Non-Ferrous Metals 1

 In metallurgy, a non-ferrous metal is a metal, including

alloys, that does not contain iron (ferrite) in appreciable
amounts.
 Non-ferrous metals are divided into two principal
categories: Heavy and Light.
 Aluminum, magnesium, titanium and their alloys are
among the light metals, with a density up to 5 kg/dm3.
 Heavy metals are all those with a density above 5 kg/dm3.
The most important are copper, zinc, tin, lead,
nickel…etc. and the alloys of these metals. 2
 Aluminum (Al):
 It is a silvery-white, soft, nonmagnetic,
ductile metal.
 By mass, aluminum makes up about 8% of
the Earth's crust. The chief ore of aluminum
is bauxite.
 Aluminum is remarkable for the metal's low
density and its ability to resist corrosion.
 Aluminum and its alloys are vital to the
aerospace industry and important in
transportation and building industries,
such as building facades and window
frames.
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 Video:
 https://www.youtube.com/watch?v=mvDHe
YI-a00
 https://www.youtube.com/watch?v=NW1k4
wNEq14

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I. Aluminum and wrought aluminum
alloys:
 Aluminum and wrought aluminum alloys
are used in the shaping processes: rolling,
forging, extrusion, pressing, stamping.
 There are two principal groups of the
wrought aluminum alloys:
a. Non-heat-treatable alloys (MMTH p. 166).
b. Heat-treatable alloys (MMTH p. 167).

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a. Non-heat-treatable alloys:
 Non-heat-treatable alloys cannot be strengthened by heat treatment.
Alloys of 1xxx, 3xxx, 4xxx and 5xxx series are non-heat-treatable
(MMTH p. 166).
 The initial strength of these alloys is achieved due to the hardening
effect of the alloying elements: manganese (Mn), silicon (Si),
magnesium (Mg). Additional hardening of these alloys is done by
cold work (strain hardening).
 Non-heat-treatable alloys are ductile and moderately strong
(depending on the alloying elements concentration).
 Non-heat-treatable alloys are used for manufacturing deep drawn
parts, sheets, foil, tubes, wire, extruded parts, pressure vessels. 8
b. Heat-treatable alloys:
 Heat-treatable alloys can be strengthened by heat treatment. Alloys
of 2xxx, 6xxx and 7xxx series are heat-treatable (MMTH p. 167).
 The initial strength of these alloys is achieved due to the hardening
effect of the alloying elements: copper (Cu), silicon (Si), magnesium
(Mg) and zinc(Zn).
 Since solubility of these elements in solid aluminum depends on the
temperature, it is possible to harden the alloys from this group by a
heat treatment, called precipitation hardening (age hardening).

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 Designation system:
 There are 2 types of designation system for aluminum and
wrought aluminum alloys:
1. Numerical designation system (EN 573-1)
 The International Alloy Designation System is the most widely
accepted naming scheme for wrought alloys. Each alloy is given a
four-digit number.
2. Chemical symbol based designation system (EN 573-2)

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1. Classification of wrought aluminum alloys according
to numerical designation system :
 Each wrought aluminum alloy is given a four-digit number, where the
first digit indicates the major alloying elements, the second — if
different from 0 — indicates a variation of the alloy, and the third and
fourth digits identify the specific alloy in the series.
 For example, in alloy 3105, the number 3 indicates the alloy is in the
manganese series, 1 indicates the first modification of alloy 3005, and
finally 05 identifies it in the 3000 series.

