Non ferrous metal


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Compiled by : FD Architects Forum
Gr. Floor , Ashoka apartment
Bhawani Singh Road
C-scheme , Jaipur -302001
Rajasthan ( INDIA)
Ph. 91-0141-2743536

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Non ferrous metal

  1. 1. NONFERROUS METAL & ALLOY Compiled by : FD Architects Forum Gr. Floor , Ashoka apartment Bhawani Singh Road C-scheme , Jaipur -302001 Rajasthan ( INDIA) Ph. 91-0141-2743536 Email: Web :
  2. 2. NONFERROUS METALS  Nonferrous metals contain either no iron or only insignificant amounts used as an alloy. Some of the more common nonferrous metals Steelworkers work with are as follows: copper, brass; bronze, copper-nickel alloys, lead, zinc, tin, aluminium, and Duralumin.  NOTE: These metals are nonmagnetic.
  3. 3.  Brass (Copper+Zinc)  Bronze (Copper+Tin) •Yellow colour •Very ductile and malleable •Good tensile endurance •Dark yellow colour •More endurance than brass •Very corrosion resistant •Good sonority •Very fluid when melting, good for molding. Non-Ferrous Metals: Alloys
  4. 4.  Aluminum, Copper & Magnesium  Magnesium & Aluminum  Titanium & Aluminum •Lightness and more endurance than pure aluminum. •This alloy is more resistant than each metal. • Cheaper than pure titanium parts. Non-Ferrous Metals: Alloys
  5. 5. Aluminium and aluminium alloys  Al and its alloys are characterized byAl and its alloys are characterized by  relatively low density (2.7 g/cmrelatively low density (2.7 g/cm33 as comparedas compared to 7.9 g/cmto 7.9 g/cm33 for steel),for steel),  high electrical and thermal conductivities,high electrical and thermal conductivities,  resistant to corrosion in some commonresistant to corrosion in some common environments, including the ambientenvironments, including the ambient atmosphere.atmosphere.  Many of these alloys are easily formed due to highMany of these alloys are easily formed due to high ductility;ductility;  thin aluminum foil sheet (of relatively purethin aluminum foil sheet (of relatively pure material) may be rolled.material) may be rolled. • White shiny colour • Light and good endurance • No toxic Cheap Stainless
  6. 6. Aluminium and aluminium alloys its ductility is retained even at very lowits ductility is retained even at very low temperatures.temperatures. The chief limitation:The chief limitation:  low melting temperature [660°C],low melting temperature [660°C],  restricts the maximum temperature atrestricts the maximum temperature at which it can be used.which it can be used.
  7. 7. Aluminium and aluminium alloys  The mechanical strength of aluminum may beThe mechanical strength of aluminum may be enhanced byenhanced by cold workcold work and byand by alloyingalloying;;  however, both processes tend to diminishhowever, both processes tend to diminish resistance to corrosion.resistance to corrosion.  Principal alloying elements includePrincipal alloying elements include copper,copper, magnesium, silicon, manganese, and zinc.magnesium, silicon, manganese, and zinc.
  8. 8. Aluminium and aluminium alloys  Non heat-treatable alloysNon heat-treatable alloys consist of a singleconsist of a single phase,phase,  for which an increase in strength is achieved byfor which an increase in strength is achieved by solid-solution strengthening.solid-solution strengthening.  Rendered heat treatableRendered heat treatable  capable of being precipitation hardened as a resultcapable of being precipitation hardened as a result of alloying.of alloying.  In several of these alloys precipitation hardening isIn several of these alloys precipitation hardening is due to the precipitation of two elements other thandue to the precipitation of two elements other than aluminum, to form an intermetallic compound suchaluminum, to form an intermetallic compound such as MgZnas MgZn22..
  9. 9. Aluminium Composite Panel Structural section of aluminum composite panel 1. Protective film 2. PVDF clear coating 3. PVDF top coating 4. PVDF primer 5. Chromate treatment 6. Aluminum skin 7. Chromate treatment 8. Bonding lamination layer 9. Nontoxic PE core material 10. Optional fire resistant and nontoxic PE core material 11. Optional back coating
  10. 10. Aluminium Composite Panel Characteristics of aluminium composite panel (ACP) 1. Economy Due to our adoption of high quality coatings, our aluminum composite panels are dispensed with frequent maintenance, thus saving a lot on maintenance cost. Hence, our composite panels are good decorative building material for high-rise buildings. 2. Durability Fluorocarbon coated aluminum composite panels are characterized by long service life, good weather resistance, high heat resistance and wear resistance, and good resistance to pollutions, and more.
