ENGINEERING

MANUFACTURING II
(MMF22A)

UNIT 1
LECTURE 3: NON FERROUS METALS AND ALLOYS
 INTRODUCTION
• Non ferrous metals and alloys cover a wide range, of metals
such as aluminium, copper, and magnesium to high-strength,
high-temperature alloys such as tungsten, tantalum, and
molybdenum.
• Although generally more expensive than ferrous metals,
nonferrous metals and alloys have numerous important
applications because of properties such as good corrosion
resistance, high thermal and electrical conductivity, low density,
and ease of fabrication.
INTRODUCTION
 INTRODUCTION
• Typical examples of non ferrous metal and alloy
applications are:
• Aluminium for cooking utensils and aircraft
bodies.
• Copper wire for electrical power cords.
• Zinc for galvanized sheet metal for car bodies.
• Titanium for jet-engine turbine blades and for
orthopedic implants.
• Tantalum for rocket engines.
ALUMINIUM AND ALUMINIUM ALLOYS

• The important advantages of Al and its alloys are:

• High strength-to weight ratios.
• Resistance to corrosion by many chemicals.
• High thermal and electrical conductivities.
• Ease of formability and machinability.
• Nonmagnetic properties.
ALUMINIUM AND ALUMINIUM ALLOYS
• Applications include:
• Containers and packaging (aluminium cans and foil).
• Architectural and structural applications.
• Transportation (aircraft and aerospace applications,
buses, automobiles, railroad cars, and marine craft).
• Electrical applications (as economical and
nonmagnetic electrical conductors).
• Consumer products (appliances, cooking utensils, and
furniture).
• Portable tools.
 ALUMINIUM AND ALUMINIUM ALLOYS
• Aluminium alloys are wrought products made into
various shapes by rolling, extrusion, drawing, and
forging.
• Aluminium ingots are available for casting.
• Aluminium in powder form for powder-metallurgy
applications.
• Mostaluminium alloys can be machined, formed,
and welded with relative ease.
ALUMINIUM AND ALUMINIUM ALLOYS
• 1xxx-Commercially pure aluminium:
• Excellent corrosion resistance, high electrical and thermal
conductivity, good workability, low strength, not heat
treatable.
• 2xxx-Copper:
• High strength-to-weight ratio, low resistance to corrosion,
heat treatable.
• 3xxx-Manganese:
• Good workability, moderate strength, generally not heat
treatable.
• 4xxx-Silicon:
• Lower melting point, forms an oxide film of a dark gray to
charcoal color, generally not heat treatable.
 ALUMINUM AND ALUMINUM ALLOYS
• 5xxx-Magnesium:
• Good corrosion resistance and weldability,
moderate to high strength, not heat treatable.
• 6xxx-Magnesium and silicon:
• Medium strength; good formability, machinability,
weldability, and corrosion resistance; heat
treatable.
• 7xxx-Zinc:
• Moderate to very high strength, heat treatable.
• 8xxx-Other elements.
 ALUMINIUM AND ALUMINIUM ALLOYS
• The temper designations for both wrought and cast
aluminium are as follows:
• F:As fabricated (by cold or hot working or by
casting).
• O: Annealed (from the cold-worked or the cast
state).
• H:Strain hardened by cold working (for wrought
products only).
• T: Heat treated.
• W: Solution treated only
ALUMINIUM AND ALUMINIUM ALLOYS
ALUMINIUM AND ALUMINIUM ALLOYS
• Is the second most produced metal.
• The principal ore for aluminium is bauxite, which is a
hydrous (water-containing) aluminium oxide and includes
various other oxides.
• Ore is crushed into powder and treated with hot caustic
soda (sodium hydroxide) to remove impurities.
• Alumina (aluminium oxide) is extracted from this solution
and then dissolved in a molten sodium-fluoride and
aluminium-fluoride bath at 940° to 980°C.
 ALUMINIUM AND ALUMINIUM ALLOYS
• This mixture is then subjected to direct- current
electrolysis.
• Aluminium metal forms at the cathode (negative
pole), while oxygen is released at the anode
(positive pole).
• The production process consumes a great deal of
electricity, which contributes significantly to the cost
of aluminium.
 MAGNESIUM AND MAGNESIUM
ALLOYS
Magnesium (Mg)
• Is the lightest engineering metal available, and it
has good vibration damping characteristics.
• Its alloys are used in structural and
nonstructural applications wherever weight is of
primary importance.
• Magnesium is also an alloying element in
various nonferrous metals.
 MAGNESIUM AND MAGNESIUM
ALLOYS

