Unit 1 Nonferrous Metals and Alloys - 1.pptx

Sanjivani Rural Education Society’s
Sanjivani College of Engineering, Kopargaon-423 603
(An Autonomous Institute, Affiliated to Savitribai Phule Pune University, Pune)
NAAC ‘A’ Grade Accredited, ISO 9001:2015 Certified
Department of Mechanical Engineering
Dr.S.R.Thorat
Assistant Professor
E-mail : thoratsandipmech@sanjivani.org.in
Subject :- Advanced Materials and Technology (ME405D)
B. Tech
Unit 1- Nonferrous Metals and Alloys

Contents
• Classification of nonferrous metals.
• Importance of nonferrous metals in engineering applications & compositions,
• study of different mechanical properties: Cu & Cu based alloys, Al and Al based alloys,
Ni and Ni based alloys, Co and Co based alloys, Titanium & its alloys, Tin & Lead base
alloys,
• Bearing materials: important properties & applications.
Dr. S.R.Thorat/Mech Engg Dept/Sanjivani COE Kopargaon

Introduction
• The important non-ferrous materials:
• Copper and its alloys
• Aluminium and its alloys
• Nickel and its alloys
• Bearing materials
• Titanium and its alloys
• Soldering and brazing alloys
• Importance of Non-Ferrous Metals in Engineering:
• Low density, hence light in weight.
• High electrical conductivity.
• Easy to fabricate.
• High corrosion resistance
Thorat S.R. Department Of Mechanical Engineering, Sanjivani COE, Kopargaon

Comparison between Ferrous and Non ferrous Metals
Prof. S.R.Thorat/Mech Engg Dept/Sanjivani COE Kopargaon
S
N
Ferrous metals Non-ferrous metals
1
Ferrous metals mostly containsiron as a main
constituent.
Non-ferrous metals do notcontain iron.
2 Ferrous metals are magnetic. Non-ferrous metals are non- magnetic
3 They give little resistance tocorrosion
They are usually more
resistant to corrosion thanferrous metals.
4
Ferrous metals includes mildsteel, carbon steels,
cast iron, wrought iron etc.
Non-ferrous metals includes copper, aluminium, nickel,
tin, lead, zinc etc.
5
Ferrous metals are heavier, have high strength
anddurability.
Non-ferrous metals are much higher and malleable than
ferrous metals.
6
They are suitable for building construction, rail-
road,bridges, piping etc.
They are suitable forelectrical wiring, electronic
components, heat exchangersetc.

1.Copper and its Alloys (Cu):
• The total consumption of copper and copper alloys in the form of different
products:
Fig.Different use of copper and copper alloys
Fig.Alloying element added in copper
• Copper is available in wires, rods, tubes, thin sheets,
stripsand foils.
• The relative density of copper is 8.93 and the
melting point is 1083°C, with FCC structure
• Major alloying elements are: Zn, Sn, Al, P, Pb, Be,
Fe, Si, Ni, Mg and Mn.

• Copper, which is a pinking red metal possesses the following
properties:
• Good ductility and malleability
• High electrical and thermal conductivity
• Non-magnetic
• Can be easily alloyed with other metals
• Good corrosion resistance

1.1 Brasses:
• Brasses are alloys of Copper and Zinc with small amount of other alloying elements.
Fig.Copper-Zinc Equilibrium Diagram
The phases in Copper-Zinc system are:
α : Highly ductile
β : Increases the tensile strength and lower ductility
γ : Hard and brittle
Classification of Brasses:
1) α-brasses : Containing Zinc <30%
• They contain Zn up to 30%.
• α-phase is a soft and ductile phase.
2) α-β brasses : Containing Zinc 30-44%

1.α-brasses : Containing Zinc <30%
A. Red Brass:
Brasses containing Zn <20% are referred
as Red Brasses
i)Cap Copper:
• Composition
• Zn- 2 to 5%
• Balance is Cu.
• Properties
• Zn is used as a de-oxidizer to avoid formation of
copper oxide.
• Copper oxide is a hard, brittle layer.
• Cap copper is highly ductile.
• Applications
• Caps of detonators in ammunition factories, coins,.
ii)Gliding Copper:
• Composition
• Zn- 5 to 15%
• Balance is Cu.
• Properties
• Addition of Zn improves strength.
• It has good ductility and pressing ability.
• Improved corrosion resistance.
• Applications
• Coins, needles, emblems, jewellery, bullet envelopers,
• condenser tubes.

