
solidification.
Applications: automobile castings, motor housings.
 LM 2(10% Si, 2% Cu, 88% Al), LM 25(8.5%Si, 3.5 %Cu,
88% Al), LM 4(5% Si, 3% Cu, 92% Al) in this alloys Si is
reduced and Cu is added to make the alloy responsive
to precipitation hardening.
 Important Aluminium alloys
2. Al-Mg alloys:
 LM 5 (5% Mg, 0.5 %Mn, 94.5% Al) this alloy has high
corrosion resistance & good machinability makes this alloy
suitable formarine environment applications
3. Al-Cu alloys:
 LM 11 (4.5% Cu, 95.5% Al) it is a precipitation hardenable alloy and
produces good strength after precipitation hardening
Application :aircraft castings
4. Y-alloy or LM 14 (4%Cu, 2% Ni, 1.5%Mg):
 It has high ability to retain the strength up to elevated temperature and
good corrosion resistance
Application: pistons, cylinder heads
5. Hinduminium-RR 350 (5% Cu, 1.5%Ni and small
amounts of Mn, Ti, Co, Zr,Sb):
 It has good creep resistance
Application: Aero engines
 Applications of aluminium and itsalloys
1. Low density and strength make aluminium idealfor
construction ofaircraft, lightweight vehicles,
and ladders.
2. Easy shaping and corrosion resistance make
aluminium a good material for drink cans androofing
materials.
3. Corrosion resistance and low density leads to its use
for greenhouses and window frames.
4. Good conduction of heat leads to its use for boilers,
cookers and cookware.
5. Good conduction of electricity leads to its use for
overhead power cables
6. High reflectivity makes aluminium ideal for mirrors
& reflectors
Copper and its alloys
General properties of copper
Advantages of Copper
 APPLICATIONS

• Locomotive fire box plates

• Radiator elements
• Domestic boilers
• Cooking utensils
• Kettles
• Electrical conductors
• Switch gear parts
• telegraph and telephone wire
and cables
Types of unalloyed copper
Types of unalloyed copper
 BRASS(Cu&Zn)
PROPERTIES:
ALPHAPHASE
• Most ductile
• Good strength
• Good corrosion resistance
• Excellent cold working properties
HETEROGENEOUSALPHAAND BETAPHASE
• Hot working applications
BETAPHASE
• Harder and more brittle

PROBLEMS
• High zinc tends to “dezincification” leads to corroding the parts and leaves holes which
become porous, weak and prone to complete break down. ANTIMONY, P, ARSENIC ARE
ADDEDTOPROVIDEEXTRAPROTECTION
• “STRESSCORROSIONCRACKING” IN WINTERSEASON
APPLICATIONS
 CLASSIFICATION OFBRASSES
• Cartridge brass

• Admiralty brass

• Muntz metal(yellow brass)

• Leaded brass

• Naval brass
CARTRDIGEBRASS
Composition

• Cu-70%
• Zn:30%
Properties:

• Most ductile
• Good tensile strength
• Easily cold worked by drawing
• Pressing and spinning
Applications:

• Cartridge cases
• Locomotive and condenser tubes
ADMIRALTY BRASS
Composition

• Cu-70%
• Zn-29%
• Sn-1%
Properties:

• Resistance to corrosion
Applications:

• Marine parts and condensertubes

Muntz metal(yellow brass)
Composition

Cu-60%
Zn:40%
Properties:

• Strong and hard

Applications:

• Valves
• Marine fittings
• Electric equipment
• fuses
 Leaded brass
Composition

Cu: 62.5%
Zn:36%
Pb:1.5%
Properties:

• Resistance to corrosion
• Good machinability
• less ductile and impact strength
Applications:

• Plates and
• tubes
Naval brass
Composition

• Cu-60%
• Zn:39%
• Sn-1%
Properties:

• Resistance to corrosion
• Good tensile strength
• Suitable for hot rolled forgings and castings
Applications:

• Marine parts such as Valves and fittings

BRONZE(Cu & Sn)

• Low coefficient of friction

• Rolled into sheets or cast into intricate castings

• Stronger than brasses

• Better corrosion resistance

• Cost is more
BRONZE(Cu & Sn)
 Classification of BRONZES

• Phosphorusbronze

• Aluminium bronze

• Gun metal

• Bell metal

• Silicon bronze
 Phosphorus bronze
Composition:

Cu-93.7%
Sn-6%
Others(P)-0.3%
Properties:

GOODCASTABILITY
HIGH FATIGUE STRENGTH
Applications:

SPRINGSAND BERAINGS
BUSHES
GEARS ELECTRICAL
PARTS
 Aluminium bronze
Composition:
Cu-90-95%
Sn--%
Others(Al)-5-10%
Properties:
• Good corrosion and wear resistance
• High strength and hardness at elevated temperatures
Applications:
• Marine engineering guides
• Seats
• Flanges
• Moulding dies for plastics
• Condenser tubes
• Aircraft engine parts
• Valves and parts in chemical plants
 Gun metal
Composition:
Cu-

