Non-Ferrous Metals Non-ferrous metals include aluminum, copper, lead, zinc and tin, as well as precious metals like gold and silver. Their main advantage over ferrous materials is their malleability. They also have no iron content, giving them a higher resistance to rust and corrosion, and making them ideal for gutters, liquid pipes, roofing and outdoor signs. Lastly they are non-magnetic, which is important for many electronic and wiring applications. Aluminum Aluminum is lightweight, soft and low strength. Aluminum is easily cast, forged, machined and welded. It’s not suitable for high-temperature environments. Because aluminum is lightweight, it is a good choice for the manufacturing of aircraft and food cans. Aluminum is also used in castings, pistons, railways, cars, and kitchen utensils.

1. Nonferrous ores

2.  Non-Ferrous Metals
• Non-ferrous metals include aluminum, copper, lead, zinc and
tin, as well as precious metals like gold and silver. Their
main advantage over ferrous materials is their malleability.
They also have no iron content, giving them a higher resistance
to rust and corrosion, and making them ideal for gutters,
liquid pipes, roofing and outdoor signs. Lastly they are non-
magnetic, which is important for many electronic and wiring
applications.
 Aluminum
• Aluminum is lightweight, soft and low
strength. Aluminum is easily cast, forged, machined and
welded. It’s not suitable for high-temperature environments.
Because aluminum is lightweight, it is a good choice for the
manufacturing of aircraft and food cans. Aluminum is also used
in castings, pistons, railways, cars, and kitchen utensils.

3.  Copper
• Copper is red in color, highly ductile, malleable and has high
conductivity for electricity and heat. Copper is principally used in
the electrical industry in the form of wire and other conductors.
It’s also used in sheet roofing, cartridge cases, statutes, and
bearings. Copper is also used to make brass, an alloy of copper and
zinc.
 Lead
• Lead is a soft, heavy, malleable metal with a low melting point and
low tensile strength. It can withstand corrosion from moisture and
many acids. Lead is widely used in electrical power cables,
batteries, building construction and soldering.

4.  Tin
• Tin is very soft and malleable, ductile
with low tensile strength. It’s often used
to coat steel to prevent corrosion.
Tinplate steel is used to make tin cans to
hold food. In the late 19th century, tin
foil was commonly used to wrap food
products, but has since largely been
replaced by aluminium foil. Tin is can also
be alloyed with copper to produce tin brass
and bronze.
 Zinc​
• Zinc is a medium to low strength metal with a very low
melting point. It can be machined easily, but heating may
be required to avoid cleavage of crystals. Zinc is most
widely used in galvanizing, the process of applying a
protective zinc coating to iron or steel to prevent rust.​

5. Properties of aluminum:
• 1.Light Weight:
• Aluminum is a very light
metal with a specific weight
of 2.7 g/cm3, about a third of
that of steel. This cuts the
costs of manufacturing with
aluminum. Again, its use in
vehicles reduces dead-weight
and energy consumption
while increasing load
capacity. This also reduces
noise and improves comfort
levels.

6. 3. Electrical and Thermal Conductivity:​
Aluminum is an excellent heat and electricity conductor and in relation
to its weight is almost twice as good a conductor as copper.​
4.Reflectivity:​
Aluminum is a good reflector of visible light as well as heat, and
that together with its low weight, makes it an ideal material for
reflectors in, for example, light fittings or rescue blankets.
•2.Corrosion Resistance:​
•Aluminum naturally generates a protective thin oxide coating
which keeps the metal from making further contact with the
environment.​
5.Ductility:
Aluminum is ductile and has a low melting point and density. It can be
processed in several ways in a molten condition.
ratures drop.

7. 6.Strength at Low Temperatures:​
In contrast to steel, which rapidly becomes brittle at low
temperatures, aluminum shows increased tensile strength as Tempe
7.Impermeable and odorless:
Moreover, the metal itself is non-toxic and odorless, which makes it
ideal for packaging sensitive products such as food or pharmaceuticals.
The fact that recycled aluminum can be used reduces the carbon footprint
for this stage of food and beverage manufacturers as well.
8.Non-magnetic:
Aluminum is non-magnetic, making it useful for electrical shieldings as
in computer disks, dish antennas, busbars or magnet housings.
9.Non-toxic:
Aluminum is non-toxic and is used to make woks, pressure cookers and
many other cooking utensils without fear. It is easily cleaned and does
not contaminate the food at any stage.

