Copper and its alloys are discussed. Copper is extracted via both pyrometallurgical and hydrometallurgical methods from ores like chalcopyrite. Blister copper undergoes electrolytic refining to obtain pure copper. Copper alloys include brasses, bronzes, aluminum bronzes, beryllium bronzes and cupro-nickels. These alloys find applications in electrical, automotive and other industries due to copper's high thermal and electrical conductivity.

1. Non-Ferrous Metals
and Their alloys

2. Copper and its alloys

3. Copper
• Copper (Cu) atomic weight 63.546 is a soft, malleable and ductile metal
with very high thermal and electrical conductivity from the group of
Coinage metals in the modern periodic table.
• There are 29 isotopes of copper. Cu and Cu are stable, with Cu comprising
approximately 69% of naturally occurring copper. The other isotopes are
radioactive.
• Copper is present in the Earth's crust at a concentration of about 50 parts
per million (ppm)
• Copper occurs as native copper or in mineral such as the copper sulfides
chalcopyrite and chalcocite, copper carbonates azurite and malachite and
the copper(I) oxide mineral cuprite.

4. Extraction Techniques
• Copper ore is mined both underground and on the surface. Large excavations
formed by surface mining are called open-pit mines.
• Most of the copper ores mined today are oxide or sulfide ores.
• HYDROMETALLURGICAL operations are required for treating very poor
grade oxide ores (LEACHING)
• PYROMETALLURGICAL treatments are given to the sulphide ores for their
smelting and roasting.
• ELECTROMETALLURGICAL techniques are employed for the electro refining
of blister copper or copper scrap.

5. Extraction of Cu from sulphide ores
• Copper is extracted usually from the sulphide ore chalcopyrite (CuFeS2)
by smelting process.
• Ores containing 4% or more copper are treated by smelting process.
• There are following steps for the Pyrometallurgical extraction of copper
from Chalcopyrite.
1. CONCENTRATION - By froath floatation Method
2. ROASTING
3. SMELTING
4. BESSEMERIZATION - Blister copper is obtained

6. Refining of Blister Copper
• Blister copper is refined by electrolysis. The blister copper then undergoes "fire
refining.“
• Air and natural gas are blown through the copper to remove any remaining sulfur
and oxygen.
• The copper is cast into copper anodes and placed in an electrolytic cell. Once
charged, the pure copper collects on the cathode and is removed as 99% pure.
• Blocks of blister copper are used as anodes and thin sheets of pure copper act as
cathodes. The cathode plates are coated with graphite in order to remove
depositing copper.
• The electrolyte is copper sulphate (CuSO4) mixed with a little amount of H2SO4 to
increase the electrical conductivity.
• Optimum potential difference is 1.3 volt for this electrolytic process.

7. Electrolytic Refining
Cu → Cu+2
+2e-
Cu+2
+2e- → Cu
Fe(s) → Fe2+
(aq) + 2e–
Zn(s) → Zn2+
(aq) + 2e–

8. Copper Alloys
Deformable and heat treatable
1) Al-Cu-Mg-alloys (duraluminium)
2) Al-Cu-Mg-Si-alloys (forgable)
3) Al-Mg-Si-alloys (corrosion resistance)
4) Al-Zn-Mg-Cu-alloys (high strength)
5) Al-Cu-Mg-Ni-Fe-alloys (heat resistance)
Rm → 500 N/mm2
; Rp0,2 → 390 N/mm2
; A → 25%
Deformable and non heat treatable
1) Al-Mn-alloys
2) Al-Mg-alloys (magnalium)
Rm → 300 N/mm2; Rp0,2 → 150 N/mm2; A → 25%
Plane bearing alloys (for mono- and bimetallic bearing shells)
Al-Sn; Al-Ni; Al-Cu-Sb Typical structure of bearing material

