Non-Ferrous Alloy

MATERIAL SCIENCE AND
METALLURGY
Unit – 11
Non-ferrous alloys
Prepared by
Amit L. Dudhatra
Assi. Professor
Mechanical engg. Dept.

• Classification of materials:

• INTRODUCTION:
• Ferrous alloys are consumed in exceedingly large quantities because
they have such a wide range of mechanical properties, can be
fabricated with relative ease and are economical to produce.
However, they possess some distinct limitations, chiefly
– A relatively high density therefore heavier in weight.
– A comparatively low electrical conductivity and
– An inherent susceptibility to corrosion in some common
environments.
• Thus, for many applications it is advantageous or even necessary to
utilize other alloy e.g. non-ferrous alloys having more suitable
property combinations.
• On occasion, a distinction is made between cast and wrought alloy.
Alloy that are so brittle that forming or shaping by appreciable
deformation is not possible ordinarily, are cost, there are classified as
cast alloys. on the other hand, those that are enable to mechanical
deformation are termed wrought alloys.

• In addition, the heat treat ability of an alloy system is mentioned
frequently heat treatable designates an alloy whose mechanical
strength is improved by precipitation hardening etc.
• Non-ferrous metals/alloy are not iron-based.
• The more common non-ferrous materials are the following metallic
element and their alloys.
1. Copper 2. Aluminum
3. Magnesium 4. Lead
5. Nickel 6. Tin
7. Zinc 8. Cobalt etc.

• Copper:
• The main grades of raw copper used for cast copper base alloy are:
1. High conductivity copper having not less than 99.9% Cu. The
oxygen content may be of the order 0.40% .Pb And Fe less than
0.005% each. Ag 0.002% and Bi less than 0.001%. Electrolytic
copper is used for electrical purposes.
2. Deoxidized copper having not less than 99.85% Cu, less than
0.05% As, 0.03% Fe, and 0.003% Bi other elements may be of
the order of 0.05% P, 0.01% Pb, 0.10% Ni, 0.003% and 0.005% Ag
and Sb respectively.
3. Arsenical de-oxidized copper having 0.4% As, 0.04% P and
remaining copper. It is used for welded vessels and tanks.
4. Arsenical touch pitch copper containing 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.
5. Oxygen free copper contains 0.005% Pb, 0.001% Ni, 0.001% Ag
and less than 0.0005% and 0.001% Fe, and Bi respectively. It is
melted and cast in non-oxidizing atmosphere.

• Copper possesses following properties:
– Excellent resistance to corrosion.
– Non-magnetic properties
– Easy to work, it is ductile and malleable.
– Moderate to high hardness and strength
– High thermal and electrical conductivity.
– It can be easily polished, plated and possesses a pleasing appearance.
– Resistance to fatigue, abrasion, and corrosion.
– It can be soldered, brazed or welded.
– Very good machine ability.
– Ease of forming alloys with other elements like zn, sn, al, ph, si, ni, etc.
• Copper is used for the following:
– Electrical parts
– Heat exchangers’
– Screw machine products
– For making various copper alloy, such as brass and bronze
– Household utensils, etc.

• Copper Alloys:
– Copper normally possess excellent corrosion resistance electrical
and thermal conductivities and formability.
– Some copper alloys combine high strength and corrosion
resistance, a combination desirable for marine applications.
– Some copper alloys because of their wearing properties, high
hardness or corrosion resistance are used as surfacing metals.
– Some copper alloys are selected for decorative applications
because of appearance.
– Elements such as aluminum, zinc, tin, beryllium, nickel, silicon,
lead etc. form alloys with copper.
– Copper alloys may be classified as:
1. Brasses – Alloys of copper and zinc
2. Bronze – up to 12% of alloying element
3. Cupronickels – alloy of copper and nickel
4. Nickel silvers – alloy of copper, nickel and zinc.

