ch5. Non-Ferrous Materials

5.6. Non-ferrous alloys 5.6.
Non-ferrous alloys
HUST – MSE HUST – MSE
5.6.1. General introduction

5.6.2. Aluminum and aluminum alloys
5.6.3. Copper and copper alloys
5.6.4. Magnesium and magnesium alloys
5.6.5. Titanium and titanium alloys
5.6.6. Bearing alloys
5.6.7. Powder alloys
SCHOOL OF MATERIALS SCIENCE & ENGINEERING mse.hust.edu.vn fb.com/mse.hust.5 (fb.com/MSE.EDU) SCHOOL OF MATERIALS SCIENCE & ENGINEERING mse.hust.edu.vn fb.com/mse.hust.5 (fb.com/MSE.EDU)
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5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

5.6.1. General introduction 5.6.1. General introduction - Classification

• In metallurgy, a non-ferrous metal is any metal, including alloys, a) Density based:
3
• Light metals and alloys ρ < 5000 kg/m (Mg, Al, Ti)
that does not contain iron in appreciable amount. Generally, more 3

• Medium metals and alloys ρ = 5000...10000 kg/m (Sn, Zn, Sb, Cr, Ni,
Mn, Fe, Cu)
expensive than ferrous metals, non-ferrous metals are used beca 3
• Heavy metals and alloys ρ >10000 kg/m (Pb, Ag, Au, Ta, W, Mo)
use of desirable properties such as low weight (e.g., aluminium), b) Melting temperature based:
• Low melting point Tm < Tm
Pb = 327 °C (Sn, Pb, Bi)
higher conductivity (e.g., copper), non-magnetic property or resist • Medium melting point = 327…1539 °C (Al, Mg, Mn, Cu, Ni, Co, Ag,
Au)
ance to corrosion (e.g., zinc). Important non-ferrous metals includ Fe = 1539 °C
• Refractory Tm > Tm
e aluminum, copper, lead, nickel, tin, titanium and zinc, and alloys
Element Ti Cr V Nb Mo Ta W
such as brass.
Tm, °C 1660 1875 1900 2415 2610 2996 3410
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5.6.1. General introduction - Classification 5.6.1. General introduction

Aluminium Al alloys
Non-ferrous materials
Magnesium Mg alloys
Copper Brass
Pure Alloys Cu+Zn
Zinc
Bronze
Tin Cu+Sn
Solder
Lead Pb+Sn
Nickel Ni alloys
5 6
1
5.6.2. Aluminum and aluminum alloys 5.6.2. Aluminum and aluminum alloys
• Properties: • Classification:
Aluminum-based
- High strength to weight ratio
- Resistance to corrosion Pure Al Al-Alloys Powder aluminium
- High thermal and electrical conductivity
- Ease of machinability
- Non-magnetic Deformable alloys Cast alloys
Heat-treatable Non heat-treatable Heat-treatable Non heat-treatable

(Partial solubility) (No solubility) (Partial solubility) (No solubility)
7 8


• Designation system of Al and Al-alloys
• Classification:  Vietnam standard 1659-75
b
660 L Alxx Cuxx Mgxx…
L+ α 600
Indicates Alloying Element + xx (%wt)
c E
L+  - Pure Al: Al + xx(%wt)
α
t, C
548 - Al-Alloys: No indicate xx (Al balance)
α + Eutectic +  Eutectic +   US standard (AA) (Aluminum Association) xxxx and xxx.x

Wrought Cast alloys xxxx (Wrought Al alloys) x x x.x (Cast Al alloys)
alloys
- Min. Al% after decimal point pure Al - .0 for final casting
α+ - .1 or .2 for ingot
 - Arbitrary numbers
100%Al a
(CuAl2) Modification of specific alloy Modification of specific alloy
Non HT HT 5.7 33 Cu, % 55
Alloy group (Principal elements) Alloy group (Principal elements)
9 10


Wrought aluminum alloy groups
5.6.2. Aluminium and aluminium alloys
• Classification: designation of heat treatment
• O – annealed (for ex. 01, 02, 03)
• H – work hardened (for ex. H1, H2...H9)
• W – quenched
• T – heat treated (for ex. T1, T2...T10, T31, T3510)
Cast aluminum alloy groups
Mainly used: T4 – quenching + natural ageing
T6 – quenching + artificial ageing
11 12
2
13 14


