۲ chapter

Cu & Al
COPPER

 Non ferrous metal

 Good formability
 Softness
 Attractive and good colour
 Cold working characteristics
 Special electrical properties
 Magnetic properties
 Easy castability
 Low coefficient of friction
 Atmospheric corrosion resistance
 Low density
COPPER
 COPPER ALLOYS
(a)High conductivity copper (electrolytic)
99.9%copper
0.40% oxygen ,lead and iron less than 0.005% .
silver 0.002%and Bi less than 0.001%.
Electrolyte copper is used for electrical purpose.

(b) Deoxidised copper

99.85% copper,
less than 0.05% As,0.003% iron, and 0.003% Bi.
Other elements may be of the order of 0.005% P,
0.01% lesd,0.10% Ni,0.003%and 0.005% Ag and Sb
respectively
(c) Arsenical deoxidised copper
0.4% As, 0.04% P and remaining copper .
It is used for welded vessels and tanks
(d) Arsenical touch pitch copper
0.4% As,0.065% oxygen,0.02% Pb,0.15% Ni,
0.006% Ag,0.01% Sb and less than 0.005% Bi ,less
than 0.020% Fe and remaining copper.
(e) Oxygen free copper
0.005% Pb, 0.001% Ni, 00.001% Ag and less than
0.0005% and 0.001% Fe and Bi respectively.
It is melted and cast in non oxidising atmosphere.
APPLICATION OF COPPER

 For making electrical parts,

 Heat exchangers,
 Screw maching products,
 For making various copper alloys, such as
brass and bronze,
 For household utensils, etc
BRASS
 Brasses contain zinc as the principle alloying
element. brasses are sub divided in to three
groups;
 Cu-Zn alloys
 Cu-Pb-Zn alloys or leaded brasses
 Cu-Zn-Sn alloys or tin brasses
 Brasses are high resistance to corrosion
and it is easily machinable. It also act as good
bearing material. Zinc in the brass increases the
ductility along with strength. Brass prossesses
greater strength than copper , however it has a
lower thermal and electrical conductivity..
BRASS
TYPES OF BRASSS
(1) Giliding metal
 5% to Zn (balance copper) and posses shades of colour from
the red of a brassy yellow. Gliding metal is used for making
coins, medals, tokens, fuse caps etc

(2) cartridge brass

 70% Copper and 30% zinc. In the fully annealed condition it
has strength of over 300N/mm2. caps of electric lamp bulbs,
door furniture etc. This brass, harden when deformed in the
cold An annealing temperature of about 6000C is satisfactory
in the most cases.

(3) Admiralty brass

 Cu 71%, Zn 28% and Sn 1%. used for the tubes and other parts
of condenser cooled by fresh water and for many other
purpose.
(4) Aluminium brass
 76% Cu, 22% Zn and 2% Al, a little arsenic is added to
inhibit dezincification.

(5)Basis brass
 61.5-64%, the remainder being zinc.Used for press work
where a relatively cheap material is required and the
main commercial forms are sheet, strips and wire.

(6)Muntz metal or yellow metal

 60% of copper and 40% of zinc and is essentially a hot
working material.
 ship sheathing, perforated metal, valve stems,
condenser tubes, architecture works etc
BRONZE

 An alloy of copper and elements other than nickel

or zinc.bronze is baisicaly an alloy of copper and
tin.
 It possesses superior mechanical properties and
corrosion resistance than brass.
 it is comparatively hard and it resist surface wear.
 It can be rolled in to wire, rod, and sheets
TYPES OF BRONZE
(1) Phosphor bronze
 The most important copper-tin alloys are
those which have been deoxidized with phosphorus during
the refining process and hence are known as phosphor
bronze. A phosphor

(2)Aluminium bronze
89% Cu, 7% Al, and 3.5% Sn. It possess the following
properties, good strength, high corrosion resistance,
good heat resistance, good cold working properties etc
(3)Silicon bronze
 1-4% si,0.5-1.0% iron, 0.25-1.25% Mn, and balance amount
of copper. When lead added as 0.05% improves
machinability. It possess high strength and toughness as
that of mild steel and corrosion resistance as that of
copper.,
 GUN METAL
 Gun metal is an alloy of copper, tin and zinc.
Zinc cleans the metal and increase its
fluidity. A small amount of lead may be
added to improve castability and
machinability.
 TYPES OF GUN METAL
(a)Admirality gun metal
 % of Sn,2% Zn,1.5% Pb,1.5% Ni, and balance Cu.
 It has tensile strength of 260-340 N/mm2.
 It is widely used for pumps, valves and miscellaneous castings and
is also used for statuary.