  11. 11. Aluminium Composite Panel 3. Flatness Our aluminum composite panels are manufactured with smooth and even surface, which can satisfy people's high demand on the appearance of modern constructions. 4. Light weight By adopting light-weight aluminium alloy and superior quality plastics as primary raw material, aluminum composite panel is lighter than other types of decorative construction material. Hence, it is easy to install and needs shorter installation period. 5. Easy installation Our aluminium composite panels are adaptable to various decoration requirements, because they are easy to be cut, grooved and bended.
  12. 12. Aluminium Composite Panel 6. Fireproofing The exterior aluminium sheet of aluminum composite panels can effectively protect interior PE core material, because it can prevent heat conduction at the initial stage of combustion. The flame resistance of our aluminum plastic composite panels has reached international standard. 7. Design performance Aluminum composite panels can be made into different colors and styles, thus satisfying the diversified design requirements of architects. 8. Eco-friendliness The surface coating is durable and has no changes, which produces no pollutants.
  13. 13. Application of Aluminium Composite Panel 1. Wall and interior decoration of air ports, docks, stations, metros, hotels, restaurants, recreation places, top-grade residence, villas, office, and many other buildings. 2. Big billboards, shop windows, roadside news kiosks, bookstalls, telephone booths, traffic sentry boxes and filling stations. 3. Internal walls, ceilings, compartments, kitchens, toilets, etc. 4. Decoration for shops, cabinets, pillars, furniture, trains, automobiles, ships and carriages, etc. 5. Renovation and reconstruction of old buildings. 6. Cleaning and dust control projects.
  14. 14. PVDF Aluminium Composite Panel The PVDF aluminum composite panel consists of two sheets of corrosion resistant aluminum permanently bonded to polyethylene core material. The front aluminum coats PVDF (Fluor resin) paint. Because of its excellent weather proof and other features, this aluminium composite material becomes a very popular cladding material in the world. Specifications Panel thickness 3mm,4mm.5mm,6mm Panel width 1000mm,1220mm, 1250mm,1350mm,1500mm,1570mm Panel length 2440mm-5800mm,or per customer’s request Alu skin thickness 0.25mm,0.30mm,0.35mm, 0.40mm,0.45mm,0.50mm Standard size 1220(W) ×2440(L)mm paint polyester coating core : Normal PE core
  15. 15. PVDF Fluoropolymers have been used in a multitude of high performance coating applications for over thirty five years. Poly(vinylidene fluoride) (PVDF) has been used especially in architectural applications, where both excellent appearance and substrate protection must be maintained over a very long period of time. PVDF coatings can be applied by conventional coil or spray coating techniques, and baked at temperatures of 230-250 ºC.
  16. 16. Fireproof Aluminium Composite Panel Our fireproof aluminum composite panel is made of fireproof plastic core with two layers of aluminum sheets. This new decorative material comes with B1 fireproof grade according to GB8624 test. It is green material, as there is no harmful gas during burning.
  17. 17. Fireproof Aluminium Composite Panel
  18. 18. Mirror Finished Aluminium Composite Panel The front side of the mirror finished aluminum composite panel is treated like a mirror. The panel looks more beautiful and widely used in interior decoration, kitchen, especially in ceiling and household appliance and furniture etc. Specification Panel thickness 3mm,4mm.5mm,6mm Panel width 1220mm Panel length 2440mm-5800mm,or per customer’s request Alu skin thickness 0.30mm,0.40mm Standard size 1220(W) ×2440(L)mm core Normal PE core
  19. 19. PE Aluminium Composite Panel PE Aluminum Composite Panel The PE aluminum composite panel consists of two sheets of corrosion resistant aluminum permanently bonded to polyethylene core material. The front aluminum coats PE (Polyester) paint. Due to its excellent flexibility and sound insulation performance, etc., this aluminum composite panel is widely used as interior decoration materials all around world. Specification : Panel thickness :3mm,4mm.5mm,6mm Panel width: 1000mm,1220mm,1250mm,1350mm,1500mm,1570mm Panel length: 2440mm-5800mm,or per customer’s request Alu. skin thickness 0.15mm,0.21mm,0.30mm,0.40mm, 0.50mm Standard size 1220(W) ×2440(L)mm Paint Polyester coating Core Normal PE core
  20. 20. Manufacturing of Aluminium Alumina recovery begins by passing the bauxite through screens to sort it by size. It is then crushed to produce relatively uniformly sized material. The ore is then fed into large grinding mills and mixed with a caustic soda solution (sodium hydroxide) at high temperature and pressure. The grinding mill rotates like a huge drum while steel rods - rolling around loose inside the mill - grind the ore to an even finer consistency. The process is a lot like a kitchen blender only much slower and much larger. The material finally discharged from the mill is called slurry. The resulting liquor contains a solution of sodium aluminate and undissolved bauxite residues containing iron, silicon, and titanium. These residues - commonly referred to as "red mud" - gradually sink to the bottom of the tank and are removed. Five major steps in recovering alumina from bauxite. STEP 1- Crushing and Grinding: Four tons of bauxite are required to produce 2 tons of alumina. bauxite.
