Lecture

Non ferrous metals and alloys and their heat treatment

 Metals
 All metals belong to one of these two groups.

 Ferrous metals are metals, which are mainly made of iron

with small amounts of other metals or elements added in order
to give the correct properties. Almost all ferrous metals are
magnetic and can be picked up with a magnet. These metals
rust or oxidise if not treated as they contain iron.

 Non-Ferrous metals are those metals, which do not contain

iron. These metals are not magnetic and cannot be attracted
by a magnet. Examples of these are aluminium, copper, lead,
zinc and tin. These metals do not oxidise as they do not
contain iron.
New Non-metals
Following metals have been available
after world war II.
Common non ferrous metals
 Material Type Uses Properties

Mild steel Ferrous Nails, screws, nuts and Tough, malleable, high tensile
metal bolts, girders, car bodies strength, easily joined, poor
resistance to corrosion,
general-purpose metal.

Brass Non-ferrous Ornaments, boat fittings, Corrosion resistant, polishes

metal castings. well. Hard, easily joined, good
conductor of heat and
electricity.

Copper Non-ferrous Hot water storage Good conductor of heat and

metal cylinders, central heating electricity, corrosion resistant,
easily joined, polishes well,
pipes, electrical wires,
solders and brazes well,
copper clad electronics expensive to buy.
boards

Stainless steel Alloy Sinks, cutlery, dishes, Hard and tough, resists wear,
teapots corrosion resistant, difficult to
cut and file.

Aluminium Non-ferrous Kitchen cooking utensils, High strength to weight ratio,

metal pans, packaging, cans, light, soft, difficult to join, good
conductor of heat and
window frames
electricity, corrosion-resistant,
polishes well.
 Non-ferrous Alloys

Metal Alloys

Ferrous Non-ferrous

Ti & Super Refractory

Al alloys Cu alloys Mg alloys Ni alloys alloys metals
Alloying Pure Cu Alloying Monel Nb (2468C)
Fe-based
Element Brasses Elemen Ta (2996C)
Inconel Ni-based
s Bronzes ts W (3410C)
Cu Cupronickel Al Hastealloy Co-based Mo (2617C)
Mg
Be-copper Zn
Mn
Si
Nickel silver Mn
Zn V
General Properties of Al
Low density (2.3g/mm3)
◦ ~1/3 of that of steel
◦ higher strength-to-weight ratio
High electrical conductivity
◦ 60% of that of Cu
◦ higher conductivity-to-weight ratio
◦ High thermal conductivity
High oxidation resistance
Non-magnetic
Non-toxic
Properties of aluminium
General Properties of Al – cont’d
Ductile and good formability - easy to process
Easily machined, cast and most are weldable
Most recyclable metal - only 5% of production
energy required.
Al alloys are used mostly for four reasons:
◦ specific strength
◦ corrosion resistance
◦ electrical conductivity
◦ nontoxity.
 Aeroplane wing made of Al alloys
Al and its Alloys for their high strength-weight ratio

Containers and
packaging (non-
toxic)
Structural
applications
(strength-to-
weight ratio)
Electrical
conductors
(conductivity)

Architectural
construction
(corrosion
resistance)
Wrought Al and its Alloys
 Pure Al is too soft for structural applications.
◦ A single crystal of Al can not even support its own weight
 Therefore it is alloyed to improve strength.
 Common five elements (usually more than one):Cu, Mn,
Mg, Zn, Si
 Al alloys are also hardened by cold working (rolling)
and by precipitation hardening (heat treatment).
 Typical mechanical properties:
◦ Young’s modulus: ~70 GPa (steel ~210GPa)
◦ Yield strength: 100~400MPa
◦ UTS: 200-600MPa
◦ Ductility: up to 30%
Series Alloying Property Overview Example Applications
Elements
A1xxx pure Al (>99%)  Extremely low strength 1199 Electrical conductors
 High conductivity 99.99% Al Chemical process equipment
Al foil
A2xxx Cu  High strength after 2014 Aircraft structures
 heat treatment Al-4.5Cu-1Si-0.6Mg Automotive body panels
 Moderate ductility
 Not weldable
A3xxx Mn  Moderate strength 3003 Al cans
 High ductility Al-1.5Mn Cooking utensils
 Excellent corrosion Roofing sheet
resistance
A4xxx Si  Moderate strength 4043 Architectural applications
 Good corrosion Al-1.5Mn
resistance
 Low ductility
A5xxx Mg  Reasonable strength 5005 Boat hulls
 Rapid work hardening Al-1.0Mg Structural plate/flooring
 High corrosion resistance
A6xxx Si + Mg  Medium strength 6061 Architectural extrusions
 Good weldability Al-1Mg-0.6Si General extrusions
 Good corrosion resistance
A7xxx Zn  Highest strength 7075 High strength aircraft components
 Weldable Al-6Zn-2.5Mg-1.5Cu
Division
 Casting alloys

• Sand Casting • Investment Casting • Die Casting

High Temperature Alloy, High Temperature Alloy, High Temperature Alloy,
Complex Geometry, Rough Complex Geometry, Moderately Moderate Geometry,
Surface Finish Smooth Surface Finish Smooth Surface
 Sand Casting
Description: is used to make large parts. Molten
metal is poured into a mold cavity formed out of
sand (natural or synthetic).
Various core materials can be used. Molds are
broken to remove castings. Specialized binders
now in use can improve tolerances and surface
finish.
Metals: Most castable metals. typically Iron, but
also Bronze, Brass, Aluminum
SizeRange: Limitation depends on foundry
capabilities. Ounces to many tons.
Die casting
Description: Molten metal is injected,
under pressure, into hardened steel dies,
often water cooled. Dies are opened, and
castings are ejected.
Metals: Aluminum, Zinc, Magnesium,
and limited Brass.
Size Range: Not normally over 2 feet
square. Some foundries capable of larger
sizes.
 Die Casting – Hot-Chamber Casting
Cycle in hot-chamber casting:
(1) with die closed and plunger withdrawn,
molten metal flows into the chamber;
(2) plunger forces metal in chamber to flow into
die, maintaining pressure during cooling and
solidification; and
(3) plunger is withdrawn, die is opened, and
solidified part is ejected.
Finished part is shown in (4).
 Non-ferrous Alloys