Rp0.2, Z, %
Deformable alloys: Non heat-treatable
N/mm2 100
Pure Al – 1xxx HB
HB
• Metallurgical (99,5…99,8% Al + Fe + Si A%
+ 0.12% Cu), refined (up to 99,9% Al) 400 40 80
• Al 99,9% Rm = 70…135 N/mm2
• Work hardening of Al
300 30 Z 60
• VN: A0, A5, A6…; A85, A95, A995…
• USA: AA1060 (Tanks), AA1350 (Electric
al wires) 20
200
A Rm
100 10
Rp0.2
0
0 20 40 60 80 10
,0%
15 16

Deformable alloys: Non heat-treatable Deformable alloys: Heat-treatable
Al – Mn: 3xxx alloys Al – Cu: 2xxx alloys Al + Cu + Mg
• Manganese is principle alloying element, the • Copper is principle alloying element
solubility limit of 1.8%Mn at 659C • Al2024 = Al + 4.5% Cu + 1.5% Mg +0.6%Mn
• Al 3003 = Al 1100 + 1.25% Mn
• Tensile strength = 442 MPa
• Tensile strength = 110 MPa
• General purpose alloy
• Used for aircraft structures.
Al – Mg: 5xxx alloys Al – Mg - Si: 6xxx alloys Al + Mg + Si
• Al + up to 5% Mg • Al6061 = Al + 1% Mg + 0.6%Si + 0.3% Cu + 0.2% Cr
• Al5052 = Al + 25%Mg + 0.2% Cr • Tensile strength = 290 MPa
• Tensile strength = 193 MPa • Used for general purpose structure.
• Used in bus, truck and marine sheet metals Al – Zn: 7xxx alloys Al + Zn + Mg + Cu
• Zinc is principle alloying element
• Al7075 = Al + 5.6% Zn + 2.5% Mg + 1.6% Cu + 0.25% Cr
• Tensile strength = 504MPa
• Used for aircraft structures.
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5.6.2. Aluminum and aluminum alloys b 5.6.2. Aluminum and aluminum alloys
660
L Deformable alloys: Heat-treatable
Deformable alloys: Heat-treatable 600
L+ α Duralumin (4%Cu)
Duralumin (4%Cu) E
c L+  Al -4% Cu is solutionized at about 5150C
• Precipitation Strengthening : Creates fine
α
t, C
dispersion of precipitated particles in the metal 548 Alloy is rapidly cooled in water.
and hinder dislocation movement. Alloy is artificially aged in 130 – 1900C
α + Eutectic +  Eutectic + 
Basic steps: Structures formed :
 Solution heat treatment: Alloy sample heated  GP1 Zone: At lower aging temperature, copper atom
Cu+CuAl2
to a temperature between solvus and solidus and is segregated in supersaturated solid solution.
α+ 
soaked at that temperature. a
 GP2 Zone: Tetragonal structure, 10-100 nm diameter.
100%Al (CuAl2)
 Quenching: Sample then quenched to room 4% 5.7 33 Cu, % 55  θ’ Phase: Nucleates heterogeneously on dislocation.
temperature in water.  θ Phase: Equilibrium phase, incoherent (CuAl2).
 Aging: Solutionized and quenched sample is Type of Ageing t, °C Structural Change Property Change
then aged to form finely dispersed particles.
Natural and low-temperature artificial ageing ≤100-150 Guinier-Preston zones (ZGP 1) ↑ σy; σy/σu≤0,7;
↑ δ, impact toughness,
Long-term artificial ageing 100-150 Guinier-Preston zones (ZGP 2) corrosion resistance
Annealing Quenching Ageing Artificial ageing 150-200 Phase θ σy/σu < 0,95;
60 HB 75 HB 140 HB ↓δ, Impact toughness,
Artificial ageing 200-250 Phase θ corrosion resistance
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Aluminum cast alloys
13 3s23p1 Properties required for good casting:
Heat-treatable
Al Nonheat-treatable • Low melting temperature
• Low solubility of gases except H2
Aluminium
• Good fluidity
26.982
• Good surface finishes
Disadvantage
• High solidification shrinkage (3.5-3.8%)
13 3s23p1 29 3d103s1 5 3d105s25p2 14 3s23p2 12 3s2 12
Mg
3s2
30 3d104s2 Factors controlling properties
Al Cu Mn Si Mg Magnesium
24.305 14 3s23p2
Zn OTHER • Melting and pouring practices
Aluminium Copper Manganese Silicon Magnesium Si Zinc
26.982 63.546 118.71 28.086 24.305 Silicon
28.086 65.39 • Impurity levels
1xxx 2xxx 3xxx 4xxx 5xxx 6xxx 7xxx 8xxx • Grain size
• Solidification rate
21 22