• Typical uses of magnesium alloys are:

• Aircraft and missile components.
• Material-handling equipment.
• Portable power tools.
• Sporting goods.
• General lightweight components.
 MAGNESIUM AND MAGNESIUM
ALLOYS
• Because it is not sufficiently strong in its pure form,
magnesium is alloyed with various elements in order
to gain certain specific properties, such as a high
strength-to-weight ratio.
• Because they oxidize rapidly (i.e., they are
pyrophoric), a fire hazard exists, and precautions
must be taken when machining or processing.
• Productsmade of magnesium and its alloys are,
nonetheless, not a fire hazard during normal use.
 MAGNESIUM AND MAGNESIUM
ALLOYS

• Magnesium is the third-most-abundant metallic

element (2%) in the earth’s crust, after iron and
aluminium.
• Most magnesium comes from seawater, which
contains 0.13% magnesium in the form of
magnesium chloride.
 COPPER AND COPPER ALLOYS
• Copper are among the best conductors of electricity
and heat, and they have good corrosion resistance.
• Copper and its alloys can be processed easily by
various forming, machining, casting, and joining
techniques.
• Copper alloys often are attractive for applications in
which a combination of electrical, mechanical,
nonmagnetic, corrosion-resistant, thermally
conductive, and wear-resistant qualities are
required.
 COPPER AND COPPER ALLOYS
• Applications include:
• Electrical and electronic components
• Plumbing components
• Heat exchangers
• Consumer goods (such as cooking utensils,
jewelry, and other decorative objects).
• Although aluminium is the most common material for
dies in polymer injection moulding, copper often is
used because of its better thermal properties.
 COPPER AND COPPER ALLOYS

