Non ferrous metal

NONFERROUS METAL &
ALLOY
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NONFERROUS METALS
 Nonferrous metals contain either no iron or
only insignificant amounts used as an alloy.
Some of the more common nonferrous
metals Steelworkers work with are as follows:
copper, brass; bronze, copper-nickel alloys,
lead, zinc, tin, aluminium, and Duralumin.
 NOTE: These metals are nonmagnetic.

 Brass (Copper+Zinc)
 Bronze (Copper+Tin)
•Yellow colour
•Very ductile and malleable
•Good tensile endurance
•Dark yellow colour
•More endurance than brass
•Very corrosion resistant
•Good sonority
•Very fluid when melting, good for
molding.
Non-Ferrous Metals: Alloys

 Aluminum, Copper & Magnesium
 Magnesium & Aluminum
 Titanium & Aluminum
•Lightness and more endurance
than pure aluminum.
•This alloy is more resistant than
each metal.
• Cheaper than pure titanium
parts.
Non-Ferrous Metals: Alloys

Aluminium and aluminium alloys
 Al and its alloys are characterized byAl and its alloys are characterized by
 relatively low density (2.7 g/cmrelatively low density (2.7 g/cm33
as comparedas compared
to 7.9 g/cmto 7.9 g/cm33
for steel),for steel),
 high electrical and thermal conductivities,high electrical and thermal conductivities,
 resistant to corrosion in some commonresistant to corrosion in some common
environments, including the ambientenvironments, including the ambient
atmosphere.atmosphere.
 Many of these alloys are easily formed due to highMany of these alloys are easily formed due to high
ductility;ductility;
 thin aluminum foil sheet (of relatively purethin aluminum foil sheet (of relatively pure
material) may be rolled.material) may be rolled.
• White shiny colour
• Light and good endurance
• No toxic Cheap Stainless

its ductility is retained even at very lowits ductility is retained even at very low
temperatures.temperatures.
The chief limitation:The chief limitation:
 low melting temperature [660°C],low melting temperature [660°C],

restricts the maximum temperature atrestricts the maximum temperature at
which it can be used.which it can be used.

 The mechanical strength of aluminum may beThe mechanical strength of aluminum may be
enhanced byenhanced by cold workcold work and byand by alloyingalloying;;
 however, both processes tend to diminishhowever, both processes tend to diminish
resistance to corrosion.resistance to corrosion.
 Principal alloying elements includePrincipal alloying elements include copper,copper,
magnesium, silicon, manganese, and zinc.magnesium, silicon, manganese, and zinc.

 Non heat-treatable alloysNon heat-treatable alloys consist of a singleconsist of a single
phase,phase,
 for which an increase in strength is achieved byfor which an increase in strength is achieved by
solid-solution strengthening.solid-solution strengthening.
 Rendered heat treatableRendered heat treatable
 capable of being precipitation hardened as a resultcapable of being precipitation hardened as a result
of alloying.of alloying.
 In several of these alloys precipitation hardening isIn several of these alloys precipitation hardening is
due to the precipitation of two elements other thandue to the precipitation of two elements other than
aluminum, to form an intermetallic compound suchaluminum, to form an intermetallic compound such
as MgZnas MgZn22..

Aluminium Composite Panel
Structural section of aluminum composite panel
1. Protective film
2. PVDF clear coating
3. PVDF top coating
4. PVDF primer
5. Chromate treatment
6. Aluminum skin
7. Chromate treatment
8. Bonding lamination layer
9. Nontoxic PE core material
10. Optional fire resistant and nontoxic PE core
material
11. Optional back coating

Characteristics of aluminium composite panel (ACP)
1. Economy
Due to our adoption of high quality coatings, our aluminum
composite panels are dispensed with frequent maintenance,
thus saving a lot on maintenance cost. Hence, our composite
panels are good decorative building material for high-rise
buildings.
2. Durability
Fluorocarbon coated aluminum composite panels are
characterized by long service life, good weather resistance,
high heat resistance and wear resistance, and good
resistance to pollutions, and more.

