nonferrous teaching mat

7/28/2019 Nonferrous Teaching Mat

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Metal Alloys(Nonferrous Alloys)


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Nonferrous metals and their alloys do not contain iron as a

principle ingredient, although they may contain small

percentages.


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Al alloys Cu alloysTi alloysMg alloy Ni alloys

Superalloys

Non-ferrous

Metal Alloys

Ferrous

Pure Cu

BrassesBronzesCupronickelBe-copperNickel silver

Cu

MgMnSiZn

Al

ZnMn

V

Refractorymetals

Nb (2468C)

Ta (2996C)W (3410C)Mo (2617C)

Fe-based

Ni-based

Co-based

Monel

Inconel

Hastelloy

2. Non-ferrous Alloys


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2.1. Al and its Alloys

http://www.world-aluminium.org/http://www.alcoa.com/global/en/home.asp

Low density (2.7) - ~1/3 of that of steelhigher strength-to-weight ratio

High electrical conductivity - 60% of that of Cuhigher conductivity-to-weight ratioHigh thermal conductivityHigh oxidation resistanceFCC creystal structure: ductile and good formability - easymechanical processingEasy machining, castable and mostly weldableNonmagnetic; nontoxicMost recyclable metal - only 5% of production energy required

Al alloys are used mostly for four reasons: specific strength,

corrosion resistance, electrical conductivity and nontoxity.

Pure Al (1xxx)

Al-Cu(2xxx)

Al-Mn(3xxx)

Al-Si(4xxx)

Al-Mg(5xxx)

Al-Si+Mg(6xxx)

Al-Zn(7xxx)


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Consumption of Al and its Alloys

Containers andpackaging

(nontoxity)

Electricalconductors

(conductivity)

Architecturalconstruction(corrosionresistance)

Structuralapplications

(strength-to-weight ratio)

Aeroplane wing madeof Al alloys for theirhigh strength-weight

ratio


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Al and its Alloys

Al is too soft for structural applications. It is alloyed toimprove strength. Al is mainly alloyed with any or combination offive elements:

Cu, Mn, Mg, Zn, Si

In addition to alloying, Al alloys are also hardened by coldworking and by precipitation hardening.

Typical mechanical properties:Low elastic modulus: ~70 GPaYield strength: 100~400MPaNo ductile-brittle transition at low temperatures


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Al Alloys Designation

Aluminium Association designation:1xxx industrial pure Al (>99%):electrical wires, sheets & foils, rivets, heat exchangers2xxx Cu:vehicle and aircraft frames and parts, fasteners, high-strength weldments, castings3xxx Mn:sheet metal parts - ducts, guards, hoods; tanks and piping; castings4xxx Si5xxx Mg: sheet metal parts, tubing, pressure vessels, boats, aircraft parts

6xxx Si+Mg: ship building, aircraft parts, extruded shapes, architectural parts, pipes, channels, fixtures7xxx Zn:

UNS: A9xxx (xxxx are the 4 AA designation digits)

example:6061-T6 (A96061-T6): an Al-Si-Mg alloy aged-hardened to T6 conditionO: annealedT: aged hardened

process H: work hardenedcondition: F: as fabricated

W: solution treated


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Problems of Al Alloys in Application

Low fatigue resistance - virtually no

endurance limitUnsuitable for working at elevatedtemperatures

Low elastic modulus

Prone to pitting in waters containingheavy ions

Attacked readily by strong causticsolutions

Anodic to most metals

0 50 100 150 200 250

Al

Cu

Ti

Steel

Modulus of Elasticity (GPa)

There are some 200 Al alloys commerciallyavailable. The following are commonly used ones:Wrought: 1100 (pure), 3003, 5052, 6061*, 7075*Sand cast: 355.0*Die cast: 380.0

*: can be hardened by heat treatment


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Recycling of Al

Al is the most recyclable metal. Theenergy (cost) consumed to reproduce one

tone of Al from scrap is 5% of thatconsumed to produce 1 tone premier Alfrom minerals. This is mainly due to twofacts: (1) Al has a low melting temperature(little energy is required for melting) and

(2) Al is corrosion resistant (so little metalis lost). Currently ~30% of the world Alconsumption comes from recycled products.In developed countries, 41% Al beveragecans are recycled.


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2.2. Cu and its Alloyshttp://www.copper.org/

General properties

Yield strength: 20-200 MPa

Tensile: 200-400 MPaYoungs modulus: 117 GPaFCC structure: excellent formabilityExhibits no sub-zero T embrittlementCastable and weldable

Corrosion resistantHigh thermal conductivityHigh electrical conductivity

50% copper produced areconsumed as electrical conductors

Copper

Brass(Cu-Zn)

Berryliumcopper(Cu-Be)

Bronze(Cu-Sn,Al,Si)

Cupronickel(Cu-Ni)

Nickelsilver

(Cu-Ni-Zn)


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Cu Alloys Designation

(Copper Development Association: CDA)