  21. 21. Manufacturing of Aluminium The slurry is pumped to a digester where the chemical reaction to dissolve the alumina takes place. In the digester the slurry - under 50 pounds per square inch pressure - is heated to 300 °Fahrenheit (145 °Celsius). It remains in the digester under those conditions from 30 minutes to several hours. More caustic soda is added to dissolve aluminum containing compounds in the slurry. Undesirable compounds either don't dissolve in the caustic soda, or combine with other compounds to create a scale on equipment which must be periodically cleaned. The digestion process produces a sodium aluminate solution. Because all of this takes place in a pressure cooker, the slurry is pumped into a series of "flash tanks" to reduce the pressure and heat before it is transferred into "settling tanks." . Five major steps in recovering alumina from bauxite. STEP 2-Digesting:
  22. 22. Manufacturing of Aluminium Settling is achieved primarily by using gravity, although some chemicals are added to aid the process. Just as a glass of sugar water with fine sand suspended in it will separate out over time, the impurities in the slurry - things like sand and iron and other trace elements that do not dissolve - will eventually settle to the bottom. The liquor at the top of the tank (which looks like coffee) is now directed through a series of filters. After washing to recover alumina and caustic soda, the remaining red mud is pumped into large storage ponds where it is dried by evaporation. The alumina in the still warm liquor consists of tiny, suspended crystals. However there are still some very fine, solid impurities that must be removed. Just as coffee filters keep the grounds out of your cup, the filters here work the same way. The giant-sized filters consist of a series of "leaves" - big cloth filters over steel frames - and remove much of the remaining solids in the liquor. The material caught by the filters is known as a "filter cake" and is washed to remove alumina and caustic soda. The filtered liquor - a sodium aluminate solution - is then cooled and pumped to the "precipitators." Five major steps in recovering alumina from bauxite. STEP 3-Settling:
  23. 23. Manufacturing of Aluminium  Imagine a tank as tall as a six-story building.  Now imagine row after row of those tanks  called precipitators. The clear sodium  aluminate from the settling and filtering  operation is pumped into these precipitators.  Fine particles of alumina - called "seed  crystals" (alumina hydrate) - are added to  start the precipitation of pure alumina  particles as the liquor cools. Alumina crystals  begin to grow around the seeds, then settle  to the bottom of the tank where they are  removed and transferred to "thickening tanks." Finally, it is filtered again then  transferred by conveyor to the "calcination kilns."  Five major steps in recovering alumina from bauxite. STEP 4-Precipitation:
  24. 24. Manufacturing of Aluminium Calcination is a heating process to  remove the chemically combined water  from the alumina hydrate. That's why,  once the hydrated alumina is calcined, it  is referred to as anhydrous alumina.  "Anhydrous" means "without water." Five major steps in recovering alumina from bauxite. STEP 5-Calcination From precipitation, the hydrate is filtered and washed to rinse away  impurities and remove moisture. A continuous conveyor system delivers the  hydrate into the calcining kiln. The calcining kiln is brick-lined inside and gas- fired to a temperature of 2,000 °F or 1,100 °C. It slowly rotates (to make sure  the alumina dries evenly) and is mounted on a tilted foundation which allows  the alumina to move through it to cooling eqipment. (Newer plants use a  method called fluid bed calcining where alumina particles are suspended  above a screen by hot air and calcined.) The result is a white powder like that shown below: pure alumina. The  caustic soda is returned to the beginning of the process and used again.
  25. 25. Manufacturing of Aluminium At this point, the alumina is ready for conversion  into aluminum at a smelter.  Alumina is also used in making chemical and  ceramics.
  26. 26. Manufacturing of Aluminium Smelting: In 1886,  Charles Hall of the USA  and Paul L.T. Heroult of  France, made the same  discovery -  molten cryolite (a sodium  aluminum fluoride mineral)  could be used to dissolve  alumina and the resulting  chemical reaction would  produce metallic  aluminum. The Hall- Heroult process remains  in use today. Converting Alumina to Aluminum Two tons of alumina are required to make one ton of aluminum.