Aluminum cast alloys Aluminum cast alloys
Casting method Al-Si (silumin): 4xx.x
• Sand Casting: Simple and used for small
quantities and complex jobs. • Si = 10-13%. The most important group
• Permanent mold casting: Molten metal is and constitute for 85-90% of the total
poured into permanent metal mold. aluminum casting.
 Finer grain structure and strength due to
fast cooling. • Eutectic (Al –12.7%Si) is formed just over
 Less shrinkage and porosity. 1% Si addition, which contains a coarse
 More shrinkage and simple parts only. microstructure of large plates or needles of
• Die casting: Molten metal forced into molds Si in a continuous Al matrix.
under pressure.
 Almost finished parts, automatic. • Large Si plates  low ductility and
 Good tolerance and surface finish. brittleness.
 Fine grain structure. Al-Si-Mg: 3xx.x
Requirements:
- Apart from Al and Si, cast alloys have %Mg < %1, 3-5%Cu to improve
• Low Tm (Al-Si eutectic alloys - 577 °C at 11,7 % Si, by modification 564 °C at 14 % Si)
• High fluidity (short interval of liquidous and solidus lines) castability and mechanical properties through solution treatment and ageing.
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4
Aluminum cast alloys Aluminum cast alloys
Modification of microstructure
• Apart from fast cooling to refine the microstructure, modification can be carried out by adding 1) Al-Si-alloys ↓ Rm (250), A = 1,7 % Pumps and engine
certain alkali fluorides to the melt prior to pouring. bodies, cylinder heads
• Additions of Sr or Na change eutectic microstructure from needle-like or lamellar to fibrous.
2) Al-Cu-alloys Rm ↑ than I group Cylinder heads,
• Higher concentration of 0.02% Sr fully modifies to fibrous structure.
• Grain refinement improves resistance to hot tearing, decreases porosity and increases mass ↓ high temp. strength apparatures bodies
feeding.
3) Al-Si-Cu-alloys Rm ↑ than I group → 350 °C
• Modified with 0.05-0.08% (2/3NaF+1/3NaCl): increase mechanical properties (from u =
130MPa,  = 3% to u = 180MPa,  = 8%) ↓ high temp. strength
4) Al-Mg-alloys Rm, A; good corr. resist.; → 100 °C
Modified
(magnalium) ↓ castability
5) Al- other inclusions high temperature → 350 °C
strength parts of aircraft engines
Rm → 340 N/mm2; A → 8% (depending on casting mode)

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Aluminum cast alloys
13 3s23p1
Al
Aluminium
26.982
29 3d 10 3s1
13 3s23p1 29 3d103s1
14 3s2 3p 2
12 3s2
Si Cu 14 3s23p2 30 3d104s2 50 3d105s25p2
Al Cu
Silicon
28.086
12 3s
Copper
63.546
2 Si Mg Zn Sn OTHER
Aluminium Copper Mg Silicon Magnesium Zinc Tin
26.982 63.546 Magnesium
28.086 24.305
24.305 65.39 118.71
1xx.x 2xx.x 3xx.x 4xx.x 5xx.x 7xx.x 8xx.x 9xx.x