1.α-brasses : Containing Zinc <30%
B. Yelow Brass:
Brasses containing Zn >20% are referred
as Yellow Brasses
i) Cartridge Brass (70:30 Brass)
• Composition
• Zn- 30%, Balance is Cu.
• Properties
• It has high resistance to corrosion.
• It has high ductility and malleability.
• After cold working and subsequent annealing, its
microstructure is observed to be equi-axed grains.
• Applications
• Cartridge cases, radiator fins, headlight reflectors,
lamp fixtures, rivets, springs, plumbing accessories etc.
ii) Admiralty Brass (71:28:1 Brass)
Composition
Zn- 28%
Sn-1%
Balance is Cu.
Properties
• It has properties similar to cartridge brass.
• Addition of Sn improves corrosion resistance.
• In applications such as marine environments, excessive de-
zincification occurs, i.e. zinc corrodes preferentially leaving
behind copper in porous form.
• To overcome this, sometimes Al and small amount of Ar is
also added to Admiralty Brass.
• Applications
• Condenser tubes, heat exchanger in steam power plants.

2.α-β-brasses : Containing Zinc -30-40%
 They contain Zn in the range of 30 to 40%.
 β-phase has more strength.
 They are generally hot worked for fabrication work.
 These are cheaper than α-brasses as zinc is cheaper thancopper.
 They have poor corrosion resistance

A. Muntz Metal (60:40 Brass) :
• Composition
• Zn- 40%
• Balance is Cu.
• Properties
• It becomes single phase above 700°C.
• They are hard and strong as compared to α-brasses.
• At high temperature, β has more ductility and
malleability.
• Hence, it is usually hot worked, rolled and extruded.
• It has tensile strength in the range of 35 to 40 kg/mm2
and hardness of 100 to 120 VPN.
• Applications
• Pump parts such as valves, condenser tubes, shafts,
nuts, bolts, utensils, brazing rods etc.
B.Naval Brass (60:39:1 Brass)
Composition
• Zn- 39%
• Sn-1%
• Balance is Cu.
• Properties
• It has properties similar to Muntz Metal.
• Addition of Sn improves corrosion resistance.
• It is used in marine environment, hence called Naval
Brass.
• Applications
• Marine hardware, propeller, piston rods, welding rods,
nuts and bolts, water taps etc.

C) Leaded Brass / Free Cutting Brass
(60:38:2 Brass) Composition
• Zn- 38%
• Pb-up to 2%
• Balance is Cu.
• Properties
• Addition of lead improves machinability.
• Lead exists in the alloy in the form of globules
(insoluble) which aids in breaking of chips during
machining.
• Hence it is also referred as free cutting brass.
• Applications
• Machine parts and hardware's.
D) High Tensile Brass Composition
• It is typically a 60:40 brass (Muntz metal) with alloying
elements added to it.
• The alloying elements that are added include Al, Fe, Mn,
Sn and Ni.
• Properties
• The alloying elements improve the tensile strength of
brass.
• It is further classified as Al-brass, Mn-brass, Sn-brass
(Naval brass) etc.
• It has tensile strength in the range of 40 to 55 kg/mm2
and elongation of 20 to 30%.
• It has high corrosion resistance.
• Applications
• Marine pump parts, propeller shafts, gear and valve
bodies.

• E) Brazing Brass (50:50 Brass) Composition
• Zn- 50%
• Balance is Cu.
• Properties
• Zn has low melting point - 870°C.
• At low temperature, Zn-brass melts and can be used
for joining of two individual brass alloy components.
• It is a brittle phase and can be easily crushed to
powder.
• Applications
• Brazing (Joining) of brasses.

3.Season Cracking of Brasses
• Both α and α-β brasses are prone to a defect phenomenon known as
Season Cracking.
• It is a defect, wherein spontaneous cracks are observed in the material.
• During cold working of brasses, internal/residual stresses of tensile nature
are induced in the component.
• These stresses can be due to pressing, drawing or some other cold
working operation.
• The localized stressed area becomes anodic with respect to the other area
of the component.
• It leads to intergranular corrosion resulting in subsequent disintegration
and failure of the component.
• Such a defect phenomenon is called as season cracking.
• Season cracking can be avoided by annealing the component to remove
internal stresses.
• Annealing of brasses is performed at a temperature in between 280° C and

4.Bronzes
• Bronzes are alloys of Copper and any other major alloying element but not Zinc (such as Al, Be, Sn
etc).
• Bronzes sometimes also contain zinc but in small properties to take advantages of its properties.
• The major bronzes that are commercially used and discussed in this chapter are:
• Al-bronze
• Sn-bronze
• Be-bronze
• Si-bronze

4.1 Al- Bronze (Aluminium-Bronze)
• Aluminium bronzes are alloys wherein, copper is the base metal and aluminium is the major
alloying element.
• The solubility of Al in copper increase with decrease in temperature.
• The solubility of Aluminium in Copper is 7.4 % at 1040°C and 8.4 % at
565°C
• The eutectoid transformation occurs at 11.8% Al and 565°C.
𝛽 → 𝛼 + 𝛾2
• Commercial Al-Bronzes contain Al in the range of 4 to 11%.
• In addition alloying elements such as Fe, Ni, Si, Zn, Mn etc. are added for
improvement of certain properties.
• Al-bronzes are also referred as imitation gold due to their lustrous finish,
golden colour and fine polishing.

