Engineering Metallurgy

ME 3215
-Non-Ferrous Metals-

Md Abdullah Al Bari
md.abdullahbari@gmail.com
Department of Mechanical Engineering
Khulna University of Engineering & Technology

Tuesday and Thursday (Sec. A) Room ME # 312

Tuesday and Thursday (Sec. B) Room ME # 401

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 Chapter outcome
At the end of this chapter you should be learn about:

•Properties and uses of following non-ferrous metals

and their alloys
– Copper —Alloys of noble metals
– Aluminum —Bearing materials
– Nickel —Spring materials
– Tin
– Lead

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 Non-Ferrous Metals
• Nonferrous metals- Metals that contain little to no iron

• Alloys- Base metals combined with other metals or

chemicals to enhance the base metals properties

• Non-ferrous metals and alloys are important because they

posses important properties such as, corrosion resistance,
high thermal and electrical conductivity, low density, and/or
ease of fabrication

• Al, Cu, Zn, Mg, Ti, Sn, Pb, Ni, Co, W, V

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Non-ferrous metals and alloys

Classification of non-ferrous materials

a) Density based:
– light metals and alloys ρ < 5000 kg/m3 (Mg, Al, Ti)
– medium metals and alloys ρ = 5000...10000 kg/m3 (Sn, Zn, Sb, Cr, Ni, Mn, Fe, Cu)
– heavy metals and alloys ρ >10000 kg/m3 (Pb, Ag, Au, Ta, W, Mo)

b) Melting temperature based:

– low melting point Tm < TmPb = 327 °C (Sn, Pb, Bi)
– medium melting point = 327…1539 °C (Al, Mg, Mn, Cu, Ni, Co, Ag, Au)
– refractory Tm > TmFe = 1539 °C

Element Ti Cr V Nb Mo Ta W
Tm, °C 1660 1875 1900 2415 2610 2996 3410

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 Copper

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 General Properties of Copper

• Moderate strength in the pure state

• Malleable and ductile
• Very good electrical and thermal conductor
• Good corrosion resistance
• Alloys with Zinc to give brass
• Alloys with Tin and others to make bronze

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 CopperCopper
and Major
and Copper
copperAlloys
alloys

Pure Cu Cu-alloys

Brasses Bronzes Cupronickels

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 Details Properties of Copper
In a sufficient pure form copper has following properties-

1. Colour: In a clean polished condition it is lustrous yellowish

red

2. Resistance to atm. corrosion: When exposed to the air in

the presence of moisture and carbon dioxide it becomes
coated with a greenish basic carbonate which under normal
atm. conditions acts as a protection against further
corrosion.

3. Density: It has a density of 8.96X103 kg/m3

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 Copper corrosion

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 Details Properties of Copper
4. Conductivity: Good heat and electricity conductor
Thermal conductivity = 3.95 W/(cm-K)
Electricity conductivity = 50X106 ohm-1 m-1 at 20 oC

5. Melting and boiling points: Melting point of 1083 oC and

boiling point of 2325 oC

6. Co-efficient of expansion: It has co-efficient of linear expansion

equal to 16.7 X10-6 (K-1)

7. Specific Heat Capacity: Between 0 and 100 oC, it is 390 J/kg.K

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 Details Properties of Copper
8. Malleability and Ductility: Its percentage elongation in the
annealed form is 50-60%
9. Other Mechanical Properties:
E= 117 Gpa,
U.T.S. = 220 N/mm2
Y.P. = 69 N/mm2
B.H.N. = 47

10. Crystal Structure: It has face centred cubic structure in its pure
form at ordinary temp.

11. Machinability and Weldability: It possesses good machinability

and weldability as well as castability.

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 Details Properties of Copper
12. Hot and Cold Workability: It is easily worked by cold and hot
processes like rolling, forging, extrusion etc.

13. Fracture: The fracture of cast copper is granular but when

forged or rolled it is slightly fibrous.