• Copper
is found in several types of ores, the most
common being sulfide ores.
• The ores are generally of low grade (although some
contain up to 15% Cu) and usually are obtained
from open-pit mines.
 COPPER AND COPPER ALLOYS
• The most common copper alloys are brasses and
bronzes.
• Brass (an alloy of copper and zinc) is one of the earliest
alloys developed and has numerous applications,
including decorative objects.
• Bronze is an alloy of copper and tin
• There are also other bronzes, such as aluminum bronze
(an alloy of copper and aluminum) and tin bronzes.
• Beryllium copper (or beryllium bronze) and phosphor
bronze have good strength and hardness for applications
such as springs and bearings.
• Other major copper alloys are copper nickels and nickel
silvers.
 NICKEL AND NICKEL ALLOYS
Nickel (Ni)
• Is a major alloying element that imparts strength,
toughness, and corrosion resistance.
• It is used extensively in stainless steels and in nickel-
based alloys (also called super alloys).
• Nickel alloys are used in:
• High-temperature applications (such as jet engine
components, rockets, and nuclear power plants).
• Food-handling and chemical-processing equipment.
• Coins, and in marine applications.
 NICKEL AND NICKEL ALLOYS
• Because nickel is magnetic, nickel alloys also are used in
electromagnetic applications, such as solenoids.
• The principal use of nickel as a metal is in the
electroplating of parts for their appearance and for the
improvement of their corrosion and wear resistance.
• Nickel alloys have high strength and corrosion resistance
at elevated temperatures.
• The main sources of nickel are sulfide and oxide ores, all
of which have low concentrations of nickel.
• Nickel metal is produced by preliminary sedimentary and
thermal processes.
NICKEL AND NICKEL ALLOYS
 SUPER ALLOYS
• Super alloys are important in high-temperature applications.
• Super alloys have good resistance to corrosion, mechanical and
thermal fatigue, mechanical and thermal shock, creep, and
erosion, at elevated temperatures.
• Applicationsof super alloys are in jet engines, rocket engines
and gas turbines.
• Other applications are in reciprocating engines, tools and dies for
hot working of metals, and the nuclear, chemical, and
petrochemical industries.
• Most super alloys have a maximum service temperature of about
1000°C.
 TITANIUM AND TITANIUM ALLOYS
Titanium (Ti)
• Although titanium is expensive, its high strength-to-weight
ratio and corrosion resistance at room and elevated
temperatures make it attractive for many applications such
as:
• Aircraft components
• Jet engines
• Racing cars
• Golf clubs
• Chemical, petrochemical, and marine components
• Submarine hulls
• Armor plate
• Medical applications, such as orthopedic implants
 TITANIUM AND TITANIUM ALLOYS
• Titaniumalloys have been developed for service at
550°C for long periods of time and at up to 750°C for
shorter periods.
• Unalloyed titanium, known as commercially pure
titanium, has excellent corrosion resistance for
applications where strength considerations are
secondary.
• Aluminium, vanadium, molybdenum, manganese,
and other alloying elements impart properties such
as improved workability, strength, and hardenability.
 TITANIUM AND TITANIUM ALLOYS
• Control of composition and processing are important,
especially the prevention of surface contamination by
hydrogen, oxygen, or nitrogen during processing
• These elements cause embrittlement of titanium and
reduce toughness and ductility.
 TITANIUM AND TITANIUM ALLOYS
• Ores containing titanium first are reduced to titanium
tetrachloride in an arc furnace, then converted to
titanium chloride in a chlorine atmosphere.
• Thiscompound is reduced further to titanium metal
by distillation and leaching adds considerably to the
cost of titanium.
TITANIUM AND TITANIUM ALLOYS
 REFRACTORY METALS AND ALLOYS
• These metals are called refractory because of their high
melting points.
• More than most other metals and alloys, the refractory
metals maintain their strength at elevated temperatures.
• They are of great importance in rocket engines, gas
turbines, and various other aerospace applications; in the
electronic, nuclear-power, and chemical industries; and as
tool and die materials.
• The temperature range for some of these applications is
on the order of 1100 to 2200°C, where strength and
oxidation are of major concern.
 MOLYBDENUM
Molybdenum (Mo)
• Has a high melting point, high modulus of elasticity,
good resistance to thermal shock, and good
electrical and thermal conductivity.
• Solid-propellant
rockets, jet engines, electronic
components, heating elements, and dies for die
casting.
 NIOBIUM
Niobium (Nb),
• Niobium possesses good ductility and formability
and has greater oxidation resistance than other
refractory metals.
• Withvarious alloying elements, niobium alloys
can be produced with moderate strength and
good fabrication characteristics.
• These alloys are used in rockets and missiles
nuclear, chemical, and superconductor
applications.
 TUNGSTEN
Tungsten (W)
• Tungsten has the highest melting point of any metal
(3410°C).
• As a result, it is notable for its high strength at elevated
temperatures.
• It has a high density (hence it is used for balancing
weights and counterbalances in mechanical systems,
including self-winding watches)
• Is brittle at low temperatures, and offers poor resistance to
oxidation.
• As an alloying element, tungsten improve strength and
hardness to steels at elevated temperatures.
 TUNGSTEN
• The filament wire in incandescent light bulbs is made
of pure tungsten and is produced by the use of
powder metallurgy and wire-drawing techniques.
• Tungsten carbide, with cobalt as a binder for the
carbide particles, is one of the most important tool
and die materials.
 TANTALUM
Tantalum (Ta)
• Ithave a high melting point (3000°C), high
density, good ductility, and resistance to corrosion
• Ithas poor chemical resistance at temperatures
above 15O°C.
• Tantalum is used in electrolytic capacitors and in
various components in the electrical, electronic, and
chemical industries.
• It also is used for thermal applications, such as in
furnaces and in acid-resistant heat exchangers.
 BERYLLIUM
Beryllium (Be)
• Unalloyed beryllium is used in rocket nozzles, space and
missile structures, aircraft disc brakes, and precision
instruments and mirrors.
• It is used in nuclear and X-ray applications because of its low
neutron absorption.
• Beryllium is also an alloying element, and its alloys of copper
and nickel are employed in various applications, such as
electrical contacts, and non-sparking tools for use in
explosive environments as mines and metal-powder
production.
• Beryllium
and its oxide are toxic - their associated dust and
fumes should not be inhaled.
 ZIRCONIUM
Zirconium (Zr)
• It has good strength and ductility at high
temperatures and has good corrosion resistance
because of an adherent oxide film.
• Zirconium is used in electronic components and in
nuclear-power reactor applications because of its
low neutron absorption.
 LEAD
Lead (Pb)
• High density, resistance to corrosion (due to a lead-oxide
layer that forms to protect the surface), softness, low
strength, ductility, and good workability.
• Cable sheathing, foil (as thin as 0.01 mm), roofing, and lead-
acid storage batteries.
• Lead also is used for damping sound and vibrations,
radiation shielding against X-rays, ammunition, as weights,
and in the chemical industry.
• Because of its toxicity, environmental contamination by lead
(causing lead poisoning) is a major concern therefore lead
are being replaced by other elements.
 ZINC
Zinc (Zn),
• Fourth most used in the industry after iron, aluminium and
copper.
• Used include:
• Galvanizing iron,
• An alloy in other metals
• A material in castings.
• In galvanizing, zinc serves as an anode and protects the
steel (cathode) from corrosive attack
• Brass is an alloy of copper and zinc.
 ZINC
• Zinc based alloys are used extensively in:
• Die casting for making such products as fuel
pumps and grills for automobiles
• Components for household appliances such as
vacuum cleaners and washing machines,
• Kitchen equipment,
• Machinery parts, and photoengraving equipment.
 TIN