• Properties of Aluminium
• Its specific weight is only 2.7 gm/cm3 compared to 7.8 gm/cm3 for steel and 8.8
gm/cm3 for copper.
• Its electrical conductivity is about 60% of that of copper.
• It has high thermal conductivity.
• It has high corrosion resistance because of oxidation and formation of protective
Al2O3 layer.
• It has great affinity for oxygen.
• It is non-magnetic.

• Types of Al-Bronzes :
• Single phase Al-bronze (Contains Al in the range of 4 to 7.5%).
• Two phase Al-bronze (Contains Al in the range of 7.5 to 11%).

Single Phase Al-Bronze
• Composition
• Al content (4 to 7.5%)
• Properties
• The tensile strength is 35 kg/mm2 & % elongation is 50%.
• They have good ductility and malleability because of single phase structure.
• They can be cold worked by processes such as drawing, pressing, rolling etc.
• They are available in the form of sheet, tubes and plates.
• Applications
• Jewellery, condenser tubes, marine applications, cigarettes cases, heat exchangers,
corrosion resistant vessels, chemical plants etc.

Two Phase Al-Bronze
Composition
• Al content (7.5 to 11%)
Properties
• The tensile strength is 45 kg/mm2 & % elongation is 20 to 30%.
• At high temperature it consists of α and β structure.
• They can be hot worked at elevated temperature.
• They have high shrinkage %, hence adequate tolerance is provided on dies.
Applications
• Pump casting parts, valve fittings, propellers, cylinder heads, gears, forming and
drawing dies, bearings, spark plug bodies, electrical contacts etc.

II)Sn- Bronze (Tin-Bronze)
• Tin bronzes are alloys wherein, Copper is the base metal and Tin is the
major alloying element.
Reaction Temperature Transformation
Peritectic Reaction 798°C α + L ⟶ β
Eutectoid Reaction of β 586°C β ⟶ α + γ
Eutectoid reaction of δ 350°C δ ⟶ α + ε
•The solubility of Tin in copper varies with the temperature and is higher in the
temperature region of 350°C to 798°C.
•The following reactions take place at different temperatures in the
equilibrium diagram.
Applications % content ofTin (Sn)
Sheets, wires, coins, electrical
switches
Up to 8%
Pumps, gears, marine
components
8-12%
Bearings, Bushings 12-20%
Bells
20-25%

I) Coinage Bronze- Composition
• Cu- 94% ,Sn-5%,Zn-1%
• Properties -It is soft and ductile.
• Zinc is added for de-oxidation of the melt.
• Applications -Coins.
II) Gun Metal- Composition
• Cu- 88%,Sn-10% ,Zn-2%
• Properties -Zinc is used as a de-oxidizer.
• Zinc also improves fluidity.
• The solid alloy shows dendrites of α and islands of α + δ eutectoid. It has excellent
corrosion resistance.
• Applications-Gun barrels and ordinance parts, marine castings, gears, bearings, valve
bodies etc.

III) Phosphor Bronze
• Phosphor bronze is an alloy of Cu, Sn and P.
• Phosphorous is an excellent de-oxidizer.
• Higher amount of Phosphorous improves mechanical properties and castability of the
alloy.
A) Wrought Phosphor Bronze
Composition -Sn- 2.5 to 8% , P-0.1 to
0.35% , Balance is Cu.
Properties-It is a single phase α solid
solution. It can be cold worked to improve
strength and contacts etc.
Applications-Wire gauges, springs, wire
brushes, electrical contacts etc.
B)Cast Phosphor BronzeComposition-
 Sn- 5 to 13%
 P-0.3 to 1%
 Balance is Cu.
Properties
 It has better fluidity than wrought phosphor bronze.
 It also leads to formation of Cu3P, which is brittle.
Applications
 Gears, bushings, valves etc.

