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1. Non-Ferrous Materials
Group 2 – Andang, Crusis, Macaso, Pagtalunan

2. • The elements of tools, machines and
equipment should be made of such a material
which has properties suitable for the
conditions of operation.
• An engineer should always be familiar with
various kinds of engineering materials
including non-ferrous materials, their
properties, and applications to meet the
functional requirements of the design
product.

3. • Although the nonferrous metals as a group cannot
match the strength of the steels, certain
nonferrous alloys have corrosion resistance
and/or strength-to-weight ratios that make them
competitive with steels in moderate-to-high stress
applications.
• The non-ferrous metals are used for the following
purposes namely resistance to corrosion, special
electrical and magnetic properties, softness,
facility of cold working, fusibility, ease of casting,
good formability, low density and attractive color.

4. Aluminum

5. • Prepared from a mineral called bauxite
• Extraction of Aluminum can be summarized
in 3 steps: (1) washing and crushing of
bauxite into fine powders, (2) the Bayer
process that converts bauxite into pure
alumina (Al2O3); and (3) electrolysis that
separates alumina into aluminum and
oxygen gas.

6. Properties
• has silvery color and lusture
• ductile, malleable and very good conductor of heat
and electricity
• has a very high resistance to corrosion than the
ordinary steel
• tensile strength varies from 95 to 157 MN/m2
• when mixed with small amounts of other alloys, it
becomes hard and rigid
• a very ductile metal and is noted for its formability

7. Applications
• mainly used in aircraft and automobile parts
where saving of weight is an advantage
• useful metal for cooking utensils under
ordinary conditions
• widely used for reflectors, mirrors and
telescopes
• Aluminium foil is used as silver paper for
food packing etc.

8. Alloys
• may be easily alloyed with other elements
like copper, magnesium, zinc, manganese,
silicon and nickel to improve various
properties
• converts the soft and weak metal into hard
and strong metal, while still retaining its
light weight
• Various aluminum alloys are: Duralumin, Y-
alloy, Magnalium and Hindalium

9. Copper

10. • one of the most widely used non-ferrous
metals in industry
• extracted from ores of copper such as copper
glance, copper pyrites, melachite and azurite
• Copper ore is first ground and then smelted
producing an impure alloy. Then the air is
blown through the molten metal to obtain
blister copper. Copper is then refined further
using electrolysis processes.

11. • has a distinctive reddish-pink color
• soft, malleable and ductile metal
• good conductor of electricity and heat
• non-corrosive under ordinary conditions and
resists weather very effectively
• tensile strength varies from 300 to 470
MN/m2
• can withstand severe bending and forging
without failure

12. Applications
• mainly used in making electric cables and
wires for electric machinery, motor winding,
electric conducting appliances, and
electroplating etc.
• easily forged, casted, rolled and drawn into
wires
• in the form of tubes is used widely in heat
transfer work

13. • used in production of boilers, condensers,
roofing etc.
• used in making valves and bearings

14. Alloys
• Important copper alloys are: Copper-zinc
alloys (Brasses) and Copper-tin alloys
(Bronzes)
• Has wide range of applications

15. Brasses
• widely used alloy of copper (main
constituent) and zinc
• by adding small quantities of other
elements, properties of brass may be greatly
changed
• has a greater-strength than that of copper,
but has a lower thermal and electrical
conductivity

16. • very resistant to atmospheric corrosion and
can be easily soldered
• Phases of brass are: Alpha phase, Beta phase
and Gamma phase
• Various types of brasses are: Red Brass,
Yellow brass or Muntz Metal, Cartridge Brass,
Admiralty Brass, Naval Brass, Manganese
Brass, Iron Brass or Delta Metal, Gilding
Brass, Free Cutting Brass, and Lead Brass

17. Bronzes
• a common alloy of copper and tin
• comprises 75 to 95% copper and 5 to 25%
tin
• has higher strength, better corrosion
resistance than brasses
• comparatively
• hard and resists surface wear and can be
shaped or rolled into wire, rods and sheets
very easily

18. • has antifriction or bearing properties
• tensile strength of bronze increases
gradually with the amount of tin, reaching a
maximum when tin is about 20%
• most ductile when it contains about 5% of
tin
• presence of zinc in the bronze increases
fluidity of molten metal, strength and
ductility

19. • Common types of bronze are: Phosphor
Bronze, Silicon Bronze, Beryllium Bronze,
Manganese Bronze, Aluminum Bronze and
Bell Metal

20. Constantan
• Composed of
Cu = 55%
Ni = 45%
• has high specific resistance
• Specific resistance is unaffected by
temperature variation
• used for accurate resistors like thermo-
couples, Wheet-stone bridge, low
temperature heaters and resistances.

