1. TOPIC : NON-FERROUS METALS AND ALLOYS

2. GROUP MEMBERS : 1) 140280119009 : Bhoya sandip k. 2) 140280119012 : Chaudhari ankit z. 3) 140280119027 : Gamit ankur a.

3. 1) INTRODUCTION  Non-ferrous metals are those which do not contain iron as base. The chief pure metals in the Non-ferrous group are aluminium, copper, lead, Tin and zinc.  The non-ferrous alloy which have gained popularity and largely replaced steels and cast iron in many engineering fields are light alloys.

4.  Non-ferrous metals are used for following reasons. Low density good formability Resistance to corrosion Softness and facility of cold working special electrical and magnetic propeties fusibility and ease of casting Attractive colour

5. 2) Copper and its alloys Copper and its alloys are most extensively Used among non-ferrous materials due to high Electrical conductivity and corrosion resistance. Copper is easily distinguished from all other metals due to its pinkish-red colour. It is relatively soft and it is very malleable, Ductile and flexible, yet very tough and strong. It is largly used in wire and sheet form for electrical Purposes owing to its second highest thermal and electrical conductivity among metals.

6. It can be easily fabricated, welded, brazed, soldered and machined. It is non-corrosive under ordinary conditions and it resists weather very effectively. Copper in the form of tubes is widely used in mechanical engineering(heat exchanger tubes etc. ) Copper alloys : Copper dose not find many engineering application due to its poor strength. Addition of Alloying elements such as zinc, tin, Aluminium, nickel etc. Result in the increase in the strength of copper by the method called “solid solution hardening “. some of the important copper alloys are as follows :

7. 1) Brasses : These are fundamentally copper and zinc alloys, with as much as 50 percent zinc. Various classes of brasses depend upon the proportion of copper and zinc are available for various uses. They are cartridge brasses (70 percent copper, 30 percent zinc). Muntz metal(60 percent copper,40 percent zinc) etc. Brasses can be subjected to the processes like casting, hot forging, cold forging, cold rolling into sheets, wire drawing and extrusion. Brasses are used in hydraulic fittings, pump linings, bearings, bushings, utensils etc.

8. 2) Bronzes : Bronze is an alloy of mainly copper and tin. The useful composition range is 5 to 25percent tin and 75 to 95 percent copper. The alloy as compared to brass is harder and stronger.  It resists surface wear and can be cast into shape Or rolled into wire, Rods and sheets very easily. It has better corrosion resistance than brass. It is used in hydraulic fittings, pump linings, utensils, bearings, bushes, sheets, rods, wires and many other stamped and drawn articles. Some of the important :

9. A)Phosphor bronze : A common type of wrought phosphor bronze contains 93.7 percent copper, 6 percent tin and 0.3 percent phosphorous. Phosphorous increases the strength, ductility, and soundness of castings. It is used for bearings for carrying heavy loads, worm wheels, gears, springs etc. B) Gun metal : it contains 88 percent copper, 10 percent tin and 2 percent zinc. It is very strong and resistant to corrosion by water and atmosphere. typical application of gun metal include gear-wheels, pump castings, bearings, bushings and marine fittings. C) Bell metal : It contains 20 percent tin and balance Copper. It is hard and resistant to surface wear. Bell metal is used for making bells such as church bells, School bells, bells for hospitals etc.

10. 3) Copper-nickel alloys : Copper and nickel form an isomorphous system in which copper are nickel are completely soluble in each other. With 20 percent nickel, the alloy is practically white. The corrosion resistant of these alloy increase with the nickel content. These alloy do not respond to heat treatment and their properties are altered only by cold working. Example of some of these alloy are cupronickel(2 to 30 percent nickel, balance copper) etc. cupronickels are used for surgical insrtuments, coins, utensils, ornaments, condensers, heat exchanger tubes etc.

11. 3) ALUMINIUM AND ITS ALLOY  Aluminium is a whit metal produced by electrical processes from the oxide. Its meting point is 600⁰C.  It has high electrical and thermal conductivity. It has high corrosion resistance in water, industrial and marine atmospheres. Aluminium has good machinability, Formability, workability, castability. It has high reflectivity and nontarnishing characteristics. It is nontoxic, nonmagnetic and nonsparking.  The main drawback of aluminium is its low hardness and poor strength. It is used widely in aircraft and automobile Industry, for overhead cables and electrical wiring, cooking Utensils etc.

12. Aluminium alloys : Aluminium finds widest uses when alloyed with small amounts of other metals.  The addition of small quantities of other alloying elements converts this soft, weak metal into a hard And strong metal.  Alloy can be classified as “Cast” or “Wrought” alloys. Some of the important aluminium alloys are as follows (1) Duralumin : It contains 3.5 to 4.5 percent copper, 0.4 to 0.7 percent manganese, 0.4 to 0.7 percent magnesium,0.4 percent silicon and remainder aluminium. It is widely used in wrought condition for forging, stampings, bars, sheets, tubes and rivets.  it posseses age-hardening property. On account of its high strength to weight properties it is used in automobile and aircraft industries. because of good electrical conductivity it is also used in electrical cables.