(b)Nickel gun metal

 7% Sn, 2.25% Zn, 0.3% Pb, 5.5% Ni and balance copper.
 When sand cast and heat treated it has a tensile strength of 430-
480 N/mm2.

(c)Leaded gun metal

 5% Sn, 5% Zn, 5% Pb, 2.0% Ni.
 When sand cast it has a tensile strength of 200-270 n/mm2.
 Gun metal is used for bearings, steam pipe fittings, hydraulic valve
and gears, marine casting.
ALUMINIUM

1
 INTRODUCTION
• Aluminium occurs in abundance on the surface
of the earth. It is available in various forms such
as oxides, sulphates, silicates, phosphates, etc.
But is commercially produced mainly from
Bauxite.
• Aluminium is the third most abundant element
(after oxygen and silicon), and the most
abundant metal, in the Earth's crust. It makes
up about 8% by weight of the Earth's solid
surface

4
• Aluminium is remarkable for the metal's
low density and for its ability to
resist corrosion due to the phenomenon
of passivation. Structural components made
from aluminium and its alloys are vital to
the aerospace industry and are important in
other areas of transportation and structural
materials. The most useful compounds of
aluminium, at least on a weight basis, are the
oxides and sulfates.

5
PROPERTIES OF ALUMINIUM
1. It is a very good conductor of heat
and electricity.
2. It is a silvery white metal with a
bluish tinge and it exhibits bright
lusture on a freshly broken surface.
3. It is a non-magnetic substance.
4. It is highly resistant to corrosion.
12
5. It is light in weight, malleable,
and ductile.
6. It is very soft.
7. It possesses great toughness
and tensile strength.
8. Readily dissolves in HCl

13
 Characteristic of Aluminium
• Aluminum can be recycled easily.
• Almost all aluminum are used in construction.
• High scrape value
• Non corrosive and non toxic so used for both indoor
and outdoor application
• It resist corrosion by water, snow and moisture
without any coating.
• Light weight and high strength and flexible
• It dose not strikes spark nor get brittle under
extreme cold or heat.
14
 AIR TIGHTNESS
• A well designed
aluminium door ,
window etc. is
pertfectly air tight a nd
sealed out for dust and
rain water, when closed.
• This is usefull in fully air
conditioned buildings.

16
 APPEARANCE
• Aluminium can be
anodized or painted in
any colour, to any optical
effect, number of surface
touches, in order to meet
a decorative needs. It
serves to enhance the
material’s durability and
corrosion resistance, as
well as providing an easy-
to-clean surface.

17
 CRYOGENICS
• Where as steel becomes brittle at low temperatures,
aluminium increases in tensile strength and retains
excellent toughness.

18
EASE IN FABRICATION & ASSEMBLY
• Aluminium can be easily
fabricated into various
forms such as foil,
sheets, geometric
shapes, rod, tube and
wire.
• Aluminium could be
easily assembled using
welding.

19
 HANDLING AND TRANSPORTION
• Require fewer joints,
producing fast and
economical installation.
• Aluminium can be
sawed, drilled, riveted,
screwed, bent, welded
and soldered in the
workshop or on the
building site.

20
 HIGH CORROSION RESISTANCE
• Aluminium building
products are made from
alloys, which are
weather-proof,
corrosion-resistant and
immune to the harmful
effects of UV rays,
ensuring optimal
performance over a
very long serviceable
lifetime.

21
 HIGH REFLECTIVITY
• This characteristic feature
makes aluminium a very
efficient material for light
management. Aluminium
solar collectors can be
installed to lower energy
consumption for artificial
lighting and heating in
winter, while aluminium
shading devices can be
used to reduce the need
for air conditioning in
summer.

22
 HIGH SCRAP VALUE
• To produce aluminum
from recycled material,
for example, requires
only 5% of the energy
required to produce
aluminum from bauxite.
In addition, every ton of
recycled aluminum
saves four tons of
bauxite.

