Engineering Alloys (Non Ferrous)

Engineering Alloys
Non - Ferrous
NON FEROUS MATERIALS
 COPPER AND ITS ALLOYS
 ALUMINUM AND ITS ALLOYS
 TITANIUM AND ITS ALLOYS

COPPER AND ITS ALLOYS
 COPPER
 BRASSES (Cu- Zn ALLOY)
 BRONZES
 COPPER- NICKEL ALLOYS

COPPER
PROPERTIES OF COPPER
 High electrical conductivity (best among

conductors)
 It has good ductility and malleability

because of its FCC structure
COPPER
 Good corrosion resistance to general

atmospheric conditions
 Good thermal conductivity
 Good machinability and ease of

fabrication
COPPER
APPLICATIONS
 Used for making electrical

conductors(99.9% purity)
 Automobile radiators and in

refrigerators for circulating fluids.
COPPER
 Used in distillery and in other process
equipments (due to its good corrosion
resistance and non-toxic nature of
copper ions)
 The free cutting copper ( 0.6%

tellurium copper), which has excellent
machinability, is used for bolts, welding
tips, switch gears, relays, etc.
NEXT
BRASSES
 Brasses are the alloys of Copper and
Zinc.
 Equilibrium diagram of Cu-Zn
  -Brasses
  + Brasses
BRASSES
L
+L +L
910°C
 
+ +
 450ºC
+' '
10 20 30 40 50 %Zn
ga tion
n
%Elo
t r e ngth
S
Cu-Zn Equilibrium diagram and mechanical properties

BRASSES
 The equilibrium solubility of Zn in Cu is

around 38% ( i.e, the  phase or FCC
structure) and is sharply influenced by
cooling rate.
 Under industrial cooling rates, the

solubility reduces to 30%.
BRASSES
 As the Zn addition exceeds the solubility
limit a second phase  (BCC) is formed.
 And around 450°C the  phase

undergoes a order-disorder
transformation and below 450 °C it
forms ordered structure of  ( i.e, '
phase)
BRASSES
 The tensile strength and ductility of
brass increases with increasing amount
of Zn upto 30% ( i.e, the solubility limit)
 With the appearance of the  phase (ie,

>30%) the strength continues to
increase but the ductility begins to
decrease.
BRASSES
 Therefore, most commercial alloys

contains less than 40%Zn.
 Upto 20% the colour of brass is red and

beyond 20% it becomes yellow.
NEXT
 -BRASSES
TYPES, PROPERTIES & APPLICATIONS
 These are the alloys contain less than

30%Zn.
 They are soft, ductile, malleable and

have fairly good corrosion resistance in
annealed condition and are suitable for
cold rolling, wire drawing, etc.
 -BRASSES
 Gliding metal (5%Zn) used for making
coins, medals, bullet envelops,
condenser tubes, etc.
 Cartridge brass ( 30%Zn) has

maximum ductility and malleability
among all the -brasses.
 -BRASSES
 Cartridge brass is also called 70-30
brass.
 Formed by deep drawing, stretching

and press work operations.
 Used for making cartridge cases,

radiator fins, rivets and springs.
NEXT
 + BRASSES
 These are the 30 - 40%Zn alloy which

contains two (  + ) phases.
 They are hard and strong and fabricated

by hot working process (above 600°C) .
 Corrosion resistance of these alloys are

less compared to - Brasses.
 + BRASSES
 Muntz metal ( 40%Zn) is used for
utensils, nuts, bolts, pump parts,
condenser tubes, and similar applications
where corrosion resistance is not severe.
 Naval brass or Tobin brass ( 60Cu/ 39Zn/

1Sn) has good corrosion resistance
towards marine environments.
 + BRASSES
 The addition of tin increases the

corrosion resistance towards marine
environment in Naval brass.
 It is used for marine hardware,

propeller shafts, piston rods, welding
rods, etc.
NEXT
BRONZES
 Bronze is the alloy of copper containing

elements other than zinc ( i.e, Sn, Al, Be,
etc.)
 Originally the name bronze was used to

denote Copper- Tin alloy.
BRONZES
 Bell metals (20-25%Sn) used for making

bells are very hard and brittle and give
ringing sound.
 Gun metal (88Cu/10Sn/2Zn) used for

gun barrels and ordinance parts,gears,
bearings, etc (Here Zn acts as deoxidiser
and improves fluidity of melt)
BRONZES
 Statuary bronze (86Cu/10Sn/2Zn/2Pb)
used for making statues( Here Pb gives a
brownish black colour called patina to
statues)
 Wrought phosphor bronze ( 2.5-8% Sn

and 0.1-0.35%P) are used for making
springs and electrical contacts.
BRONZES
 Commercial aluminum bronze or