8. 10.Sound and Shock Absorption:
Aluminum is an excellent sound absorber and is used for
constructing ceilings. It is also used in auto bumpers due to its
shock-absorbing properties.
11.Non-sparking:
Aluminum produces no sparks when it comes into contact with itself
or non-ferrous metals.
12.Recyclability:
Aluminum is 100% recyclable and recycled aluminum is identical to
the virgin product. This makes it a much more cost-effective
source material for production runs.

9. USE OF ALUMINIUM IN HOUSES:
Exterior :
1. Window frames
2. Doors
3. Sliding doors
4. Green houses
Interior:
1. Partition
2. Door handles
3. Locker
4. Furniture
5. Book shelf

10. USE OF ALUMINIUM IN BUILDINGS:
• Roofing
• Curtain walls
• Solar panels
• Shades
• Bridges
• Domes

11. Uses of aluminum:
• Aluminum is used in a large variety of products including :
1. Cans
2. Foils
3. Kitchen utensils
4. Window frames
5. Aeroplan parts
6. Coins
• Aluminum is a good electrical
conductor and is often used
in electrical transmission lines.
• Aluminum coatings have many uses including
1. Telescope mirrors
2. Decorative paper
3. Packages
4. Toys

12. Zinc Ore:
• Zinc is a chemical
element with the symbol
Zn and atomic number
30. Zinc is a slightly
brittle metal at room
temperature and has a
silvery-greyish
appearance when
oxidation is removed.
It is the first element
in group 12 (IIB) of
the periodi

13. • In some respects, zinc is chemically similar to magnesium:
both elements exhibit only one normal oxidation state (+2),
and the Zn2+ and Mg2+ ions are of similar size.[note 1]
Zinc is the 24th most abundant element in Earth's crust
 ores of zinc:
• The solid material from
which the pure metals can
be obtained, it is called
as ores. Zinc ores are
sphalerite (ZnS), zincite
(ZnO), franklinite
[ZnO(Fe,Mn)2O3], calamine
[Zn2(OH)2SiO3], and smith
stone (ZnCO3). Zinc ores
normally contain 5–15%
zinc.
zincite franklinite
calamine smith stone

14. The metal zinc can be mainly obtained from oreS which are
called as sphalerite and Calamine.
 Sphalerite:
• It is commonly called as zinc blend.
• Its chemical formula is .(ZnS)
• Pure zinc is obtained from sphalerite through a process
called froth flotation method.
 Calamine:
• It is made up of two compounds namely zinc carbonate and zinc
silicate.
• The chemical formula is and .[Zn2(OH)2SiO3]
 PRODUCTION OF ZINC METAL
• Extraction and refining
• Roasting and sintering
Both of the main extraction methods for the production of zinc,
electrolysis and smelting, require the prior removal of sulfur in a
highly exothermic oxidation reaction:

15. • The small fraction of zinc sulfide minerals present in the ore makes
beneficiation necessary in order to produce a concentrate suitable
for treatment.The most common method for accomplishing this
concentration is to isolate the sulfide mineral from the impure
constituents, or gangue, by flotation separation.
• In this process, the ore initially is crushed to about 1.9
centimetres (0.75 inch), combined with water, and ground to less
than 0.1 millimetre in a ball mill.
• The finely ground particles and water form a slurry that flows from
the mill to flotation cells or tanks, where, in the presence of
selected chemical reagents that create a suspension of air bubbles,
the slurry is agitated by beaters. The mineral particles cling to
the bubbles and float to the surface, forming an oily froth that is
constantly skimmed, while the gangue is wetted by the action of the
chemicals and sinks in the cell.
 Production of zinc
 concentration of ore:

16. Chemical
Equation:

17.  Electrolysis
• The basic steps in this process include (1) preparation of a
zinc sulfate solution by leaching zinc oxide calcines (produced
by the roasting of sulfide concentrates) in dilute sulfuric
acid, (2) purification of the resulting zinc sulfate solution,
and (3) electrolysis of the purified solution.
• The theoretical voltage required to deposit zinc from zinc
sulfate solution onto a cathode is about twice the voltage
necessary to decompose water, so that, in theory, electrolysis
should result in the production of hydrogen at the cathode and
not the deposition of zinc. When a zinc cathode is used,
however, overvoltage prevents the generation of hydrogen, and,
hence, zinc is deposited. The hydrogen overvoltage depends
crucially on the purity of the zinc sulfate electrolyte; the
presence of certain impurities at even very low concentrations
can cause a drastic lowering of the overvoltage and thus
interfere with zinc deposition

18. • For this reason, extreme purification of the electrolyte is a
critical necessity in the process and is accomplished in two
stages. The first stage is the removal of iron as a solid
residue in the form of either jarosite (a basic ferric
sulfate) or the oxides goethite or hematite. This is then
followed by cementation with zinc dust to remove other
metallic impurities (including copper, nickel, cadmium,
cobalt, and germanium) from the solution.
• Electrolysis is performed in lead-lined concrete cells with
anodes of lead containing 0.5–1.0 percent silver and cathodes
of aluminum sheet. The zinc deposits are stripped from the
cathodes every 24 to 48 hours and remelted in an induction
furnace before casting into ingots or pigs. The purification
of the electrolyte ensures that the normal product will reach
a purity of 99.99 percent or more. In existing plants,
outputs vary from 50,000 to 300,000 tons per annum.

19.  The zinc-lead blast furnace:
• Sintered zinc and lead concentrates, mixed with metallurgical
coke, are charged into the top of a shaft furnace, into which
preheated air is blown through nozzles, or tuyeres, at the base
(see figure). This procedure is similar to that followed in an
iron blast furnace, with the important difference that the major
products of reduction here are a zinc-bearing gas and liquid
phases that separate in the furnace hearth and are tapped
periodically.
• (The liquids consist of molten lead, containing recoverable
copper and silver, and the gangue content of the charge, in the
form of a molten oxide slag.
• The gas stream, containing 8 percent zinc, 10 percent carbon dioxide,
and 20 percent carbon monoxide, is directed from the upper shaft to a
lead-splash condenser, a chamber in which an intense shower of lead
droplets is thrown up by rotors revolving in a pool of molten lead.

20. • In existing smelters, shaft furnaces vary in area
from 15 to 27 square metres (180 to 290 square
feet), and capacities range from 50,000 to 100,000
tons of zinc and 30,000 to 50,000 tons of lead per
annum. The zinc-lead blast furnace has the
flexibility to accept a wide range of mixed ores
and residues in its feed.
• Complex sulfide ores have to be sintered, but
oxidized residues such as zinc ashes and drosses
recovered from galvanizing processes, oxides
produced from low-grade residues, lead smelter
dusts, and steel-mill dust high in lead and zinc
can bypass the sinter roasting process.
• A number of cold and hot briquetting techniques are
available to consolidate these low-grade materials
so that they may be charged directly to the
furnace.

21.  Distillation refining:
• The blast furnace produces an ordinary grade of zinc containing
1.2 percent lead. This can be used in general galvanizing, but
an additional refluxing operation must be performed to produce
high-grade zinc.
• The operation is performed in two fractionating columns, each
consisting of a series of superposed rectangular trays made of
bonded silicon carbide refractory material and arranged to allow
a descending flow of liquid metal and an ascending flow of metal
vapour.
• In the first column, a large part of the zinc is vaporized and
freed from impurities with higher boiling points, such as lead
and iron. The distilled vapour is condensed and fed into the
second column, where the liquid’s remaining impurity, cadmium,
with a boiling point lower than that of zinc, is distilled.
High-purity zinc is then run off from the bottom of the column.

22.  Common Alloys:
• Brass: 3-45% Zn by weight, it's used in musical
instruments, valves, and hardware.
• Nickel silver: 20% Zn by weight, it's used for
its shiny silver appearance in jewelry,
silverware, model train tracks, and musical
instruments.
• Zinc die casting alloys: >78% Zn by weight, it
usually contains small amounts (less than a few
percentage points) of Pb, Sn, Cu, Al, and Mg to
improve die casting characteristics and
mechanical properties. It's used to make small
intricate shapes and suitable for moving parts
in machines. The cheapest of these alloys are
referred to as pot metal, and they serve as
inexpensive replacements for steel.

