This document provides an overview of non-ferrous alloys, including copper and its alloys, aluminum and its alloys, magnesium, titanium, nickel, tin, and lead. It discusses the properties and production of these materials as well as some of their common uses. Key alloys described include brasses, bronzes, duralumin, Y-alloys, nickel alloys like monel and nichrome. The document is intended as an educational guide on non-ferrous metals and alloys for engineering students.

1. Title
NON FERROUS ALLOYS
PREPARED BY:
JADAV PARTH.V
MOTVANI SATISH.M
GUIDED BY:
ASSISTANT PROFESSOR,
MECHANICAL ENGINEERING DEPARTMENT
GOVERNMENT ENGINEERING COLLEGE, PALANPUR
MATERIAL SCIENCE AND METALLURGY

2. PRESENTATION OUTLINE
• Introduction
• Copper and its alloys
• Aluminum and its alloys
• Magnesium
• Titanium
• Nickel
• Tin
• Lead
• Zinc

3. Introduction
• As the name suggests, the materials which do not contain iro
n as major element are known as non-ferrous materials.
• Aluminum, Copper, Tin, Lead, Magnesium, Zinc, Titanium and
their alloys are the significant non-ferrous metals and alloys.
• Certain properties of non-ferrous materials such as a good th
ermal and electrical conductivity, better ductility, non toxicity, l
ight in weight, better corrosion resistance and higher strength
to weight ratio, make non-ferrous metals and alloys widely ap
plicable all over the world.
• However, there are some drawbacks such as lower hardness a
nd relatively poor strength.

4. COPPER AND ITS ALLOYS
• Copper and its alloys are widely used non-ferrous materials a
nd occupy second place among all engineering materials. This
is because of its two important properties that are not posses
sed by steel.
• One of them is high electrical conductivity and other is corros
ion resistance, which make copper never substituted by steel.I
ts melting point is 1083•C and density is 8.89gm/cc.

5. Production of Copper
• Copper is produced in the form of ores containing sulphides, sulph
ates, silicate, oxides and carbonates.
• The largest amount of copper is produced from sulphides ores, suc
h as, chalcopyrite (Cu2S Fe2S3),chalcocite (Cu2S), and Covellite(Cu
S). The ores are crushed and concentrated by flotation or any other
physical separation techniques. The concentrated ores are heated
in the furnace to remove the volatility. Hot ores are melted in the f
urnace at some controlled temperature to produce cuprous sulphi
de (Cu2S) and ferrous sulphide (FeS). The mixture is called matte.
• The remaining ore is separated from matte and molten matte copp
er is converted into metallic copper by blowing the air or oxygen in
the furnace, which is called as converter. Blister copper is formed b
y oxidation of copper sulphides. Blister copper is impure and contai
ns some dissolved oxygen and other impurities. This is called as 98
% to 99% copper.

6. Properties of Copper
• Copper is a brownish in color, easily workable, soft and has a g
ood corrosion resistance.
• It Processes the highest thermal and electrical conductivity a
mong metals.
• It can easily be machined, fabricated, welded, brazed and sold
ered.
• Having good ductility and malleability because of its FCC struc
ture but yet very tough and strong.
• It is nonmagnetic with adequate mechanical properties.

7. Electrical Conductivity
• The most desirable property of the copper is electrical condu
ctivity.
• The conductivity is usually expressed as a percentage of a sta
ndard value that was established in 1913, and which represen
t the average value for the best commercial copper produced
at that time. It was called the International Annealed Copper S
tandard (IACS)
• This standard designated a wire of 1 meter length and 1 squa
re millimeter cross section as having a conductivity of 58 mho
s at 20•C.
• This corresponds to a resistance of 1.7241 microhms across a
centimeter cube or a resistance of 0.15328 ohm in a wire weig
hing one gram and measuring one meter long.
• Electrical conductivity of copper depends on its purity. It incre
ases with the increase in the purity.

8. Corrosion Resistance
• There are many events like atmosphere, natural fresh water/s
alts, alkaline solution and many organic chemicals, affecting t
he properties of different materials.
• Among them copper is highly resistant to these all. Its behavi
our with acids highly depends on the oxidizing condition of th
e atmosphere.
• Sulphur compound of the atmosphere combines with copper
and produces copper sulphide as a corrosive product.
• However, addition of the zinc in the copper remarkably incre
ases resistance to corrosion.

9. Uses of Copper
• Due to cooper’s outstanding conductivity and corrosion resist
ance property, copper widely used in electrical application, str
ucture purposes, water carrying pipes, telecommunication an
d railways.
• Over a 50% of the copper produced is used for the electrical a
pplication. Apart from the high electrical conductivity propert
y, the combination of the properties like high corrosion resista
nce and formability, copper is used as electrical conductor.
a. ETP is generally used for current carrying members.
b. ETP ‘s toughness can be reduced by increasing the
temperature up to 200•C, and this is used in the parts such as
turbo generator and high speed commutator.