21. Nickel

22. • similar to iron in many aspects
• a silvery shining white metal having
extremely good response to polish
• most important nickel’s ore is pentlandite
• the ore is first crushed and ground with
water
• Flotation techniques are used to separate
the sulfides from other minerals mixed with
the ore

23. • nickel sulfide is then heated to burn off
some of the sulfur, followed by smelting to
remove iron and silicon
• further refinement is accomplished in a
Bessemer-style converter to yield high-
concentration nickel sulphide (NiS).
• electrolysis is then used to recover high-
purity nickel from the compound

24. Properties
• is as hard as steel but is more corrosion
resistant and the high temperature
properties of its alloys are generally
superior
• possesses good heat resistance
• Nickel alloys are sometimes used for their
high potential field strengths, some for their
permeability and some for their high
coercive force

25. • when it contains small amount of carbon, it
is quite malleable
• less ductile than soft steel, but small amount
of magnesium improves ductility
considerably

26. Applications
• used in kitchen utensils and appliances, and
in laundry and dairy machinery
• extensively useful for electroplating plating
work for protecting surfaces of iron and
brass from corrosion
• helpful for making stainless steel

27. Alloys
• Important nickel alloys are: Monel Metal,
Inconel, nomonic and ni-chrome

28. Lead

29. • a bluish grey metal with a high metallic
lusture when freshly cut
• a very durable and versatile material

30. Properties
• Has high density and easy workability
• has very good resistance to corrosion and
many acids have no chemical action on it
• softest and heaviest of all the common
metals
• very malleable and may be readily formed
into foil
• can readily be scratched with fingernail
when pure

31. Application
• used in safety plug in boilers, fire door releases
and fuses
• finds extensive applications as sheaths for
electric cables, both overhead and underground
• sheets are used for making roofs, gutters etc.
• employed for chemical laboratory and plant
drains
• an alloy of lead and tin is most widely utilized as
a solder material for joining metals in joining
processes

32. Zinc

33. • zinc blende or sphalerite is the principal ore
of zinc
• other important ores include smithsonite,
which is zinc carbonate (ZnCO3), and
hemimorphate, which is hydrous zinc silicate
• The oxide is heated in an electric furnace
where the zinc is liberated as vapor. The
vapors are then cooled in condensers to get
metallic zinc.

34. Properties
• tensile strength is 19 to 25 Mpa
• becomes brittle at 200°C and can be
powdered at this temperature
• possesses high resistance to corrosion
• can be readily worked and rolled into thin
sheets or drawn into wires by heating it to
100-150°C

35. Applications
• zinc is the fourth most utilized metal after iron,
aluminium, and copper
• commonly used as a protective coating on iron
and steel in the form of a galvanized or sprayed
surface
• used for generating electric cells and making
brass and other alloys
• Parts manufactured by zinc alloys include
carburetors, fuel pumps, automobile parts, and
so on.

36. Tin

37. • recognized as brightly shining white metal
• Main source of tin is tinstone
• To obtain crude tin, the ores of tins are
crushed, calcined, washed and then smelted in
a furnace using anthracite coal and sand.
• The crude tin is then refined in a reverberatory
furnace to get commercially pure tin.
• Chemically pure tin is made by electrolytic
deposition from commercial tin.

38. Properties
• does not corrode in wet and dry conditions
• soft and ductile material
• possesses very good malleability

39. Applications
• commonly used as a protective coating
material for iron and steel
• commonly used to make bearings that are
subjected to high pressure and load
• used as coating on other metals and alloys
owing to its resistance to corrosion
• employed in low melting point alloys as a
substitute for Bismuth

40. • generally preferred as moisture proof
packing material
• finds application in tin cans for storing food
and food items

41. Alloy
• also known as Babbitt metal
• Contains
Sn = 88%
Sb = 8%
Cu = 4%
• possesses excellent antifriction properties and
sufficient mechanical strength
• can be easily casted
• expensive because of high tin content

42. Bearing or anti-
friction alloys

43. • commonly possesses good wearing quality,
low coefficient of friction, high thermal
conductivity, good casting qualities, non-
corrosive properties, ability to withstand
high pressure and impact, low shrinkage
after coating and less cost
• Various bearing metals are: Admiralty Gun
Metal, Lead Bronze and Hard Bearing
Bronze

44. Cutting tool Material

45. High Speed Steel
• have superior hot hardness and it can retain
the hardness up to 900°C
• Its three types are: 18-4-1 High Speed Steel
– has 18% tungsten, 4% chromium, 1% vanadium
and 0.7% carbon: This is used for machining or
metal cutting speed above 50 m/min.
– for higher cutting speed vanadium is increased.

