DEBERE BERHAN

UNIVERSITY
COLLAGE OF ENGINEERING
Department:-Mechanical Engineering

Cores Code :-Meng 2092

Cores Title:-Engineering Material II

Title :-Lights Metals And Alloys

Name= Bogale Niguse

Id No=2830/11

Section=A

Summited To: Mr.Habtamu.M

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CHAPTER THERE LIGHT METALS AND ALLOYS

Nonferrous metals

Steel and other ferrous alloys are consumed in exceedingly large quantities because they have
such a wide range of mechanical properties, may be fabricated with relative ease, and are
economical to produce. However, they have some distinct limitations chiefly (1) a relatively high
density, (2) a comparatively low electrical conductivity, and (3) an inherent susceptibility to
corrosion in some common environments.Thus,for many applications it is advantageous or even
necessary to use other alloys that have more suitable property combinations. Alloy systems are
classified either according to the base metal or according to some specific characteristic that a
group of alloys share. This section discusses the following metal and alloy systems: copper,
aluminum, magnesium, and titanium alloys; the refractory metals; the super alloys; the noble
metals; and miscellaneous alloys, including those that have nickel, lead, tin, zirconium, and zinc
as base metals.2

Nonferrous metals Characteristics

Nonferrous metals (characteristics) are used for the following purposes namely.

:-resistance to corrosion, low density and attractive color

:- electrical and magnetic properties.

:-facility of cold working

:-ease of casting

:-good formability

Types of Nonferrous Alloys

⨳ Aluminum and its alloys ⨳Magnesium and its alloys

⨳Titanium and its alloys ⨳Copper and its alloys

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⨳Zinc and its alloys ⨳Nickel and its alloys

Aluminum and Its Alloys

Aluminum and its alloys are characterized by a relatively low density (2.7 g/cm3 as compared to
7.9 g/cm3 for steel), high electrical and thermal conductivities, and a resistance to corrosion in
some common environments, including the ambient at. Many of these alloys are easily formed
by virtue of high ductility; this is evidenced by the thin aluminum foil sheet into which the
relatively pure material may be rolled. Because aluminum has an FCC crystal structure, its
ductility is retained even at very low temperatures. The chief limitation of aluminum is its low
melting temperature [660C (1220F)], which restricts the maximum temperature at which it can
be used. The mechanical strength of aluminum may be enhanced by cold work and by alloying;
however, both processes tend to diminish resistance to corrosion. Principal alloying elements
include copper, magnesium, silicon, manganese, and zinc. Generally, aluminum alloys are
classified as either cast or wrought. Composition for both types is designated by a four-digit
number that indicates the principal impurities, and in some cases, the purity level. For cast
alloys, a decimal point is located between the last two digits.

Attractive Properties

Pure aluminum has silvery color It is high ductile, light weight, malleable ease of machining and
very good conductor of heat and electricity has a very high resistance to corrosion than the
ordinary steel In its pure state; the metal would be weak and soft for most purposes It may be
blanked, formed, drawn, turned, cast, forged and die cast The chief limitation of aluminum is its
Low melting temperature(666°C).
Applications

It is mainly used in aircraft and automobile parts where saving of weight is an advantage .useful
metal for cooking utensils under ordinary condition widely used for reflectors, mirrors and
telescopes is used in making furniture, doors and window components, rail road, trolley cars,
automobile bodies and pistons, electrical cables and rivets .Aluminum foil is used as silver paper
for food packing etc.
Aluminum Alloys

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Aluminum may be easily alloyed with other elements like copper, magnesium, zinc, manganese,
silicon and nickel to improve various properties. Addition of small quantities of alloying
elements into aluminum helps to convert the soft and weak properties into hard and strong
metal, still retaining its light weight

Types of aluminum alloys

Based on method of fabrication; aluminum alloys can be classified as ;Wrought alloys and Cast
alloys designated by a four-digit number that indicates the principal impurities, and in some
cases, the purity level Wrought aluminum alloys – they are used in wrought (Shaped) form such
as rolled sheet, strip or plate, drawn to wire and extruded as rods or tubes.

Wrought aluminum alloys:- Non-heat-treatable alloys

Properties & Applications

Applications: Electrical conductors, Chemical process equipment Foils and Decorative

finishes, Roofing sheet, manufacturing beverage cans, Transportation structural plates, Large
tanks for petrol, milk, grain, Pressure vessel, Architectural components, Bottle caps and soft
bearings.

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Properties: Low tensile strength (90 to 310 MPa), Yield strength (10 – 160 MPa), High
ductility, excellent corrosion resistance at high temperature and pressure.

2.Cast aluminum alloys:-Properties required for good casting are, Low melting temperature,
Low solubility of gases except H2,Good fluidity, good surface finishes. But the Disadvantage is
High solidification shrinkage (3.5-8.5%).Factors controlling properties are melting and pouring
practices, Impurity levels, Grain size and Solidification rate.

