MT-102 Lecture Weeks 9 online class.pdf

Properties of Materials
MT-102
Weeks 9
Ferrous Metals & Alloys,

PART 1: FUNDAMENTALS OF
MATERIALS: BEHAVIOR & MAN. PROP.
Chapter 6. Nonferrous Metals and Alloys: Production, General
Properties, & Applications
• Aluminum and Aluminum Alloys,
• Magnesium and Magnesium Alloys,
• Copper and Copper Alloys,
• Nickel and Nickel Alloys,
• Titanium and Titanium Alloys
• Super alloys
• Refractory Metals and Alloys,
• Beryllium, Zirconium, Low-melting Alloys
• Precious Metals,
• Shape-memory Alloys (Smart Materials)
• Amorphous Alloy and Metal - Foams
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3/26/2020 Manufacturing Engineering & Technology, 6/E, By S. Kalpakjian, S. R. Schmid

Chapter 6. Nonferrous Metals and Alloys:
Production, Properties, & Applications
6.1 INTRODUCTION
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Nonferrous metals and alloys - good corrosion resistance, high thermal and electrical conductivity, low density,
and ease of fabrication

6.1 INTRODUCTION
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3/27/2020 Manufacturing Engineering & Technology, 6/E, By S. Kalpakjian, S. R. Schmid 5

6.2 ALUMINUM AND ALUMINUM ALLOYS
The important advantages of aluminum (Al) and its alloys
- High strength-to weight ratios
- Resistance to corrosion by many chemicals
- High thermal and electrical conductivities
- Nontoxicity
- Appearance
- Ease of formability and machinability
- Nonmagnetic
The principal uses of aluminum and its alloys, in decreasing order of consumption, are
- In containers and packaging (aluminum cans and foil),
- Architectural and structural applications, transportation (aerospace applications, automobiles,
train and marine)
- Electrical applications (as economical and nonmagnetic electrical conductors)
- Consumer durables (appliances, cooking utensils, and furniture), and portable tools
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The Tesla Model S is an electric vehicle, requiring
around 455 kg (1000 lbs) of batteries to supply
power to its electric motors. In order to achieve a
curb weight of around 1900 kg (4200 lbs), while
seating up to seven passengers, a number of design
innovations were required, including a lightweight
aluminum space frame and an aluminum body
(though with some selected steel reinforcement in
some pillars for the operator zone). The aluminum
sections are held together using a mix of cold-metal
transfer welding, conventional spot welding, self-
piercing rivets, and structural adhesives. The design
also allows the batteries to be mounted low in the
car, thus lowering the center of gravity and
maximizing interior space

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Aluminum alloys are available in Cast and Wrought .
The fundamental difference between Cast and aluminum is that
Cast aluminum is the aluminum that was melted in a furnace and poured into a mold.
Wrought aluminum is when the metal is worked in the solid form with the help of specific
tools. The wrought products made into various shapes by rolling, extrusion, drawing, and
forging.

Designation of Wrought Aluminum Alloys - are identified by four digits and by a temper designation
that shows the condition of the material.
The first digit indicates the major alloying element:
1xxx-Commercially pure aluminum: excellent corrosion resistance, high electrical and thermal conductivity,
good workability, low strength, not heat treatable
2xxx-Copper: high strength-to-weight ratio, low resistance to corrosion, heat treatable
3xxx-Manganese: good workability, moderate strength, generally not heat treatable
4xxx-Silicon: lower melting point, forms an oxide film of a dark gray to charcoal color, generally not heat
treatable
5xxx-Magnesium: good corrosion resistance and weldability, moderate to high strength, not heat treatable
6xxx-Magnesium and silicon: medium strength; good formability, machinability, weldability, and corrosion
resistance; heat treatable
7xxx-Zinc: moderate to Very high strength, heat treatable
8xxx-Other element
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The second digit in these designations indicates modifications of the alloy. In alloy 5183,
the number 5 indicates that it is of the magnesium alloy series, the 1 indicates that it is the 1st
modification to the original alloy 5083
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.
The third and fourth digits
1xxx series, the third and fourth digits
stand for the minimum amount of
aluminum in the alloy.
- for example, 1050 indicates a minimum
of 99.50% Al, and 1090 indicates a
minimum of 99.90% Al.