9. Copper alloy designations
Generic name UNS numbers Composition
Wrought alloys
Coppers C10100-C15760 >99%Cu
High-copper alloys C16200-C19600 >96%Cu
Brasses C20500-C28580 Cu-Zn
Leaded brasses C31200-C38590 Cu-Zn-Pb
Tin brasses C40400-C49080 Cu-Zn-Sn-Pb
Phosphor bronzes C50100-C52400 Cu-Sn-P
Leaded phosphor bronzes C53200-C54800 Cu-Sn-Pb-P
Copper-phosphorus and copper-silver
phosphorus alloys
C55180-C55284 Cu-P-Ag
Aluminum bronzes C60600-C64400 Cu-Al-Ni-Fe-Si-Sn
Silicon bronzes C64700-C66100 Cu-Si-Sn
Other copper-zinc alloys C66400-C69900
Copper-nickels C70000-C79900 Cu-Ni-Fe
Nickel silvers C73200-C79900 Cu-Ni-Zn
wrought alloys
designated C16000 - C79999
forged,rolled,hot and cold work can be
done

10. Cast Alloys
Generic name UNS numbers Composition
Wrought alloys
Coppers C10100-C15760 >99%Cu
High-copper alloys C16200-C19600 >96%Cu
Brasses C20500-C28580 Cu-Zn
Leaded brasses C31200-C38590 Cu-Zn-Pb
Tin brasses C40400-C49080 Cu-Zn-Sn-Pb
Phosphor bronzes C50100-C52400 Cu-Sn-P
Leaded phosphor bronzes C53200-C54800 Cu-Sn-Pb-P
Copper-phosphorus and copper-silver
phosphorus alloys
C55180-C55284 Cu-P-Ag
Aluminum bronzes C60600-C64400 Cu-Al-Ni-Fe-Si-Sn
Silicon bronzes C64700-C66100 Cu-Si-Sn
Other copper-zinc alloys C66400-C69900
Copper-nickels C70000-C79900 Cu-Ni-Fe
Nickel silvers C73200-C79900 Cu-Ni-Zn
Designated C81300 - C99999
These alloys can be casted

11. Classification of copper alloys
There are five different classification of copper
alloys
1)Unalloyed
Copper
2)Brasses
Copper – Zinc alloys
Copper – Lead alloys
Copper – Zinc alloys with
Tin and Aluminium additions
3)Bronze
• Copper – Tin alloys
• Copper – Aluminium alloys
• Copper – Silicon alloys
• Copper – Beryllium alloys
4) Cu-Ni
based
• Cupronickel (Cu-Ni)
• Nickel silver (Cu-Ni-
Zn
5) Nickel silver

12. 1)Unalloyed Copper
• Copper content > 99.3%
Roughly classify into three categories
• Electrolytic tough pitch: This copper contains 99.9% Cu with 0.045 O content
• Oxygen – free: Oxygen-free copper is produced from electrorefined cathode
copper which is melt and cast in a reducing atmosphere of CO and N to
prevent O.
• Phosphorus deoxidized: Phosphorus is sufficiently added to produce
phosphoruspentoxide P2O5

13. 2)Brass
There are two Class of brass
• The alpha alloys
with less than 37% Zinc. These
alloys are ductile and can be cold
worked.
• The alpha/beta or duplex alloys
with 37-45% Zinc. These alloys
have limited cold ductility and are
typically harder and stronger
• Families of Brass
– Cast alloy brasses
• Copper-Tin-Zinc alloys (red,
semi-red and yellow brasses)
• Cast Copper-Bismuth and
Copper-Bismuth-Selenium
alloys.
• Copper-Zinc-Silicon alloys
(Silicon brasses and bronzes)
– wrought alloy brasses
• Copper-Zinc alloys
• Copper-Zinc-Tin alloys (Tin
brasses)
• Copper-Zinc-Lead alloys
(Leaded brasses)

14. 3)Bronze
• Cast bronze alloys
– Copper-Tin alloys (Tin
Bronzes)
– Copper-Tin-Lead alloys
(Leaded and high leaded Tin
Bronzes)
– Copper-Tin-Nickel alloys
(nickel-tin bronzes)
– Copper-Aluminium alloys
(Aluminium Bronzes)
• Wrought alloys
– Copper-Tin-Phosphorus alloys
(Phosphor Bronzes)
– Copper-Tin-Lead-Phosphorus
alloys (Leaded Phosphor
Bronzes)
– Copper-Aluminium alloys
(Aluminium Bronzes)