Metal Alloys

Ferrous Non-ferrous

Ti & Super Refractory

Al alloys Cu alloys Mg alloys Ni alloys alloys metals
Alloying Pure Cu Alloying Monel Nb (2468C)
Fe-based
Element Brasses Elemen Ta (2996C)
Inconel Ni-based
s Bronzes ts W (3410C)
Cu Cupronickel Al Hastealloy Co-based Mo (2617C)
Mg
Be-copper Zn
Mn
Si
Nickel silver Mn
Zn V
 Production of Cu

First evidence of Cu ~5000BC

Modern Smelting:
heat
2CuFeS2 + 2SiO2 Cu2S + 2FeSiO3 + 2SiO2
then
heat
Cu2S + O2(air) 2Cu + SO2 (blister Cu)

Blister Cu is refined by electrolysis to 99.99% Cu

Sufficient strength to be
used analloyed.
Density=8.93g/mm3
Very ductile
Excellent electrical and
thermal conductivity
Good corrosion
resistance
Forms oxide layer
which prevents its
further corrosion
Cu – General Properties
 Yield strength: 20-200 MPa
 Tensile: 200-400 MPa
 Young’s modulus: 117 GPa
 Excellent formability
 temperature embrittlement
 Castable and weldable
 Corrosion resistant
 High thermal conductivity
 High electrical conductivity

50% copper produced is made

into electrical conductors
Beryllium Copper
Cu with 1.5-2.0%Be.
◦ precipitation hardened, high strength, used for
springs and clips in electrical applications.
Properties:
◦ Yield Strength: up to 1000MPa
◦ UTS: up to 1500 MPa
◦ Ductility: <5% (fully hardened)
◦ Resistivity: ~10x10-6 -cm
Itis used for,
Instrument springs
Flexible bellows
Corrugated diaphrams
Bourdon tubes of pressure guages
Brass
 Cu with up to 50%Zn.
 Relatively easy to cast
◦ -brass: up to 35%Zn
 Mallaeble and used in forgings (eg rivets,
◦ red-brass: 2%Zn-10%Sn
 Gunmetal
◦ yellow-brass: 30%Zn
 Used when sever plastic deformation is required
◦ Naval Brass: 40%Zn-1%Sn
 Similar to -brass but with 1%Sn for corrosion
resistance
◦ brass: 40-50%Zn
 Can only be worked hot.
 Strongest of all brasses.
Bronze
 Cu with up to 13%Sn (also have P,
Mn, Al or Si)
 Used as early as 1000BC (the Bronze
age)
 Good corrosion resistant (esp in sea
water)
 High conductivity
 Very low metal-on-metal friction
(bearing material)
 Strength between Al and steel
Other Cu-alloys
Copper-Nickel Alloys (Cupronickel, 90/10 and
70/30)
◦ High ductility and formability
◦ Strengthened by cold working

Copper-Zinc-Nickel Alloys (Nickel Silver)

◦ Pale yellow at 10-12%Ni, silver white at 20-30%Ni
◦ Decorative applications and silver plated dinnerware
Cupro-nickel alloys
These two metals are completely soluble
in liquid as well as in solid state.
They are relatively expensive,but having
High strength
Ductility
Corrosion resistant
 Tin-bronze alloys
Alloys of copper and tin together with the
‘deoxidiser’.
This is essential to prevent the tin content
oxidizing during casting or hot working,bcoz
oxidation of tin would result in a weak
‘scratchy’ bronze.
Two deoxidisers commonly used are,
Phosphorous in the ‘phosphor bronze’ alloys.
Zinc in the ‘gunmetal’ alloys.
Tin-bronze alloys are more expensive
than brass alloys,but
More stronger
Corrosion resistant
Wear resistant
Give sound pressure castings which are
widely used for steam and hydraulic valve
bodies and mechanisms.
Al-bronze alloys
Predominant metal present is copper.
Al is alloying element.
These alloys are more expensive then
Tin-bronze alloys but,
Are more corrosion resistant at high
temperatures
Summary
Aluminium
◦ Used for lightweight, corrosion resistance,
conductivity or non-toxicity
◦ Either wrought (common alloy 6061, 2014, 5005)
◦ Or cast (eg A380, 356)
Cu
◦ Pure Cu used for conductivity properties
◦ Alloys used for strength, conductivity formability and
corrosion resistance.
 Magnesium alloys
Mg is the lightest of engineering metals with a
density of 1.7g/mm3
Electrical and thermal conductivity is abt 60%
that of high conductivity copper.
High affinity of oxygen and burns readily
Not as strong as aluminum alloys,but these
alloys have much lower density so preferred
in the applications where high strength/weight
ratio is desired
Two categories,
I. Casting alloys
II.Wrought alloys
Zinc Alloys
Pure metal is relatively weak.
Zinc based alloys have high
fluidity,which enables complex castings
with thin sections to be made.
Low meling point.
Easy polishing and electroplating
properties.
Adequate strength for small components.
Donot react with and erode the die steel.