Si- Bronze (Silicon-Bronze)
• Silicon bronzes are alloys wherein, Copper is the base metal and Silicon is the major
alloying element.
• The maximum solubility of silicon in copper is 5.3% at 845°C and decreases to less
than 4% at room temperature.
• Si-Bronze composition is Cu-94.5 to 99%; Si- 1 to 5.5%.
• These bronzes have high corrosion resistance, tensile strength and toughness.
• They are cheaper than Sn-bronzes.
• Other alloying elements that are added to Si-bronzes include Mn, Zn, Sn, Pb and Fe.
• Applications
• High strength bolts, rivets, springs, pressure vessels, marine containers, propeller
shafts, bells etc

Be- Bronze (Beryllium-Bronze)
• Beryllium Bronzes are alloys wherein, Copper is the
base metal and beryllium is the major alloying element.
• The solubility of Be in Cu is 2.1% at 864°C and
decreases further to 0.25% at room temperature.
• This drastic change in solubility gives rise to
precipitation hardening.
• The precipitation cycle consists of heating the alloy at
around 800°C and quenching in water.
• This is followed by further heating from 300 to 320°C
for a couple of hours to accelerate ageing treatment.
• Applications
• Springs, diaphragms, flexible bellows, gears, bearings,
electrical appliances, non-sparking tools etc.

SN Brasses Bronzes
1 Brasses are alloys of Copper and zinc
with small amount of other alloying
elements
Bronzes are alloys of Copper and any other
major alloying element but not Zinc (Such
as Al, Be, Sn etc.)
2 Brasses are classified on the basis of the
phases in Copper-Zinc system such as α-
Brass and α-β Brass.
Bronzes are classified on the basis of
alloying element such as Al-Bronze, Sn
Bronze, Be-Bronze, Si Bronze
3 Brass appears more greenish, bluish in
colour.
Bronze appears brownish golden in colour
4 Not expensive than bronze Expensive
5 Brass is less strong, harder and corrosion
resistance than bronze
Bronze is much stringer, harder and
corrosion resistant than brass
6 Brass machines and polishes much easily Bronze is difficult to machine and polish.
7 Brass melts at lower temperature. Bronze melts at higher temperature.

Aluminium and its Alloys (Al)
 Aluminium is one of the most widely used non-ferrous
metals.
 It is the second most used non-ferrous metal. In pure form
i.e. 99.9% pure aluminium does not have sufficient strength
and hardness. It is very soft and ductile.
Properties of Aluminium:
• It is ductile and malleable.
• Its specific weight is only 2.7 gm/cm3 compared to 7.8 gm/cm3 for
steel and 8.8 gm/cm3 for copper.
• Its electrical conductivity is about 60% of that of copper.
• It has high thermal conductivity.
• It has high corrosion resistance because of oxidation and formation
of protective Al2O3 layer.
• It has great affinity for oxygen.
• It is non-magnetic.

Aluminium-Copper Alloys (Al-Cu)
• Aluminium is the base metal and copper is the major alloying element.
I ) LM 11
Composition
 Al-95.5%
 Cu-4.5%.
Properties
 It is precipitation Hardenable alloy.
 It produces good strength after
precipitation hardening.
 It has good mechanical and shock
resisting properties.
 It is susceptible to hot tearing.
Applications
 Castings for aircrafts and high stressed
parts.
II) Duralumin
Composition
 Al-94.5%
 Cu-4.5%
 Mg-0.5%
 Mn-0.5%
Properties
 It produces good strength after precipitation
hardening.
 It has good mechanical and shock resisting
properties.
 It also has good corrosion resistance.
Applications
 Aircraft industry.

Aluminium-Copper Alloys (Al-Cu)
III) LM 14 (Y-alloy)
Composition
Al-92.5%
Cu-4%
Mg-1.5%
Ni-2%
Properties
It has excellent ability to retain strength at
elevated temperature.
It has low thermal expansion.
It has high resistance to corrosion.
It can be easily cast and rolled.
Applications
Pistons, Cylinder heads of I.C. Engines.
IV) RR 350 (Hinduminium) Al
94.5%
Composition
Al-92%
Cu-5%
Ni-1.5%
Small amount of Mn, Ti, Sb, Co and Zr.
Properties
It has excellent ability to retain strength at elevated
temperature.
It is superior to Y-alloy in regards to creep resistance.
Applications
Aircraft engines, high temperature.

Aluminium-Silicon Alloys (Al-Si)
• Aluminium is the base metal and silicon is the major alloying element
I)LM 6
Composition
 Al-88%
 Si-12%.
Properties
 It has excellent fluidity due to presence of
Silicon.
 It has high corrosion resistance.
 It has less shrinkage during solidification.
Applications
 Intricate castings such as water cooled
manifolds and jackets, motor housings,
pump castings, etc.
II)LM 13
Composition
 Al-83.4%
 Si-12%
 Ni-2.5%
 Cu-0.9%
 Mg-1.2%.
Properties
 It is a precipitation Hardenable alloy.
 It has excellent ability to retain strength at
elevatedtemperature.
 It has low coefficient of thermal expansion.
 It has good bearing properties.
Applications
 Forged pistons and other automobile parts.