imitation gold (4-11%Al) are lustrous
and their colour is the finest of all the
copper alloys.
 The imitation gold is used in jewellery,

heat exchangers, chemical plants, etc.
NEXT
Cu – Ni ALLOYS
 Copper and Nickel are completely
soluble with each other both in solid and
liquid states and hence form a
continuous series of solid solutions.
 All the alloys are ductile and malleable

and can be worked in both hot and cold
conditions.
Cu – Ni ALLOYS
 The corrosion resistance of the alloy
increases as the Ni content increases.
 Tensile, proof and fatigue strengths

increases with the Ni content, and reaches a
maximum between 60 - 70%Ni.
 The alloy becomes progressively white and

beyond 20%Ni it becomes practically
white.
Cu – Ni ALLOYS
 Constantan (45%Ni) has a very high
electrical resistivity and a extremely low
(i.e nearly zero) temperature coefficient
of resistance over a temperature range
of 20- 350°C.
 Constantan is used for resistors and in

thermocouples.
Cu – Ni ALLOYS
 German silver (5-30%Ni, 5-40%Zn)

alloys have silver-blue white colour and
good resistance to the action of food
chemicals, water and atmosphere and
are used for rivets, screws, costume
jewellery, name plates, etc.
NEXT
ALUMINUM AND ITS ALLOYS
 ALUMINUM
 ALUMINUM – COPPER ALLOYS
 ALUMINUM – SILICON ALLOYS
 Y-ALLOY
 CORROSION RESISTRANCE OF Al & ITS ALLOYS

ALUMINUM
PROPERTIES OF ALUMINUM
 It has FCC structure, good

machinability and workability.
 Low density (1/3 of steel or Cu alloys)
 Good electrical conductivity (about 60%

of Cu, but for equal weight the
conductivity is 200% of Cu)
ALUMINUM
 High thermal conductivity.
 Excellent corrosion resistance and

oxidation resistance due to the
formation of Al2O3 film on the metal
surface.
 Excellent ability of getting alloyed with

other elements like Cu, Si, Mg, Zn, etc.
ALUMINUM
APPLICATIONS
 It has applications where good

formability or very good resistance to
corrosion or both are required and high
strength is not required.
 Used in food packing due to the non-

toxic nature of Al2O3.
ALUMINUM
 Due to very low ductile to brittle
transition temperature (i.e, - 40°C),
finds application in refrigeration.
 It is a powerful grain refiner and is used

in Copper and Brasses to reduce their
cast grain sizes, thereby to increase
mechanical properties with improved
surface finish at lower cost.
ALUMINUM
 Used in the de-oxidation of steel in
manufacturing of killed steels.
 Used in making permanent magnets,

shape memory alloys and space alloys.
 Used as electrical conductors, cooking

utensils, transportation industry, etc.
NEXT
ALUMINUM-COPPER ALLOYS
 The Al-Cu alloys are heat treatable

alloys.
 Max solubility of Copper in aluminum is

5.65% (at 550°C) and <0.5% at room
temp.
ALUMINUM-COPPER ALLOYS
 Duralumin (4%Cu) is used for making
rivets for aircrafts.
 Has high specific strength (200MPa)

(for high strength steels 170MPa).
 It is a natural ageing alloy and is stored

in refrigerators.
NEXT
ALUMINUM-SILICON ALLOYS
 The Al-Si alloys are used in castings due to

excellent fluidity.
 Higher the silicon content, better the

mechanical properties, corrosion and
oxidation resistance and lower the coefficient
of thermal expansion with improved fluidity
and casting characteristic.
 However, with increase in silicon
content the amount of eutectic increases
which reduces the mechanical
properties.
 For hypereutectic compositions, the

presence of primary silicon further
reduces the mechanical properties.
577°C
Temperature
1.65
4 8 12 16
%Si
Al – Si Phase diagram
 The eutectic composition is increased
and the eutectic temperature is reduced
by adding small amount of modifying
agents such as metallic sodium to the
melt prior to pouring.
 Therefore, the alloys upto 16%Si gets

solidified as eutectic or hypoeutectic
without the presence of primary silicon.
 The 12% Si alloy has excellent fluidity
and shows less shrinkage during
solidification.
 They are used for casting intricate

shapes in automobile industries such as
water cooled jackets, motor housing,
etc. and for pump parts in chemical
industries.
NEXT
Y - ALLOY
 The composition of this alloy is 4%Cu,
2%Ni and 1.5%Mg and the rest is
aluminum.
 It has excellent high temperature

strength with fairly good corrosion
resistance and can be easily cast.
 It is used for piston and cylinder heads

of diesel and heavy duty petrol engine.
NEXT
CORROSION RESISTRANCE
 The high corrosion resistance is due to

the formation of self protecting thin
oxide film.
 The thickness of the thin film can be

increased by placing the material in
aqueous solution containing 15-25%
sulfuric acid and is called anodizing.
 The high strength alloys like Al- Cu and

