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Mse Notes - Unit - 3

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Department of Mechanical Engineering

UNIT-3
NON-FERROUS METALS AND ALLOYS

• A non-ferrous metal is a metal, including alloys, that does not contain iron (ferrite) in
appreciable amount.
• Non-ferrous metals include aluminum, copper, lead, zinc and tin, as well as
precious metals like gold and silver .alloys such as Brass.
• Their main advantage over ferrous materials is their malleability.
• They find there application in industries because of there ease of
fabrication(forging,casting,rolling,welding,and machining).
• They are good conductor of heat and electricity,resistance to corrosion.
• At high temperature there strength will be lowered and shrinkage will be more than ferrous
materials

Types of Non-ferrous metals


1. Copper
2. Aluminium
3. Zinc
4. Tin
5. Lead
6. Cobalt
7. Nickel
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8. Chromium
9. Magnesium…etc

1.Copper

Copper is a chemical element with the symbol Cu (from Latin: cuprum) and atomic
number 29. It is a soft, malleable, and ductile metal with very high thermal and
electrical conductivity. A freshly exposed surface of pure copper has a pinkish-
orange color.

Properties of copper
1. It is reddish brown in color
2. It is soft,strong,tough,malleable and ductile.
3. It becomes brittle just before melting.
4. It resists corrosion.
5. It is good conductor of both heat and electricity next to silver.
6. It can forged,soldered,rolled,and drawn into thin wires.
7. Specific gravity is 8.93,melting point is 1083.

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Department of Mechanical Engineering

Uses of copper.

• It is used in making cables and wires for electric appliances.

• It is used for electroplating, electrotyping.

• Used for the manufacture of utensils and making of copper alloys.

• It is used in roofing, plumbing, industrial machinery(Heat exchangers).

• Most copper is used in electrical equipment such as wiring and motors.

ALLOYS OF COPPER

• Copper alloys are broadly classified into two groups

1. Brasses or copper-zinc alloys

2. Bronzes or copper-tin alloys

Brass
• Brass are primarily alloys of copper and zinc with small quantity of other
elements.
• Brass is most commonly used copper alloy
• Brass have greater tensile strength than copper metal,but have lower thermal
and electrical conductivity.
• They have high resistivity to corrosion,they are soft ductile and malleable.
• The machinability and hardness can be increased by varying the elements in
brass.
• The melting point of brass varies from 800-1000⁰C

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Department of Mechanical Engineering

TYPES OF BRASS

1. Muntz metal
2. White brass
3. Yellow brass
4. Catridge brass
5. Delta metal
6. Low brass
7. Red brass
8. Naval brass

Properties and applications of brass

• Brass is the generic term for a range of copper-zinc alloys with differing
combinations of properties, including strength, machinability, ductility,
wear-resistance, hardness, colour, electrical and thermal conductivity,
hygiene and corrosion resistance.

• Applications for Brass

1. Locks.

2. Gears.

3. Bearings.

4. Valves.

5. Braces.

6. Brackets.

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Department of Mechanical Engineering

7. Base plates

Bronze

• Bronze is one of the earliest metals known to man. It is defined as


an alloy made of copper and another metal, usually tin. Compositions vary,
but most modern bronze is 88% copper and 12% tin. Bronze may also
contain manganese, aluminum, nickel, phosphorus, silicon, arsenic, or zinc

Properties of bronze
• Highly ductile.
• Bronze exhibits low friction against other metals.
• Many bronze alloys display the unusual property of expanding a small amount
when solidifying from a liquid into a solid. For sculpture casting, this is
desirable, as it helps to fill a mold.
• Brittle, but less so than cast iron.
• Upon exposure to air, bronze oxidizes, but only on its outer layer. This patina
consists of copper oxide, which eventually becomes copper carbonate. The
oxide layer protects the interior metal from further corrosion. However, if
chlorides are present (as from seawater), copper chlorides form, which can

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Department of Mechanical Engineering

cause "bronze disease" -- a condition in which corrosion works through the


metal and destroys it.
• Unlike steel, striking bronze against a hard surface won't generate sparks. This
makes bronze useful for the metal used around flammable or explosive
materials.
• Unlike steel, striking bronze against a hard surface won't generate sparks. This
makes bronze useful for the metal used around flammable or explosive
materials

Uses of bronze

• Bronze is used in architecture for structural and design elements, for bearings
because of its friction properties, and as phosphor bronze in musical
instruments, electrical contacts, and ship propellers. Aluminum bronze is used
to make machine tools and some bearings.
• Bronze has been used to make coins. Most "copper" coins are actually bronze,
consisting of copper with 4% tin and 1% zinc.