3. Flatness
Our aluminum composite panels are manufactured with
smooth and even surface, which can satisfy people's high
demand on the appearance of modern constructions.
4. Light weight
By adopting light-weight aluminium alloy and superior quality
plastics as primary raw material, aluminum composite panel
is lighter than other types of decorative construction material.
Hence, it is easy to install and needs shorter installation
period.
5. Easy installation
Our aluminium composite panels are adaptable to various
decoration requirements, because they are easy to be cut,
grooved and bended.

6. Fireproofing
The exterior aluminium sheet of aluminum composite panels
can effectively protect interior PE core material, because it
can prevent heat conduction at the initial stage of
combustion. The flame resistance of our aluminum plastic
composite panels has reached international standard.
7. Design performance
Aluminum composite panels can be made into different colors
and styles, thus satisfying the diversified design requirements
of architects.
8. Eco-friendliness
The surface coating is durable and has no changes, which
produces no pollutants.

Application of Aluminium Composite
Panel
1. Wall and interior decoration of air ports, docks,
stations, metros, hotels, restaurants, recreation
places, top-grade residence, villas, office, and many
other buildings.
2. Big billboards, shop windows, roadside news
kiosks, bookstalls, telephone booths, traffic sentry
boxes and filling stations.
3. Internal walls, ceilings, compartments, kitchens,
toilets, etc.
4. Decoration for shops, cabinets, pillars, furniture,
trains, automobiles, ships and carriages, etc.
5. Renovation and reconstruction of old buildings.
6. Cleaning and dust control projects.

PVDF Aluminium Composite Panel
The PVDF aluminum composite panel consists of two sheets of
corrosion resistant aluminum permanently bonded to
polyethylene core material. The front aluminum coats PVDF (Fluor
resin) paint. Because of its excellent weather proof and other
features, this aluminium composite material becomes a very
popular cladding material in the world.
Specifications
Panel thickness 3mm,4mm.5mm,6mm
Panel width 1000mm,1220mm,
1250mm,1350mm,1500mm,1570mm
Panel length 2440mm-5800mm,or per customer’s request
Alu skin thickness 0.25mm,0.30mm,0.35mm,
0.40mm,0.45mm,0.50mm
Standard size 1220(W) ×2440(L)mm
paint polyester coating
core : Normal PE core

PVDF
Fluoropolymers have been
used in a multitude of high
performance coating
applications for over
thirty five years.
Poly(vinylidene fluoride)
(PVDF) has been used
especially in architectural
applications, where both
excellent appearance and
substrate protection must
be maintained over
a very long period of time.
PVDF coatings can be applied by
conventional coil or spray coating
techniques, and baked at temperatures of
230-250 ºC.

Fireproof
Our fireproof aluminum composite panel is made of fireproof plastic
core with two layers of aluminum sheets. This new decorative
material comes with B1 fireproof grade according to GB8624 test. It
is green material, as there is no harmful gas during burning.

Fireproof

Mirror Finished
The front side of the mirror finished aluminum composite panel is
treated like a mirror. The panel looks more beautiful and widely used
in interior decoration, kitchen, especially in ceiling and household
appliance and furniture etc.
Specification
Panel thickness 3mm,4mm.5mm,6mm
Panel width 1220mm
Panel length 2440mm-5800mm,or per customer’s request
Alu skin thickness 0.30mm,0.40mm
core Normal PE core

PE Aluminium Composite Panel
PE Aluminum Composite Panel
The PE aluminum composite panel consists
of two sheets of corrosion resistant
aluminum permanently bonded to
polyethylene core material. The front
aluminum coats PE (Polyester) paint. Due to
its excellent flexibility and sound insulation
performance, etc., this aluminum composite
panel is widely used as interior decoration
materials all around world.
Specification :
Panel thickness :3mm,4mm.5mm,6mm
Panel width: 1000mm,1220mm,1250mm,1350mm,1500mm,1570mm
Panel length: 2440mm-5800mm,or per customer’s request
Alu. skin thickness 0.15mm,0.21mm,0.30mm,0.40mm, 0.50mm
Paint Polyester coating
Core Normal PE core

Manufacturing of Aluminium
Alumina recovery begins by passing
the bauxite through screens to sort it
by size. It is then crushed to produce
relatively uniformly sized material.
The ore is then fed into large grinding
mills and mixed with a caustic soda
solution (sodium hydroxide) at high
temperature and pressure.
The grinding mill rotates like a huge drum while steel rods - rolling around loose
inside the mill - grind the ore to an even finer consistency. The process is a lot
like a kitchen blender only much slower and much larger. The material finally
discharged from the mill is called slurry.
The resulting liquor contains a solution of sodium aluminate and undissolved
bauxite residues containing iron, silicon, and titanium. These residues -
commonly referred to as "red mud" - gradually sink to the bottom of the tank and
are removed.
Five major steps in recovering alumina from bauxite.
STEP 1- Crushing and Grinding:
Four tons of bauxite are required to produce 2 tons of alumina.
bauxite.

