lecture non-ferrous
TRANSCRIPT
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LectureLectureNon ferrous metals and alloys and their heat
treatment
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MetalsMetalsy All metals belong to one of these two groups.
y Ferrous metals are metals, which are mainly made of ironwith small amounts of other metals or elements added inorder to give the correct properties. Almost all ferrous metalsare magnetic and can be picked up with a magnet. Thesemetals rust or oxidise if not treated as they contain iron.
y Non-Ferrous metals are those metals, which do notcontain 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 theydo not contain iron.
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New NonNew Non--metalsmetals
y Following metals have been available after
world war II.
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Common non ferrous metalsCommon non ferrous metals
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Material Type Uses Properties
Mild steel Ferrousmetal
Nails, screws, nuts and
bolts, girders, car bodies
Tough, malleable, high tensile
strength, easily joined, poor
resistance to corrosion,general-purpose metal.
Brass Non-ferrousmetal
Ornaments, boat fittings,
castings.
Corrosion resistant, polishes
well. Hard, easily joined, good
conductor of heat and
electricity.
Copper Non-
ferrousmetal
Hot water storage
cylinders, central heatingpipes, electrical wires,
copper clad electronics
boards
Good conductor of heat and
electricity, corrosion resistant,easily joined, polishes well,
solders and brazes well,
expensive to buy.
Stainlesssteel
Alloy Sinks, cutlery, dishes,teapots
Hard and tough, resists wear,
corrosion resistant, difficult to
cut and file.
Aluminium Non-ferrousmetal
Kitchen cooking utensils,
pans, packaging, cans,window frames
High strength to weight ratio,
light, soft, difficult to join, goodconductor of heat and
electricity, corrosion-resistant,
polishes well.
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Ti &Mg alloys Ni alloys
Superalloys
Non-ferrous
Metal Alloys
Ferrous
Cu alloys
Pure CuBrassesBronzesCupronickelBe-copperNickel silver
Al alloys
Alloying
ElementsCuMgMnSi
Zn
Alloying
Elemen
ts
AlZnMnV
Refractorymetals
Nb (2468rC)Ta (2996rC)W (3410rC)Mo (2617rC)
Fe-basedNi-based
Co-based
Monel
Inconel
Hastealloy
NonNon--ferrous Alloysferrous Alloys
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General Properties of Al
General Properties of Al
y Low density (2.3g/mm3) ~1/3 of that of steel
higher strength-to-weight ratio
y High electrical conductivity 60% of that ofCu
higher conductivity-to-weight ratio
High thermal conductivity
y
High oxidation resistancey Non-magnetic
y Non-toxic
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Properties of aluminiumProperties of aluminium
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General Properties of AlGeneral Properties of Al contdcontd
y Ductile and good formability - easy to process
y Easily machined, cast and most are weldable
y Most recyclable metal - only 5% of production
energy required.
y Al alloys are used mostly for four reasons:
specific strength
corrosion resistance
electrical conductivity
nontoxity.
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Containers andpackaging (non-
toxic)
Electricalconductors
(conductivity)
Architecturalconstruction(corrosionresistance)
Structuralapplications
(strength-to-weight ratio)
Aeroplane wing made of Al alloysfor their high strength-weight ratio
Al and its AlloysAl and its Alloys
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Wrought Al and its AlloysWrought Al and its Alloysy Pure Al is too soft for structural applications.
A single crystal of Al can not even support its own weight
y Therefore it is alloyed to improve strength.
y Common five elements (usually more than one):Cu,Mn,
Mg, Zn, Siy Al alloys are also hardened by cold working (rolling) and
by precipitation hardening (heat treatment).
y Typical mechanical properties:
Y
oungs modulus:~70
G
Pa (steel~
210G
Pa) Yield strength: 100~400MPa
UTS: 200-600MPa
Ductility: up to 30%
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Series Alloying
Elements
Property Overview Example Applications
A1xxx pure Al (>99%) yExtremely low strengthyHigh conductivity
119999.99% Al
Electrical conductorsChemical process equipment
Al foil
A2xxx Cu yHigh strength after
yheat treatment
yModerate ductility
yNot weldable
2014
Al-4.5Cu-1Si-0.6MgAircraft structures
Automotive body panels
A3xxx Mn yModerate strengthyHigh ductility
yExcellent corrosion
resistance
3003Al-1.5Mn
Al cansCooking utensils
Roofing sheet
A4xxx Si yModerate strength
yGood corrosion
resistance
yLow duct
ility
4043
Al-1.5MnArchitectural applications
A5xxx Mg yReasonable strengthyRapid work hardening
yHigh corrosion resistance
5005
Al-1.0MgBoat hullsStructural plate/flooring
A6xxx Si +Mg yMedium strengthyGood weldability
yGood corrosion resistance
6061
Al-1Mg-0.6SiArchitectural extrusionsGeneral extrusions
A7xxx Zn yHighest strengthyWeldable
7075Al-6Zn-2.5Mg-1.5Cu High strength aircraft components
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DivisionDivision
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Casting alloysCasting alloys
Sand CastingHigh Temperature Alloy,
Complex Geometry, Rough
Surface Finish
Investment CastingHigh Temperature Alloy, Complex
Geometry, Moderately Smooth
Surface Finish
Die CastingHigh Temperature Alloy,
Moderate Geometry,
Smooth Surface
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Sand CastingSand Castingy
Description: is used to make large parts.Moltenmetal is poured into a mold cavity formed out ofsand (natural or synthetic).
y Various core materials can be used.Molds are
broken to remove castings. Specialized bindersnow in use can improve tolerances and surfacefinish.
y Metals:Most castable metals. typically Iron, but
also Bronze, Brass, Aluminumy Size Range: Limitation depends on foundry
capabilities. Ounces to many tons.