  27. 27. Manufacturing of Aluminium The Hall-Heroult process takes place in a large carbon or graphite lined steel  container called a " reduction pot". In most plants, the pots are lined up in long  rows, called potlines. The key to the chemical reaction necessary to convert the alumina to metallic  aluminum is the running of an electrical current through the cryolite/alumina  mixture. The process requires the use of direct current (DC) - not the alternating  current (AC) used in homes. The immense amounts of power required to produce  aluminum is the reason why aluminum plants are almost always located in areas  where affordable electrical power is readily available. Some experts maintain  that one percent of all the energy used in the United States is used in the making  of aluminum. The electrical voltage used in a typical reduction pot is only 5.25 volts, but the  amperage is VERY high - generally in the range of 100,000 to 150,000  amperes or more. The current flows between a carbon anode (positively charged),  made of petroleum coke and pitch, and a cathode (negatively charged), formed by  the thick carbon or graphite lining of the pot. Converting Alumina to Aluminum : The Hall-Heroult process
  28. 28. Manufacturing of Aluminium When the electric current passes through the mixture, the carbon of the anode  combines with the oxygen in the alumina. The chemical reaction produces metallic  aluminum and carbon dioxide. The molten aluminum settles to the bottom of the  pot where it is periodically syphoned off into crucibles while the carbon dioxide - a  gas - escapes. Very little cryolite is lost in the process, and the alumina is  constantly replenished from storage containers above the reduction pots. The metal is now ready to be forged, turned into alloys, or extruded into the  shapes and forms necessary to make appliances, electronics, automobiles,  airplanes cans and hundreds of other familiar, useful items. Aluminum is formed at about 900 °C, but once formed has a melting point of only  660 °C. In some smelters this spare heat is used to melt recycled metal, which is  then blended with the new metal. Recycled metal requires only 5 per cent of the  energy required to make new metal. Blending recycled metal with new metal  allows considerable energy savings, as well as the efficient use of the extra heat  available. When it comes to quality, there is no difference between primary metal  and recycled metal. Converting Alumina to Aluminum : The Hall-Heroult process
  29. 29. Manufacturing of Aluminium The smelting process required to produce aluminum from the alumina is  continuous the potline is usually kept in production 24 hours a day year-round. A  smelter cannot easily be stopped and restarted. If production is interrupted by a  power supply failure of more than four hours, the metal in the pots will solidify,  often requiring an expensive rebuilding process. The cost of building a typical,  modern smelter is about $1.6 billion. Most smelters produce aluminum that is 99.7% pure - acceptable for most  applications. However, super pure aluminum (99.99%) is required for some special  applications, typically those where high ductility or conductivity is required. It  should be noted that what may appear to be marginal differences in the purities of  smelter grade aluminum and super purity aluminum can result in significant  changes in the properties of the metal. Converting Alumina to Aluminum : The Hall-Heroult process About 6.2 kWH (kilowatt hours) of electricity is required to produce one pound of aluminum from alumina.
  30. 30. Aluminium Smelter (Norway)
  31. 31. Aluminium and aluminium alloys Factors for selecting are: 1. High strength to weight ratio 2. Resistance to corrosion 3. High thermal and electrical conductivity 4. Ease of machinability 5. Non-magnetic Aldural Duralumin Aluminum Bronze Y-alloy It is duralumin with thin coating of pure aluminium Used in under water application. 94% Al + 4% Cu+ 0.5% Mg + 0.5% Mn + 0.5% Si+ 0.5% Fe Used in aircraft and automobile 10 % to 22%Al + 90% to 78% Cu Used in die casting and pump rods. 92.5% Al + 4% Cu+ 1.5% Mg + 2% Ni Used for making pistons , cylinder heads and gear boxes
  32. 32. Cast Structure of Al Ingot
  33. 33. Boat Hulls Aluminium boat hulls  offer corrosion  resistance and light  weight.
  34. 34. XJ6 Aluminium Body
  35. 35. XJ6 Aluminium Chassis
  36. 36. Aluminium Bumper Beams
  37. 37. Aluminium Engine Blocks (Lupo)
  38. 38. Audi A2 engine block
  39. 39. Aluminium Bottles
  40. 40. Aluminium Forging
  41. 41. Forged Aluminium Wheels
  42. 42. Al heat transfer components
  43. 43. Aluminium Roofing
  44. 44. Copper and copper alloys • Copper alloys have electrical and mechanical properties, corrosion resistance, thermal conductivity and wear resistance. • Applications are electronic components, springs and heat exchangers. • Brass is an alloy of copper and zinc. • Bronze is an alloy of copper and tin. Copper Properties •Red colour •Excellent thermal and electric conductor •Corrosion resistant •Good welding •Very ductile and malleable
  45. 45.  Have been utilized in quite a variety ofHave been utilized in quite a variety of applications since antiquity.applications since antiquity.  Unalloyed copper is so soft and ductile that itUnalloyed copper is so soft and ductile that it is difficult to machine;is difficult to machine;  it has an almost unlimited capacity to be coldit has an almost unlimited capacity to be cold worked.worked.  it is highly resistant to corrosion in diverseit is highly resistant to corrosion in diverse environments including the ambientenvironments including the ambient atmosphere, seawater, and some industrialatmosphere, seawater, and some industrial chemicals.chemicals. Copper and copper alloys
  46. 46.  The mechanical and corrosion-resistanceThe mechanical and corrosion-resistance properties of copper may be improved byproperties of copper may be improved by alloying.alloying.  Most copper alloys cannot be hardened orMost copper alloys cannot be hardened or strengthened by heat-treating procedures;strengthened by heat-treating procedures;  Only cold working and/or solid-solutionOnly cold working and/or solid-solution alloying can be utilized to improve thesealloying can be utilized to improve these mechanical properties.mechanical properties. Copper and copper alloys
  47. 47. Copper Alloys: brassesbrasses Cartridge Brass : 70% Cu+ 30% Zn Used in Cartridges , tubes , springs etc. Muntz Metal 60% Cu+ 40% Zn, Used in Casting , Condenser Tubes etc. Naval Brass 60% Cu+ 39% Zn+ 1% Sn Used in Marine and engineering casting like condeser tubes , pump parts , motor boat shafting.
