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NON FERROUS METALS
This document discusses non-ferrous metals and provides details about copper, copper alloys, and aluminum. It defines non-ferrous metals as metals that do not have iron as their major constituent. Copper is highlighted as the oldest and most widely used non-ferrous metal in industry. Important copper alloys discussed include brass, bronze, gun metals, and cupronickels. Aluminum is described as the most widely used non-ferrous material due to its light weight, corrosion resistance, and other desirable properties. Common aluminum alloys and their characteristics are also summarized.
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NON FERROUS METALS
- 1. NON FERROUS METAL (Otherthan 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 containinglittle or no iron content NON-FERROUS METAL - Aluminum Copper - 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 aoldest and most widely used non-ferrous metal in industry. Melting point 1083˚C
- 6. Copper extraction • Copper isconverted 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)
- 7. 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.
- 8. Applications of copper Mostlyused 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
- 9. COPPER ALLOYS • Copperalloyed with number of elements to provide a range of useful alloys Characteristics: high thermal and electrical conductivity high corrosion resistance high ductility and formability
- 10. Important copper alloys •Brasses (பித்தளை) ( copper – Zinc alloys) • Bronze(வெண்கலம்) (copper – Tin alloys) • Gun Metals ( copper – tin – Zinc alloys ) • Cupro Nickels (copper – nickel alloys)
- 11. 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
- 12. BRASS ----பித்தளை - •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
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- 14. 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
- 15. Types of Brasses Dependon the copper and zinc they are, • Gliding metal • Cartridge brass • Standard brass • Naval brass • Admiralty brass • High tensile brass • Free cutting brass
- 16. Bronze(வெண்கலம்) • Its analloy 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
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- 18. 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
- 19. BELL BRONZE • Bellbronze --------- 78 cu, 22 Sn
- 20. Phosphor bronze • Phosphorbronze – 88 cu, 10 Sn 0.3 P, 1 Zn, 0.7 Pb
- 21. Silicon bronze • Siliconbronze ------ 95 cu, 3 Si , 1 Mn , 1 Fe
- 22. Aluminium bronze • Aluminiumbronze – 89 cu, 7Al, 3.5 Fe, 0.35 Sn
- 23. Coinage bronze • Coinagebronze ---- 95.5cu, 3 Sn, 1.5 Zn
- 24. Leaded bronze • Leadedbronze ----- 75 cu, 5 Sn , 18 Pb , 2 Ni
- 25. Gun Metal • Gunmetals 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
- 26. Types of gunmetal 1.Admiralty Gun Metal 2.Leaded Gun Metal
- 27. Cupronickel • Its aalloy 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
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- 29. Types of cupronickels S.NOALLOY NAME COMPOSITI ON PROPERTIES APPLICATIO NS 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
- 30. ALUMINIUM • It’s amost 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.
- 31. EXTRACTION OF ALUMINIUM Bauxite ore Purification Dissolvedin fused cryolite(Aluminium and sodium) Electrolysis process Aluminium
- 32. 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
- 33. Aluminium alloys • Aluminiumcan 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
- 34. Types of aluminiumalloys • Heat treatable aluminium alloys • Non – Heat treatable aluminium alloys
- 35. Heat treatable aluminiumalloys • 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
- 36. Non – Heattreatable 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
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- 40. Al – CuAlloys 1.Duralumin 2.Y-alloy
- 41. 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
- 42. BEARING ALLOYS For makingbearings
- 43. Characteristics of abearing 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.
- 44. Bearing Materials Widely usedbearing materials: • White metals • Copper base alloys • Aluminium base alloys • Plastic materials • Ceramics. • The selection based on loading, running speed and service conditions.
- 45. 1) White bearingmetal • 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.
- 46. i) Tin basedbearing 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.
- 47. 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.
- 48. 2)COPPER BASED BEARINGALLOYS • 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.
- 49. Uses of copperbase bearing alloys • Used in aero engines, • Automobile and diesel crank shaft bearings. • Vacuum cleaners • Washing machines, • Extractor fan • Audio equipments
- 50. 3)Aluminium based bearingmaterials • 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 and main bearings.
- 51. 4) Plastic bearingmaterials • 1. nylon (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
- 52. 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.