This document provides information on non-ferrous metals such as copper, aluminum, and their alloys. It discusses the extraction and properties of copper, as well as common copper alloys like brass, bronze, gun metal, and cupronickel. It also covers the extraction of aluminum from bauxite, its alloys, and properties. Bearing materials like white metals, copper alloys, aluminum alloys, plastics, and ceramics are also summarized.

1. NON FERROUS METAL
(Other than iron as a major
constituent)
.

2. NON FERROUS MATERIALS
• Elements other than iron
(OR)
• Other than iron is a major constituent
• More costly than ferrous materials
CHARACTERISTICS:
1. Lighter in weight
2. Electrical and thermal conductivity
3. Resistance to corrosion

3. A metal containing little or no iron content
NON-FERROUS METAL
- Aluminum
- Bronze
- Brass
- Copper
- Lead
-Nickel
-Tin

4. Engineering
Materials
Metals
Ferrous
Iron
Steel
Pig iron
Cast iron
Wrought
iron
Non-
Ferrous
Copper &
Alloys
Aluminium
Zinc
Tin
Lead
Non-Metals
Rubber
Plastics
Resin

5. COPPER (செம்பு)
Its a oldest and most widely used non-ferrous metal in
industry. Melting point 1083˚C

6. Copper extraction
•
Copper is converted in to IRON
SULPHIDE and COPPER
SULPHIDE MATTE
OXYGEN INTRODUCED
( Iron sulphide in to Iron oxide)
(COPPER SULPHIDE IN TO
AN IMPURE COPPER)
Impure copper is
purified to pure
copper
Ore ( Copper pyrites) Chemically combined (With
Iron and Sulphur)

8. Properties of copper
• High electrical conductivity
• High thermal conductivity
• Excellent resistance to corrosion
• It’s a soft, ductile and malleable.
• It can be worked in hot and cold condition
• It cannot be welded
• Its become brittle just below its melting
point.

9. Applications of copper
Mostly used in cable
• telephone cables
• Cables for computer network
• Printed circuit boards
• connectors
• Used in the form of sheets and in agriculture
purposes
• Domestic items like vessels
• Used chemical and food industries
• Used as a tubes in heat exchangers.
• Used mainly in the manufacturing of brass and
bronze alloys

10. COPPER ALLOYS
• Copper alloyed with number of elements to
provide a range of useful alloys
Characteristics:
high thermal and electrical conductivity
high corrosion resistance
high ductility and formability

11. Important copper alloys
• Brasses (பித்தளை) ( copper – Zinc alloys)
• Bronze(வெண்கலம்) (copper – Tin alloys)
• Gun Metals ( copper – tin – Zinc alloys )
• Cupro Nickels (copper – nickel alloys)

12. Other elements results
• Small amount of beryllium or chromium to copper give
high strength alloy
• A small addition of cadmium gives a significant
increases in strength with little loss in electrical
conductivity
• Addition of terrilium gives very good machinability

13. BRASS
• Its an alloy of copper(cu) and zinc (zn)
sometimes other elements like tin(sn), lead(pb), aluminium(al)
and manganese(mn) may be added.
Upto 36% of zinc, the brass is a single phase α solid solution
----- These alloys are called α brasses
-These are soft, ductile and easily cold worked
More than 36% of zinc have two phases α and β phases at
room temperature
-- these are stronger than α brasses

14. Brasses

15. Characteristics of brasses
• Its stronger than copper
• Low thermal and electrical conductivity than
copper
• It can be into moulds, drawn into wires, rolled
into sheets and turned into sheets.
• For improving machining property in brass they
are adding 1 – 3% of lead.
• The brass color varies from reddish to white
depend on the amount of zinc present

16. Types of Brasses
Depend on the copper and zinc they are,
• Gliding metal
• Cartridge brass
• Standard brass
• Naval brass
• Admiralty brass
• High tensile brass
• Free cutting brass

18. Bronze
• Its an alloy of copper(cu) and tin (sn)
• They have high strength with corrosion resistance than brass
• The strength of the bronze increase with the increase of tin
content.
• The tin content should be below 12% because they lead to
be brittle
• Bronze can be shaped or rolled into wires , rods and sheets