46. Molybdenum High Speed Steel
• has 6% Molybdenum, 4% chromium and
2% vanadium

47. Cobalt High Speed Steel
• also known as super high speed steel
• has 1-12% cobalt, 20% tungsten, 4%
chromium and 2% vanadium
• very good for high cutting speed

48. • Other cutting tool materials are as follows:
ceramics tool, carbides tool and diamond

49. Ceramics Materials

50. • are non-metallic solids made of inorganic
compounds such as oxides, nitrides, borides
and carbides
• are fabricated by first shaping the powder with
or without the application of pressure into a
compact form and after that it is subjected to
high temperature
• possesses electrical, magnetic, chemical and
thermal properties which are exceptionally
good

51. Applications
• utilized for making electronic control
devices, computers, structures, components
of nuclear engineering and aerospace field

52. COMPOSITES

53. • are mixture of materials such as metal and
alloys and ceramics, metals and organic
polymers, ceramics and organic polymers

54. Applications
• Examples of composites are: Vinyl coated
steels, steel reinforced concrete, fiber
reinforced plastics, carbon reinforced
rubber etc.
• used for making sports items, structures,
and electrical devices

55. SemiConductors

56. • are solid materials, either non-metallic
elements or compounds which allow
electrons to pass through them
• occupy intermediate position between
conductors and insulators
• usually have high resistivity, negative
temperature coefficient of resistance and
are generally hard and brittle

57. Applications
• Examples of Semiconductors are:
Germanium (Ge), Arsenic (As), Silicon (Si),
Boron (B), Sulphur (S), Selenium (Se).
• utilized in making devices used in areas of
telecommunication and radio
communication, electronics and power
engineering, photocells, rectifiers etc.

58. Organic Polymers

59. • consist of carbon chemically combined with
usually with hydrogen, oxygen or other non-
metallic substances
• formed by polymerization reaction in which
simple molecules are chemically combined
into long chain molecules

60. Applications
• Examples of organic polymers are: Nylon,
Teflon, Polyethylene, PVC, Terylene, Cotton
etc.
• used in making packings, pipes, covers and
insulating materials etc.

61. Plastics

62. • commonly known as synthetic resins or
polymers
• plastic materials are fairly hard and rigid
and can be readily molded into different
shapes by heating or pressure or both
• Various useful articles can be produced
from them rapidly, accurately and with very
good surface quality

63. • are recognized by their extreme lightness, good
corrosion resistance and high dielectric
strength
• are very attractive organic engineering
materials and find extensive applications in
industrial and commercial work such as
electrical appliances, automotive parts,
communication products bodies (Telephone,
Radio, TV), and those making household goods

64. Properties
• Plastics are light in weight and at the same
time they possess good toughness strength
and rigidity
• They are less brittle than glass, yet they can
be made equally transparent and smooth
• Their high dielectric strength makes them
suitable for electric insulation
• They resist corrosion and the action of
chemicals

65. • The ease with which they can be mass-
produced contributes greatly to their
popularity as wrappers and bags
• They possess the property of low moisture
absorption
• They can be easily molded to desired shapes
• They can easily be made colored
• They are bad conductance of heat

66. • They are hard, rigid and heat resistance
• They possesses good deformability, good
resiatance against weather conditions, good
colorability, good damping characteristics
and good resistance to peeling

67. Classification
• Plastics are classified into thermo plastics and
thermo-setting plastics.
• Thermo Plastics
– plastics which can be easily softened again and
again by heating
– retain their plasticity at high temperature
– On cooling they become hard
– Sometimes also called as cold-setting plastics
– can be very easily shaped into tubes, sheets,
films, and many other shapes as per the need

68. – Types of thermo plastics are:
• Amorphous
– Polysterene
– Acrylonitrite-butadiene-styrene
– Mrthacrylate
– P.V.C (Polyvinyl chloride)
– Polychloroacetal
– Auorinated polymers
– Polycarbonate
• Crystalline
– Polyethylene
– Polyamides
– Polyacetal
– Polypropylene

69. • Thermo-Setting Plastics
– plastics which are hardened by heat, effecting a
non-reversible chemical change, are called
thermo-setting
– acquire a permanent shape when heated and
pressed and thus cannot be easily softened by
reheating

71. Fabrication
• Thermo plastics can be formed by:
– Injection molding
– Extrusion
– Blow molding
– Calendaring
– Thermo-forming
– Casting

72. • Thermo-setting plastics can be formed by:
– Compression or transfer molding
– Casting
• Thermo plastics can be joined with the help
of :
– Solvent cements
– Adhesive bonding
– Welding
– Mechanical fasteners

73. • Thermo-setting plastics can be joined with
the help of:
– Adhesive bonding
– Mechanical fasteners

74. Additions in Polymers
• Catalysts
• Fillers
• Modifiers
• Plasticizers
• Stabilizers
• Initiators
• Dyes and pigments