• BRASSES:
– Brasses contain zinc as the principle alloying element.
– Brasses are sub-divided into three groups.
• cu-zn allos
• cu, pb-zn alloys or leaded brass,
• cu-zn-sn alloys or tin brass
– Brass has high resistance to corrosion and is easily machinable. It
also acts as good bearing material.
– Zinc in the brass increases ductility along with strength.
– Brass possesses greater strength than copper however it has a
lower thermal and electrical conductivity.
– Various types of brasses are discussed below.
(1) Gilding Metal (2) Cartridge Brass (3) Admiralty Brass
(4) Aluminum Brass (5) Basis Brass (6) Muntz metal or yellow metal
(7) Leaded 60:40 brass (8) Naval brass

• Gilding Metal:
• The gilding metals cover a range from 5% to 15% Zn. And possess shades of
color from the red of copper to a brassy yellow.
• Cartridge Brass:
– Normally contains 70% Cu and 30% Zn. In the fully annealed condition it has a
tensile strength of over 300 N/mm2
• Admiralty Brass:
– Admiralty brass contains Cu 71%, Zn 28% and Sn 1%. The small amount of tin
added to brass improves its resistance to certain types of corrosion.
• Aluminum Brass:
– It contains 76% Cu, 22% Zn and 2% Al a little arsenic is added to inhibit
dezincification.
• Basis Brass:
– It contains copper 61.5 – 64%, the remainder being Zinc.
– Basis brass is used for press work where a relatively cheap material is required
and the main commercial forms are sheet, strip, and wire.

• Muntz metal or yellow metal:
– It contains 60% of copper and 40% of zinc and is essentially a hot working
material.
– It is manufactured in the form of hot rolled plate and hot rolled or extruded
section in a great variety of shapes and sizes. Yellow metal is frequently used as
a brazing alloy for steel.
• Leaded 60:40 brass:
– It the chief material fed to automatic lathes and similar machines. Usually in
the form of extruded bar.
– Lead is added to Cu-Zn alloy to promote machinability. The lead content ranges
from about 0.5% to as much as 3.5%.
• Naval brass:
– It contains Cu 60%, Zn 39.25% and Sn 0.75%. The purpose of tin is to improve
the resistance to corrosion.

• Bronzes:
– Bronze is a broad term defining an alloy of copper and elements
other than nickel or Zinc.
– Bronze is basically an alloy of copper and tin. Bronze possesses
superior mechanical properties and corrosion resistance than
brass. Bronze is comparatively hard and it resists surface wear.
– Bronze can be shaped or rolled in to wire rod and sheets.
– Different types of bronze are:
(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.
– The amount of residual phosphorus may range from a trace to
about 0.35% or even higher in some special grades.

– The excess phosphorus, which exists in solid solution, materially
increases the hardness and strength of the alloy, but it does so at
the expense of ductility.
– In amounts greater than 1.0% phosphorus causes excessive
brittleness and impairs surface appearance but affords a good
bearing surface, as is evident by the use of high phosphorus
bronze compositions for gears and other machine parts subject to
wear.
– A phosphorus bronze containing approximately 4% each of tin,
lead and zinc has excellent free cutting characteristics.
– Standard phosphor bronze for bearing applications contains 90%
Cu, 10% Sn, and 0.5% P, in sand cast condition it has a tensile
strength of 220-280 N/mm2 and % elongation 3 to 8 %.
– Phosphor bronze for gears contains 88% Cu, 12% Sn, 0.3% Zn,
0.50% Pb and 0.15 P. in sand cast condition, it has a tensile
strength of 220-310 N/mm2 and 5-15% elongation. This alloy is
also utilized for general bearings, where its rigidity of advantages.

(2) Aluminum bronze:
– Have the following compositions:
Cu Al Fe Sn Mn0.1
89 7 3.5 0.35 -
91 6.8 1.5-3.5 - 1 (max)
– Aluminum bronzes possess the following properties good strength
high corrosion resistance good heat resistance good cold working
properties.
– Aluminum bronze finds the following uses:
– Bearings, gears, slide valves, imitations jewellery, valve seat,
propellers, cams, pump part etc.