23.  Applications of the commodity zinc:
• Zinc is used in a number of applications.
1. Galvanizing against corrosion
Zinc is commonly used to coat iron or steel to protect these metals
against corrosion. As it is more reactive than iron or steel, zinc
will attract almost all oxidation until corrosion completely erodes
the coated sheet. What is left is a surface protection layer of
oxide and carbonate. This protection even functions after minor
scratches and dents and can survive for many years.
Galvanization is used on metal roofing, bridges, guard rails, light
posts, heat exchangers and most visible to the consumer: car
bodies.
Coating zinc on another metal is accomplished by electrolytic
plating of the metal – much like chrome plating a metal – or
dipping it into molten zinc.

24. 2. Intricate machine parts
An alloy made of very high grade zinc and aluminium is used to
create die-cast parts which require little machining before they
are used in an assembly. By injecting the alloy under pressure
into the cavity of a two-part steel die, it fills the entire
void within the mold. After the metal cools and the die halves
are taken apart, the resulting zinc-alloy part is very close to
the desired shape.
Die-casting is used, among others, to create parts for aircraft,
medical instruments and car parts like emblems and doorhandles.
3. Electrodes
An unique application of zinc uses its ability to transfer its
corrosion resistance properties by electrical contact. In this
manner, zinc is used as a sacrificial electrode. An example
application for this kind of electrode is when it is attached to
aluminium marine engines.

25. • Especially in salt water, the oxidation process of the
metals on the ship forms a weak electrical current, which
may lead to corrosion of the hull and engine parts. By
having a zinc sacrificial electrode present, it sacrifices
itself by corrosion, negating the electrical current and
thus protecting the aluminium hull and/or engine.
4. Alloys
• One widely used alloy which contains a large amount of zinc is brass.
Brass is an alloy of copper mixed with 3% to 45% zinc, depending on
the type of brass. Brass is superior to copper in areas like
ductability, strength and corrosion resistance. This makes it useful
in water valves, musical instruments and communication equipment.
Other used alloys that contain substantial amounts of zinc include
aluminium solder, commercial bronze and nickel silver. It is also the
primary metal used in producing one cent coins in the United States.
The zinc coin is coated with a layer of copper to give the false
impression of a copper coin.

26. • Galena is the
primary ore of lead, and is
often mined for its silver
content, such as at the Galena
Mine in northern Idaho.
• Color: Lead gray and silvery
• Streak: Lead gray
• Category: Sulfide mineral,
octahedral subgroup
• Other characteristics: Natural
semiconductor
LEAD ORE:

27. There are many different uses of Lead. It may be used as a
pure metal, alloyed with other metals, or as chemical
compounds.
 Various Uses of Lead:
1. Lead Acid Battery:
The principal consumption of Lead is for the Lead-Acid storage battery
in which grid or plate is made of Lead or Lead with other metal more
commonly with antimony.
2. Rolled Extrusions:
• Lead Sheet is used in the building industry for flashings or
weathering to prevent water penetration & for roofing and cladding.
By virtue of its resistance to chemical corrosion, Lead Sheet also
finds use for the lining of chemical treatment baths, acid plants
and storage vessels.

28. 3. Lead Pipes:
Lead pipes due to its corrosion resistant properties are used for
carriage of corrosive chemicals at chemical plants. Also Lead
pipe of appropriate composition is still extruded for cutting
into short length 'sleeves' for use in the jointing of Lead
sheathed cables.
4. Pigments:
Used extensively in paints,
although recently the use of Lead in
paints has been drastically curtailed to
eliminate or reduce health hazards. White
Lead, 2PbCO3 • Pb(OH)2, is the
most extensively used Lead pigment. Other
Lead pigments of importance are basic Lead
sulfate and Lead chromates.​
​

29. 6. Ammunition
• Use of ammunition with Lead Bullets, which are commonly used in
sport shooting with small arms
7. Lead Alloys:
Lead forms alloys with many metals. Alloys formed with tin, copper,
arsenic, antimony, bismuth, cadmium, and sodium are all of industrial
importance.
Lead is used to make bearings, solder, antifriction metals, and type
metal.
Soft solders are largely Lead-tin alloys with or without antimony
while fusible alloys are various combinations of Lead, tin, bismuth,
cadmium and other low melting point metals.
Shot Lead is an Alloy of Lead, Antimony, and Arsenic. Lead Foil is
made with Lead alloys.