10. c. High tensile strength, as high as 50 kg/mm2,can be obtained by
heat treatment of chromium copper. These can be used for spot
welding tips and seam welding wheels
•A large application of the copper is in automobile radiator, water h
eater, refrigerator, air conditioning units, heat exchanger, etc.
•An important use of the copper is to handle the sea water in the shi
ps and tide water power stations. For these purposes copper alloys a
re used.
• Due to its higher corrosion resistance, copper and its alloys are wid
ely used where the resistance against the atmospherics corrosion re
quired.
• Copper alloys like brasses and bronzes are used to manufacture the
industrial pipes and tubes.

11. Copper Alloys
• Although copper possesses combination of mechanical, electrical
and physical properties, copper is found to have a limited use bec
ause of its poor strength. Copper possesses the tensile strength of
about 22 kg/mm2, which is sufficient for the structural constructi
on.
• It tensile strength can increase by up to 45 kg/mm2 by cold worki
ng process. The increasing in strength is because of strain hardeni
ng effect. Some important copper alloys are.
(1) Brasses
(2) Bronzes

12. (1) Brasses
• A brass in an alloy of the copper and zinc.
• Its mechanical properties can be varied by varying the percentage
of the zinc. The improvement in color, strength, machinability, hard
ness, etc. Can be varied because of the variation of the zinc.
• Copper dissolve 39% of zinc to from a FFC structure, called as α-sol
id solution.
• The α-brass are relatively stable, soft, ductile and easily cold worke
d. Further increasing the zinc, results in formation of another phas
e, called β-phase.
• It is an intermediate solid solution and has BBC Structure ,β-phase
is formed due to the peritectic reaction at 903•C and at 37% zinc.
• It is stronger, harder but less ductile than the α-phase.

13. • Brasses are available in different forms, some of the common for
ms are red brass, yellow brass, cartridge brass, naval brass, admir
alty brass, muntz metal and gliding metal, etc. It possesses some i
mportant properties as follows :
• Higher strengh than copper
• Good thermal and electrical conductivity
• Good atmospheric corrosion resistance
• High machinability less expensive then copper
• Common uses of the brasses are to manufacture the cartridge cas
ting, automotive radiator, medals, coins, screws, sockets, shafts, p
iston rods, etc.
• High machinability less expensive then copper .
• Common uses of the brasses are to manufacture the cartridge cas
ting, automotive radiator, medals, coins, screws, sockets, shafts, p
iston rods, etc.

14. (2) Bronzes
• Bronzes is an alloy of copper containing elements containing elem
ents other than zinc. Several other elements included in alloy are
tin, aluminum, silicone and nickel.
• Zinc is in very small percentage. Commercially important bronzes
are tin bronzes, aluminum bronzes, silicon bronzes and beryllium
bronzes. Originally the term bronze was used to denot copper-tin
alloys. Generally, the percentage of tin varies from 5% to15% and
remaining in copper.
• Also the tensile strength of the copper is varied by varying the a
mount of the tin.
• At room temperature, the solubility of tin in copper is very low.
• A larger proportion of the tin decrease the ductility of the alloy by
forming the hard electron compound Cu3Sn. While tensile strengt
h of the alloy will increase by increasing the tin content.

15. • Tin bronze is also called as the phosphorous bronze, because pho
sphorous always there up to 0.3%.
• It is deoxidizer and removes the oxygen from alloy. By forming the
Cu3P it improves hardness and strength of the alloy.
Some important properties of the bronzes are:
• Higher tensile strength than brasses
• Better corrosion resistance than brasses
• Antifriction or bearing properties
• Good ductility and malleability properties
• Bronzes can be used for bushes, springs, gears, cylinder heads, di
es , bearing, bell metals , etc.

17. Aluminium and its alloys
• Aluminium is a white metal produced by electrical processes from
the oxide.In India they are chiefly available in Bihar,Madhya Prade
sh, Karnataka,Maharashtra and Tamilnadu.
• Aluminium is silvery -white and about one-third in weight as com
pared to steel and copper.Its melting point is 660degree.It has hig
h electrical and thermal conductivity. It has high corrosion resista
nce in water,industrial and marine atmospheres.
• Aluminium has good machinability,formability,workability and cas
tability.It has high reflectivity and nontarnishing characteristics. It
is nontoxic,nonmagnetic and non sparking.The main drawback of
aluminium is its low hardness and poor strength.It is used widely i
n aircraft and automobile industry,for overhead cables and electri
cal wiring,cooking utensils.Aluminium foil is used as "silverfoil" for
packing cigarettes,chocolates and other eatables etc.