Aluminium-Magnesium Alloys (Al-Mg)
I) LM 5 (Magnalium)
Composition
 Al-94.5%
 Mg-5.0%
 Mn-0.5%.
Properties
 It has high resistance to corrosion.
 It has good machinability and
weldability.
 It can be easily anodized and gives
better finish.
Applications
 Marine applications.
II) LM 10
Composition
 Al-90%
 Mg-10%.
Properties
 It has poor castability because the molten
metal gets easilyoxidized and picks up gas on
standing.
 Hence, small amount of beryllium is added to
reduceoxidation.
 Sometimes degassing is also done to remove
trappedgases.
Applications
 Aircraft and automobile components, dairy
equipment,architectural work etc.

Nickel and its Alloys (Ni)
 World demand for nickel is growing constantly, at anaverage
rate of 5% per annum.
 The consumption of pure nickel is Which clearly shows that
the majority of pure nickelmetal (66%) is consumed for
making stainless steel and alloys.
 While only 10% and 5% is consumed in chemical industry and
tooling.
 There for nickel alloys has great importance in engineering
application.
 The important properties of Nickel are:
1. It has FCC structure.
2. It has good ductility and malleability.
3. It exhibits good resistance to corrosion and oxidation.
4. It has fairly good electrical conductivity.
5. It has better formability.
6. It is chemically inert hence used for electroplating.
7. It is highly used in production of stainless steel, nickelalloys, permanent magnets etc.

I) Dura Nickel
• Composition
• Ni-94%
• Al-4.5%
• Small amount of C, Mn, Fe, S, Si, Cu, Ti etc.
• Properties
• It is age Hardenable alloy.
• It can also be cold-worked to increase
strength.
• It has good corrosion resistance.
• Applications
• Diaphragms, bellows, snap-switch blades,
fish hooks, jewellery and optical frames.
II) Perma Nickel
Composition
 Ni-98.5%
 Small amount of C, Mn, Fe, S, Si, Cu, Ti, Mg etc.
Properties
 It is age Hardenable alloy.
 It also has high corrosion resistance and good
mechanicalproperties.
 It has better electrical and thermal conductivity.
 It has better magnetic properties than Dura-Nickel.
Applications
Similar to Dura-Nickel alloy where higher electrical
conductivity and better magnetic properties are
required

III) Hastelloys D
Composition
• Ni-87%
• Si-10%
• Cu-3%.
• Properties
• It has good casting properties.
• It has better mechanical strength and toughness.
• Due to its high hardness, it is difficult to machine.
• It has high corrosion resistance even at elevated
temperatures.
• Applications
• Evaporators, reaction vessels, pipelines for
chemical industry.
IV) Monel
Composition
 Ni-64%
 Cu-30%
 Si-2%
 Small amount of other elements.
Properties
 It has good casting properties.
 It has high corrosion resistance.
Applications
 Marine casting parts, valve seats, pump liners etc.

V) Invar
• Composition
• Ni-36%
• Fe-64%
• Properties
• Invar means invariable.
• It has the lowest coefficient of thermal
expansion.
• It has good resistance to corrosion.
• Applications
• Length standards, measuring tapes and
instruments such as scales, Vernier's etc.
• Variable condensers, tuning forks, special
springs etc.
VI) Elinvar
Composition
 Ni-36%
 Cr-12%
 Fe-52%
Properties
 The modulus of elasticity remains fairly constant for a
widerange of temperature.
 It has negligible elastic changes with respect to
temperature.
Applications
 Hair springs, balance wheel in watches, other springs
usedin precision instruments.

VII )Ni-Cr-Fe-Alloys
Composition
 Ni-60%, Cr-16%, Fe-24%
 Ni-35%, Cr-20%, Fe-45%
Properties
 These alloys have high resistance to oxidation and
to theaction of carburizing gases.
 They have high thermal conductivity and
emissivity.
 They have high melting point because of presence
of Feand Cr.
Applications
 Electrical heating elements for toasters, hair
driers, hotwater heaters, rheostats etc.
 Heat treating equipment’s, furnace parts,
carburising andnitriding containers etc.
VIII) Inconel
Composition
 Ni-77%
 Cr-15%
 Fe-8%
Properties
 It has good corrosion and oxidation
resistance.
 It maintains good strength at elevated
temperatures.
 It can withstand repeated heating and
cooling cycles.
Applications
Heaters, furnace parts, carburizing containers,
thermocouple covering tubes, exhaust
manifolds of aero engines, mufflers etc.