The slurry is pumped to a digester
where the chemical reaction to
dissolve the alumina takes place. In
the digester the slurry - under 50
pounds per square inch pressure - is
heated to 300 °Fahrenheit (145
°Celsius). It remains in the digester
under those conditions from 30
minutes to several hours.
More caustic soda is added to dissolve aluminum containing compounds in the
slurry. Undesirable compounds either don't dissolve in the caustic soda, or
combine with other compounds to create a scale on equipment which must be
periodically cleaned. The digestion process produces a sodium aluminate
solution. Because all of this takes place in a pressure cooker, the slurry is
pumped into a series of "flash tanks" to reduce the pressure and heat before it
is transferred into "settling tanks."
.
STEP 2-Digesting:

Settling is achieved primarily by using
gravity, although some chemicals are added
to aid the process. Just as a glass of sugar
water with fine sand suspended in it will
separate out over time, the impurities in the
slurry - things like sand and iron and other
trace elements that do not dissolve - will
eventually settle to the bottom.
The liquor at the top of the tank (which looks like coffee) is now directed through a
series of filters. After washing to recover alumina and caustic soda, the remaining
red mud is pumped into large storage ponds where it is dried by evaporation.
The alumina in the still warm liquor consists of tiny, suspended crystals. However
there are still some very fine, solid impurities that must be removed. Just as coffee
filters keep the grounds out of your cup, the filters here work the same way.
The giant-sized filters consist of a series of "leaves" - big cloth filters over steel
frames - and remove much of the remaining solids in the liquor. The material caught
by the filters is known as a "filter cake" and is washed to remove alumina and
caustic soda. The filtered liquor - a sodium aluminate solution - is then cooled and
pumped to the "precipitators."
STEP 3-Settling:

Imagine a tank as tall as a six-story building.
Now imagine row after row of those tanks
called precipitators. The clear sodium
aluminate from the settling and filtering
operation is pumped into these precipitators.
Fine particles of alumina - called "seed
crystals" (alumina hydrate) - are added to
start the precipitation of pure alumina
particles as the liquor cools. Alumina crystals
begin to grow around the seeds, then settle
to the bottom of the tank where they are
removed and transferred to "thickening
tanks." Finally, it is filtered again then
transferred by conveyor to the "calcination
kilns."
STEP 4-Precipitation:

Calcination is a heating process to
remove the chemically combined water
from the alumina hydrate. That's why,
once the hydrated alumina is calcined, it
is referred to as anhydrous alumina.
"Anhydrous" means "without water."
STEP 5-Calcination
From precipitation, the hydrate is filtered and washed to rinse away
impurities and remove moisture. A continuous conveyor system delivers the
hydrate into the calcining kiln. The calcining kiln is brick-lined inside and gas-
fired to a temperature of 2,000 °F or 1,100 °C. It slowly rotates (to make sure
the alumina dries evenly) and is mounted on a tilted foundation which allows
the alumina to move through it to cooling eqipment. (Newer plants use a
method called fluid bed calcining where alumina particles are suspended
above a screen by hot air and calcined.)
The result is a white powder like that shown below: pure alumina. The
caustic soda is returned to the beginning of the process and used again.

At this point, the alumina is ready for conversion
into aluminum at a smelter.
Alumina is also used in making chemical and
ceramics.

Smelting: In 1886,
Charles Hall of the USA
and Paul L.T. Heroult of
France, made the same
discovery -
molten cryolite (a sodium
aluminum fluoride mineral)
could be used to dissolve
alumina and the resulting
chemical reaction would
produce metallic
aluminum. The Hall-
Heroult process remains
in use today.
Converting Alumina to Aluminum
Two tons of alumina are required to
make one ton of aluminum.