23
HIGH STRENGTH TO WEIGHT RATIO
• Aluminium sections are generally thinner and deeper
than equivalent steel sections to achieve the required
strength and rigidity of same level.

24
 MAINTENANCE COST
• While Aluminium has a
natural, built-in durability
(it forms a protective
layer of oxide as soon as
it is exposed to air), most
Aluminium construction
products are treated or
coated. One way in which
the oxidization process
can be enhanced is
anodization

25
Tools to cut aluminum

26
 Advantages of aluminium

• Slim profile • Water resistant

• Durable • Salt and even air resistant
• low maintenance
• Anti corrosive
• Light yet strong
• Available in anodised and
baked with finishing long
lasting color

27
 Anodising

• Electrolytic process used to

increase the thickness films
on aluminium.
• The anodic films are
normally between 5 to25
microns thick depending on
its use.
• Anodic films can also be
used as a base of dyes of
any color basically
golden,silver and black.

28
 Forms of Aluminium
• Casting Based
• Extrusion Based
• Foil and Powdered Based
• Sheet Based

29
 Casting Based
• Baluster head
• Hardware and fittings
• Security and decorative grills

30
 Sheet based
• Cable trays
• Flat type false ceiling
• Prefabricated houses
• Rain water
• Ridging and angel of
roof
• Roofing and sliding

31
 Types of sheet
• Anodising sheets
• Pre painted sheets
• Reflector sheets
• Lighting sheets
• Trailer roofed sheets
• Rural roogfing sheets
• Decorative panel sheets
Decorative Sheet
• Patterned sheets
• Vinyl coated sheets

32
 Sheet and plate
• Aluminium plate : 6.35 mm (0.250inch)

• Aluminium sheet :0.006 inch -0.250inch

• Sheet is supplied either flat, rolled or in coils,
also available in large sizes

Coils of Aluminium
33
 Extrusion Based

• Doors and Window

frames
• Panels and curtain walls
• Geodesic domes
• Green house and roof
tops gardens
• North light glazing
frame
• Space divider and
partition

34
 Foil and powder based
• Decorative laminates
• Insulative foils
• Paints
• Water proofing sheets

35
36
 False Ceiling

1)FLAT FALSE CEILING:

The use of such ceiling is
done to enhance the
look of the building.

37
 Prefabaricated house
• The use of
prefabaricated house in
cold and tropical
climates.It can also
prove to be an effective
panelling material for
caravan

38
 Rain water articles
• The non corrosive
material is best choice
for the gutter,
spouts,etc. for the
disposal of rainwater.

39
 RIDGING AND ANGLE OF ROOF
• The aluminium can be
used for all building
requirement of corner
flashings,ridgings,monit
or roofs,and gable end
flashings.

40
 FOIL AND POWDER BASED
• DECORTIVE
LAMINATES: The
printed decorative
laminates are
extensively used as
wallpapers ,partition
panels,etc.

41
 INSULATIVE FOILS
• These can be
conventionally used for
for insulatingair
conditioning duct in
large air conditioned
system.

42
 PAINTS
• Aluminium powder based paints are useful to
grant building protection against corrosion

43
 FASCIA PANELS AND CURTAIN WALLS
 External non-load
bearing wall designed
to carry its own weight
Sufficient strong to
carry wind loads
 Larger sizes can be
produced by using
interlocking sections.

47
 GEODESIC DOMES
• Vaulted structure of
light weight straight
elements that form
interlocking polygons

48
 GREEN HOUSES
• A greenhouse is a
building or complex in
which plants are grown.
These structures range
in size from small sheds
to industrial-sized
buildings

49
 ROOF TOP GARDENS
• A roof garden is
a garden on the roof of
a building.
• Besides the decorative
benefit, roof plantings
may provide food,
temperature control,
hydrological benefits,
architectural
enhancement.
50
 Difference
• Cost- Aluminum is much more costly than upvc
• Durability-although upvc has a long life it degrade
over along time but aluminum does not corrode
• Cleaner profile-upvc has a thick channel profile while
aluminum is thinner but the strength of aluminum Is
good
• Flexibility-flexibility in upvc is less than compared to
aluminum
• Colors- aluminum offer the vide range of colors as
compared to upvc.

54
55