Properties:-Good cast ability and high fluidity. High corrosion resistance and Good
weldability.Strength and hardness at Temperature up to 250ºC.ductile.Yield Strength 345-
480MPa and Tensile Strength 415- 550Mpa.

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Applications:-Automotive cylinder heads/blocks in place of cast iron. Elevated temperature
applications, diesel engine pistons and air-cooled cylinder heads for aircraft, Chemical and
sewage, Kitchen utensils.

Magnesium and Its Alloys

Perhaps the most outstanding characteristic of magnesium is its density, 1.7 g/cm3 which is the
lowest of all the structural metals; therefore, its alloys are used where light weight is an
important consideration (e.g., in aircraft components). Magnesium has an HCP crystal structure,
is relatively soft, and has a low elastic modulus: 45 GPa (6.5 106 psi). At room temperature
magnesium and its alloys are difficult to deform; in fact, only small degrees of cold work may be
imposed without annealing. Consequently, most fabrication is by casting or hot working at
temperatures between 200 and 350C (400 and 650F). Magnesium, like aluminum, has a
moderately low melting temperature [651C (1204F)]. Chemically, magnesium alloys are
relatively unstable and especially susceptible to corrosion in marine environments. On the other
hand, corrosion or oxidation resistance is reasonably good in the normal atmosphere; it is
believed that this behavior is due to impurities rather than being an inherent characteristic of Mg
alloys. Fine magnesium powder ignites easily when heated in air; consequently, care should be
exercised when handling it in this state.

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Extraction of Magnesium7

1.Calcination :-MgCO3 is claimed to produce MgO is then mixed with petroleum coke and
pressed into solid block, called briquet.Briquet is heated to ~2500ºC to give Mg gas and cooled
down to ~120ºC to give Mg solid.7

2.Pidgeon process:-Dolomite is calculated to produce MgO and CaO.Powdered ferrosilicon

and magnesium oxide are charged in an air-tight steel retort and heated under vacuum at
T~1200ºC to give Mg vapor Mg vapor is then condensed into crystals.

3.Electrolysis of magnesium:-Dolomite and seawater is precipitated as insoluble magnesium

hydroxide Mg(OH)2 which is subsequently treated with HCl to give MgCl2.MgCl2 is fed into
electrolysis cell to produce Mg metal at cathode and Cl2 at anode.

Physical properties of magnesium:-

Alloyed with Al, Zn, MN, rare earth metals to produce alloys with high strength-to weight ratios.
Not readily plastically deformed at RT due to HCP structure. Cast magnesium alloys dominate
85-90% of all magnesium alloy products, with Mg-Al-Zn system being the most widely used
Limitations Low strength, toughness and corrosion resistance. Easily flammable with oxygen.

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Classification of Magnesium Alloys:-No international code, but can use ASTM system
designated by two capital letters followed by two or three numbers. The letters stand for the two
major alloying element first letter - the highest amount second letter- the second highest amount
The numbers stand for the amount of the two major alloying elements first number following the
letters stands for the-wt.% of the first letter element.- second number stands for the wt% of the
second letter element.

Commercial Magnesium Alloys:-

1_Mg-Al casting alloys:- Al is alloyed to increase strength,castability and corrosion resistance.

Maximum solid solubility is ~ 12.7% at 473ºC Light weight and superior ductility Solid solution
treatment of these alloys however produce non-coherent, coarse precipitates of equilibrium
Mg17Al12 no solid solution strengthening achieved by adding Zn.8

2. Mg-Al-Zn casting alloys:-Light weight, strength and relatively good corrosion resistance and
easily cast’s addition increases strength by solid solution strengthening and precipitation
hardening A network of Mg17Al12 or β phase is formed around GBs in the as-cast condition, fig
(a). reduce pts., %Edmore slowly cooled alloy appears discontinuous β phase at GBs with a
cellular or paralytic structure, fig (b).T6 temper Mg17Al12 is refined and Uniformly distributed
improved prop8

3. Mg-Zn and Mg-Zn-Cu casting alloys:-Mg-Zn alloy Response to age hardening• not amenable
to grain refining• susceptible for micro porosity. Not used for commercial castings. Mg-Zn-Cu
alloy• Cu addition notably improves ductility and large response to age hardening.• σy ~130-160
MPa, σTS ~215-260MPa• Ductility 3-8%.• Cu addition also raises eutectic temp.8

84. Mg-Zn-Zr and Mg-RE-Zn-Z

r casting alloys:-Mg-Zn-Zr alloys ZK51 and ZK61 are sand cast 5-6% Zn addition-SS
strengthening 1% Zr addition-grain refinement. The alloys have limited use due to their
susceptibility to micro porosity during casting and not weldabl due to high Zn content Mg-RE-
Zn-Zr alloys RE (Ce, Nd) is added to produce EZ33 and ZE41 (sand cast), giving good cast
ability due to low- melting point displayed a good aging hardening effect has better tensile
properties.