Castability 3xx.x > 4xx.x > 5xx.x > 2xx.x > 7xx.x
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5.6.3. Copper and copper alloys
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5.6.2. Aluminum and aluminum alloys 5.6.3. Copper and copper alloys
• Properties: • Classification:
- Copper alloys have electrical and mechanical prop Copper-based
erties, corrosion resistance, thermal conductivity a
nd wear resistance. Pure Cu Cu-Alloys
- Applications are electronic components, springs a
nd heat exchangers. Brasses Bronzes Cupronickels
- Brass is an alloy of copper and zinc.
- Bronze is an alloy of copper and tin.
Deformable alloys Cast alloys Deformable alloys Cast alloys
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5.6.3. Copper and copper alloys 5.6.3. Copper and copper alloys
• Designation system of Cu and Cu-alloys • Designation system of Cu and Cu-alloys
 Vietnam standard TCVN 1695-75  US standard (CDA) (Copper Development
Association) CDAxxx
L(B)Cuxx Znxx Pbxx… xxx
Indicates Alloying Element + xx (%wt) Arbitrary numbers identifies specific alloy
• Pure Cu: Al + xx(%wt)
• Cu-Alloys: No indicate xx (Al balance) Alloy group (Principal elements)
- Brasses (L) Classification Example America (ASTM) America (CDA)
Copper, Be-Cu 1.9Be,0.20Co C1xx00 1xx
- Bronze (B) Brass (Cu-Zn) CuZn30 C2xx00 2xx
Brass (Cu-Zn-Pb) CuZn32pb2 C3xx00 3xx
Brass (Cu-Zn-Sn) CuZn38Sn1 C4xx00 4xx
- LCuZn40Pb1
Bronze (Cu-Sn) CuSn4 C5xx00 5xx
- BCuSn10Pb1 Bronze (Cu-Al-Si) C6xx00 6xx
Bronze (Cu-Ni-Ag) C7xx00 7xx
Cast alloy C8xx00 8xx
Cast alloy C9xx00 9xx
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5.6.3. Copper and copper alloys  US standard (CDA) (Copper Development

5.6.3. Copper and copper alloys  US standard (CDA) (Copper Development
• Designation system of Cu and Cu-alloys Association) CDAxxx • Designation system of Cu and Cu-alloys Association) CDAxxx
• Numbers C10100 to C79900 designate wrought alloys.
• Numbers C80000 to C99900 designate casting alloys.
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5.6.3. Copper and copper alloys 5.6.3. Copper and copper alloys - Brass
Rm HV Cu-Zn Brass: CDA2xx
Deformable alloys: Non heat-treatable
Rp0.2, • Copper forms substitutional solid solution with Z
Pure Cu – CDA1xx HV n till 45% Zn.
• Annealed Cu (99,85% Cu); Rm → 250 NN/mm
2 120
• Cartridge brass  70% Cu & 30% Zn  single p
/mm2 A, % 100 hase: Annealing twins observed in the α grains in
• El. conductivity 1/ρ = 58 Ω·mm2/m = 10 creases with the Zn contents.
0% IACS 80 • Muntz brass  60% Cu & 40% Zn  two phase.
Commercial bronze Cartridge brass
• Strengthening of Cu at work hardening 500 50 Z (90%Cu-10%Zn) (70%Cu-30%Zn)
Rm 60
structure of beta phase (dark) and

400 40
Cast structure shows dendrites
Hot rolled Muntzmetal sheet

of alpha (dark) in a matrix of
40
300 30 Rp0.2
alpha phase (light)

200 20
A
beta (white)
100 10
0
α phase - FCC structure
0 10 20 30 40 50 60 , % β phase - BCC structure (disordered)
β’phase -BCC structure (ordered)
γ phase –complex structure (brittle)
37 38