IX) Inconel X
• Composition
• Ni-73.5%, Cr-15%, Fe-8%
• Ti-2.5%
• Al-1%
• Properties
• It is age Hardenable alloy.
• It can retain mechanical strength
and toughness even at elevated
temperatures of up to 800°C.
• Applications
• High temperature applications
such as gas turbines,
superchargers, jet propulsion
parts.
X)Pe malloys
Composition
 Ni-78%
 Fe-22%.
Properties
 It has high magnetic permeability.
 It has low hysteresis losses, and
low electrical resistivity.
Applications
 Used for apparatus that work on
magnetic waves such asradio,
transmitters, communication
circuits etc.
XI) Alnico
Composition
 Ni-14 to 28%
 Al-8 to 12%
 Co-5 to 35%
 Fe-25 to 73%.
Properties
 It has excellent magnetic
properties.
Applications
 Permanent magnets in motors,
generators, speakers,
microphones etc.

Cobalt and its Alloys (Co)
• Cobalt is a silvery white metal with a faint bluish touch.
• It is similar to nickel in appearance and mechanical properties.
• Its chemical properties are combination of nickel and iron
I) Stellite 21
Composition
 Ni- 2%
 Cr- 28%
 n- 5.5%
 C- 0.3%
 Balance Co.
This alloy has a good wear resistance.
II) Stellite 31
Composition
 Ni- 10%
 Cr- 20%
 W- 15%
 C- 0.1%
 Balance Co.
III) Mar M 302
Composition
 Cr- 21.5%
 W- 10%
 Ta- 9%
 Zr- 0.05%
 C- 0.85%
 Balance Co

• Applications of Cobalt Alloys
• Cobalt alloys are used as high temperature alloys.
• They can be used as permanent magnets.
• They are used in components of jet aircraft engine like gas turbines, super chargers, turbines blades, nozzles
etc.
• They are used in nuclear reactors and wear resistance components in nuclear submarines, dies, cutting
tools, search light reflectors, motor cases etc.
• Advantages
• They have high melting point, due to which very suitable for making jet turbine blades.
• Good hot corrosion resistance.
• Good wear resistance.
• Disadvantages
• They have low strength.
• Lower ductility and fracture toughness.

Titanium and its Alloys (Ti)
• Titanium is a strong, light weight and corrosion resistant metal.
• Titanium ores are initially reduced to titanium in a furnace and then converted into Ticl4 in chlorine
atmosphere.
• This compound is reduced with magnesium to produce titanium sponge.
• Titanium has two allotropic forms i.e. HCP alpha phase and BCC beta phase.
• The transformation occurs at 885°C from alpha to beta phase. To affect the transformation alloying
elements are added.
• Major characteristics and properties of Titanium
• They are 40% lighter than the steel and 60% heavier than the aluminium.
• Titanium has good corrosion resistance.
• Melting point of titanium is higher than the iron.
• It has low thermal conductivity.
• Its electrical resistivity is also high.

I) Alpha Alloys (Rich in alpha
stabilizers)Composition
 Ti- 92%
 Al- 5%
 Sn- 2.5%
 Small amount of zirconium, vanadium and
columbium.
Properties
 It has excellent weldability and good strength at
hightemperatures.
 It has good oxidation resistance.
 It has good formability.
Applications
 It is used in aircraft engine compressor blades
and ducts,steam turbine blades etc.
II) Beta Alloys (Rich in beta stabilizers)
Composition
 Ti- 73%
 Al- 3%
 V- 13%
 Cr- 11%
Properties
 These alloys are less strong, easier to work and
unstable athigh temperature.
 It responds to heat treatment.
 They have low toughness and fatigue strength.
 They become brittle at temperature below - 40C.
Applications
 It is used in high strength fasteners, rivets, sheet
metal partsand tubing for aerospace.

III) Alpha-Beta AlloysComposition
 Ti- 90%
 Al- 6%
 V- 4%
Properties
 It has high formability.
 It has low toughness and it is difficult to weld.
 Due to its high hardness, it is difficult to machine.
 It has good impact and fatigue strength.
Applications
 It is used in rocket motor cases, blades and discs of
aircraft turbines and compressors, structural
forgings and fasteners,orthopaedic implants etc.

Tin and its Alloys (Sn)
• Tin is normally white, soft and malleable metal.
• It is very much similar in properties to lead.
• Tin can available as granulated, fine powder, sheet, foil and wire.
I) Copper-Tin Alloys (Cu-Sn)
 Copper-tin alloys (Bronzes) or
phosphor bronze containing 8
to 12% tin with small
additions of phosphorus is
used for springs, condenser
tubes, bearings etc.
 The gun metals, tin-bronze
casting alloys with 1 to 6 %
zinc are used for valves and
fittings for water and steam
lines.
 Babbit bearing metals are
basically tin base alloys.
II) Aluminium-Tin Alloys
(Al-Sn)
 Al-Sn alloys possesses
high fatigue strength and
hence itcan carry
fluctuating loads.
 The 6% Tin-Aluminium
alloys can be bonded to
steel byrolling.
III) Pewter or Britannia Metal
 It is a tarnish resistant alloy
containing 7% antimony, 2%
copper and remaining lead.
 It is used for domestic
applications like trays, plates,
bowlsetc.
 It is also used for decorative
applications like vases, candle
sticks, book ends etc.

