NON-FERROUS METALS/ALLOYS

• No iron• Melting point less than iron• Low strength at high temperature• Al, Cu, Pb, Sn, Zn, Ni etc

CONTENTS1. Al2. Pb3. Sn4. Cu5. Zn6. Ni

ALUMINIUM• Ore:- Bauxite• Light weight• Soft & weak (pure Al)• High reflectivity• Pure Al can’t be heat treated• MP=658 C• Specific gravity= 2.65• Note:- Pure Al is MORE corrosion resistant than Al

alloys• Uses:- aircraft, automobiles, utensils, overhead cables

etc.

BAUXITE

ALUMINIUM

ALUMINIUM ALLOYS• Al:- soft & weak• Al alloys:- hard & strong

ALLOY %Mg %Cu %Mn %Ni %Al

DURALUMIN 0.4-0.7 3.5-4.5 0.4-0.7 - Rest

Y-Alloy 1.2-1.7 3.5-4.5 - 1.8-2.3 Rest

LEAD & ALLOYS• Heaviest common metal• Ore: Galena• Color:- Bluish grey, surface becomes dull on exposure to air• Soft, malleable, ductile, corrosion resistant• Use:- water pips, roof covering, sheathing of electric cables etc.• MP= 327C• Alloys:- Solder: Pb & Sn

Bearing metal: Pb & other metals

LEAD

GALENA

TIN & ALLOYS• Ore: Tin stone• Color: White with yellowish tinge• MP= 232C• Soft, malleable, ductile, does not corrode• Use: Coating of iron & steel, tinning Cu

wire before use TIN

BEARING METALS (TIN ALLOYS)4 types:1) Lead base (Lead, tin, antimony): light loads & pressure2) Tin base (Tin, antimony, copper): high pressure & load3) Copper base (Copper, tin, lead): harder & stronger than white

metals. Used to resist heavier pressure4) Cadmium base (Cadmium, nickel): used at high temperature.

Compressive strength > tin based

COPPER• Color:- Red• Ore:- Copper pyrites• Soft, malleable, ductile, flexible, tough &

strong• Electrical conductivity:- Second to silver• MP=1083C

COPPER ORE

COPPER

COPPER ALLOYS (Mainly Bronze)ALLOY COMPOSITION PROPERTIES

Bronze Cu: 75-95%, Sn: 5-25% Hard, resist surface wear

Phosphor Bronze Bronze containing phosphorus Increased strength, ductility & soundness of castings, good wearing qualities, high elasticity, resistant to salt water corrosion

Silicon Bronze Cu, Si, Mn/Zn Good corrosion resistance, higher strength, can be welded by all means

Manganese Bronze Cu, Mn, Zn, Pb Highly corrosion resistant, harder than phosphor bronze

Gun metal Cu-88%, Sn-10%, Zn-2% Strong, corrosion resistant due to water & atmosphere

Ball metal Cu, Sn Hard, resistant to surface wear

Babbit material Cu-4%, Sn-88%, Sb (Antimony)-8% Soft, low coeff. of friction, low strength.Use: Bearing

ZINC• Ore: Zinc Blende (ZnS), Calamine (ZnCO3)• Heavy, low cost, corrosion resistant• Color: Bluish white• MP= 419C• Use: Galvanizing, roof covering

Zn-Cu AlloysALLOY COMPOSITION PROPERTIES USES

BRASS Cu-50%, Zn-50% • MP= 800-1000C• Non-corrosive, soft,

ductile, good tensile strength & fusibility, surface finish, non-magnetic, poor conductor of electricity

• Hydraulic fittings, pump linings, utensils, bearing, bushes etc.

MUNTZ Cu-60%, Zn-40% • Stronger, harder, more ductile than brass

• Good for hot working• Resist wear

• Machine components, electrical equipments, fuses, bolts etc.

Note: Corrosion resistance of Bronze > Brass

NICKEL• Ore: Sulphide ores• Color: Silver• Tough, harder but less ductile than copper, same strength as that of

copper• Malleable, magnetic, weldable (like iron)• Less corroded by external factors (unlike iron)• Use: Nickelplating iron & steel alloys, catalyst etc.

NICKEL ALLOYSALLOY COMPOSITION (%) PROPERTIES USES

MONEL METAL Ni-60, Cu-38, Al/Mn White, tough, ductile, weldable, corrosion resistant, high strength at high temp.

Steam turbine, impeller of centrifugal compressors

GERMAN SILVER Ni-10-35, Cu-25-50, Zn- 25-35

Hard, white, ductile, good mechanical & corrosion resisting properties

Utensils, electrical work.Also known as Ni-silver

INCONEL Ni-75-80, Cr- 10-15, Fe-rest Less reactive than nichrome to acids

For parts exposed to high temp for long periods

NICHROME Ni, Cr Used for resistance wire in electrical appliances

NIMONICS Ni, Cr, Mo, Co, Ti, Al Very high temp. service