5.6.3. Copper and copper alloys - Brass 5.6.3. Copper and copper alloys - Brass
Cu-Zn Brass: CDA2xx Rm A, % HV Cu-Zn-Pb complex brasses: CDA3xx, CDA4xx
• Cartridge brass:  single phase, < 35%Zn; Rp0.2, 70 • Has Small amounts of Pb (0.5-3.0%) which are added to
A many types of brasses to improve their machinability
- 20%Zn (LCuZn20, CDA 240): yellow color; N/mm
2
600 60 100 and castability;
- 30%Zn (LCuZn30, CDA 260): max ductility 90 • 1% of Sn addition in cartridge brass improve corrosion
(30%Zn) 500 50 80 resistance in sea water;
HB 70 • Replacing Sn with Al (2-3%) gives brass a self-healing
• Muntz brass ( + ): β phase makes this 40 60
400 protective oxide on its surface.
alloy heat-treatable 50  Called aluminum brasses;
- 40%Zn (LCuZn40, CDA 280) easy 300 Rm • corrosion resistance  used for marine condensers;
machining, higher strength and hardness, hot Rp0.2 (20% külmdef.) • Added Si – increase strength, improve weldability and
200 castability, Ni (10-20%) – increase high strength and
rolling; Rp0.2 corrosion resistance;
100
• LCuZn40Pb: free cutting brass, LCuZn29Sn: naval brass
0 Zn
Cu 0 10 20 30 40 50
Zn%
39 40

5.6.3. Copper and copper alloys - Bronze 5.6.3. Copper and copper alloys - Bronze
• Cu alloys with elements: Sn, Al, Be… • Cu-Sn: CDA5xx
• Bronze (Cu-Sn) - Wrought Cu-Snbronzes contain about 1.25-10% Sn with up to 0.1% P; hence
• Bronze (Cu-Al-Si) usually called phosphor bronzes. P is added as deoxidizing agent to improve c
• Bronze (Cu-Ni-Ag) astability. Pb is added to improve machinability. Microstructure of 92%Cu-8
• Bronze (Cu-Ni): cupronickels %Sn consists of recrystallised α grains with annealing twins. The wrought tin
• Cu-Sn: CDA5xx bronzes possess higher strength than brasses, especially in the cold-worked c
- Cu-Sn can form solid solution upto15. ondition and has better corrosion resistance: BCuSn4Zn4Pb4.
8% at about 520-586C;
grains with annealing twins
Microstructure of phosphor
bronze 92%Cu-8%Sn-trace
- Cu-Sn bronze castings containing up to

P, showing recrystallised α
- Solid solubility limit of Cu-Sn is lowe

r than that of Cu-Zn; 16% Sn are used for high strength beari
- Up to about 11% Sn, precipitation of ε ng and gear blanks. High Sn (>10%) gi
phase is found sluggished when coole ves strength but unworkable  casting:
d from above 350C to RT, but the for BCuSn5Zn5Pb5, BCuSn10Sn2
mation of metastable ε’ has been obser
ved.
41 42
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• Cu-Al: CDA6xx • Cu-Al: CDA6xx
- Al forms solid solution in Cu (α phase) up to 9.4% at - Aluminum bronzes have high strength, excellent corrosion and good resistance to wear and fatigue.
565C. - Self-healing surface film of aluminum oxide  excellent corrosion resistance.
- Microstructure of α aluminium bronzes consists of sin - Added Ni (5%), Fe (4%): increase strength, wear and corrosion resistance; Si (2%): increase strength a
gle α phase solid solution. nd hot working.
- The solid solubility of the α phase increases with decr - Single phase Al bronze: (5-9)%Al, corrosion resistance in industrial gas environment and seawater: C
easing temp. DA 614 (marine parts), CDA 608 (coins)
- Above 9.5% Al, rapid quenching to RT produces mart
- Two phase Al bronze: > 9,4%Al,  +  (Cu3Al BCC), quenching from 900C and tempering at 500C.
ensitic transformation of metastable β’ tetragonal struc
ture. - Cast alloy (CDA8xx): > 10%,  + 2
Cu-5%Al, showing α grains
Annealed microstructure of
with twin bands.
BCuAl11Fe4Ni4 BCuAl10Ni5Fe3 Industrial Steam Condenser
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• Cu-Si: CDA6xx • Cu-Be: CDA1xx
- Si has a maximum solid solubility with Cu at - Be has maximum solid solubility of 2.7% in Cu at
5.3% at 843C. 866C.
- Most silicon bronzes contain 1-3% Si, which a 843C
- Alloys contain as much as 2.7% beryllium (cast),
re not precipitation hardenable.
or 1.6-2% beryllium with about 0.3% cobalt (wro
- Mn and Fe are sometimes added to improve pr
5.3 ught).
operties.
- Annealed structure of a bronze consists of α gr - Cu-Be alloys with up to 2% Be are precipitation h
ains with twin bands. ardenable due to a rapid decrease in Be solubility.
- Cu-Be alloys can be solution heat-treated (at ~800
Annealed 96%Cu-3%Si 1%Mn
bronze, showing α grains with
C) to produce the highest tensile strength (~470-