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 The first digit indicates the alloy group according to the
major alloying element:
 1xxx Aluminum 99.0% minimum;
 2xxx Copper (1.9%...6.8%);
 3xxx Manganese (0.3%...1.5%);
 4xxx Silicon (3.6%...13.5%);
 5xxx Magnesium (0.5%...5.5%);
 6xxx Magnesium and Silicon (Mg 0.4%...1.5%, Si 0.2%...1.7%);
 7xxx Zinc (1%...8.2%);
 8xxx Others.
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Numerical designation system for aluminum and wrought aluminum alloys:

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2. Chemical symbol based designation system for aluminum and wrought
aluminum alloys:

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1. How many tons of bauxite to produce 2,5 tons of Aluminum?
2. What are the chemical compositions of EN AW-3005, EN AW-6011 and EN AW-
7050 in wrought aluminium alloy?
3. What are the chemical compositions of EN AW-Al Mn1Cu; EN AW-Al Mg3,5Mn
and EN AW-Al Zn6Mg2Cu in wrought aluminum alloy?
4. What is the number related to the designation EN AW-Al 99.5; EN AW-Al
Cu4PbMgMn and EN AW-Al Mg5?
5. What are the applications of EN AW-Al Mg3, EN AW-Al MgSi and EN AW-Al
Zn5Mg3Cu aluminum wrought alloy designation?
6. What are the wrought aluminum alloy which has elongation at fracture equal
20%?

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II. Aluminum casting alloys:
 Aluminum casting alloy composites parallel
wrought alloy compositions in many
respects.
 Hardening and desired properties are
achieved through the addition of alloying
elements and though heat treatment.
 The most important consideration in
differentiating wrought and casting alloy
compositions is castability (sand casting,
chill casting, pressure die casting).
 They are capable of being mechanically
polished, highly resistant to weathering and
sea water, cutable and weldable. In addition,
advantages are gained by the specific alloy
chosen.
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 Designation system:
 There are 2 types of designation system for aluminum
casting alloys:
1. Numerical designation system (EN 1780-1)
 In European standardisation, aluminum casting alloys are
designated by five figures, followed by the metallurgical temper
designation, such as EN AC - 51300KF
2. Chemical symbol based designation system (EN 1780-2)

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DIN EN
1706

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 Designations of aluminum casting
alloys (American standards):
 The Aluminum Association (AA) has
adopted a nomenclature similar to that
of wrought alloys. British Standard and
DIN have different designations.
 In the AA system, the second two digits
reveal the minimum percentage of
aluminum, e.g. 150.x correspond to a
minimum of 99.50% aluminum for 1xx.x
series.
 The digit after the decimal point takes a
value of 0 or 1, denoting casting and
ingot (ingot used to make the casting)
respectively.
See Aluminum Cast
Alloys
 The main alloying elements in the AA
system are as follows:
 1xx.x series are minimum 99%
aluminum
 2xx.x series copper
 3xx.x series silicon, copper and/or
magnesium
 4xx.x series silicon
 5xx.x series magnesium
 7xx.x series zinc
 8xx.x series tin
 9xx.x other elements
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 Chemical compositions of some cast aluminum alloys:

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 Properties of some cast aluminum
alloys:

 For more:
http://www.substech.com/dokuwiki/do
ku.php?id=cast_aluminum_alloys
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 Some standard of aluminum profiles: (see HB p.169-171 for more detail)

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1. According to DIN EN - 1706 standards, what are the chemical composition of the aluminum
casting alloys below:
1. EN AC-Al Si7Mg0.3
2. EN AC-Al Si10Mg(Cu)
3. EN AC-Al Si9Cu1Mg
4. EN AC-Al Mg9
2. According to DIN EN - 1706 standards, what are the mechanical properties of the aluminum
casting alloys below:
1. EN AC-21000
2. EN AC-46400
3. EN AC-Al Si5Cu1Mg
4. EN AC-Al Cu4MgTi
3. According to American standards (Aluminum Association) what is the main alloying element
by the following numbers of aluminum casting alloys:
1. 413.0
2. 222.1

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 Magnesium (Mg):
 Magnesium (Mg) is a silvery white
metal that is similar in appearance to
aluminum but weighs one-third less. it
is the lightest structural metal known.
 In its pure form, it lacks sufficient
strength for most structural
applications.
 However, the addition of alloying
elements improves these properties to
such an extent that both cast and
wrought magnesium alloys are widely
used, particularly where light weight
and high strength are important.