19. Bronze வெண்கலம்

20. Types of Bronze
• Bell bronze --------- 78 cu, 22 Sn(tin)
• Phosphor bronze – 88 cu, 10 Sn 0.3 P, 1 Zn, 0.7 Pb
• Silicon bronze ------ 95 cu, 3 Si , 1 Mn , 1 Fe
• Aluminium bronze – 89 cu, 7Al, 3.5 Fe, 0.35 Sn
• Coinage bronze ---- 95.5cu, 3 Sn, 1.5 Zn
• Leaded bronze ----- 75 cu, 5 Sn , 18 Pb , 2 Ni

21. BELL BRONZE
• Bell bronze --------- 78 cu, 22 Sn

22. Phosphor bronze
• Phosphor bronze – 88 cu, 10 Sn 0.3 P, 1 Zn, 0.7 Pb

23. Silicon bronze
• Silicon bronze ------ 95 cu, 3 Si , 1 Mn , 1 Fe

24. Aluminium bronze
• Aluminium bronze – 89 cu, 7Al, 3.5 Fe, 0.35 Sn

25. Coinage bronze
• Coinage bronze ---- 95.5cu, 3 Sn, 1.5 Zn

26. Leaded bronze
• Leaded bronze ----- 75 cu, 5 Sn , 18 Pb , 2 Ni

28. Gun Metal
• Gun metals are the alloys of copper(cu), tin(sn) and
zinc(zn)
• Zinc act as a deoxidiser and it improves fluidity during
casting
• Small amount of lead improve
castability and machinability.
• Zinc is cheaper than Tin so
we reduced alloy cost

29. Types of gun metal
1.Admiralty Gun Metal
2.Leaded Gun Metal

31. Cupronickel
• Its a alloy of copper and nickel.
• It’s a single phase uniform solid solution
• Thus all copper nickel alloys are relatively ductile and
malleable.
• They have better corrosion resistance
• It can be hot worked or cold worked.
• It can be shaped by rolling, pressing, drawing and
spinning

32. CUPRONICKEL

33. Types of cupronickels
S.NO ALLOY
NAME
COMPOSIT
ION
PROPERTIES APPLICATIONS
1 Cupronickel 70 Cu, 30 Ni Good corrosion
resistance
Can be cast into
any forms
Salt water piping's ,
condenser tubings
2 Monel Metal 29 cu , 68 Ni
, 1.25 Fe ,
1.25 Mn
Good corrosion
resistance,
Good mechanical
properties
Propellers, pipe
fittings, condenser
tubes, steam turbine
blades, tanks, food
and chemical
industry plants
3 ‘K’ monel 29 cu , 66 Ni
, 2.75 Al, 0.4
Mn, 0.6 Ti
A heat treated
alloy
Good mechanical
properties
Used in motor boat
propeller shafts

34. ALUMINIUM
• It’s a most widely used and important
Non-ferrous material
Characteristics of aluminium:
• Light weight ( 1/3 rd of weight of steel)
• High thermal and electrical conductivity
• Excellent corrosion resistance
• Non – toxicity
• Soft and ductile
• Low specific gravity
• High strength to weight ratio
• High reflectivity.

36. EXTRACTION OF ALUMINIUM
Bauxite
ore
Purification
Dissolved in fused
cryolite(Aluminium and
sodium)
Electrolysis processAluminium

37. Aluminium Vs Copper
• Less cost than copper
• Specific gravity of aluminium 2.7 compared to 8.9
for copper
• Better electrical conductivity (20 % more than
copper)
• But it cannot be welded or soldered.
• To over come this defect they are using tin coating
on aluminium
• Aluminium having low strength, for that its alloyed
with Cu, Ni, Mn, Mg and Si

38. Aluminium alloys
• Aluminium can be alloyed with one or more elements
like Cu, Ni, Mn, Mg and Si
• These elements convert the soft and weak elements into
strong and hard non metal
CHARACTERISTICS:
1. Properties less than steel,
2. Equal to alloys
3. Superior to manganese alloys