18. Aluminium alloys:
• aluminium finds widest uses when alloyed with small amount of o
ther metals.The addition of small quantities of other alloying elem
ents converts this soft, weak metal into a hard and strong metak ,
while still retaining it's light weight. Alloys can be classified as "c
ast" or """"Wrought" alloys. Some of the important aluminium all
oys are as follows:
(1)Duralumin
(2)Y-alloy

19. (1) Duralumin
• It is one of the oldest and best known alloys of aluminium.It conta
ins 3.5 to 4.5 percent copper,0.4 to 0.7 percent manganese,0.4 to
0.7 percent magnesium,0.4 percent silicon and remainders alumi
nium. It is widely used in wrought condition for forging,stampings
, bars,sheets, tubes and rivets.It possesses age-hardening propert
y, i.e.,after working if the metal is allowed to age for 3 to 4 days it
will be hardened.In the heat-treated and aged condition, Duralum
in may have tensile strength up to 40 kgf/mm'2.
• It has hardness from 56 to 95 BHN and coefficient of thermal expa
nsion as 0.0023 per degree celciance.Its strength rapidly falls abo
ve 200'degree.

20. • On account of its high strength to weight properties it is used in a
utomobile and aircraft industries.It is also employed on surgical a
nd orthopaedic works and for nonmagnetic and other instrument
s parts.Because of good electrical conductivity. It is also used in el
ectrical cables.

21. (2) Y-alloys
• This is an important aluminium alloys developed from the binary
copper-aluminium alloy by small additions of nickel,magnesium,si
licon and iron.It contains 3.5 to 4.5 percent copper, 1.8 to 2.3 perc
ent nickel, 1.2 to 1.7 percent magnesium, 0.6 percent silicon 0.6 p
ercent iron and remainders aluminium. This alloy has the characte
ristics of retaining good strength at high temperatures. Y-alloys is,
therefore, useful for piston and other components of aeroengines
.
• It is also largely used in the form of sheets and strips. After proper
heat treatment it develops minimum tensile strength of about 35
kgf/mm'2.

23. Magnesium
• Magnesium is having density of 1.7g/cm3,and is the lightest struc
tural metal.
• It is having HCP crystal structure. It is relatively soft and low modu
lus of elasticity.
• At room temperature it is difficult to deform magnesium. It has lo
w melting point.
• It is fabricated by either casting or hot working in the temperatur
e range of 200 to 350°C.
• It is susceptible to corrosion in marine surronding atmosphere, bu
t in normal atmosphere it has good corrosion and oxidation resist
ance.
• Magnesium alloys are either cast or wrought, some are heat treat
ment. Main alloying elements are aluminium, zinc,manganese an
d rare earth metals.

24. • Magnesium aluminium alloys have good tensile strength, yield s
trength and ductility. It is used in pressure tight casting and high
ly stressed extrusion.
• Magnesium-zinc-zirconium and Magnesium-zinc-thorium are c
asting alloys. The addition of zirconium up to 0.7% results in grai
n refinement and improvers mechanical properties. Addition of
thorium produce sound castings, free of micro porosity and hot
cracks.Magnesium-zinc-zirconium alloys are used in forgings as
maximum strength for aircraft.

26. TITANIUM
• Titanium has density of 4.5g/cm3,high melting point 1668°C, ext
remely strong, high tensile strength, highly ductile metal.
• It is easily forged and machined.only limitation of titanium is that
it is chemically reactive with other materials at elevated temperat
ure.
• Titanium - aluminium - tin alloys have good weldability and high t
emperature strength.
• Aluminium is the most effective strengthtner of alpha alloys.It is u
sed in aircraft tailpipe assembly, missile fuel tanks,etc
• Titanium-aluminium-vanadium alloys are alpha-beta alloys.It has
high strength. It is used in sheet metal air frame parts,forged airfr
ame parts,forged airframe fittings,etc.
• Titanium-aluminium-vanadium-chromium alloys are beta alloys a
nd can be strengthen by heat treatment.

27. • It is weldable alloys.It is used as high strength fastener, aerospace
components requiring high strength at moderate temperature.

28. NICKEL
• Many of the properties of nickel in its pure form, remains same as
that of annealed low carbon steel. It is ferromagnetic.
• It possesses density (8.9 gm/cc) higher as compared to steel (7.85
gm/cc).
• It is normally ductile and malleable, cold work can increase the te
nsile strength of the material.
• It is highly corrosion resistance, extremely resistant to caustics at
all concentration and temperature up to boiling point.
• Nickel does not rust and because of these properties it is widely u
sed in different engineering applications.
• Nickel is widely used in the industry because of its anticorrosive p
roperty.
• It is used as coating material in many components in chemical ind
ustries.