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 Both dolomite and magnesite are
mined and concentrated by
conventional methods.
 Carnallite is dug as ore or separated
from other salt compounds that are
brought to the surface by solution
mining.
 Commercial production follows two
completely different methods:
electrolysis of magnesium chloride or
thermal reduction of magnesium oxide.
 Where power costs are low, electrolysis
is the cheaper method—and, indeed, it
accounts for approximately 75 percent
of world magnesium production.

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 Application:
 Magnesium is mainly used as base metal for
magnesium alloys, and also as an additive to various
aluminum alloys.
 Pure magnesium is not employed as a construction
material on account of its low strength.
 It is used only as a deoxidant in steel and other
metal foundries, and also for manufacture of
fireworks.
 >95% of all structural parts made of magnesium
casting alloys produced by pressure die-casting.
 30% lighter of that made of aluminum pressure
castings, and are around the same strength.
 These alloys are used in motor parts (crankcases,
camshaft castings), blower castings, instrument
panels, cameras, portable pruning saws and similar
objects which must be light.
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 Magnesium alloys:
 Are mixtures of magnesium with other metals (called an alloy), often aluminum,
zinc, manganese, silicon, copper, rare earths and zirconium. Magnesium is the
lightest structural metal.
 Magnesium alloys are typically used as cast alloys, and wrought alloys. Cast
magnesium alloys are used for many components of modern automobiles have
been used in some high-performance vehicles; die-cast magnesium is also used
for camera bodies and components in lenses.
 As in the case of aluminium alloys, wrought and casting alloys are governed by
norms.

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 Titanium (Ti):
 Titanium (Ti) a silvery gray metal.
Titanium is a lightweight, high-
strength, low-corrosion structural
metal.
 Titanium is widely distributed and
constitutes 0.44 percent of the Earth’s
crust. The metal is found combined in
practically all rocks, sand, clay, and
other soils.
 The two prime commercial minerals
are ilmenite (FeTiO3) and rutile
(TiO2).

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 Properties:  Application:
 Physical:  It is used for engine and running-
 Melting point : 1668oC. gear components on racing cars, in
 Density: 4.55 kg/dm3 aircraft and rockets and as an
alloying additive for steel and
 Chemical: aluminum.
 More corrosion resistance than
stainless steel.
 Mechanical:
 Commercially pure (99.2% pure)
grades of titanium have ultimate tensile
strength of about 434 MPa (63,000 psi),
equal to that of common, low-grade
steel alloys, but are less dense.

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 Titanium alloys :
 Titanium alloys retain the same strength and corrosion resistance as
pure Ti, but takes on the greater flexibility and malleability of the
metal it is combined with. Titanium alloys, therefore, have more
applications than pure titanium.
 Titanium alloys typically contain traces of aluminum, molybdenum,
vanadium, niobium, tantalum, zirconium, manganese, iron,
chromium, cobalt, nickel, and copper.

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1. Does Mg always used as a pure state? If not why?
2. What are the ores of Magnesium?
3. What are the most common alloy elements used with magnesium?
4. How many types of magnesium alloys?
5. Provide the mechanical properties of the below alloys:
1. MgAl8Zn
2. MCMgAl8Zn1
6. How is Titanium looks like? What are the prime ore mineral of Ti?
7. Provide the mechanical properties of these designation of Ti and Titanium alloy?
1. ASTM grade 2
2. Ti-6Al-2Sn-4Zr-2Mo
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1. How are non-ferrous metals classified?
2. How is aluminum extracted?
3. What are the properties of aluminum?
4. How are aluminum alloys classified?
5. Compare the densities, melting points and chemical behaviors of aluminum and
magnesium?
6. What do you know about the occurrence and extraction of magnesium?
7. What are the applications of magnesium?
8. What are the properties of magnesium?
9. Which materials do the following symbols designate: AlMg5, AlSi5, AlCuMgPb,?
10. What do you know about the working materials: MgAl3Zn, MCMgAl19Zn2?