15. Alloying additions in Copper

16. Brasses-General
Alpha Brasses (Alloys containing 36
% Zinc)
• Yellow Alpha Brasses
• Red Alpha Brasses
Alpha + Beta Brasses (54-62%
copper)
• Defects in Brasses
• Intergranuler corrosion (Seasonal
Cracking)
• Dezincification
Phase Diagram

17. Tin Bronzes
• Alloys of copper and tin
• Other Alloying Elements may
also be present With The
Exception of Zinc
• Also called Phosphor bronzes
• Phosphorus content (0.01-0.5%)
• Tin Content (1-11%)
• High corrosion resistance ,
Toughness ,Low coefficient of
friction, free from seasonal
cracking
Phase Diagram

18. Silicon Bronzes
• Alloys of Copper And Silicon
• Maximum Solubility In Alpha
Phase is 5.3 and decrease with the
temperature
• Alloys contains less than 5% Si
are single Phased
• These are the Strongest of the
work hard enable Copper Alloys
• Their Mechanical Properties are
comparable to mild steel and
corrosion resistance is comparable
to copper
• These are used for Tanks ,
pressure vessels , Marine
construction , hydrulic preassure
lines
Phase Diagram

19. Aluminium Bronzes
• Alloys of Al & Cu
• Maximum solubility of Al in α-solid
solution is 9.5%
• Commercial Al bronzes contain (4-
11%)Al
• Alloys containing up to 7.5% al are
single phase, other are double phase
• Other elements are also added
intentionally e-g , Fe , Mn , Si , Ni
• Iron Increases strength , silicon
improves machinability , Mn
improves sound casting
• Single phase Bronze show good
cold working propertis along with
high corrosion resistance to water
and atomsphere
• These are used for water condenser
tubes,nuts , bolts, corrosion
resistance vessels ,and in marine
application
Phase Diagram

20. Beryllium Bronzes
• Alloys of Cu & Beryllium
• Maximum solubility in Alpha solid
Solution is 2.1 % and decreases to
0.25 % to room temperature
• It is increased by age hardening
• They have excellent formability
,high tensile strength , creep
resistance , high electrical
conductivity
• These are used in diaphrames ,
surgical instrument ,bolts & screws ,
firing pins , dies.
Phase Diagram

21. Cupro-Nickels
• Alloys of Cu & Ni , contains upto
30 % Ni
• Cupronickels Alloys are single
phase alloys
• No heat treatment is required
• Properties are improved only by
cold working
• They have high fatigue resistance ,
high corrosion & erosion resistance
toward sea water
• These are widely used in
condenser , heat exchanger tubes ,
coastal power plants
Phase Diagram

22. Nickel Silver
• Alloys of Cu-Ni-Zn
• Commercial Alloys are contain Cu (50-70%) , Ni (5-10%) , Zn (5-40%)
• If copper is more than 60 % these are single phased ,ductile & easily
workable at room temp.
• Addition of Zinc imparts silver-blue-white colour ,good corrosion
resistance.
• These are Excellent base metals for plating with Cr ,Ni ,Ag
• These are used For Rivets, screws, Costume jewelry , name plates & radio
dials

23. Electrical Applications
• Approximately 65% of copper produced is used for electrical applications.
• Power generation and transmission
generators, transformers, motors, busbars and cables provide and
deliverelectricity safely and efficiently to homes and businesses.
• Electrical equipment - providing circuitry, wiring and contacts for PCs,
TVs and mobile phones.

24.  Copper is used in the manufacturing of heatsinks.
 In a microchip, copper is commonly used for what is known as the 'global
interconnects' because of its good conductivity. These are the wires that
connect different sections of the chip together.
 Cu-Ni 70-30 alloy is used in steam generators, heat exchangers, coolers,
condensers, tanks, pipework, valves and fittings in electricity generation by
Nuclear means

25. Automotive Applications
• Almost all automation components
• Automotives radiator is made of copper-brass alloy.

26. Other Applications
Inner grooved Heat radiation technology
Hardware: Gears and pinions
Industrial: Automatic high speed
screw
machine
parts