(3) Silicon bronze:
– Have the following compositions:
Si 1 – 4% Fe 0.5 – 1.0%
Mn 0.25 – 1.25% Cu Balance.
– Lead when added as 0.5% improves machine ability.
– Silicon bronzes posses high strength and toughness as that of mild
steel and corrosion resistance as that of copper.
– Silicon bronzes find the following uses.
– Bearings, roll mill sleepers, turntable bushing marine hardware,
ways and gibs, screw down nuts, boiler parts, Die cast parts etc.

• Gun Metal:
– Gun metal is an alloy of copper, tin and Zinc.
– Zinc cleans the metal and increases its fluidity
– A small amount of lead may be added to improve castability and
machiability.
(1) Admirality gun-metal:
– It contains 10% Sn, 2% Zn, 1.5% max pb, 1.5% max Ni, and balance
Cu, it has tensile strength of 260-340 N/mm2. It is widely used for
pumps, valves and miscellaneous casting and is also used for
statuary.
(2) Nickel gun-metal:
– It contains 7% Sn, 2.25% Zn, 0.3% pb, 2% max Ni when sand cast it
has a tensile strength of 200-270 N/mm2. This is among the most
widely used grades, particularly where pressure tightness is
required.
– In general gun metal is used for Bearings, steam pipe fittings,
marine castings, Hydraulic valves and gears, etc.

• Bearing materials:
– Bearings support moving parts, such as shaft and spindles, of a machine or
mechanism.
– Bearings may be classed as.
• Rolling contact bearings.
• Plain bearings.
– Rolling contact bearings are almost invariant by made of steel that can be
hardened after machining both plain carbon and alloy steel are employed for
different applications.
– For making plain bearings, an extremely wide range of materials is available
and will be discussed below.
• Properties of Bearings Materials:
– A bearing material should:
– Possess low co-efficient of friction.
– Provide hard wear resistance surface with a tough core.
– Have high compressive strength.
– Have high fatigue strength.
– 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 strength at high temp.
– Be such that it can be easily fabricated.

• Aluminum and Aluminum Alloys
– Aluminum is a silvery white metal and it possesses the following
characteristics.
1. It is a light metal, with a density about a third that of steel and
brass(2.7 gm/cm3)
2. Its electrical conductivity is about 60% of that of copper.
3. It has high thermal conductivity.
4. It is ductile and malleable.
5. It has a non magnetic and
non sparking in character.
6. Easy formability and
machinability.
7. It is good conductor of heat.

• Types of Al Alloys
– Aluminum alloy Can be classified.
1. Wrought alloy
2. Cast alloy
3. Heat treatable alloy
4. Non-heat-treatable alloys.
– Aluminum alloy contain
1. Al-Mn
2. Al-Mg
3. Al-Mg-Mn
4. Al-Mg-Si
5. Al-Cu-Mg
6. Al-Cu-Si
7. Al-Cu-Mg- Pb
8. Al-Mg-Si- Pb
9. Al-Zn-Mg-Cu