Lead and its Alloys (Pb)
• Lead is the oldest of the commonly used metals and the softest of the heavy metals.
• In the nature, lead exist in the form of sulphide or oxide.
• When it is cast or cut, it is lustrous silvery colour initially, but after some time, the surface turns a dull bluish
grey because of oxidation.
I) Lead-Antimony (Pb-Sb) Alloy
 The Pb-Sb phase diagram is of eutectic type
with eutectic composition of 11.2% Sb and
eutectic temperature of 251.2C.
 The commercial alloys containing 1 to 12%
antimony are used for storage battery plates,
collapsible tubes, building construction,
cable sheathing, drain pipes etc.
II) Lead-Tin (Pb-Sn) Alloy
 In case of Pb-Sn equilibrium
diagram the eutectic point isat
61.9% Sn and 183°C
temperature.
 Lead-tin alloys have good flow
characteristic hence theyare
commonly used as solders.
 A solder of Pb-Sn alloy of
eutectic composition is knownas
Timman’s Solder or Quick Solder
(62% Sn).

• Properties of Lead
• Lead has a FCC crystal structure.
• It has good ductility and malleability.
• It is poisonous and should not be brought into contact
with food items.
• It is very soft and it has low melting point (327°C) with
high density.
• It has high coefficient of thermal expansion and low
electrical conductivity.
• It can be easily soldered, welded and cast.
• It has high resistance to corrosion against most acids.
• Its X-rays and γ-rays absorbing power is high.
• It has low strength.
• It also possesses good lubricating properties.
Applications of Lead
 It is commonly used in the manufacturing of
storagebatteries.
 In case of high grade petrol tetraethyl lead is
used as anantiknocking ingredient.
 Used in tank linings for corrosion protection.
 It is used in pipe and drainage fittings.
 It is used as compounds in paints and
sheathing (Protection) of electric cable.
 It is used as an alloying element to improve
the machinability of bronzes, brasses and
free machining steels.
 It is used as a coating on steel wires, used as
a joining material for cast iron pipes and
used in the manufacturing of alloys like
babbits, solders etc.
 It is also used for shielding against X-rays and
γ-rays.

Bearing Materials
• Bearing materials are anti-friction materials used as rotating shaft holders or supporters.
• These shaft holders or supporters transmit loads to a shaft rotating relative to the bearing.
• Bearings are required in various applications such as machinery, engines, reciprocating parts etc.
• Requirements of Bearings
• The bearing and rotating parts should have the least friction to reduce power loss in
transmission.
• The bearing material should be hard and wear resistance for longer life.
• It should possess high fatigue strength
• It should have good resistance to corrosion, galling and seizing.
• It should possess better thermal conductivity to dissipate the frictional heat generated during
working.
• It should be able to retain oil on the bearing surface.

I)White Metal Alloys (Babbitt’s)
A)Lead-Based Babbitt’s
Composition
• Pb- 80%, Sb- 10%, Sn- 10%
• Small amounts of Cu, Cd and As.
• Properties
• During solidification, Sn-Sb combines
early and forms hard cuboids.
• These hard cuboids float on the
surface of the material, while the
internal microstructure consists of
soft matrix of eutectic.
• This makes the bearing hard at the
surface and soft from within.
B)Tin-Based Babbitt’s- Composition
 Sn- 90%, Sb- 5%,Cu- 5%, Small amount of Pb and As.
Properties
 To reduce formation of hard cuboids and it’s floating onthe
surface, rapid cooling is usually done.
 Sometimes, copper is also added to avoid / reduce
formation of hard cuboids.
 Copper will combine with Sn to form hard needles of Cu-Sn
and reduce formation of Sn-Sb.
 Tin-based Babbitt’s have better corrosion and wear
resistance.
 Lead is a soft material and reduces the load carryingcapacity
of the bearing.
Applications
Bearings of I.C. engines, lathe machine, milling machine,electric
motors etc.

II) Copper-Lead Alloys
Composition
 Pb- 20 to 40%
 Cu- 60 to 80%
 Small amount of Sn.
Properties
 Lead is insoluble in Copper.
 It is a soft material and gets uniformly distributed
in thehard matrix of Copper.
 Tin added in the bearing prevents acidic attack of
oil onLead.
 These bearings are manufactured by castings or
powdermetallurgy.
Applications
Bearings in automotive and aerospace applications.