Tin (Sn)
• Is used as a protective coating on steel
sheets used in making containers (tin cans)
for food and for various other products.
• The low shear strength of the tin coatings on
steel sheets improves deep drawability.
 PRECIOUS METALS
Gold (Au)
• Is soft and ductile and has good corrosion resistance at
any temperature.
• Typical applications include jewelry, coinage, reflectors,
gold leaf for decorative purposes, dental work,
electroplating, and electrical contacts and terminals.
Silver (Ag)
• Is ductile and has the highest electrical and thermal
conductivity of any metal
• Applications include tableware, jewelry, coinage,
electroplating, electrical contacts, solders, bearing linings,
and food and chemical equipment.
• Sterling silver is an alloy of silver and 7.5% copper.
 PRECIOUS METALS
Platinum (Pt)
• Has good corrosion resistance even at high
temperatures.
• Platinum alloys are used as:
• Electrical contacts for spark-plug electrodes
• Catalysts for automobile pollution-control devices
• Thermocouples
• Dies for extruding glass fibers
• Jewelry and dental work.
 SUMMARY
• The selection of a nonferrous material for a
particular application requires a careful
consideration of many factors, including:
• Design and service requirements
• Long-term effects
• Chemical affinity to other materials
• Cost.
 Homework
• Work through pages 150 to 166 in handbook
• Do Review questions 6.1 to 6.6 & 6,8 to 6,11,
& 6,13
• Do Qualitative problems 6,16 to 6.19 to 6,25