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 Copper (Cu):
 Copper is a soft, malleable, and
ductile metal with very high
thermal and electrical conductivity.
 Pure copper is reddish brown color
and acquires a reddish tarnish when
exposed to air.
 Copper is used as a conductor of
heat and electricity, as a building
material, and as a constituent of
various metal alloys.

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 Video:
 https://www.youtube.com/watch?v=
KBPv2p7T1wo
 https://www.youtube.com/watch?v=
VAiCiFD-Rjg

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 Application:
 It is used for electrical
conductors, solid and water
pipes, coolers, soldering irons,
heating and cooling coils,
…etc.

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1. Where does copper used?
2. What are the main ores of copper?
3. What are the mains copper alloys?
4. What is brass? What is bronze?
5. What are the alloys of these designations; CuZn31Si, CuZn38Mn1Al,
CuAl10Ni3Fe2-C, CW708R and CC483K?

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 Zinc (Zn):
 Is one of the most widely used metals. Zinc is of
considerable commercial importance.
 Zinc is the fourth most common metal in use,
trailing only iron, Aluminium, and copper.
 A little more abundant than copper, zinc makes
up an average of 65 grams (2.3 ounces) of every
ton of Earth’s crust.
 The most common zinc ore is sphalerite (zinc
blende), a zinc sulfide mineral.
 Zinc is a bluish-white, lustrous, diamagnetic
metal, though most common commercial grades
of the metal have a dull finish.

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Video:
https://www.youtube.com/watch?v=6fzLVK-9eMU
https://www.youtube.com/watch?v=LcU5miQbtNE

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 Application:
 Major applications of zinc include:
 Galvanizing (55%)
 Brass and bronze (16%)
 Other alloys (21%)
 Miscellaneous (8%)

 Zinc is most commonly used as an anti-corrosion agent,and galvanization (coating

of iron or steel) is the most familiar form.
 The zinc is applied electrochemically (electro-galvanizing) or as molten zinc by
hot-dip galvanizing or spraying.
 Galvanization is used on chain-link fencing, guard rails, suspension bridges, light-
posts, metal roofs, heat exchangers, bolts and car bodies.

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 Casting alloys (Continued):
 A widely used zinc alloy is brass, in which copper is alloyed with anywhere
from 3% to 45% zinc, depending upon the type of brass.
 Brass is generally more ductile and stronger than copper, and has superior
corrosion resistance. These properties make it useful in communication
equipment, hardware, musical instruments, and water valves.
 Other widely used zinc alloys include nickel silver, aluminum solder, and
commercial bronze.
 Alloys of zinc with small amounts of copper, aluminum are useful in die casting
as well as spin casting, especially in the automotive, electrical, and hardware
industries. These alloys are marketed under the name Zamak.

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 Material numbers for castings of zinc alloys:

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 Standards:
 Zinc casting alloy chemical composition standards are defined per country by the
standard listed below:

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 Zamak:
 Goes by many different names based on standard and/or country: (more info on
Zamak see: https://en.wikipedia.org/wiki/Zamak

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1. What is the ore of Zinc?
2. What are the major application of Zinc?
3. What are the mechanical properties of the material number below:
1. ZP1110
2. ZP0430

4. What is Zamak?
5. What is the European standard designation of Zamak3?

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 Tin (Sn):
 It is a soft, silvery white metal with a
bluish tinge, known to the ancients in
bronze, an alloy with copper.
 Tin is widely used for plating steel
cans used as food containers, in
metals used for bearings, and in
solder.
 Tin is the 49th most abundant
element in Earth's crust, representing
2 ppm compared with 75 ppm for
zinc, 50 ppm for copper, and 14 ppm
for lead.

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 Application:
 About half of all tin produced
was used in solder.
 The rest was divided between
tin plating, tin chemicals,
brass and bronze alloys, and
niche uses.