  48. 48. Bell Metal
  50. 50. The Manufacturing Process : Copper Pure copper is rarely found in nature, but is usually combined with other chemicals in the form of copper ores. The most common are known as sulfide ores in which the copper is chemically bonded with sulfur. Others are known as oxide ores, carbonate ores, or mixed ores depending on the chemicals present. Many copper ores also contain significant quantities of gold, silver, nickel, and other valuable metals, as well as large quantities of commercially useless material. The most common sulfide ore is Chalcopyrite, CuFeS 2 , also known as copper pyrite or yellow copper ore. Chalcocite, Cu 2 S, is another sulfide ore. Cuprite, or red copper ore, Cu 2 O, is an oxide ore. Malachite, or green copper ore, Cu(OH) 2 •CuCO 3 , is an important carbonate ore, as is Azurite, or blue copper carbonate, Cu(OH) 2 •2CuCO 3 . Other ores include tennantite, boronite, chrysocolla, and atacamite.
  51. 51. The Manufacturing Process : Copper Mining 1 Most sulfide ores are taken from huge open-pit mines by drilling and blasting with explosives. In this type of mining, the material located above the ore, called the overburden, is first removed to expose the buried ore deposit. This produces an open pit that may grow to be a mile or more across. A road to allow access for equipment spirals down the interior slopes of the pit. 2 The exposed ore is scooped up by large power shovels capable of loading 500-900 cubic feet (15-25 cubic meters) in a single bite. The ore is loaded into giant dump trucks, called haul trucks, and is transported up and out of the pit.
  52. 52. The Manufacturing Process : Copper Concentrating The copper ore usually contains a large amount of dirt, clay, and a variety of non- copper bearing minerals. The first step is to remove some of this waste material. This process is called concentrating and is usually done by the flotation method. 3 The ore is crushed in a series of cone crushers. A cone crusher consists of an interior grinding cone that rotates on an eccentric vertical axis inside a fixed outer cone. As the ore is fed into the top of the crusher, it is squeezed between the two cones and broken into smaller pieces. 4 The crushed ore is then ground even smaller by a series of mills. First, it is mixed with water and placed in a rod mill, which consists of a large cylindrical container filled with numerous short lengths of steel rod. As the cylinder rotates on its horizontal axis, the steel rods tumble and break up the ore into pieces about 0.13 in (3 mm) in diameter. The mixture of ore and water is further broken up in two ball mills, which are like a rod mill except steel balls are used instead of rods. The slurry of finely ground ore that emerges from the final ball mill contains particles about 0.01 in (0.25 mm) in diameter.
  53. 53. The Manufacturing Process : Copper 5The slurry is mixed with various chemical reagents, which coat the copper particles. A liquid, called a frother, is also added. Pine oil or long-chain alcohol are often used as frothers. This mixture is pumped into rectangular tanks, called flotation cells, where air is injected into the slurry through the bottom of the tanks. The chemical reagents make the copper particles cling to the bubbles as they rise to the surface. The frother forms a thick layer of bubbles, which overflows the tanks and is collected in troughs. The bubbles are allowed to condense and the water is drained off. The resulting mixture, called a copper concentrate, contains about 25-35% copper along with various sulfides of copper and iron, plus smaller concentrations of gold, silver, and other materials. The remaining materials in the tank are called the gangue or tailings. They are pumped into settling ponds and allowed to dry. The process of extracting copper from copper ore varies according to the type of ore and the desired purity of the final product. Each process consists of several steps in which unwanted materials are physically or chemically removed, and the concentration of copper is progressively increased.
  54. 54. The Manufacturing Process : Copper Smelting Once the waste materials have been physically removed from the ore, the remaining copper concentrate must undergo several chemical reactions to remove the iron and sulfur. This process is called smelting and traditionally involves two furnaces as described below. Some modern plants utilize a single furnace, which combines both operations. 6 The copper concentrate is fed into a furnace along with a silica material, called a flux. Most copper smelters utilize oxygen-enriched flash furnaces in which preheated, oxygen-enriched air is forced into the furnace to combust with fuel oil. The copper concentrate and flux melt, and collect in the bottom of the furnace. Much of the iron in the concentrate chemically combines with the flux to form a slag, which is skimmed off the surface of the molten material. Much of the sulfur in the concentrate combines with the oxygen to form sulfur dioxide, which is exhausted from the furnace as a gas and is further treated in an acid plant to produce sulfuric acid. The remaining molten material in the bottom of the furnace is called the matte. It is a mixture of copper sulfides and iron sulfides and contains about 60% copper by weight.