ALUMINIUM

• AlUminium is mainly obtained from bauxite ore


• Its a chemical element with the symbol Al and atomic number 13.
• Aluminium has a density lower than those of other common metals, at
approximately one third that of steel.
• Aluminium visually resembles silver, both in color and in great ability to
reflect light.

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• Aluminium is soft, non-magnetic and ductile.

Properties of ALUMINIUM

1. It is a silvery white metal.

2. It is excellent conductor of heat and electricity.

3. It is light in weight and specific gravity of 2.7

4. It is good reflector of light.

5. It is non magnetic and has high resistance to corrosion.

6. It is soft,tough,malleable and ductile.

7. It has high tensile strength.

8. Its melting temperature is about 658⁰c.

9. It is resistant to organic acids,salt solutions etc….

Uses of Aluminium

1. It is used in the manufacture of equipments for chemical and food industries,


cooking utensils, cookers, steam jacketed kettles, etc

2. Due to its light weight and high tensile strength it is used in the structural work
of aeroplanes, ships, trains, buses, trucks, etc

3. These are used for roofing, sheathing(protective casing or covering),window


frames, foils, posts,etc..

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Department of Mechanical Engineering

4. It is used in the manufacture of electric cables.

5. Used in the manufacture of of reflectors and mirrors.

6. Aluminium powders are used for preparing paints.

7. It is used in iron and steel making as a deoxidiser.

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Department of Mechanical Engineering

Alloys of Aluminium

• Aluminium alloys (or aluminum alloys; see spelling differences) are alloys in
which aluminium (Al) is the predominant metal. The typical alloying elements
are copper, magnesium, manganese, silicon, tin and zinc.

• The main aluminium alloys are

1. Duralium.

2. Y-Alloy.

3. Hindalium.

4. Magnalium.

1.Duralium

• Duralumin is strong, hard, lightweight alloy of aluminum, widely used in


aircraft construction.

• Its compositions

1. Copper-3.5 to 4.5%

2. Manganese-0.4 to 0.7%

3. Magnesium- 0.4 to 0.7%

• These alloys posseses high strength maximum strength after heat treatment
and age hardening(spontaneous hardening of a metal which occurs if it is
quenched/sudden cooled and then stored at ambient temperature or treated
with mild heat).

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Department of Mechanical Engineering

• It is widely used in wrought condition(Beaten out or shaped) for


forging,stamping,bars ,sheets,tubes,rivets.

• It can be worked under hot condition at a temperature of 500⁰c.

• Due to its high strength and light weight,this alloy may be used in automobile
and aircraft components.

2.Y-Alloy

• It is also called copper-aluminium alloy.The addition of copper to pure


aluminium will increase its strength and machinability.

• Its compositions

1. Copper-3.5 to 4.5%

2. Manganese-1.2to 1.7%

3. Nickel - 0.4 to 0.7%

4. Magnesium,silicon,iron-0.6%

5. Remaining aluminium

• This alloy is heat treated and age hardened like duralium.the age hardening is
carried out for 5 days.

• These are mainly used for cast purposes,

• These alloy have better strength than duralium these are more used in aircraft
engines for cylinder head and pistons.

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Department of Mechanical Engineering

3.HINDALIUM

• It is an alloy of aluminium and magnesium with a small quantity of chromium.


It is manufactured as rolled product in 16 gauge mainly used in manufacture
of anodized utensils.

• Many people use cooking vessels made of aluminium or hindalium (Alloy of


aluminium magnesium, manganese, chromium and silicon etc.) for cooking
food.

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