CDA UNS100 C10000...799 C79900

800 C80000999 C99900

Wrought

Cast


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Cu and its Alloys

Commercially Pure CoppersElectrical tough pitch (ETP) copper: used for conductorsDeoxidised phosphorus copper: heat conductors, piping, tubing,

heat exchangers

Beryllium Copper (1.5-2.0%Be) (C172000)precipitation hardenedhigh strength comparable to steels: up to 1400 MPaused for springs, bearings, high-strength components

Bronzes (up to 13%Sn)Silicon bronze (Cu-Sn-Si,


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Cu and its Alloys

Brasses (up to 50%Zn)a-brass: FCC, up to 35%Zn

red-brass: 15%Znyellow-brass: 30%Zn, (strength increases with increasing Zn%)Naval brass, admiralty brass:yellow brasses + 2% Sn to improve

pitting resistance in seawater.

b-brass:BCC+FCC, 40-50%Zn: Muntz metal (UNSC28000)

Copper-Nickel Alloys (Cupronickel, 90/10 and 70/30)High ductility and formabilityexcellent corrosion resistance in seawater

Strengthened by cold working85/15 alloy for coinage70/30 alloy for seawater piping, heat exchangers

Copper-Zinc-Nickel Alloys (Nickel Silver)Pale yellow at 10-12%Ni, silver white at 20-30%NiDecorative applications and silver plated dinnerware


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Cu and its Alloys

There are some 800 Cu alloys commercially available. Theaverage designer could solve most application problems with ~10alloys:

ETP copper: C11000 (99.9%) (electric tough pitch copper)DHP copper: C12200 (99.9%) (deoxidized high phosphorus copper)Beryllium copper: C17200Red brass: C23000 (85Cu-15Zn)Yellow brass: C26000 (70Cu-30Zn)

Free cutting, yellow brass: C36000 (62Cu-35Zn-3Pb)Tin bronze: C90700 (89Cu-11Sn)Lead tine bronze: C94300 (70Cu-5Sn-25Pb)


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2.3. Ni and its Alloys

http://www.incoalloys.com/http://www.haynesintl.com/http://www.nidi.com/

Pure Ni has a FCC structure, similar melting temperature (1450C),

elastic modulus and density (7.85) to steels, but twice electricalconductivity. It is highly corrosion resistant in many environments.Some 2/3 of it production are consumed in stainless steels. MostNi alloys are proprietary: they are often identified by trade names.

Pure NiNickel 200 (UNSN02200), very corrosion resistant in strongcaustics, used as coating or cladding in pipes, pumps, valves,autoclaves, etc.

Ni-Cu

Ni

Ni-Cr Ni-Cr-Fe Ni-Mo Ni-Cr-Mo


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Ni-Cu AlloysMostNi-Cu alloys come from the Monel series, manufactured by Inco Alloys

(Special Metals). These alloys are excellent in resisting corrosion in seawaterand are also used to handle H2SO4, HCl and deaerated HF. Typical applicationinclude marine engineering, chemical and petrochemical processing

equipment, valves, pumps, shafts, fittings, heat exchangers, etc.

Example: Monel 400 (UNS N04400): 66Ni-30Cu-1Fe-3%Al

Ni-Cr, Ni-Cr-Fe AlloysMostNi-Cr alloys come from the Inconel and Incoloy series manufacturedby Inco Alloys. These alloys are particularly good for resisting oxidation athigh temperatures and corrosion in Chloride-containing environments, whilehaving high strengths. Typical applications include marine engineering,

chemical processing, gas turbine engines, rocket engines, nuclear reactors,pressure vessels, heat treatment equipment, heat exchangers, heatingelement sheathing, etc

Examples: Inconel 600 (UNS N06600): 72Ni-15.5Cr-8FeInconel X725 (UNS N07750): 73Ni-15.5Cr-7Fe-2.5TiIncoloy 800 (UNS N08800): 32.5Ni-46Fe-21Cr


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Ni-Mo, Ni-Cr-Mo Alloys

These alloys are manufactured byHaynes International as Hastelloyseries. They are used in severecorrosion environments, such as HF,high temperature and high stress-corrosion cracking risk conditions.

Example: Hastelloy B-2(UNS N10665):65Ni-28Mo-2Fe

Stainlesssteels

Othermetallurgical

products:Ni alloys

Superalloys

Plating

Miscellaneous

65%20%

9% 6%


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2.4. Ti and its Alloys

Light alloys:

Al (2.7), Be (1.85), Mg (1.74), Ti (4.51)

The demand for materials of highstrength-to-weight ratios from theaerospace and aircraft industry andmore recently from automobile andother transportation industries haspromoted the development of these

light alloys.

0 2 4 6 8 10

Mg

Be

Al

Ti

Steel

Cu

Density (kg/m3)

World consumption of titanium and titanium alloy mill products was about 56,000t in

2000, and a further 29,000t was consumed mainly as ferro-titanium in steel and other

alloys.


