Académique Documents
Professionnel Documents
Culture Documents
Resistance to corrosion
Ease of fabrication - low melting
points
High electrical and thermal
conductivity
Light weight
Strength at elevated temperatures
high ductility with low yield points
2
Applications of copper
Only second to silver for electrical conductance
Copper trolley wires
Electronic products
Electronic products
5
Approximate Cost Per Unit Volume for Wrought Metals and Alloys
formation of a series of
solid solutions
Percentage composition
Constituent just below
cooling to 400C
Copper
Zinc
100 to 67.5
0 to 32.5
67.5 to 63
32.5 to 37
63 to 61
37 to 39
+ `
61 to 55.5
39 to 45.5
+ `
55.5 to 50
45.5 to 50
50 to 43.5
50 to 56.5
` +
43.5 to 41
56.5 to 59
` +
11
13
Microstructure of brasses
Annealing twins
Annealing twins can be observed in the grains when the alloy
has been cold worked and followed by annealing.
A pair of grains is said to be twinned when the arrangement of
atoms in one of the grains can be generated from the other
(during recrystallization) by reflection across a common
plane.
14
Commercial bronze
(90%Cu-10%Zn)
Cartridge brass
(70%Cu-30%Zn)
15
Nominal Composition:
Cu 68.5-71.5
Zn 28.38-31.38,
Pb 0.07,
Fe 0.05
18
phase
200X
Air cooled from the all region at 8250C.
Widmanstatten structure - dendrites of phase surrounded by
precipitates.
appears inside the grains and on the grain boundaries.
appears as long, fat needles in a matrix.
much less if this specimen had been quenched.
more and "rounder" if slowly cooled
20
Applications
replacement for copper sheathing placed
on the bottom of boats - anti-fouling
abilities of the pure copper can be
maintained cost effectively
- as it cost around two thirds of the
pure
copper
architectural work
for valve stem and condenser tubes
21
22
Leaded brasses has Small amounts of Pb (0.53.0%) which are added to many types of brasses
to improve their machinability.
Essentially pure lead (99.99%Pb) will be distributed
inter-dendritically in the copper as small
globules.
Cold deformation makes elongated Pb globules.
Free-cutting brass extruded rod showing elongated
lead globules with the remained phase
23
Tin Brasses
Increasing Sn contents gives a lighter
coloured microstructure of + multi-phase.
25
Aluminum Bronze
(10Al5Ni5Fe)
phase
phase
kappa coarse
particles
26
27
formation of a series of
solid solutions
Percentage composition
cooling to 400C
Copper
Tin
100 to 87
0 to 13
87 to 86
13 to 14
86 to 78
14 to 22
78 to 74
22 to 26
>( + )
29
30
Tin bronze
8-10% Sn 2-4% Zn, remaining copper.
Pressure castings, bushings and bearings
32
Gun metal
5-10% Sn, 2-5% Zn, remainder copper.
Originally used for guns
Good tensile strength and resistance to corrosion.
Used for bearings, steam pipe fittings, marine castings,
hydraulic valves and gears.
Cu-10 Sn4Pb
50X
200X
34
Copper-Nickel Alloys
Cu and Ni are both FCC and can form solid
solution throughout.
Microstructure consists of phase- solid
binary system exhibits complete solid
solubility.
Ni (10, 20, 30%) are added to Cu to form
solid solution alloys, called cupronickel.
Ni addition improves strength, oxidation, and
corrosion resistance.
Ni greatly increases electrical resistivity of Cu
Ex:55%Cu-45%Ni used for wire-wound
resistance for electrical instrument.
35
Microstructure of cupronickel
70%Cu-30%Ni
consisting of
recrystallised
grain with twin bands
36
General Applications
Pipe work in chemical plants
Automotive Applications
Extra surface protection is not required
employed for brake, hydraulic suspension systems
and cooling systems
37
Marine Applications
good resistance to biofouling - undesirable
accumulation of microorganisms, plants and algae on
wetted structures.
resistance to sea water corrosion.
cladding for ships hulls, fouling legs of oil rig platforms
and sea water intake screens.
coins, medals
- The copper with 25% nickel with 0.05-0.4%
manganese .
Thermocouples
copper-45% nickel alloy ; develops a high and uniform
EMF when coupled with other metals such as copper and
iron.
Resistance Wire
copper with 45% nickel alloy is used for resistance wire
in high precision resistors.
38
Cu-Al Alloys
(Aluminum Bronzes)
Al forms solid solution in Cu ( phase) up to
9.4% at 565oC.
Annealed microstructure of
Cu-5%Al,showing grains
with twin bands.
39
40
41
Applications
Electronic components - electronic connectors
high strength, formability, and favorable elastic
modulus.
Electrical equipment - switch and relay blades.
fatigue strength, conductivity, and stress
relaxation
resistance.
Resistance welding systems
hot hardness and conductivity are important
42
Superalloy
Excellent mechanical strength.
High temperature strength through
solid solution strengthening.
Precipitation strengthening Carbides.
Creep resistance at high temperatures.
Good surface stability.
Corrosion and oxidation resistance.
-Protective oxide layer (Al2O3, Cr2O3)
43
Aerospace
Industrial gas turbine
Marine turbine industry
Turbine blades for hot sections of jet Engines- Ni base
super alloys.
Submarines
Nuclear reactors
Military electric motors
Chemical processing vessels, and heat exchanger tubing.
44
45
Types of Superalloys
Hastelloy
Predominant alloying ingredient is Ni.
Other alloying ingredients Mo , Cr, Co, Fe, Mn, Ti, Zr, Al, C.
Primary functions
Effective survival under high-temperature.