1400 MPa) among commercial copper alloys due t
o precipitation hardening.
- Aging at 3200C, high strength with non-magnetic
and non-sparking qualities, high elasticity, corrosi
on resistance at high temperature.
twin bands
 Silicon bronzes have high corrosion resistance,

- Applications: Used in electrical contacts, electric
high strength (~390-1000 MPa) and toughness. al connectors, springs, precision measurement dev
Low-cost substitutes to tin-bronze (due to high ices.
corrosion resistance to sea water).
45 46

• Cu-Ni: cupronickel • Cu-Ni-Zn: nickel silvers
- Cu and Ni are both FCC and can form solid - Ternary Cu-Ni-Zn alloys or nickel silvers do
solution throughout. not contain any silver but the colour.
- Microstructure consists of α phase solid solu - Alloys contain 17-27%Zn and 8-18% Ni.
tion. - The colour changes from soft ivory to silver
- Ni (10, 20, 30%) are added to Cu to form sol y white with increasing Ni content.
id solution alloys, called cupronickel. - Microstructure consists of α αα α phase soli
- Ni addition improves strength, oxidation, an d solutions.
d corrosion resistance. - Properties: Medium to high strength, good c
- Ni greatly increases electrical resistivity of old-workability, good corrosion resistance.
Cu (ex:55%Cu-45%Ni)  used for wire-wo - α+β structure alloys are used for medical de
und resistance for electrical instrument. vices, springs.
- Applications: condenser tubes and plates, h
eat exchangers, and chemical process equip
ment.
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5.6.4. Magnesium and magnesium alloys 5.6.5. Titanium and titanium alloys
Pure Mg Pure Ti
• Tm – 649 °C
• Tm – 1660 °C
• Density – 1.740 g/cm3 (lightest among the engineering materials)
Mg-alloys
• Density – 4.540 g/cm3
• Mg – Mn (up to 2,5 %) • Very active to O, C, N → 2x
• Mg – Al – Zn (up to 10 % Al, 5 % Zn) hardness increase
Deformable Mg-alloys
Ti-alloys, classification
Designation Rm Rp0,2 A Applications
2 % • Ti – Al – alloys (4…6 % Al)
N/mm
Mg-Mn2 200 145 15 Corrosion resistant, weldable cold

– -alloys
Mg-Al8-Zn 310 215 6 formable; conteiners, car , aircraft • Ti – Al – Cr, V, Cu, Mo - allo
and machine manufacturing ys –  + -alloys
Mg cast alloys
Mg-Al8-Zn1 240 90 8 Good castability. Dynamically • Ti – Al – Mo, Cr, Zr - alloys

Mg-Al6 190-250 120-150 4-14 loadable. Car and aircraft
manufacturing.
– -alloys
Mg-Al4-Si 200-250 120-150 3-12
49 50

5.6.6. Bearing alloys 5.6.6. Bearing alloys

Introduction to bearings Tin based alloys (Sn babbitt)
• Bearings support moving parts, such as shafts and spindles, of a machine or mechanism.
• Bearings may be classed as - 83%Sn + 11%Sb + 6%Cu: PbSnSb11Cu6 (OC
• (i) Rolling contact (Ball and roller) bearings. TƂ83); 88%Sn + 8%Sb + 3%Cu + 1%(Ni+Cd):
• (ii) Plain bearings.
• Rolling contact bearings are almost invariably made of steel that can be hardened after machining. SnSb8CuNi.
• Both plain carbon and alloy (Ni, Cr, Mo) steels are employed for different applications.
Properties of bearing materials
- Structure: -Sn(Sb)-soft matrix + ’-SnSb + Cu3
• Possess low coefficient of friction. Sn-harder intermetallic compound.
• Provide hard, wear resistant surface with a tough core.
• Have high compressive strength.
• Have high fatigue strength. β’ - SnSb
α - Sn(Sb)
• Be able to bear shocks and vibrations.
• Possess high thermal conductivity to dissipate heat generated due to friction between the bearing and the rotating shaft.
• Possess adequate plasticity under bearing load.
• Possess adequate strength at high temperatures.
• Be such that it can be easily fabricated.
• Possess resistance to corrosion.
• Be such that it does not cause excessive wear of the shaft rotating in it, i.e., bearing material should be softer than the shaft material.
• Be having small pieces of a comparatively hard metal embedded in a soft metal.
• Maintain a continuous film of oil between shaft and bearing.
Cu3Sn
51 52