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Electrolytic Production of Ti


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Ti and its Alloyshttp://www.titanium.org/http://www.roskill.co.uk/titmet.html

http://www.timet.com/http://www.britishtitanium.co.uk/

Melting temperature: 1678 C Modulus of elasticity: 127 GPa Low density: 4.5 g/cm3

Strengthenable by alloying & by heat treatment Higher specific strength and specific stiffnessthan steels

High affinity to O, H, N, C High tendency to form intermetallic compoundswith other metals

Good thermal resistance

Highly corrosion resistant

Bio-compatible

F22 jet fighter, some 36% of its weight ismade of titanium. Use of titanium in the

F22, Eurofighter, JointStrike fighter and

Rafale fighter aircraft over the next ten

years will maintain titanium demand from

the military


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Ti and its Alloys

Titanium alloys are specified by their alloying elements (e.g., Ti-6Al-4V)and are designated by grade numbers (e.g., grade 5). UNS uses R as theprefix for Ti alloys.

a-phase alloys (C,O,N,H,Al,Sn)

not quench hardenable,strengthened by solid solutionb-phase alloys (Mo,V,Nb,Fe,Cr)

formable when not heat treatedmay be quenched to form martensite or age hardenedstrength up to 1200 MPa

a/b-dual phase alloysmore than 70% of Ti productsmost common type: Ti-6Al-4V (half of the world consumption)highest strength

Commercially pure titanium (CP)


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Ti and its Alloys

~40 commercial alloys available

8 account for 90% consumption3 unalloyed TiTi-5Al-2.5Sn

Ti-6Al-4VTi-8Al-1Mo-1VTi-6Al-6V-2SnTi-13V-11Cr-3Al

Three main reasons for application:high specific strength: airframes, jet engine and rocketcomponents, pressure vessels, fasteners, transport, sport goods

high corrosion resistance: chemical industry, seawater piping,reactor vessels, heat exchangers in chemical, petrochemical, oil &gas and marine industries

Biocompatibility: surgical implants,

45%

Jet engines,

civil aviation

Military

aeroplanes,

space

45%

Industrial

corrosion

application

10%

miscellaneous


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Ti and its Alloys typical applications

Aerospace applications: aircraft; aero-engines; airframes;

commercial and military aerospace industry; space flight

Industrial applications: chemical and petrochemical; metal recovery

and refining; oil and gas industry; geothermal energy; marine

applications; thermal power generation & transmission; nuclear power

stations; water desalination; building and construction; tool &

machinery coatings; automotive applications;Land & sea based military applications: armour; field guns and

small arms; naval applications; watches;

Consumer applications: golf clubs; bicycles; sports equipment;

computer casing; spectacle frames;

Medical applications: hip & knee prostheses; spinal implants &

cages; heart components; wheelchairs; dentistry;High technology applications: sputtering targets; superconductivity;

computers; optical systems;

Alloying additives: carbon & stainless steels; superalloys; tool, die

and valve steels; shape memory alloys


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Mg and its Alloys http://www.magnesium-elektron.com/http://members.tripod.com/Mg/

Over 50% of Mg production are consumed in Al alloys & nodularcast iron production. The rest are used in alloyed forms.

Alloying for precipitation hardening: Al, ZnMn improves corrosion resistanceZr refines grain structure

Mg has a HCP structure: poor formabilityMg alloys are advantageous over Al alloys:

better machinabilitylower densityslightly higher specific modulus


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Mg and its Alloys typical applications

AutomotiveAero-transport, spaceDefense

Consumer goodsPower generationChemical reduction, electrochemicalCorrosion prevention (sacrificial anodes)Metallurguical additives: steel making, Al alloying

The use of a light weightand stiff magnesium alloyin roller blades and iceskates reduces theweight of the equipmentand at the same time

improves performance

This 1997 Buick Park Avenue featuresa sophisticated die-cast magnesiumcross-bar beam serving as the maininstrument panel structure andmounting support. In addition, an

aluminium hood helps to trim thepounds


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Chromium

Important industrial metal present in earths crust at 0.0122%. Chromite Fe(CrO2)2

Hard, maintains a bright surface, corrosion resistant.


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Chromium

Cr(H2O)62+

, blue2+

(acidic) Cr(H2O)63+, blue (basic) Cr(OH)4

-, green3+3+

(acidic) Cr2O72-, orange (basic) Cr2O42-, yellow6+

CrO Cr2O3

CrO3acidic amphoteric basic


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Vanadium Fairly abundant (0.02%)

Vanadite 3Pb3(VO4)2PbCl2 Ferrovanadium 35-95% V in Fe

Steels are used in applications

requiring strength and toughness.

Vandium pentoxide.

Catalyst.

Reversible loss of O from 700-1000 C.

Wide variety of oxidation states.

+5 +4 +3 +2


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Superalloys

Supertalloys are a special class of heatresistant alloys for high temperatureapplications, such as aircraft, marine andindustrial gas turbines, space vehiclesand rocket engines, nuclear reactors,

submarines.

Ni-based super-alloy singlecrystal turbine blades

Jet Turbineengine,manyinteriorcomponentsmade of Ni-based andco-basedsuperalloys

Fe-based

Superalloys

Ni-based Co-based


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Superalloys

Iron-Based Superalloys: Fe(65-40%)-Ni(20-40%)-Cr(13-20%)50% of its room-temperature strength retained at 750C;suitable for application at

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