14. Alloying: It can make alloys with tin, zinc, aluminium and nickel.

15. Resistance to Corrosion by Other Agents: It is practically

unaffected by caustic alkanies, sea and other waters, but is
strongly attacked by nitric acid. Slowly attacked by hydrochloric
and sulphuric acids.
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 Copper Production

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 Uses of Copper
Copper is widely used industrially mainly due to its high electrical
and thermal conductivity, good resistance to atm. corrosion and
workability
1) As a heat conducting material:
Radiator elements
Domestic boilers
Moulds of casting metals
Refrigerator tubes
Coils
Vessels
Cooking utensils
Kettles, etc.
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 Uses of Copper
2. As an electricity conducting material:
Winding of dynamos, motors, transformers and other coil
Bus-bars
Switchgear parts
Cables
Electrodes for welding machines, electric furnaces
Telephone wires
Lighting conductors, etc
3. As a corrosion resistant materials:
Plating or sheeting of wooden ships
4. Copper used for electrotyping and electroplating
5. Used for making coins
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 Copper Alloys
Two main alloys
1. Brasses (পেতল)
2. Bronzes (কাাঁসা- a type of bronze)

Brasses: Alloy of Copper and Zinc. May also contain

small percentages of nickel , lead etc.
Bronzes: Alloy of Copper and tin but generally posses
other elements like zinc, nickel, phosphorus,
aluminium etc.

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 Copper Alloys
Brasses: Alloy of Copper and Zinc. May also contain
small percentages of nickel , lead etc.
• α Alloys - (0 to 39% of Zn) – single phase –
f.c.c. - cold working alloys
• α+β Alloys – (39 to 46% of Zn) – two phase
(duplex brasses) – hot working alloys

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 Copper Alloys
• α Alloys - (0 to 39% of Zn) – single phase – f.c.c. - cold working alloys
• α+β Alloys – (39 to 46% of Zn) – two phase (duplex brasses) – hot working
alloys

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 Copper Alloys
• Cartridge brass (70:30 Brass):
• α brass
• Used for cold rolled sheets, wire drawing, deep drawing, pressing and tube
manufacturing
• T.S. : 333.5 Mpa
• Elongation: 70%
• Vickers hardness: 65
• Yellow or Muntz metal (60-40 Brass):
Delta Metal
• An α+β Brass 60 –Cu, 37 –Zn, 3 – Fe
• Suitable for hot working by rolling, extrusion
• Manufacture of casting • Good tensile strength and
improve mechanical
• T.S. : 285-480 Mpa properties
• Elongation: 25-50% • Loss of machinability
• Vickers hardness: 60-150
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 Copper Alloys
• Nickel Silvers:
• Can be both α or α+β
• Previously known as German Silver, though there is no silver
• Nickel improves the mechanical properties, specially ductility and
toughness
• T.S. : 518 Mpa (α)
• Copper: 50-65%
• Nickel: 7-30%
• Zinc: 10-25%

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 Copper Alloys
Bronzes: Alloy of Copper and tin but generally posses
other elements like zinc, nickel, phosphorus,
aluminium etc.
Typical bronzes are gunmetal, phosphor
bronze, lead-bronze, Al-bronze etc.

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 Copper Alloys
• Gunmetals:
• Originally used chiefly for making guns, it has largely been replaced by
steel.
• Alloy of copper, tin and zinc with the zinc in small proportions upto 6 %
(max)
• Typical composition
Cu : 88%
Sn : 10%
Zn : 2%
• T.S. : 221 - 310 Mpa
• Elongation: 20%
• BHN: 65 - 74
• Gunmetal, which casts and machines well and is resistant to corrosion
from steam and salt water, is used to make steam and hydraulic castings,
valves, gears, statues, and various small objects, such as buttons.
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 Copper Alloys
• Aluminium bronzes:
• Alloys of copper and aluminium along with appreciable quantities of
iron, nickel and manganese but without tin.
• Can be both α or β aluminium bronzes

• α -aluminium bronzes: 4 - 7 % Al
• Alloy containing less than 7% aluminium posses valuable cold
working properties. Suitable for components exposed to corrosion
conditions.
• Have very good ductility, upto 80% elongation
• Uses: sheet, strip, tubes and wires etc

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 Copper Alloys
• Aluminium bronzes:
• β-aluminium bronzes: 7 - 12 % Al
• Alloys containing 7 – 12% Al are of duplex structure in which beta
constituents are present in considerable quantities and are much
harder but less ductile
• With a little bit of iron (3%), this alloy can have U.T.S is about 580
Mpa and 40% elongation
• Hot worked at 950oC (max. Temp.), good casting ability, excellent
corrosion resistance properties
• Uses: roller bearing caps, plane bearings and landing gear
components on aircraft, under water fittings, piston rods, pump rods,
valves, electrical applications, cables, architecture etc

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