5.6.6. Bearing alloys 5.6.6. Bearing alloys

Lead based alloys (Pb babbitt) Aluminum based alloys
- (6-16)%Sn + (6-16)%Sb + 1%Cu: PbSn6Sb6Cu1 (Ƃ6), PbSn16Sb16Cu2 (Ƃ16)
- Structure: (Pb+Sb)-soft matrix + SbSn + Cu3Sn: harder particles - Chemical composition: Al-Sn (3-20)%Sn, 1%Cu, 1%Ni and Si: AlSn3Cu1, AlS
(Pb + Sb) β’ - SnSb
n9Cu2 – cast alloys, AlSn20Cu1 – wrought alloy (bimental), resist heavy press
ures (200-300kG/mm2), high speed (15-20)m/s.
- Excellent corrosion resistance, good ability to embed dirt, good seizure resistan
ce, good thermal conductivity, high coefficient of expansion. Used as bearings i
n diesel engines and tractors.
Cu3Sn
53 54
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5.6.6. Bearing alloys 5.6.7. Powder alloys- powder metallurgy

Copper based alloys Introduction to powder metallurgy
- Sn bronzes: BCuSn4Zn4Pb4 (wrought), BCuSn5Zn5Pb5 (cast); • Essentially, Powder Metallurgy (PM) is an art & science of producing metal or
- Pb bronzes: BCuPb30, BCuSn8Pb12, BCusn10Pb10; metallic powders and using them to make finished or semi-finished products.
Copper based alloys: gray, malleable, and nodular cast irons • Particulate technology is probably the oldest forming technique known to man.
• There are archeological evidences to prove that the ancient man knew somethi
ng about it.
• The entire material need not be melted to fuse it.
• The working temperature is well below the melting point of the major constitu
ent, making it a very suitable method to work with refractory materials, such as
: W, Mo, Ta, Nb, oxides,
• carbides, etc.
• It began with Platinum technology about 4 centuries ago… in those days, Plati
num, [MP = 1774°C], was "refractory", and could not be melted.
55 56

5.6.7. Powder alloys- powder metallurgy 5.6.7. Powder alloys- powder metallurgy
Powder metallurgy process Additives (Die
Metal Powder metallurgy process
lubricants and
powders graphite)
Mixing
Compacting
Sintering
Secondary
operations
Finished
products
57 58

Powder fabrications Powder fabrications
59 60
10
Advantages Advantages over powder Limitations as compared with
No. Process
• Elimination/reduction of machining; metallurgy powder metallurgy
• Wide range of part shapes and sizes • Some waste of material in processing
• High production rates High production rates; 1. Casting produced • Some finishing required
• Complex shapes can be produced; • Generally low mould and set up cost • May not be feasible for high-temperature alloys
• Wide composition variations are possible; • High production rate of a wide range • Some finishing required
of part sizes and shapes • Some waste of material in processing
• Wide property variations are possible; 2. Forging (hot)
• High mechanical properties through • Relatively poor surface finish and dimensional
• Scrap is eliminated or reduced. control of grain flow control
• High production rate of long parts • Only a constant cross-section shape can be prod
Disadvantages 3. Extrusion (hot) • Complex cross-sections may be prod uced
• Inferior strength properties; uced • Poor dimensional control
• Relatively high die cost; • Wide range of part shapes and sizes
• Short lead time
• High material cost. • Flexibility • Waste of material in the form of chips
4. Machining
• Good dimensional control and surfa • Relatively low productivity
ce finish
• Simple tooling
61 62