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Application of Magnesium alloys:-Used as alloying element for aluminum, steel and cast
iron. Die casting for aerospace. Light weight bodies.

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Titanium and Its Alloys:-

Titanium and its alloys are relatively new engineering materials that possess an extraordinary
combination of properties. Titanium is the forth abundant metal on earth after aluminum, iron
and magnesium Not found in its free, pure metal form in nature but as oxides,i.e., limonite
(FeTiO3) and rutile (TiO2).limonite (FeTiO3) found in IL men mountains of Russia, or rutile
(TiO2), from the beach sands in Australia, India, and Mexico. Have similar strength as steel but
with a weight nearly half of steel

Applications of titanium alloys:- Used mainly in aerospace, marine, chemical, biomedical

applications and sports.1010

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Classification of titanium alloys

\\Commercially pure (CP) titanium, alpha and near alpha titanium alloys,

\\Alpha-beta titanium .alloys

\\Beta titanium alloys.

Different crystal structures and properties allow .manipulation of heat treatments to produce
different types of alloy microstructures to suit the required mechanical properties

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Commercially pure (CP) titanium
and alpha/near alpha alloys

Microstructure contains HCP crystal structure known as α phase and can be divided into;
Commercially pure titanium alloys Alpha titanium alloy Near alpha titanium alloys.
Characteristics :Non-heat treatable .Wieldable. ,Medium strength, Good notch toughness ,Good
creep resistance at high temperature
Properties and typical applications of commercially pure (CP) titanium alloys
Properties

Lower strength, depending on contents of O, Corrosion resistance to nitric acid, moist

chlorine.0.2% Pd addition improves corrosion resistance in HCl, H2SO4, H3PO4.Less expensive

Applications
Airframes, heat exchangers, chemicals, marine, surgical implants.

Large structure used in bleaching section of pulp and paperAlpha titanium alloy

α stabilizers are more soluble in the α phase and raise the β transus temperature.Al and Sn are the
main alloying elements, which provide solid solution strengthening.O and N present as
impurities, give interstitial hardening.The amount of α stabilizers should not exceed9% in the
aluminum equivalent to prevent embrittlement due to ordering Phase diagram of α stabilized Ti
alloy 5-6% Al can lead to a finely dispersed, ordered phase (α2), which is coherent to
lattice.deleterious ductility

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 Properties

Moderate strength.Strength depends on O and AL contents. (Al <5-6%).Al also reduces its
density.Good oxidation resistance and strength at 600 to 1100ºF. Readily weldabl

Applications

Aircraft engine compressor blades, sheet-metal parts. High pressure cryogenic

vessels at -423ºC

Alpha-beta titanium alloys

With proper balancing of the α and β stabilizers, a mixture of α and β is produced at room
temperature.heat treatments can be used to control the microstructure and Properties.Annealing
provides a combination of high ductility, uniform properties, and good strength.The alloy is
heated just below the β transus temperature, permitting a small amount of α to remain and
prevent.
Beta titanium alloys
Beta stabilizers are sufficiently added to retain a fully β structure (avoid marten site formation)
when quenched from the β phase field titanium alloys possess a BCC crystal structure, which is
readily cold worked (than HCP α structure) in the β phase field. Microstructure after quenching
contains equated β phase. After solution heat treating + quenching giving very high strength (up
to 1300-1400 MPa).Metastable β Ti alloys are hard enable while stable β Ti alloys are non-hard
enable.

Composition and applications of β titanium alloys

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Tensile strength of different Ti alloys at a range of temperatures

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Figure: The effect of temperature on
the yield strength of selected titanium alloys

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References

1. Text book or or teachers ppt

Herring, Daniel H.,  Atmosphere Heat Treatment Volume I, BNP Media, 2014
2. The Making, Shaping and Treating of Steel, McGannon, H. E. (Ed), United States Steel,
9th Edition, 1971

3. German, Randall M., Powder Metallurgy of Iron and Steel, John Wiley & Sons, Inc.,
1998

4. Gray and Ductile Iron Castings Handbook, Walton, C. F. (ed.), Gray and Ductile Iron
Founders’ Society, Inc., 1971

5. Taylor, H. F, and Flemings, M.C., and Wulff, J., Foundry Engineering, John Wiley &
Sons, Inc., 1959

6. Technishche Fakultat Universitat Kiel (www.tf.uni-kiel.de)

7. McGannon, H. E. (ed), The Making, Shaping and Treating of Steel, US Steel Co., 9th
Ed., 1971

8. Walton, C. F. (ed.), Gray and Ductile Iron Castings Handbook, Gray and Ductile Iron
Founders’ Society Inc., 1971

9. Handouts, University of Tennessee, Material Laboratory Procedures, MSE 300