  55. 55. Typical Application: Copper alloy
  56. 56. types of COPPER TUBE There are six standard types of copper tube: 1. Type K (green), is the heaviest wall and is used in higher pressure applications; 2. Type L (blue), has a medium wall and is used in mid-pressure applications; 3. Type M (red), has a lighter wall that Type L and is used in low-pressure applications; 4. DWV (for Drain Waste Vent, yellow), has the thinnest walled and used in drain, waste, vent applications with little to no pressure involved; 5. ACR (for Air Conditioning/Refrigeration, blue) used primarily in HVAC/R applications; 6. OXY/MED (blue, green) used for medical gas applications.
  57. 57. Magnesium and magnesium alloys • Magnesium (Mg) is the lightest metal. • Alloys are used in structural and non-structural applications. • Typical uses of magnesium alloys are aircraft and missile components. • Also has good vibration-damping characteristics. • Compared with aluminum, magnesium is approximately two- thirds of its weight. PROPERTIES OF MAGNESIUM : Specific gravity 1.74 Melts at 651°C Boiling Point is 1110°C It is silver white processing high lustre
  58. 58. Magnesium Wrought alloys Several magnesium alloys have been developed especially for the manufacture of wrought products. The most important are M1A, AZ3IB, AZ6IA, AZ80A, and ZK60A. As in the case of the casting alloys, the principal added elements in the wrought compositions are aluminum, manganese, and zinc.M1A is used for various wrought manufactures including sheet, forgings, and extrusions. In any form, the strength of M1A is relatively low. AZ3lB is employed for sheet and extrusions. AZ6lA and AZ80A find use for extrusions. Of the extrusion alloys, only AZ80A is not extruded into hollow shapes or tubing. T A54A is employed exclusively for forgings and ZK60A for extrusions.  Magnesium properties •Very light •Expensive •Violent reaction with oxygen
  59. 59. Magnesium Wrought alloys Magnesium alloys for wrought products are classified as non-heat treatable and heat treatable. AZ80A and ZK60A are heat treated by aging the material as fabricated. The strengths are increased substantially but with loss of elongation on aging. M1A and AZ31B sheet are supplied as hot rolled, as cold rolled, and annealed. The principal wrought manufactures which are commercially available in magnesium alloys include sheet and other flat rolled products, extrusions (bars, rods, solid shapes, hollow shapes, and tubing), forgings, screw- machine stock, and impact extrusions.
  60. 60. Magnesium Burns easily when being machined
  61. 61. Magnesium Wheel Place pieces of magnesium adjacent to buried steel pipelines and water tanks. The magnesium reacts chemically to the elements found in the earth and prevents corrosion of the steel. Used with Aluminium to make lightweight alloys.
  62. 62. Nickel and nickel alloys Nickel has been used in alloys that date back to the dawn of civilization. Chemical analysis of artifacts has shown that weapons, tools, and coins contain nickel in varying amounts. Nickel in elemental form or alloyed with other metals and materials has made significant contributions to our present-day society and promises to continue to supply materials for an even more demanding future. Nickel is a versatile element and will alloy with most metals. Complete solid solubility exists between nickel and copper. Wide solubility ranges between iron, chromium, and nickel make possible many alloy combinations.
  63. 63. Nickel and nickel alloys • Nickel (Ni) has strength, toughness, and corrosion resistance to metals. • Used in stainless steels and nickel-base alloys. • Alloys are used for high temperature applications, such as jet-engine components and rockets. PROPERTIES OF NICKEL : Specific gravity 8.90 Melts at 1452°C Boiling Point is 2900°C It is grayish white lustrous metal
  64. 64. manganese & alloys • Manganese is primarily produced from the mineral pyrolusite (MnO2), which, on average, contains more than 50% manganese. • Manganese is an extremely brittle and hard, silvery-grey metal. The twelfth most abundant element in the earth's crust, manganese increases strength, hardness and wear resistance when alloyed in steel. • Excellent formability , welding and corrosion resistance PROPERTIES : Density: 7.21 g/cm³ Melting Point: 1246°C Boiling Point: 2061 °C Mohs Hardness: 6
  65. 65. Tin & alloys • Tin (Sn) , • It is very costly metal and does not occur abundantly in nature • The most important ore is tinstone or cassiterite ( SnO3 ) • Used for preparing solder material , because it melts easily and does not corrode • It is used for coating iron and steel sheets • Used in Bronze •Bluish white shiny colour •Soft •Corrosion resistant •Low melting point
  66. 66. Tin & alloys PROPERTIES OF TIN Melts at 232°C It is SOFT, ductile and malleable Bright white metal It does not rust Tin was one of the first metals known to man. Throughout ancient history, various cultures recognized the virtues of tin in coatings, alloys and compounds, and use of the metal increased with advancing technology. Today, tin is an important metal in industry even though the annual tonnage used is much smaller than those of many other metals. One reason for the small tonnage is that, in most applications, only very small amounts of tin are used at a time.