Designation of Cast Aluminum Alloys - consist of four digits.
The first digit indicates the major alloy group, as follows:
1xx.x-Aluminum (99.00% minimum)
2xx.x-Aluminum-copper
3xx.x-Aluminum-silicon (with copper and/or magnesium)
4xx.x-Aluminum-silicon
5xx.x-Aluminum-magnesium
6xx.x-Unused series
7xx.x-Aluminum-zinc
8xx.x-Aluminum-tin
The second and third digits
In the 1xx.x series, the second and third digits indicate the minimum aluminum content ie. to indicate
aluminum purity above 99%
The fourth digit (to the right of the decimal point) - indicates the product form.(casting)
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Temper Designations (table 6.3 textbook).
The temper designations for both wrought and cast aluminum are as follows:
F- As fabricated (by cold or hot working or by casting)
O- Annealed (from the cold-worked or the cast state)
H- Strain hardened by cold working (for wrought products only)
T- Heat treated
W- Solution treated only (unstable temper)
Unified Numbering System.(UNS)
Aluminum and other nonferrous metals and alloys now are identified internationally by the Unified
Numbering System (UNS), consisting of
- a letter indicating the general class of the alloy, followed by five digits indicating its chemical composition.
For example, A is for aluminum, C for copper, N for nickel alloys, P for precious metals, and Z for zinc. In
the UNS designation, 2024 wrought aluminum alloy is A92024.
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6.3 MAGNESIUM AND MAGNESIUM ALLOYS
It is the lightest engineering metal available, good vibration damping characteristics.
It is the third-most-abundant metallic element (2%) in the earth’s crust, after iron and aluminum
Most of magnesium comes from seawater, which contains 0.13% magnesium in the form of magnesium
chloride.
Its alloys are used in
Structural and nonstructural applications wherever weight is of primary importance.
Alloying element in various nonferrous metals.
Aircraft and missile components,
Portable power tools, ladders, luggage, bicycles, sporting goods, and general lightweight components.
In the automotive sector, mainly in order to achieve weight savings.
Its also used in printing and textile machinery to minimize inertial forces in high-speed components
Oxidize rapidly - a fire hazard exists, and precautions must be taken when machining, grinding, or sand-
casting. Products made of magnesium and its alloys are, nonetheless, not a fire hazard during normal
use.
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6.4 COPPER AND COPPER ALLOYS
They are best conductors of electricity and heat, good corrosion resistance, processed easily by various
forming, machining, casting, and joining techniques.
It is found in several types of ores, the most common being sulfide ores
Its alloys are used in
Electrical and electronic components
Springs, coins, plumbing components, heat exchangers, marine hardware, and consumer goods (such as
cooking utensils, jewelry, and other decorative objects)
Copper alloys
The most common copper alloys are brasses (an alloy of copper and zinc) and bronzes (an alloy of copper &
tin)
Designation of Copper Alloys.
In the Unified Numbering System, copper is identified with the letter C, such as C26200 for cartridge brass
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6.5 NICKEL AND NICKEL ALLOYS
It is a silver-white metal and major alloying element that imparts strength without loss of ductility, toughness,
and corrosion resistance.
It is used extensively in stainless steels and in nickel-based alloys (also called superalloys)
Nickel alloys are used in high-temperature applications in food-handling and chemical-processing equipment
and in marine applications.
Nickel is magnetic, nickel alloys also are used in electromagnetic applications, such as solenoids.
The main sources of nickel are sulfide and oxide ores
Designation of Nickel Alloys.
- Nickel alloys are now identified in the UNS system with the letter N. Thus, Hastelloy G is now N06007.
- Monel is a nickel-copper alloy.
- Inconel is a nickel-chromium alloy with a tensile strength of up to 1400 MPa.
- Nichrome (an alloy of nickel, chromium, and iron) has high electrical resistance and a high resistance to
oxidation and is used for electrical heating elements.
- Invar and Kovar (alloys of iron and nickel) have relatively low sensitivity to temperature
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6.6 SUPERALLOYS
They have high-temperature applications; hence, they are also known as heat-resistant or high-temperature
alloys. They have good resistance to corrosion, mechanical and thermal fatigue, mechanical and thermal
shock, creep etc.
The main applications of superalloys are in jet engines and gas turbines. They are also used in manufacturing