High-stress service in severely corrosive
enviornment.
Pressure vessels of some nuclear reactors,
chemical reactors, and pipes and valves.
46
Co
Cr
Mo
Fe
Si
Mn
B-2
1*
1*
28
2*
0.1*
1*
0.01*
B-3
3*
1.5
28.5
3*
1.5
0.1*
3*
0.01*
C-4
2*
16
16
3*
0.08*
1*
0.01*
C-2000 2*
23
16
3*
0.08*
0.01*
C-22
2.5*
22
13
0.08*
0.5*
0.01*
C-276
2.5*
16
16
0.08*
1*
0.01*
G-30
2*
30
5.5
2.5
15
1*
1.5*
0.03*
0.2*
16
0.5*
5*
1*
0.8*
0.08*
Ni
Balanc
e
65
Other
s
Al-0.5*,
min.
Ti-0.2*
Balanc
Ti-0.7*
e
Balanc
Cu-1.6
e
Balanc Ve
0.35*
Balanc
V-0.35*
e
NbBalanc
0.8*,
e
Cu-2*
Al+TiBalanc 0.5*,
e
Cu0.35*
47
Balanc
Inconel
Austenitic nickel-chromium-based
superalloys.
Inconel alloys are typically used in high
temperature applications.
Common trade names for Inconel include:
Inconel 625,
Chronin 625,
Altemp 625,
Haynes 625,
Nickelvac 625
Nicrofer 6020.
48
Element (% by mass)
Inconel
Ni
Cr
Fe
Mo
600
72
14-17
6-10
625
58
20-23
718
50
17-21
8-10
Nb
3-4
Co
Mn
Cu
0.5
0.5
0.35
Al
0.4
0.2-0.8 0.65
Ti
Si
0.5
0.15
0.4
0.5
0.1
0.3
0.35
0.08
49
Properties
Inconel alloys are oxidation and corrosion
resistant materials suited for extreme
environments.
When heated, forms a thick, stable,
passivating oxide layer protecting the
surface from further attack.
Retains strength over a wide temperature
range, attractive for high temperature
applications
where aluminum and steel would succumb to
creep.
50
51
Machining
Inconel is a difficult metal to shape and machine due
to rapid work hardening.
age-hardened Inconels (718) are machined
using an aggressive but slow cut with a hard tool,
minimizing the number of passes required.
Cutting of plate is often done with a water-jet
cutter.
Internal threads can be cut by single point
method on lathe.
New whisker reinforced ceramic cutters are also
used to machine nickel alloys.
52
Applications -
encountered in extreme
environments
Gas turbine blades, seals, combustors, turbocharger
rotors and seals
Pump motor shafts, high temperature fasteners,
chemical processing and pressure vessels, heat
exchanger tubing.
Extensively used in boilers of waste incinerators.
53
Waspaloy
Age hardening Ni-based superalloy.
Nickel 58%,
Chromium 19%,
Cobalt 13%,
Molybdenum 4%,
Titanium 3%
Aluminium 1.4%
55
Properties
Excellent strength up to 760-870C.
Structure
There are two forms of WC;
Hexagonal form, -WC,
Cubic high temperature form, -WC,
which has the rock salt structure.
Applications
Machine tools
For materials such as carbon or stainless steel
In situations where other tools would wear away.
Carbide generally produces a better finish on the
part, and allows faster machining.
Carbide tools can also withstand higher
temperatures than standard high speed steel
tools
59
Military
used in armor-piercing ammunition,
60
Domestic
Used for rotating ball in the tips of
ballpoint pens to disperse ink during writing.
Jewellery- The finish is highly resistant to
scratches.
61
Tungsten-ThO2 Alloys
The W-ThO2, alloy contains a dispersed second
phase of 1 to 2% thorium.
The thorium dispersion enhances thermo ionic
electron emission, which in turn improves the
starting characteristics of gas tungsten arc
welding electrodes.
It also increases the efficiency of electron discharge
tubes.
Imparts creep strength to wire at temperatures
above 1400 C
62
63
64
67
68
69
Amorphous Metal
Metallic material with a disordered atomicscale structure.
70
Applications
Vitreloy (41.2% Zr, 13.8% Ti, 12.5% Cu, 10% Ni,
and 22.5% Be)
Tensile strength almost twice that of high-grade
titanium.
Ti40Cu36Pd14Zr10 3 times stronger than titanium
Elastic modulus nearly matches bones.
The alloy does not undergo shrinkage on solidification.
Mg60Zn35Ca5
Biomaterial for implantation into bones as screws,
pins, or plates, to fix fractures.
72
73
Applicaions
Chemical & food processing industries
- Excellent corrosion resistance.
Resistant to salt water, sulfuric acid, high
velocity and high temperature steam.
Steam turbine blades.
Aircraft gas turbines
Excellent appearance, similar to that of
stainless steel.
Ornamentals, house hold ware.
74
75
K-Monel; 3% Al
- Precipitation hardened to a tensile
strength of 1100-1240 MPa.
H-Monel; 3% Si
S- Monel; 4% Si
- Both are used for casting applications
and
can also be precipitation hardened.
76
Nichrome
Ni-Cr alloy (80% Ni, 20% Cr)
- electrical resistors and heating
elements.
Ni-Cr alloy (60% Ni, 16% Cr, 24%Fe)
- Excellent resistance to oxidation while
retaining useful strength at red heats.
77
Alloy 718.
Ti and Nb additions
Overcome strainage cracking problems during welding and
weld repair.
Alloy X (48Ni-22Cr-18Fe-9Mo + W)
High-temperature flat-rolled product for aerospace
applications .
79