39. Types of aluminium alloys
• Heat treatable aluminium alloys
• Non – Heat treatable aluminium alloys

40. Heat treatable aluminium alloys
• Using age or precipitation hardening we cannot
strengthens the aluminum alloy.
• Al – Cu Alloys
• Al – Cu – Ni Alloys
• Al – Mg – Si Alloys
• Al – Li Alloys
• Al – Zn – Cu Alloys

41. Non – Heat treatable aluminium alloys
• These alloys are strengthened by cold working
operations
• Important Non – Heat treatable aluminium alloys
are
• Al – Mn Alloys
• Al – Mg Alloys
• Al – Si Alloys

42. Al –mg sheet

43. Al –Mg alloy
• .

44. Al-Si Alloy
• .

45. Al – Cu Alloys
1.Duralumin
2.Y-alloy

46. AGE or PRECIPITATION
HARDENING
• It’s a process of increasing the strength of an
alloy ( Al – Cu Alloy)
• Step – 1 ------ solution treatment
• Step – 2 ----- - Quenching process
• Step – 3 ------- Ageing Process

48. BEARING ALLOYS
For making bearings

49. Characteristics of a bearing material
• It should have sufficient hardness and wear resistance.
• It should have a low co-efficient of friction.
• It should have a sufficient melting point.
• It should have high thermal conductivity.
• It should have good casting qualities.
• It should have good resistance to corrosion.
• It should be tough , shock resistant and sufficient ductility.

50. Bearing Materials
Widely used bearing materials:
• White metals
• Copper base alloys
• Aluminium base alloys
• Plastic materials
• Ceramics.
• The selection based on loading, running speed
and service conditions.

51. 1) White bearing metal
• Its either tin based or lead based alloys.
• It contain 10% antimony (Sb).
• Tin(sn) + Antimony ---- form a intermetallic compound
SbSn
This form a small hard cubic crystals, termed cuboids.
cuboid is a hard, low friction substance.

52. i) Tin based bearing alloys
• They are called babbit metals.
• Sb 10 % , Sn 82 %, cu 4 %, Pb 4 %
• They are high quality high duty bearing
material than lead based alloys.
• They are used in medium and high duty
applications like in automobile industries.

53. ii)Lead based alloys
• These are cheaper than tin based alloy.
• Sb 13 % , Sn 12 % , Cu 0.75 % , As 0.25% , Pb 74 %
• Used in low pressure low speed applications.

54. 2) COPPER BASED BEARING ALLOYS
• Plain tin bronze -- Cu 85 %, Sn 15 %
• Phosphor bronzes – cu 88%, Sn 10 % P 0.3%, Zn 1%, Pb 0.7%
• Leaded bronzes - Cu 75% ,Sn 5%, Pb 18%, Ni 2%
• Sintered bronzes – Cu powder 90%, Sn powder 10%
• Phosphor bronze gives improved load bearing capacity.
• Leaded bronzes are less strong than other bearing bronzes.
but they will sustain higher loads at higher speeds than white
metal.

55. Uses of copper base bearing alloys
• Used in aero engines,
• Automobile and diesel crank shaft bearings.
• Vacuum cleaners
• Washing machines,
• Extractor fan
• Audio equipments

56. 3)Aluminium based bearing materials
• It contain alloys of tin , copper and nickel
• The expensive tin is replaced by aluminium base
bearing alloys.
• Sn(tin) 5.5 – 7 % , Cu 0.7 – 1.3 % , Ni 0.7 – 1.3 % ,
remaining aluminium
• Used in automobile big end and main bearings.

57. 4) Plastic bearing materials
• 1. Nylons (polymides)
• 2. poly tetra fluro ethylene (PTFE or Teflon)
• They have very low coefficients of friction
• USES
These bearings used in small load applications
Particularly oil lubrication is impossible or undesirable

58. 5) Ceramic Bearing Materials
• These bearings are used in small precision
instruments like jewel bearings in watch
movements
• Alumina used as a bearings in large speed
precision movements.

59. Super alloy
• It is a general term used to describe the nickel
base and cobalt base alloys which have been
developed for use at elevated temperatures.
• Super alloys produce a combination of high
strength at elevated temperatures up to
1000°C and resistance to corrosion.

60. Applications
• Blades for turbine and jet engines
• Heat exchangers, chemical reaction vessel
components and heat treating equipment.