NON TCB METALLURGY

Non-Ferrous Alloy
Definition
The term non-ferrous alloy is used for those alloys which do not have iron in their base element,
there are two type of non-ferrous alloys in common use in engineering.
Type
1-Light alloys: these alloys are characterized by low density, in general about (6.6) Mg/m3,
Aluminum alloys, and Magnesium alloy, Titanium alloys and Zinc alloys are some example for
these types of alloys.
2-Heavy alloys: these have higher densities, typically about (8.8) Mg/m3; Copper alloys, Nickel
alloys and Cobalt alloys are some example for these types of alloys.
Limitation
1- Good corrosion resistance.
2- Generally a much lower density and hence lighter weight components can be produced.
3- Often lower melting points and so casting is easier.
4- Often greater ductility and so cold working processes are easier.
5- Higher thermal and electrical conductivities.
Copper
Properties
1- Very high electrical conductivity (second after silver).
2- High thermal conductivity and corrosion resistance.
3- Very malleable and ductile so it can be rolled, drawn, forged easily.
4- Cheaper than aluminum in high production cost.
Extraction
The copper ore is chemically combined with (Fe) and (S) called copper pyrites.
the ore concentrated is heated by wet processes to remove the earthy waste, the
result is then heated in current of air to burn (S) as much as possible and to
oxidize (Fe) and (Si) to form slag and molten copper sulphide, this removed from
the slag by oxidation, copper oxide reacts chemically with sulphide to form crude
copper which is refined by either re-melting in a furnace or by electrolysis where
crude copper as anode while cathode is pure copper, figure (1-10).

Figure(1-10)
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Type
1-Oxygen Free High Conductivity (OFHC): it is eclectically refined type, the cathodes are
melted, cast, rolled and then drawn to wire or strip for electrical purpose.
2- Tough pitch copper: it is refined types which contain small amount of Cu2O as the main
impurity; it is suitable for many purposes where electrical and thermal conductivity are required.
3-Deoxidized copper: is made from the tough pitch copper by heating it with a small amount of
(P) just before casting in order to remove oxide globules, it is not suitable for electrical purpose
because of reduction in electrical conductivity introduced by the presence of dissolved (P).
Limitation
The adding of the elements in copper is to increase and improve some of its properties as:
Al and Sn: improve corrosion resistance.
Pb: improves mach inability.
Mn and Fe: increase tensile strength.
Zn: improves fluidity.
Copper Alloys
1-Brasses: copper base alloy with 45% Zn and small amount of
Pb, Sn, Al, Mn, Fe.
2-Bronzes: which have so many types:
a-Tin-bronze: copper base alloy with18% Sn.
b-Phosphor bronze: copper base alloy with 0.05%Pb.
c-Coinage bronze: copper base alloy with 3%Sn and 1.5%Zn.
d-Leaded bronze: copper base alloy with 2%Pb.
e-Aluminum bronzes: copper base alloy with 10%Al.
f-Beryllium bronze: copper base alloy with 1.75%Be and 2%Co.
3-Cu-Nickel alloys: copper base alloy with 30%Ni.
4-Cu-Chromium alloys: copper base alloy with 0.5%Cr.
5-Cu-Cadmium alloys: copper base alloy with 1%Cd.
Although Copper has twice electrical conductivity for Aluminum
in the same weight, but in equal length and weight are taken,
Aluminum is a better overall conductor than Copper because it
has a greater cross-sectional area than that of the Copper.
Aluminum
Properties
1- High affinity for O2 to form oxide.
2- High thermal and electrical conductivity.
3- Good corrosion resistance for the oxide film.
4- High malleability so easily to make thin products.
5- Have F.C.C crystal structure- non magnetic- non toxic.
6- Light weight (1/3 density of steel) and High strength / weight ratio.
7- Good ductility and low hardness (easy in forming and finishing process).

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Extraction
The only important ore of aluminum is (bauxite) which contain aluminum
oxide the crude bauxite ore is first purified by means of a chemical process and
the pure aluminum oxide (Al2O3) is then decomposed by electrolytic process
using smelting electrical furnace, since aluminum oxide has a very high
melting point, it is mixed with another aluminum mineral (cryolite) to form an
electrolyte which will melt at a low temperature. when the high electric current
passes (8000-30 000) Ampere and (7) Volt, (Al) ions being positively charged, are attracted to the
lining of the furnace which constitutes the negative electrode and release (Al), molten aluminum
collects at the bottom of the furnace and is tapped off when necessary, meantime, oxygen is given
off at the anodes which burn as a result, figure (2-10) .

Figure (2-10)
Aluminum Alloys
Aluminum has low strength, so adding of alloying elements increasing the strength by two ways:
1-Solid solution strengthening.
2-Precipitation (age) Hardening.
Types
Al materials are classified in three types:

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The most familiarly a classification is by production which has the other two types and so the
aluminum could divided into the two basic alloys:
1-Wrought Alloys: it is used for an alloy is suitable for shaping by a working process: forging,
extraction, rolling and it is divided into two groups:
a-Heat-treatment alloys as : Al-Cu, Al-Cu-Mg, Al-Mg-Si, Al-Zn-Mg
b- Non- heat treatment alloys as: Al-Mn, Al-Mg.
2-Cast Alloys: it is used for an alloy is suitable for shaping by casting process and it is also divided
into two groups: heat-treatment and non- heat treatment alloys where contain 10-13%Si to use for
die casting as it will solidify quickly in the mould.
Designation
Aluminum alloys are designated by their chemical compositional according to the AA standard
(Aluminum Association)
1-Wrought Alloys
1XXX Commercial Aluminum (more than 99% )
2XXX Al-Cu
3XXX Al-Mn
4XXX Al-Si
5XXX Al-Mg
6XXX Al -Mg-Si
7XXX Al -Zn
The second digital indicate modification to the original alloy
The last two digital indicate the particular % alloy within the family
2-Cast Alloys
1XX.X Commercial Aluminum (more than 99% )
2XX.X Al-Cu
3XX.X Al-Si-Cu
4XX.X Al-Si
5XX.X Al-Mg
7XX.X Al -Zn
8XX.X Al -Sn
The second and third digital indicate the particular % alloy within the family
The last digit (.X) indicates the product form like casting, ingot.
For heat treatment alloy, a serial letter is putting after the numerical designation as:
O Annealing process
M Manufacturing process ( rolled, draw, ext)
D Solution treatment
H Strain hardening
TB Solution treatment then aging
TD Solution treatment-cold working-aging
TE precipitation treatment
TF Solution treatment then precipitation treatment
TH Solution treatment-cold working- precipitation treatment

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