  67. 67. Tin & alloys Pewter is a tin-base white metal containing antimony and copper. Originally,  pewter was defined as an alloy of tin and lead, but to avoid toxicity and  dullness of finish, lead is excluded from modern pewter. These modem  compositions contain 1 to 8% antimony and 0.25 to 3.0% copper. Pewter Dental alloys for making amalgams contain silver, tin, mercury, and some  copper and zinc. The copper increases hardness and strength and the zinc  acts as a scavenger during alloy manufacture, protecting major constituents  from oxidation. Most dental alloys presently available contain 25 to 27% tin  and consist mainly of the inter-metallic compound Ag and Sn. When  porcelain veneers are added to gold alloys for high-grade dental restoration, 1% tin is added to the gold alloy to ensure bonding with the porcelain. Dental alloys
  68. 68. Zinc & alloys • The most important ore is zinc oxide ( ZnO), zinc carbonate ( ZnCO3 ) • Used in electric bells and for preparing printing block • Used for making brass • The mechanical properties of these zinc alloys make them attractive  substitutes for cast iron and copper alloys in many structural and  pressure-tight applications. Because zinc is less costly than copper,  these zinc alloys have a distinct cost advantage over copper-base  alloys. The ease of machining of zinc and its inherent corrosion  resistance give it advantages over cast iron.  PROPERTIES OF zinc Melts at 419°C It is brittle at ordinary temp. Crystalline blue white metal Resist corrosion
  69. 69. Wrought Zinc & alloys Wrought Zinc and Zinc Alloys Wrought zinc and zinc alloys may be obtained as rolled strip, sheet and foil; extruded rod and shapes; and drawn rod and wire. These metals exhibit good resistance to  corrosion in many types of service, and because the corrosion products that may form on them are white, other materials are not stained by them. Wrought zinc has chemical characteristics particularly  adapted to certain uses, such as dry batteries and  photoengraver`s plate, and offers combinations of  desirable physical and mechanical properties at  relatively low cost. In common with many other metals  and alloys, wrought zinc creeps under constant loads  that are substantially less than its ultimate strength; that  is, wrought zinc does not have clearly defined elastic  module, and hence creep data from service tests must  be used in designing for strength and rigidity under  conditions of continuos stress.
  70. 70. Manufacturing of Zinc Mining 1 Zinc ores are dug from  underground mines using  conventional blasting, drilling,  and hauling techniques. The  ores occur as zinc sulfide (also  called sphalerite), zinc  carbonate (smithsonite), zinc  silicate (calimine), and in  compounds of manganese  and iron (franklinite). Zinc ore is  sometimes mined in conjunction  with silver or lead ores. In  addition to the ore itself, oil and  sulfuric acid are required for the  breakdown of the ores; and  electricity, coke, or natural gas  are needed to provide the heat  energy for smelting.
  71. 71. Manufacturing of Zinc Froth flotation 2 Zinc can be produced by a process called froth flotation,  which is also used for reduction of copper and lead ores.  This process involves grinding the zinc ore to a fine  powder, mixing it with water, pine oil, and flotation  chemicals, and then agitating the mixture to "float" the zinc  to the surface. A variety of chemicals are used to coat the  important zinc particles and prevent them from becoming  wetted by the water. Then air is injected, and the coated  minerals
  72. 72. Manufacturing of Zinc attach themselves to the bubbles. The operation is  performed inside a vat and agitated with an impeller. The  rotating impeller draws the air down the standpipe that  surrounds the impeller shaft and dissipates it throughout  the mixture or "pulp." The zinc rises to the top and the  residue stays in the bottom of the pulp, since it cannot  adhere to the bubbles. Automatic scrapers remove the  mineral-laden froth containing the zinc. Filtering 3 The froth is filtered to remove the water and liquid oils.  The paste-like remainder is mixed with lime and sent to a  furnace. The furnace roasts the mixture at 2500°F  (1371°C), which fuses the minerals into solid chunks  called sinter. At this point, the material has been  completely converted to zinc oxide.