Al- Zn alloys are clad with commercial
aluminum or Al-Mg-Si to get better
corrosion resistance and this process is
called Alcladding.
 The normal cladding thickness per side

is 1½ to 2½ % of the thickness of the
base metal sheet.
 Cladding is a process of producing

composite of the coating slabs and the
core ingot.
 This is done by mechanically attaching

the coating slab and the alloy core ingot
and the chemical bonds are produced by
hot rolling.
NEXT
TITANIUM AND ITS ALLOYS
 TITANIUM
 TITANIUM ALLOYS
TITANIUM
 Titanium is produced from TiO2.
 The melting point of titanium is 1720°C.
 It exists in HCP structure () at room

temperature and transforms to BCC ()
at 882°C.
TITANIUM
 It has higher specific strength, good

corrosion resistance and other high
temperature properties.
 An adherent protective TiO2 film

provides excellent resistance to
corrosion below 535°C.
TITANIUM
 Above 535°C the film breaks and small
atoms such as Carbon, Oxygen,
Nitrogen and Hydrogen embrittle the
titanium.
 It is used in chemical processing

equipment, airframes, marine
components and biomedical implants
such as hip prostheses.
NEXT
TITANIUM ALLOYS
 Alloying elements provide solid solution
strengthening and change the allotropic
transformation temperature.
 Addition of Sn, Zr provide solid solution

strengthening without affecting the
transformation temperature.
TITANIUM ALLOYS
 Al, O, H, etc. increases the
transformation temperature (i.e,
  ) and are called -
stabilizers.
 V, Ta, Mo and Nb lowers the

transformation temperature are called
- stabilizers.
TITANIUM ALLOYS
 Single phase alpha alloys are weldable

and having good ductility.
 Two phase alloys are stronger than

single phase - alloys because BCC  is
stronger than HCP .
TITANIUM ALLOYS
 The important two phase alloy is Ti –

6Al – 4V.
 Used for making airframes, rockets, jet

engines, missile fuel tanks, human
implants, etc.

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Engineering Alloys

 COPPER AND ITS ALLOYS

 ALUMINUM AND ITS ALLOYS

 TITANIUM AND ITS ALLOYS

 BRASSES (Cu- Zn ALLOY)

 COPPER- NICKEL ALLOYS

 High electrical conductivity (best among

 It has good ductility and malleability

 Good corrosion resistance to general

 Good thermal conductivity

 Good machinability and ease of

 Used for making electrical

 Automobile radiators and in

 The free cutting copper ( 0.6%

 Equilibrium diagram of Cu-Zn

Cu-Zn Equilibrium diagram and mechanical properties

 The equilibrium solubility of Zn in Cu is

 Under industrial cooling rates, the

 And around 450°C the  phase

 With the appearance of the  phase (ie,

 Therefore, most commercial alloys

 Upto 20% the colour of brass is red and

 These are the alloys contain less than

 They are soft, ductile, malleable and

 Cartridge brass ( 30%Zn) has

 Formed by deep drawing, stretching

 Used for making cartridge cases,

 These are the 30 - 40%Zn alloy which

 They are hard and strong and fabricated

 Corrosion resistance of these alloys are

 Naval brass or Tobin brass ( 60Cu/ 39Zn/

 The addition of tin increases the

 It is used for marine hardware,

 Bronze is the alloy of copper containing

 Originally the name bronze was used to

 Bell metals (20-25%Sn) used for making

 Gun metal (88Cu/10Sn/2Zn) used for

 Wrought phosphor bronze ( 2.5-8% Sn

 Commercial aluminum bronze or

 The imitation gold is used in jewellery,

 All the alloys are ductile and malleable

 Tensile, proof and fatigue strengths

 The alloy becomes progressively white and

 Constantan is used for resistors and in

 German silver (5-30%Ni, 5-40%Zn)

 ALUMINUM – COPPER ALLOYS

 ALUMINUM – SILICON ALLOYS

 CORROSION RESISTRANCE OF Al & ITS ALLOYS

 It has FCC structure, good

 Low density (1/3 of steel or Cu alloys)

 Good electrical conductivity (about 60%

 Excellent corrosion resistance and

 Excellent ability of getting alloyed with

 It has applications where good

 Used in food packing due to the non-

 It is a powerful grain refiner and is used

 Used in making permanent magnets,

 Used as electrical conductors, cooking

 The Al-Cu alloys are heat treatable