30. 8. Lead Weights for Scuba Diving​
:
• Shot Lead is an Alloy of Lead, Antimony, and Arsenic. Lead
Foil is made with Lead alloys. Lead is added to brass to
reduce machine tool wear.​

31. • Tin is a soft, pliable,
silvery-white metal. Tin
is not easily oxidized
and resists corrosion
because it is protected
by an oxide film. Tin
resists corrosion from
distilled sea and soft
tap water, and can be
attacked by strong
acids, alkalis and acid
salts.
Tin Ore:

32.  Applications:
• Tin is used in for can coating: tin-plated
steel containers are widely used for food
preservation. Tin alloys are employed in
many ways: as solder for joining pipes or
electric circuits, pewter, bell metal,
babbit metal and dental amalgams. The
niobium-tin alloy is used for
superconductiong magnets, tin oxide is used
for ceramics and in gas sensors (as it
absorbs a gas its electrical conmductivity
increases and this can be monitored). Tin
foil was once a common wrapping material for
foods and drugs, now replaced by the use of
aluminium foil.

33. What Is Tin?
Tin is a very light, soft metal. It's a silvery-white color
and is easy to melt. Tin is too soft to use by itself, so
it's often mixed with other metals to form an alloy. Alloys
combine more than one metal so that the resulting alloy has
the helpful properties of each one.
Tin resists corrosion, it's very useful. This means that it
doesn't have a chemical reaction when it's combined with air
or water. Tin is also easily molded into different shapes

34. • Copper is a chemical element
with symbol Cu (from Latin:
cuprum) and atomic number 29.
It is a ductile metal with
very high thermal and
electrical conductivity. Pure
copper is soft and malleable;
a freshly exposed surface has
a reddish-orange color. It is
used as a conductor of heat
and electricity, a building
material, and a constituent
of various metal alloys.
Copper ore

35. • Copper is found as native metal and in minerals ie. cuprite,
azurite, chalcopyrite and bornite. Sulphides, oxides and
carbonates are the most important ores.
 Properties of Copper:
• As mentioned, copper is prized for its many useful properties.
It’s no wonder copper & brass sales have never seen a significant
decline in the last few years. Copper alloys turn out to be
extremely useful for the exact same reason. Let’s take a look at
some of copper’s more valuable properties.
 Workability
• Copper is a malleable and ductile metal. It can be hammered or
rolled into thin sheets and drawn into small wires without
breaking. In its purest form, copper can be worked cold, but a
copper sheet supplier may have to hot work it if it’s combined
with another much less pliable metal, such as zinc or lead.

36.  Electrical/Heat Conductivity
• One of the most prominent properties of copper is its high
electrical and heat conductivity. It is so conductive that
95 percent of all the transformers, cores of electrical
wires, and other conductors are made of copper. Silver is
the only metal that is more electrically conductive than
copper, but it isn’t good at handling heat, which is why
copper is still preferred for electrical applications.
 Durability​
• Most metals corrode as they oxidize. Iron, for
instance, slowly reduces to rust when exposed to
oxygen. Copper, on the other hand, oxidizes by
developing a protective layer on its surface,
called patina. The longer the exposure, the
tougher the patina gets. This green layer of
protection can preserve the inside of copper for
thousands of years.​

37. Name Formula
% Copper
when pure
Chalcopyrite CuFeS2 34.5
Chalcocite Cu2S 79.8
Covellite CuS 66.5
Bornite 2Cu2S·CuS·FeS 63.3
Tetrahedrite Cu3SbS3 + x(Fe,Zn)6Sb2S9 32–45
Digenite Cu9S5 78.1
Malachite CuCO3•Cu(OH)2 57.7
Azurite 2CuCO3·Cu(OH)2 55.1
Cuprite Cu2O 88.8
Chrysocolla (Cu,Al)2H2Si2O5(OH)4·n(H2O) 37.9
Tennantite Cu12As4S13 51.6
Dioptase CuSiO2(OH)2 45.3
Enargite Cu3AsS4 48.4
 list of minerals that serve as copper ores in the copper
mining process:

38. • The copper is manufactured by a laborious method and the
treatment to be adopted largely depends on the quality of
copper ores. Following is the general outline of the modern
process of copper manufacture:
• (i) The ores, usually pyrites, are cleaned and crushed and they
are them calcined in a reverberatory furnace.
• (ii) The calcined ores are mixed with silica and a small
quantity of coke. The evo mixture is then smelted in a blast
furnace. (iii) The melted metal is oxidized in the Bessemer
converter. It gives blister copper
• (iv) The impurities contained in blister copper are removed by
melting it a reverberatory furnace in presence of air.
• (v) The slag is removed and pure copper to the extent of about
99.70 percent is obtained.
• (vi) Very pure copper or 100 per cent copper is obtained by the
electrolysis.

39.  Anti-Bacterial
• Copper is also one of the few metals that can produce the
oligodynamic effect, a phenomenon in which ions of copper break
down certain proteins that make up single-celled organisms,
killing them eventually.
 Recyclable
• Over 80 percent of all the copper ever mined and manufactured are
still in use today, and they are all recyclable. Because of this,
copper is considered one of the most eco-friendly metals.
There are more things around you that are made of copper or copper-
based alloy than you probably know. Part of the reason is that
copper alloys come in different colors and shades depending on
their composition. This means they don’t have a single identifying
feature. Here’s a list of things copper is used for.

40.  Kitchen Sink
• Copper is a good choice for kitchen sink
because it is generally resistant to corrosion
and it has anti-microbial properties. For
those who are not a fan of patina, however,
pure copper is out of the question. They
prefer copper alloys that take longer to
tarnish, let alone develop patina.
 Table Tops
• As mentioned earlier, copper is extremely
malleable. You can turn it into thin sheets or
plates that make a perfect cover for table and
counter tops. Copper’s anti-microbial
property makes it suitable for this
application as well since these are high-touch
surfaces

41.  Jewelry
• Copper is also a good material
for accessories. Even in the
ancient times, those who can’t
afford gold jewelry wear copper
jewelry instead. It offers
design flexibility too due to
its high ductility.
 Door Knobs and Pull Handles
• Maybe you haven’t noticed this
but most, if not all, of the
door knobs and pull handles
you’ve ever held are made
partly of copper. They can only
be either brass or bronze.

42.  Railings
• When you’re in the train, at a balcony, or on the
stairs, odds are you’ll clutch on to the copper-
based railing nearest you. Like table tops, railings
are also commonly touched surfaces, which is why they
are best made of a metal with antimicrobial property.
They are conspicuous, too, so they must be made of a
naturally elegant-looking material.
 Tools
• Ever wondered what metal your wrenches, pliers, screw
drivers, and other house tools are made of? Judging
by their physical features, you can easily tell that
they are copper-based. Specifically, most of them are
made of beryllium copper, a non-sparking and non-
magnetic alloy that works well in hazardous
workspaces.

43.  Musical Instruments
• Copper alloys are also valued for their acoustic quality,
especially brass, an alloy of copper and zinc. There are so
many brass-based musical instruments that an entire subset
of them was named brass.
 Wire
• Copper’s high electrical conductivity makes it the safest
and most efficient material for wire cores. Unlike silver,
it doesn’t burn up when conducting high voltages.
 Pipes
• Copper’s antimicrobial property once again proves extremely
useful, and this time in filtration applications. Pipes used
to convey water or substances requiring zero-level
contamination are often made of copper alloys.

44. Gutter
• It’s probably not the most frugal choice, but a copper gutter
is a great addition to your roofing system. It lasts longer,
repels mold and mildew, and looks appealing. However, since
copper is a little bit more expensive than its galvanized
counterpart, you have to be ready to fork out more cash.

45. THANK YOU
By
1. NIKITHA (319106101022)
2. SANDHYA (319106101023)
3. RAVI PRAMOD (319106101024)
4. SYAMALA (319106101026)
5. GOWTHAM (319106101027)