29. • Nickel is widely used in the industry because of its anticorrosive p
roperty.
• It is used as coating material in many components in chemical ind
ustries.
• It is also used in the form of electroplating, as alloying elements i
n ferrous and mysterious materials.
• It is extensively used as alloying elements. Normally, in cast iron a
nd commercial grade steel, hardenability and toughness can be i
ncreased by adding nickel.
• In brasses and bronzes, nickel reflects the properties like strength
and impact resistance.
• The major use of nickel is in the form of alloy which forms tough,
ductile solid solution alloys with many common materials like cop
per, chromium and iron. Some of important nickel alloys are Hast
ealloys, Nimonics, Nicotine, Inconels, Monels, Constantan, etc.

30. Nickel Alloys
(1) Models
• It is an alloy of nickel and copper (65%Ni,32%Cu).It possesses an e
xcellent corrosion resistance property.
• It gives best performance against sea water, acids, alkalies and foo
d products.
• It possesses tensile strength 55 to 130 kg/mm2 with elongation of
10-30%.It is normally used for handling highly corrosive acids like
sulphuric acids and hydrochloric acids, etc.
(2) Nichrome
• It is an alloy of nickel and chromium (40-50%Ni, 40-60%Cr). It pos
sesses high electrical resistance and oxidation resistance properti
ese.
• It is normally used where higher heat resistance is required.

31. (3) Inconel
• It is an alloy of nickel, cobalt and chromium (40-50%Ni, 20-30%Co,
and 15-30%Cr).
• It is normally used for high temperature applications like manufact
uring parts of gas turbine and jet engines.
• It possesses tensile strength of 100-150 kg/mm2 with an elongatio
n of 20-40%.
(4) Nimonics
• It is an alloy of nickel, chromium and titanium (70-75%Ni
, 15-20%Cr, and 2-4%Ti).
• It possesses high strength at elevated temperature and hi
gh creep resistance.
• It possesses the tensile strength of 100-130 kg/mm2 with
an elongation of 20%-40%.

33. TIN
• Tin is awhite, soft and malleable metal. It has Good corrosion resi
stance to atmospheric conditions and to organic acids.
• It has greatest importance as a coating on steel,and as an alloy co
nstituent in soft solders, collapsible tubes,pewter ware,costumes
jawellery,bronze and bearing lining.
• In India, it's source are quite negligible. It is a brilliant White metal
with a yellowish tinge.Its melting point is 232°C.

34. LEAD
• It is the softest and the heaviest material among all the common
metals. In nature, lead exists either in the form of sulfide or oxide.
• Atleast 60 minerals containing lead are known to science, but co
mmercially lead is derived almost extensively from One mineral,
Galena(PbS).
Important properties of lead.
• Lead is very soft, ductile and malleable because of its FFC structu
re.
• It possesses low melting point of about 327•C.
• It possesses density of around 12gm/cc.
• It possesses low electrical conductivity and high coefficient of the
rmal expansion.
• It has higher corrosion resistance property and good lubricant pr
operty.

35. Applications of lead
• It is widely and satisfactorily used in chemical industries due to its a
nticorrosive property.
•Because of corrosion resistance against atmospheric moisture, soils
and other corrosive acids, it is also used as protective coating materi
al for different chemical equipments.
• In commercial applications, lead is used in three different forms :
1.lead compounds
2.Metallic leads
3.lead alloys
• Antimony and tin are the most used alloying elements for lead allo
ys. Addition of antimony increases the strength and the hardness of
the alloy.
•Addition of the tin in lead will reduce the melting point of the mate
rial and also increases mechanical property of the lead.

36. Applications of different form of lead and its alloys
• Largest portion of the manufactured lead is used for manufacturing
storage batteries in the form of metallic lead pigments.
• It is widely used as shield against the radiation as it has high radiati
on absorbing power.
•It is also used in piping to transport of water and various chemicals
because of higher anticorrosive property.
•Lead is used as alloying element to improve the machinability of bra
ss, bronzes and steels.
• Lead is also used as solders, Babbitt and fusible plugs.
•Lead is also used in printing industries because of its density and ca
stability.property.

38. Zinc
• The chief ores of zinc are zinc blend and calamine.Zinc is known a
s a white metal because of its colour and low melting point(419°
C).
• It is as heavy as iron.The protection of iron and steel from corrosio
n is done more often with zinc than with any other metal coating.
• It is done by "galvanizing".When rolled into sheets ,
• Zinc is used for roof coverings.
• Zinc casts well and forms the base of various die-casting alloys
• They are low in cost,easy to cast and have high strength.
• Zinc is also used in the production of dry cells because of its high
potential, as an alloying element in brasses, bronzes etc.

40. • Content…….
BOOKS INDIA PUBLICATINS
K.D.BHATT
V.H.CHAUDHARY
ATUL PRAKASAN
40

41. Thank You