III) Tin-Bronzes
• Composition Gun Metal
• Cu- 88%, Sn- 10%, Zn- 2%
• Phosphor Bronze
• Cu- 75 to 80%, Sn- 10 to 15%, P- 10%
• Properties
• Zinc and phosphorus added here to the function of deoxidizers.
• They have high strength and toughness.
• They have good resistance to corrosion.
• They have good bearing properties.
• Applications
• Bearings for heavy load applications where lubrication availability is scarce

IV) Silver Bearings
Composition
 Steel bearing- plated with Silver, Followed by
coating ofLead and then Iridium.
Properties
 Lead reduces risk of seizure.
 Iridium protects Lead against any acidic actions of
oil.
 They are used for heavy load conditions.
 They have high fatigue strength.
 They have high corrosion resistance and excellent
antseizing properties.
Applications
 Bearings for aircraft industry.
V) Aluminium Alloys
Composition
 It contains alloying elements such as Sn, Cu, Ni, Fe,
Si andMn.
Properties
 These are used for high loads and high speeds.
 They have high strength and toughness.
 They have high resistance to corrosion.
 They possess high fatigue strength and anti-
seizureproperty.
Applications
 Bearings required for high loads and high speeds
such asconnecting rods and I.C. engines.

VI)Porous Self-Lubricating Bearings
Composition
• Copper-Based Bearing
• Cu- 90%, Sn- 10%, Additional amount of graphite.
• Iron-Based Bearing
• Fe- 96%, C- 4%
• Properties
• These are manufactured by Powder Metallurgy Process.
• They have porosity as high as 40 to 50%.
• When the shaft is not rotating, the oil gets filled in the pores of the bearing.
• As temperature increases, due to capillary action oil comes out of the pores and forms a thin layer
between the rotating shaft and the bearing.
• Applications
• Food processing industries, paper and textiles industries.

• VII) Non-Metallic Bearings
• Composition
• Teflon, Nylon, Graphite, Molybdenum Disulphide.
• Properties
• They are dry and anti-corrosive material based bearings.
• These materials are used to avoid contamination of surrounding parts.
• They are used in areas which are difficult to access / service.
• They cannot take heavy load.
• Applications
• Food processing industries, paper and textiles industries.

Soldering Alloys
• Soldering is the joining process of metals or alloys by using another metal or alloy that has a
melting point below 500°C and below the melting point of the metals to be joined.
• In this process, the molten filler metal is drawn into the joint by a capillary action.
• In case of soldering process, rosin and rosin plus alcohol are commonly used as fluxes for
joining of electrical wires.
• These fluxes contain acid hence they are likely to corrode the joint.
• For this drawback the components are cleaned after soldering process.
• Fluxes like ammonium chloride and zinc chloride are generally used because of their quick
action to produce good joints.
• For soldering of non-electrical wires or parts these fluxes are commonly used.
• Fluxes can be available in liquid, paste, powder or in the form of core in the solder metal.

Brazing Alloys
• Brazing is the joining process of metals or alloys by using another metal or alloy that has a
melting point above 500°C and below the melting point of the metals to be joined.
• Generally, the fluxes used are combinations of boric acid, chlorides, fluorides and tetraborates
with other wetting agents.
• A commonly used flux for ferrous materials is combination of borax (75%) and boric acid
(25%).
• For brazing of stainless steel, aluminium bronze, silicon bronze etc. alkaline bifluorides are
used.
• Also for brazing of tungsten to copper a special flux that contains sodium cyanide is used.
• The brazing process consists of applying a proper flux at the joint, heating the joint to the liquid
temperature of the filler metal and applying the filler material that flows into the gap by
capillary action.

I)Aluminium-Silicon (Al-Si)
 It is a general purpose brazing filler metal
used where controlled flow is required.
II) Magnesium (Mg)
 It is used for brazing of magnesium alloys.
III) Copper and Copper-Zinc (Cu and Cu-Zn)
 It is used in all brazing processes on steel,
nickel base alloys giving a better colour
match.
IV)Gold
 It is used for joining parts in electron tube
assemblies where volatile components are
undesirable.
V) Silver-Brazing Alloys
 They are used for joining most ferrous and non-
ferrous metals except aluminium and magnesium
using allmethods of heating.

THANK YOU

Unit 1 Nonferrous Metals and Alloys - 1.pptx

Recommended

Recommended

More Related Content

Similar to Unit 1 Nonferrous Metals and Alloys - 1.pptx

Similar to Unit 1 Nonferrous Metals and Alloys - 1.pptx (20)

More from Dr. Sandip Thorat

More from Dr. Sandip Thorat (7)

Recently uploaded

Recently uploaded (20)

Unit 1 Nonferrous Metals and Alloys - 1.pptx