1. Percent composition of few wrought alloys are:
1. 4.4 Cu, 0.6 Mn, 1.5 Mg, balance Al (Duralumin)
2. 0.12 Cu, 1.2 Mn, Balance Al (Magnalium)
3. 2.5 Mg, 0.25 Cr, Balance Al (Hindalium)
4. 0.6 Si, 0.27 Cu,1.0 Mg, 0.2 Cr, Balance Al
2. Percent composition of few cast alloys are:
1. 12 Si, rest Al (LM-5) 3. 4 Cu, 3 Si, rest Al
2. 4.5 Cu, 5.5 Si, rest Al 4. 3.8 Mg, 1.8 Zn, rest Al
3. Percent composition of few heat treatable alloys are:
1. 3.9-5.0 Cu, 0.2-0.8 Mg, 0.5-1.0 Si, 0.5-1.0 Mn, rest Al
2. 0.5-1.2 Mg, 0.7-1.3 Si, 0.4-1.0 Mn, rest Al
3. 0.4-0.9 Mg, 0.3-0.7 Si, rest Al
4. Percent composition of few non heat treatable alloys are:
1. 0.8-1.5 Mn, Rest Al
2. 1.7-2.4 Mg, rest Al (LM-10)
3. 10-13 Si, rest Al
4. 5.0-5.5 Mg, 0.6-1.0 Mn, 0.05-0.20 Cr, rest Al

• Use of Al and Al-alloys
1. Transportation industry- Structural frame work, engine parts,
decorative features, hardware, doors, window frame, furnishing
and fitting.
2. Overhead conductor and heat exchanger parts.
3. In food industry, Al and its alloy find application as preparation
equipment, refrigeration, storage containers, bakery equipment,
shipping container.
4. Cryogenic application.
5. As heavy duty structure such as travelling Crain, hoists, conveyor
support, bridges.
6. In process industry, handle organic chemical petrochemicals and
drug.

• Magnesium and Magnesium Alloys
– Magnesium is a silvery white metal and has the lowest density of
the common structural materials.
– Properties:
1. High strength to weight ratio.
2. Good fatigue strength.
3. Good dimensional stability in service.
4. Good damping capacity.
5. Relative high electrical conductivity.
6. High thermal conductivity.
• Uses:
1. For making parts such as airframes, engines, gear boxes, flooring,
seating etc. for the helicopters, aero planes, missiles.
2. For material handling equipment such as hand trucks, conveyors,
foundry equipment.
3. For storage tank electric drills, chain saws, power hammer etc.
4. Moving parts of textile machines and printing equipment.
5. Binocular and camera bodies.
6. In the production of uranium, beryllium, zirconium, titanium etc.
7. Typewriters, dictating machine, calculator etc.

• Types of magnesium alloys:
1. Dow metal
• It contains 90% magnesium, 10% Aluminium and a small
addition of manganese
• It used in air craft industries and automobile industries
• It us extremely hard and can welded and machined
2. Cast alloys of magnesium
• Al 8, Zn 0.5, Mn 0.3 and mg balance
• Al 8, Zn 0.5, Mn 0.3, Be 0.0015 and mg balance
3. Wrought alloys of magnesium
• Zn 3.0, Zr (Zirconium) 0.6 and mg balance
• Th 0.8, Zn 0.6, Zr 0.6 and mg balance

• Titanium and its Alloys
• Characteristics:
– They are 40% lighter than steel and 60% heavier than aluminum.
The combination of moderate weight and high strength give
titanium alloys the highest strength to weight ration of any
structural metal.
– Melting point of titanium is higher than iron.
– It has low thermal conductivity.
– Titanium has good corrosion resistance.
– Its thermal coefficient of expansion is low.
– Its electrical resistivity is also high.
• Types of titanium alloys
1. Alpha alloys (alloying elements Al, Sn, Zr, V, Mo)
2. Beta alloys
3. Alpha and beta alloys

• Lead and its alloys
• Properties of lead:
– Resistance to corrosion and low melting point
– It is poisonous
– Heavy weight, high density, softness, malleability
– High coefficient of expansion and low electrical conductivity
• Application:
– For radiation shielding and production of paints
– For weight in counter weights
– It is used in copper alloys for good machinability
• Lead based alloys:
– It is applied where cheap and corrosion resistance material is
required. An alloy contains 8 to 10% Pb are used as bearing
metals.

• Nickel alloys (Home Work)
• Zinc alloys (Home Work)
• Tin alloys (Home Work)

Non-Ferrous Alloy

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Non-Ferrous Alloy