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Die castingDie casting
y Description:Molten metal is injected,under pressure, into hardened steel dies,often water cooled. Dies are opened, and
castings are ejected.y Metals: Aluminum, Zinc,Magnesium, and
limited Brass.
y Size Range: Not normally over 2 feetsquare. Some foundries capable of largersizes.
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Die CastingDie Casting HotHot--ChamberChamber
CastingCasting
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).
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Ti &Mg alloys Ni alloys
Superalloys
Non-ferrous
Metal Alloys
Ferrous
Cu alloys
Pure Cu
BrassesBronzesCupronickelBe-copperNickel silver
Al alloys
Alloying
ElementsCuMgMnSiZn
Alloying
Elemen
ts
AlZnMnV
Refractorymetals
Nb (2468rC)
Ta (2996rC)W (3410rC)Mo (2617rC)
Fe-based
Ni-based
Co-based
Monel
Inconel
Hastealloy
NonNon--ferrous Alloysferrous Alloys
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Production ofCuProduction ofCu
y First evidence ofCu ~5000BC
y Modern Smelting:
2CuFeS2 + 2SiO2 Cu2S + 2FeSiO3 + 2SiO2
thenCu2S + O2(air) 2Cu + SO2 (blister Cu)
y Blister Cu is refined by electrolysis to 99.99%Cu
heat
heat
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y Sufficient strength to beused analloyed.
y Density=8.93g/mm3
y Very ductiley Excellent electrical and
thermal conductivity
y Good corrosion
resistancey Forms oxide layer
which prevents itsfurther corrosion
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50% copper produced is madeinto electrical conductors
Cu
Cu
General Properties
General Properties
y Yield strength: 20-200MPa
y Tensile: 200-400MPa
y Youngs modulus: 117GPa
y Excellent formability
y temperature embrittlement
y Castable and weldable
y Corrosion resistant
y High thermal conductivityy High electrical conductivity
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Beryllium CopperBeryllium Copper
y Cu with 1.5-2.0%Be.
precipitation hardened, high strength, used for
springs and clips in electrical applications.
y
Properties: Yield Strength: up to 1000MPa
UTS: up to 1500MPa
Ductility:
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y It is used for,
y Instrument springs
y Flexible bellows
y Corrugated diaphrams
y Bourdon tubes of pressure guages
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BrassBrassy Cu with up to 50%Zn.
y Relatively easy to cast E-brass: up to 35%Zn
x Mallaeble and used in forgings (eg rivets,
red-brass: 2%Zn-10%Snx Gunmetal
yellow-brass: 30%Znx Used when sever plastic deformation is required
Naval Brass:40%Zn-1%Snx
Similar to -brass but with 1%Sn for corrosionresistance
brass:40-50%Znx Can only be worked hot.
x Strongest of all brasses.
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OtherC
uOtherC
u--alloysalloysy Copper-Nickel Alloys (Cupronickel, 90/10 and70/30)
High ductility and formability
Strengthened by cold working
y Copper-Zinc-Nickel Alloys (Nickel Silver)
Pale yellow at 10-12%Ni, silver white at 20-30%Ni
Decorative applications and silver plated dinnerware
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CuproCupro--nickel alloysnickel alloys
y These two metals are completely soluble
in liquid as well as in solid state.
y They are relatively expensive,but having
y High strength
y Ductility
y Corrosion resistant
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TinTin--bronze alloysbronze alloys
y Alloys of copper and tin together with thedeoxidiser.
y This is essential to prevent the tin content
oxidizing during casting or hot working,bcozoxidation of tin would result in a weak
scratchy bronze.
y Two deoxidisers commonly used are,
y Phosphorous in the phosphor bronze alloys.
y Zinc in the gunmetal alloys.
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y Tin-bronze alloys are more expensive
than brass alloys,but
y More stronger
y Corrosion resistant
yWear resistant
y Give sound pressure castings which are
widely used for steam and hydraulic valve
bodies and mechanisms.
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AlAl--bronze alloysbronze alloys
y Predominant metal present is copper.
y Al is alloying element.
y These alloys are more expensive then Tin-
bronze alloys but,
y Are more corrosion resistant at high
temperatures
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SummarySummary
y Aluminium
Used for lightweight, corrosion resistance,
conductivity or non-toxicity
Either wrought (common alloy6061
, 2014
, 500
5) Or cast (eg A380, 356)
y Cu
Pure Cu used for conductivity properties
Alloys used for strength, conductivity formability andcorrosion resistance.
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Magnesium alloysMagnesium alloys
y Mg is the lightest of engineering metals with a
density of1.7g/mm3
y
Electrical and thermal conductivity is abt60%
that of high conductivity copper.
y High affinity of oxygen and burns readily
y 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
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Zinc AlloysZinc Alloys
y Pure metal is relatively weak.
y Zinc based alloys have high fluidity,whichenables complex castings with thin
sections to be made.y Low meling point.
y Easy polishing and electroplatingproperties.
y Adequate strength for small components.
y Donot react with and erode the die steel.