13. (2) Y-alloy : this is an important alloy developed from the binary copper-aluminium alloy by small addition of nickel, magnesium, silicon and iron. It Contains 3.5 to 4.5 percent copper,1.8 to 2.3 percent nickel, 1.2 to 1.7 percent magnesium, 0.6 percent(max.) silicon, 0.6 percent (max.) iron and remainder aluminium.  This alloy has characterstics of retaining good strength at high temperature. Y-alloy is therefore, useful for piston and other components of aeroengines. It is also largely used in the form of sheets and stripes.

14. 4) MAGNESIUM ALLOY : Magnesium is the lightest structural metal. It is having HCP crystal structure. It is relatively soft and low modulus of elasticity. At room temperature it is difficult to deform magnesium. It has low melting point (651⁰C).it is susceptible to corrosion in marine environment. But in normal atmosphere it has good corrosion and oxidation resistance.  Mgnesium alloys are heat treatable. Main alloying elements are aluminium, zinc, manganese, and rare earth metal. Magnesium-aluminium alloy have good tensile strength, yield strength and ductility. It is used pressure-tight casting and highly stressed extrusion.Magnesium-zinc- zirconium and magnesium-zinc-thorium are casting alloys.

15. The addition of zirconium up to 0.7% result in grain refinement and improves mechanical properties.  Addition of thorium produce sound casting, free of microporosity and hot cracks. Magnesium- zinc-thorium alloys are used in missile and aircraft. Magnesium-zinc-zirconium alloys are used in forgings as maximum strength for aircraft. 5) TITANIUM ALLOYS : Titanium has high melting point 1668⁰C, extremely strong, high tensile strength, high ductile metal. It is easily forged and machined. Only limitation of titanium is that it is chemically reactive with other materials at elevated temperature.

16. Titanium-aluminium-tin(ti-5Al-2.5Sn) alloys have good strength. Aluminium is the most effective strenghtner of alpha alloys. It is used in aircraft tailpipe assembly, missile fuel tanks, etc. Titanium-aluminium-vanadium (Ti-6Al- 4V) alloys are alpha-beta alloys. It has high strength. It is used in sheet metal air frame parts, forged airframe fittings, etc. Titanium-aluminium-vanadium-chromium (Ti-3Al-13V-11Cr) alloys are beta alloys and can be strengthened by heat treatment. It is weldable alloy. It is used as high strength fasteners, aerospace components requiring high strength at moderate temperature.

17. 6) LEAD AND ITS ALLOYS :  Lead is very soft, malleable and ductile metal and can be rolled easily. It is corrosion resistance and many acid have no chemical action on it. Due to this, it is used for water-pipes, roof covering, the sheathing of electric cables and for construction materials of chemical plants. It has high absorbing power for radiation like X-rays and g-rays and therefore, is used as a shielding against these radiations. Largest tonnage of lead is used in the manufacture of storage batteries.  It is used as an alloying element to improve the machinability of bronzes, brasses and steels. Due to its high density and castability lead is used as type metal in printing industry.

18. Lead alloys : lead alloyed with tin forms “solders”. Lead alloyed with tin and antimous makes “bearings”. Lead alloyed with antimony-tin and copper makes “type metal”. Alloyed with small percentage of arsenic, lead is used to produce shots for ammunitions. 7) TIN :  Tin is white soft and malleable metal. It has good corrosion resistance to atmosphere condition and to organic acids. It has a greatest importance as a coating on steel (called tin cans), and as an alloy constitute in soft solders, collapsible tubes, pewter ware, costume jewellery, bronze and bearing lining.

19. 8) ZINC :  Zinc is known as a white metal because of its colour (bluish-white) and low melting point (419⁰C). The protection of iron and steel from corrosion is done more often with zinc than with any other metal coating.It is done by “galvanizing”. When rolled into sheets, zinc is used for roof coverings. Zinc casts well and forms the base of various die-casting alloys. They are low in cost, easy to cast and have high strength. Zinc is also used in the production of dry cells because of its high potenetial, as an alloying element in brasses, bronzes etc.

20. 9) NICKEL ALLOYS :  Nickel has FCC crystal structure and good formability. It has high strength and high melting point. Nickel alloys are used for their corrosion resistance and high temperature resistance.  Monel is an alloy of nickel, having copper as an alloying element. The nickel content is near 60%. It shows high corrosion resistance in salt water and high strength at elevated temperature. Some of the monel contains small amounts of aluminium and titanium.  Nickel base superalloy contain alloying elements to produce a combination of high strength at elevated temperature, corrosion resistance and resistance to creep. The typical application include heat exchangers, vanes and blades for turbine and jet engines, chemical reaction vessels etc.

21. 10) WHITE METAL AND BEARING ALLOYS :  White metal alloy consists of some of the alloying elements like antimony, tin, lead, cadmium, bismuth and zinc. White metal has a light coloured appearance and used for bearings, jewellery, fusible pugs, medals, etc.  Tin-lead and tin-copper alloys such as babbit metal low melting point and is used as solder.  For bearing, the ideal characteristic are hardness, wear resistance and low coefficient of friction. Thus alloying elements such as antimony is added in bearing alloy. Small and hard particles of antimony embedded in tough and ductile matrix improve the wear resistance.