88%

Sn-10%

Others(Zn)-2%

Properties:

• Castable

• Good sea water corrosion resistance

• High strength and toughness

Applications:

• Casting guns

• Boiler fittings

• Bolts & nuts in navalconstructions

 Bell metal
Composition:

Cu-
80%
Sn-20%
Properties:

• Hard
• Resistance to surfacewear
Applications:

• Making bells
• Gongs
• utensils
 Silicon bronze
Composition:

Cu-
97.5%
Sn--%
Others(Si)-2.5%
Properties:

• Corrosion resistance
• High strength
Applications:

• Marine applications
• fasteners
 COPPER-NICKELALLOYS

• Cupronickel- Cu & Ni

• German silver-Cu, Zn, Ni

CUPRONICKEL
Composition:

Cu-70%
Ni-30%
Properties:

Ductile and strong

Corrosion resistance & erosion resistance
Hardened and strengthened by coldworking
Applications:

Condenser tubes
Heat exchangers
Turbine blades
German silver
Composition:
Cu-
55%
Ni-18%
Zn-27%
Properties:
•Ductile and strong
•Corrosion resistance
•Stress corrosion resistance
•Hardened and strengthened
by cold working
Applications:
•Decorative purposes &cutlery
•Rivets
•Screws
•Radio dials
 Titanium and its alloys
General properties of Titanium

 Crystal structure- HCP(<882.5oC)

BCC(>882.5oC)
 Density- 4.54 (g.cm-3)
 Atomic number - 22
 Melting point -1667(oC)
 Experiences allotropic transformation (α to β) at 882.5oC.
 Highly react withoxygen, nitrogen, carbon and hydrogen.
 Difficult to extract expensive.
 High strength and toughness.
 Titanium is the forth abundant metal on earth crust (~ 0.86%)
after aluminium, ironand magnesium.
Advantages of titanium alloys
 Classification of titanium alloys
 Commercially pure (CP)titanium
 Alpha and near alpha titanium alloys
- Generally non-heat treatable and weldable
- Medium strength, good creep strength, good corrosion resistance
 Alpha-beta titanium alloys
- Heat treatable, good forming properties
- Medium to high strength, good creepstrength
 Beta titanium alloys
- Heat treatable and readily formable
- Very high strength, low ductility
 α- Stabilized System

Most common α- stabilizers:

Tem(oC) Al, O, N, C

α- Stabilizer
Two Types of Stabilized Systems
 Commercially pure (CP) titanium
• Purity 99.0-99.5%, HCPstructure.
• Main elements in unalloyed titanium are Feand
interstitial elements such as C, O, N, H.

• O content determines the grade and strength.

• C, N, H present as impurities. H embrittlement.
 Oxygen equivalent
 Properties and typical applications of
commercially pure (CP) titanium alloys
Properties:
 Lower strength, depending on contents ofO, N.
 Corrosion resistance to nitric acid, moist chlorine.
 0.2% Pd addition improves corrosion resistance in
HCl, H2SO4, H3PO4.
Less expensive
Applications:
• Airframes, heat exchangers, chemicals,marine,
surgical implants.
 Compositions and applications of
commercially pure (CP) titanium alloys
 Alpha titanium alloy
• Al and O are the main alloying elements, which
provide solid solution strengthening.
• The amount of α stabilisers should not exceed 9%
in the aluminium equivalent to prevent
embrittlement.
 Aluminium equivalent

• Ti-5Al-2.5Sn is the most commonly usedAlpha

titanium alloy
 Properties and typical applicationsof
Alpha titanium alloys
Properties:
– Moderate strength.
– Strength depends on O andAl
– contents. (Al <5-6%).
– Al also reduces its density.
– Good oxidation resistance and strength at 300 to 600oC.
– Readily weldable.
Applications:
– Aircraft engine compressor
– blades, sheet-metal parts.
– High pressure cryogenic vessels at -423oC.
 Near-alpha titanium alloys
• Small amounts of β stabilisers (Mo,V) are added,
giving a microstructure of β phase dispersed in the
α phase structure. improved performance and
efficiency.
• Sn and Zr are added to compensate Al contents
while maintaining strength and ductility.
• Show greater creep strength than fully α Ti alloyup
to 400oC.
• Ti-8Al-1Mo-1V and Ti-6Al-2Sn-4Zr-1Mo alloys are
the most commonly used for aerospace
applications, i.e., airframe and engine parts.
 Alpha-beta titanium alloys
• Alpha-beta titanium alloys contain both α and β.
• α stabilisers are used to give strength with 4-6% , β stabilisers
to allow the β phase to retain at Room Temperature
• Improved strength and formability in comparison to α -Ti
alloys.

• Ti-6Al-4V (IMI 318) is the most widely commercially used.

 Beta titanium alloys
• Beta stabilisers are sufficiently added to retain a
fully β structure (avoid martensite formation)
when quenched from the β phasefield.

Metastable β alloys : Mo Eq.<25

Stable β alloys : Mo Eq.25-40.

Molybdenum equivalent
Composition and applications of
β titanium alloys