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 Lead (Pb):

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 Occurrence and extraction:
 Lead is generally found combined with sulfur.It rarely occurs in its native, metallic
form.
 The main lead-bearing mineral is galena (PbS), which is mostly found with zinc
ores.
 Most other lead minerals are related to galena in some way; boulangerite,
Pb5Sb4S11, is a mixed sulfide derived from galena; anglesite, PbSO4, is a product of
galena oxidation; and cerussite or white lead ore, PbCO3, is a decomposition
product of galena.
 Arsenic, tin, antimony, silver, gold, copper, and bismuth are common impurities in
lead minerals.
 Production of lead is increasing worldwide due to its use in lead–acid batteries.

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 Application:
 Pure lead is used for roof
coating, acid holders, lead
cables, sealing paints, in
bullets, radiation protection, in
fuels as anti-knock additive, for
lead plumbing and as alloying
metal.

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 Tin-based Babbitt and lead-based Babbitt: characteristics and applications:
 When it comes to Babbitt metal, this soft metal has amazing properties when used as a
bearing material.
 Manufacturers can use Babbitt metal to perform bearing repairs or to create new
bearings that are lined with this material.
 It can bond to steel, cast iron and bronze as it has fluid forming capabilities. It is
conformable while being corrosion resistant.
 The material can withstand varying heavy loads and have a good run in when used
against other shaft materials such as steel.
 Babbitt metal is available as ingot, and as wire for flame spraying applications as well
as metalizing applications.
 There are two main Babbitt materials that are generally in use: tin-based Babbitt and
lead-based Babbitt.

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 Tin-Based Babbitt:

 Tin-based Babbitt is a material that contains more than 80% of tin alloy. The material may
also contain lesser parts of antimony, lead and copper. You can find some tin-based Babbitt
that is completely lead-free if you are using it in machinery that will handle or transport
food. Although Babbitt is considered a soft metal, the tin adds a hardness to its
characteristics to offer more load-carrying capabilities.
 One of the reasons that manufacturers select tin-based Babbitt is that it provides low wear as
well as low friction resistance. It flows well when under pressure, which is ideal when used
with machinery where there may be inadequate lubrication along bearings and shafts that
are operating at high speeds. It can absorb dirt particles from lubrication systems that
become trapped into the metal surface. Yet tin-based Babbitt will not seize or gall during
metal-to-metal contact.
 The high thermal-connectivity of tin-based alloy allows it to carry heat away from machinery.
So hot spots are less of a problem that can break down moving machine parts.
 Due to having high load capabilities, tin-based Babbitt bearings can be used in
compressors, electric motors, heavy machinery, and marine work. A common trade name for
some tin-based Babbitt is Tuftin, which is sold through our Jackson Wheeler brand. 88
 Lead-Based Babbitt:

 Lead-based Babbitt is another common bearing material as it will contain 75% or more of
lead alloy. Most commonly-used, lead-based Babbitt will also contain tin as well as antimony.
This material has excellent corrosion capabilities, which makes it ideal for shipboard
applications and other work where there will be high humidity and moisture. Like tin-based
Babbitt, lead-based Babbitt also provides good frictional capabilities and can adhere well to
both bronze or steel. It also can wear well, as it is desired in machinery that will be in
operational use for long periods of time.
 With good embeddable qualities, high thermal conductivity, and great conformity, lead-
based Babbitt is normally used by manufacturers in applications that will experience shock
loads. Several lead-based Babbitt products have a uniform grain structure so that it can be
used with heavy loads at low, steady speeds in conditions that can have high grit and
external heat. Yet more often, lead-based Babbitt is preferred for low and medium speed
machinery and bearings that will experience light loads, such as unidirectional loads and
moderate cyclic loads.
 Lead-based Babbitt is an economical alloy as it can be used for general purpose machinery,
line shafting, and machine shops. It can also be used in farm machinery, cement machinery,
conveyors, elevator applications and steel mill machinery. 89
1. Where does Tin widely used?
2. What are the applications of Lead?
3. Is lead toxic?
4. What is the Babbitt metals? Where do we use it?

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Q&A
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