  73. 73. Manufacturing of Zinc Smelting 4 The next reduction process uses a blast furnace to melt the prepared  ore into its elemental components. The blast furnace is fueled by  electricity, coke, or natural gas, which generate temperatures of up to  2200°F (1204°C). This, however, also generates carbon dioxide, which  recombines with the zinc as it cools to re-form zinc oxide. To reduce this  reformation, the zinc is sprayed with molten lead while it is still hot. The  lead, at 1022°F (550°C), dissolves the zinc and carries it to another  chamber, where it is cooled to 824°F (440°C). At this temperature, the  lighter zinc separates out of the lead and is drained off the top. The lead  is reheated and returned to the blast furnace. Refining 5 Further metal improvement can be made by keeping the zinc molten  and undisturbed for several hours. In this state, iron and other  contaminants settle to the bottom, allowing the almost pure zinc to be  carefully drawn off the top and cast into ingots
  74. 74. Manufacturing of Zinc Alloying 6 Most zinc is alloyed with other metals before use to improve its  properties. Alloying involves remelting and mixing the zinc with other  metals in precise proportions. For example, approximately 4% aluminum  is added to improve casting quality and die life in the die-casting  process. Other added alloys are small amounts of titanium, copper, and  magnesium. After alloying, the molten metal is poured into sow molds  and ingot molds. Sows can weigh several thousand pounds, while ingots  weigh about 45 pounds (20 kg).
  75. 75. Titanium and Titanium alloys Since the introduction of titanium and titanium alloys in the early 1950s,  these materials have in a relatively short time become backbone  materials for the aerospace, energy, and chemical industries. •The combination of high strength-to-weight ratio, excellent mechanical  properties, and corrosion resistance makes titanium the best material  choice for many critical applications.  •Today, titanium alloys are used for demanding applications such as  static and rotating gas turbine engine components.  •Some of the most critical and highly-stressed civilian and military  airframe parts are made of these alloys. Titanium properties •Very expensive •Endurance like steel but quite lighter. •Biocompatible
  76. 76. lead and Lead alloys Lead was one of the first metals known to man. Probably the oldest lead  artifact is a figure made about 3000 BC. All civilizations, beginning  with the ancient Egyptians, Assyrians, and Babylonians, have used  lead for many ornamental and structural purposes. Lead's chemical symbol comes from the Latin word for waterworks,  plumbum.  Many magnificent buildings erected in the 15th and 16th centuries still  stand under their original lead roofs. Lead properties •Grey colour •Very soft •Low melting point •Ductile and malleable •Very toxic
  77. 77. lead and Lead alloys The properties of lead that make it useful in a wide variety  of applications are density, malleability, lubricity, flexibility,  electrical conductivity, and coefficient of thermal  expansion, all of which are quite high; and elastic  modulus, elastic limit, strength, hardness, and melting  point, all of which are quite low. Lead also has good  resistance to corrosion under a wide variety of conditions.  Lead is easily alloyed with many other metals and casts  with little difficulty. The high density of lead (11.35 g/cm3, at room  temperature) makes it very effective in shielding  against x-rays and gamma radiation. The combination  of high density, high limpness (low stiffness), and high  damping capacity makes lead an excellent material for  deadening sound and for isolating equipment and  structures from mechanical vibrations.
  78. 78. Refractory metals • Refractory metals have a high melting point and retain their strength at elevated temperatures. • Applications are electronics, nuclear power and chemical industries. • Molybdenum, columbium, tungsten, and tantalum are referred to as refractory metal.
  79. 79. Mechanical and physical properties comparison Metals Density [g/cm3 ] Tensile Strength [MPa] at RT Electrical conductivity %IACS Modulus of Elasticity x 103 [MPa] Tungsten 19.3 689-3445 31 4.063 Tantalum 16.6 241-482 13.9 1.88 Titanium 4.5 262-689 5.5 1.034-1.087 Molybdenum 10.2 827-1379 34 3.169 Niobium 8.57 201-414 13.2 1.034 Aluminum 2.7 69-187 64.9 0.609 Zinc 7.13 203-324 28.3 0.689 Copper 8.96 228-371 100 1.171 Iron 7.87 179-283 19.1 1.99-2.01
  80. 80. Metals & Alloy Physical properties Comparison
  81. 81. Surface Colour of Metals & alloy
  82. 82. Surface Hardening Methods  Flame hardening  Induction heating  High-frequency resistance heating  Electron beam heating  Laser beam heating
  83. 83. Surface Hardening Methods Induction heating High frequency resistance heating
  84. 84. IS CODE : Aluminium & alloy is : 733-1975 Wrought aluminium and aluminium alloy bars, rods and sections (for general engineering purposes) (second revision) IS : 737-1974 Wrought aluminium and aluminium alloys, sheet and strip (for general engineering purposes) (second revision) IS : 1254-1975 Corrugated aluminium sheet (second revision) IS : 7094-1973 Aluminium and aluminium alloy welded tubes for general engineering purposes
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