tools and dies for hot working of metals, and the nuclear, chemical, and petrochemical industries.
Most superalloys have a maximum service temperature of about 1000°C in structural applications.
Superalloys are referred to as - Iron-based, Cobalt-based, or Nickel-based.
6.7 TITANIUM AND TITANIUM ALLOYS
It is a silvery white metal, expensive
It has high strength-to-weight ratio and corrosion resistance at room and elevated temperatures
Widely used in including aircraft; jet engines, racing cars; golf clubs; chemical, petrochemical, marine
components; - submarine hulls; armor plate; and medical applications, such as orthopedic implants
Unalloyed titanium, known as commercially pure titanium, has excellent corrosion resistance for applications
where strength considerations are secondary.
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6.8 REFRACTORY METALS AND ALLOYS
They are called refractory because of their high melting points
The refractory metals maintain their strength at elevated temperatures.
There are four refractory metals:
Molybdenum - is a silvery white metal, high melting point, high modulus of elasticity, good resistance to
thermal shock, and good electrical and thermal conductivity.
Niobium - good ductility and formability and has greater oxidation resistance than other refractory metals
Tungsten - the highest melting point of any metal (3410°C) – high strength at elevated temperatures.
However, it has high density, is brittle at low temperatures, and offers poor resistance to oxidation
Tantalum - is characterized by its high melting point (3000°C), high density, good ductility, and resistance
to corrosion. However, it has poor chemical resistance at temperatures above 150°C
6.9 BERYLLIUM
It is steel gray in color, has a high strength-to-weight ratio
It is used in nuclear and X-ray applications because of its low neutron absorption.
Beryllium and its oxide are toxic; their associated dust and fumes should not be inhaled.
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6.11 LOW-MELTING ALLOYS
There are four low melting alloys metals:
Lead - (Pb) high density, resistance to corrosion (lead-oxide layer that forms to protect the surface), softness, low
strength, ductility, and good workability. Lead also is used for damping sound and vibrations, radiation shielding
against X-rays, ammunition, as weights, and in the chemical industry. Toxic (causing lead poisoning)
Zinc - (Zn), is bluish white in color and is the metal that is fourth most utilized industrially, after iron, aluminum, and
copper. A number of minerals containing zinc are found in nature. Zinc has three major uses:
(1) For galvanizing iron, steel sheet, and wire - zinc serves as an anode and protects the steel from corrosive
(2) As an alloy in other metals - brass, for example, is an alloy of copper and zinc.
(3) As a material in castings - die casting for making such products as fuel pumps, vacuum cleaners, kitchen app.
Tin – (Sn) silver-white lustrous metal is as a protective coating on steel sheets tin. The low shear strength of the
tin coatings on steel sheets improves pressworking. Tin-based alloys (also called white metals) generally contain
copper (bronze), antimony, and lead. Tin-lead alloys are common soldering materials, with a wide range of
compositions and melting points.
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6.12 PRECIOUS METALS
The most important precious (costly) metals, also called noble metals, are the following:
Gold - (Au, from the Latin aurum) is soft and ductile and has good corrosion resistance at any temperature.
- applications include jewelry, coinage, reflectors, gold leaf for decorative purposes, dental work, electroplating,
and electrical contacts and terminals.
Silver (Ag, from the Latin argentum) is ductile and has the highest electrical and thermal conductivity of any metal
However, it develops an oxide film that affects its surface characteristics and appearance.
- applications for silver include tableware, jewelry, coinage, electroplating, electrical contacts, solders, bearing
linings, and food and chemical equipment. Sterling silver is an alloy of silver and 7.5% copper.
Platinum (Pt) is a soft, ductile, grayish-white metal that has good corrosion resistance even at elevated
temperatures. Platinum alloys are used as electrical contacts; for spark-plug electrodes; as catalysts for
automobile pollution-control devices; in dies for extruding glass fibers in thermocouples; in jewelry and dental work
6.13 Shape-memory Alloys (Smart Materials)
Shape-memory alloys are unique in that, after being plastically deformed into various shapes at room temperature
they return to their original shape upon heating. A typical shape-memory alloy is 55% Ni-45% Ti (Nitmol).
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