5.6.7. Powder alloys 5.6.7. Powder alloys

1. Hard alloys (carbides) and abrasive materials 1. Hard alloys (carbides) and abrasive materials
• Hard alloys (powder hard alloys) • Hard alloys (powder hard alloys)
- Heat resistance at (800-1000)C; - Fabrication process
- High speed up to several hundred m/min;
- Hardness: 70-75HRC
- Composition and fabrication:
+ WC highest content, very hard TiC, TaC carbides with
high melting temperature; Co binder material;
 Non-heat treatment.
1450 - 1500 C
63 64


1. Hard alloys (carbides) and abrasive materials Designation Grades
Chemical composition Properties
Grades
(ГОСТ) (TCVN)
• Hard alloys (powder hard alloys) Hard alloys
One carbide
- Products
Two carbides
Three carbides
65 66
11

1. Hard alloys (carbides) and abrasive materials
2. Structural materials
Abrasive cutting discs
- Powder hard alloys (HV 8000-10000) Al powder materials
- Diamond-like carbon powder + (1-2)% BN + B, - Al-Al2O3: (5-20)%Al2O3
Be, Si (binders) - u = (300-450)Mpa (300-350)C
Powder abrasives Fe powder materials
- SiO2, Al2O3, SiC, BN, diamond powders/pastes
67 68
5.6. Non-ferrous alloys

HUST – MSE
5.6.7. Powder alloys

3. Foam materials
Porous self-lubricating bearing
- Cu-10%Sn, graphite-96%Fe, Al alloys, 25%porosity;
- Oil impregnation in vacuum at 75C. MSE
Membrane materials
- Uniform powder;
mse.hust.edu.vn Thank you
- Porosity: (30-50)% fb.com/mse.hust.5
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ch5. Non-Ferrous Materials

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5.6. Non-ferrous alloys 5.6.

5.6.1. General introduction

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

5.6.1. General introduction 5.6.1. General introduction - Classification

that does not contain iron in appreciable amount. Generally, more 3

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

5.6.1. General introduction - Classification 5.6.1. General introduction

Heat-treatable Non heat-treatable Heat-treatable Non heat-treatable

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

5.6.2. Aluminum and aluminum alloys

548 - Al-Alloys: No indicate xx (Al balance)

α + Eutectic +  Eutectic +   US standard (AA) (Aluminum Association) xxxx and xxx.x

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

5.6.2. Aluminum and aluminum alloys

5.6.2. Aluminum and aluminum alloys

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

5.6.2. Aluminum and aluminum alloys

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

Rm → 340 N/mm2; A → 8% (depending on casting mode)

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

1xx.x 2xx.x 3xx.x 4xx.x 5xx.x 7xx.x 8xx.x 9xx.x

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

5.6.2. Aluminum and aluminum alloys

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

5.6.3. Copper and copper alloys  US standard (CDA) (Copper Development

structure of beta phase (dark) and

Cast structure shows dendrites

Hot rolled Muntzmetal sheet

alpha phase (light)

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

- Cu-Sn bronze castings containing up to

- Solid solubility limit of Cu-Sn is lowe

with twin bands.

BCuAl11Fe4Ni4 BCuAl10Ni5Fe3 Industrial Steam Condenser

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

C) to produce the highest tensile strength (~470-

 Silicon bronzes have high corrosion resistance,

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

Mg-Mn2 200 145 15 Corrosion resistant, weldable cold

Mg-Al8-Zn1 240 90 8 Good castability. Dynamically • Ti – Al – Mo, Cr, Zr - alloys

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

5.6.6. Bearing alloys 5.6.6. Bearing alloys

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

5.6.6. Bearing alloys 5.6.6. Bearing alloys

5.6.6. Bearing alloys 5.6.7. Powder alloys- powder metallurgy

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

5.6.7. Powder alloys 5.6.7. Powder alloys

5.6. Non-ferrous alloys 5.6. Non-ferrous alloys

5.6.7. Powder alloys 5.6.7. Powder alloys

5.6.7. Powder alloys 5.6.7. Powder alloys

5.6. Non-ferrous alloys

5.6.7. Powder alloys

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