The Hall-Heroult process takes place in a large carbon or graphite lined steel
container called a " reduction pot". In most plants, the pots are lined up in long
rows, called potlines.
The key to the chemical reaction necessary to convert the alumina to metallic
aluminum is the running of an electrical current through the cryolite/alumina
mixture. The process requires the use of direct current (DC) - not the alternating
current (AC) used in homes. The immense amounts of power required to produce
aluminum is the reason why aluminum plants are almost always located in areas
where affordable electrical power is readily available. Some experts maintain
that one percent of all the energy used in the United States is used in the making
of aluminum.
The electrical voltage used in a typical reduction pot is only 5.25 volts, but the
amperage is VERY high - generally in the range of 100,000 to 150,000
amperes or more. The current flows between a carbon anode (positively charged),
made of petroleum coke and pitch, and a cathode (negatively charged), formed by
the thick carbon or graphite lining of the pot.
Converting Alumina to Aluminum : The Hall-Heroult process

When the electric current passes through the mixture, the carbon of the anode
combines with the oxygen in the alumina. The chemical reaction produces metallic
aluminum and carbon dioxide. The molten aluminum settles to the bottom of the
pot where it is periodically syphoned off into crucibles while the carbon dioxide - a
gas - escapes. Very little cryolite is lost in the process, and the alumina is
constantly replenished from storage containers above the reduction pots.
The metal is now ready to be forged, turned into alloys, or extruded into the
shapes and forms necessary to make appliances, electronics, automobiles,
airplanes cans and hundreds of other familiar, useful items.
Aluminum is formed at about 900 °C, but once formed has a melting point of only
660 °C. In some smelters this spare heat is used to melt recycled metal, which is
then blended with the new metal. Recycled metal requires only 5 per cent of the
energy required to make new metal. Blending recycled metal with new metal
allows considerable energy savings, as well as the efficient use of the extra heat
available. When it comes to quality, there is no difference between primary metal
and recycled metal.

The smelting process required to produce aluminum from the alumina is
continuous the potline is usually kept in production 24 hours a day year-round. A
smelter cannot easily be stopped and restarted. If production is interrupted by a
power supply failure of more than four hours, the metal in the pots will solidify,
often requiring an expensive rebuilding process. The cost of building a typical,
modern smelter is about $1.6 billion.
Most smelters produce aluminum that is 99.7% pure - acceptable for most
applications. However, super pure aluminum (99.99%) is required for some special
applications, typically those where high ductility or conductivity is required. It
should be noted that what may appear to be marginal differences in the purities of
smelter grade aluminum and super purity aluminum can result in significant
changes in the properties of the metal.
About 6.2 kWH (kilowatt hours) of electricity is required to
produce one pound of aluminum from alumina.

Aluminium Smelter (Norway)

Factors for selecting are:
1. High strength to weight ratio
2. Resistance to corrosion
3. High thermal and electrical conductivity
4. Ease of machinability
5. Non-magnetic
Aldural
Duralumin
Aluminum Bronze
Y-alloy
It is duralumin with thin coating of pure aluminium
Used in under water application.
94% Al + 4% Cu+ 0.5% Mg + 0.5% Mn + 0.5% Si+ 0.5% Fe
Used in aircraft and automobile
10 % to 22%Al + 90% to 78% Cu
Used in die casting and pump rods.
92.5% Al + 4% Cu+ 1.5% Mg + 2% Ni Used for
making pistons , cylinder heads and gear boxes

Cast Structure of Al Ingot

Boat Hulls
Aluminium boat hulls
offer corrosion
resistance and light
weight.

XJ6 Aluminium Body

XJ6 Aluminium Chassis

Aluminium Bumper Beams

Aluminium Engine Blocks (Lupo)

Audi A2 engine block

Aluminium Bottles

Aluminium Forging

Forged Aluminium Wheels

Al heat transfer components

Aluminium Roofing

Copper and copper alloys
• Copper alloys have electrical and mechanical
properties, corrosion resistance, thermal
conductivity and wear resistance.
• Applications are electronic components, springs
and heat exchangers.
• Brass is an alloy of copper and zinc.
• Bronze is an alloy of copper and tin.
Copper Properties
•Red colour
•Excellent thermal and electric
conductor
•Corrosion resistant
•Good welding
•Very ductile and malleable

 Have been utilized in quite a variety ofHave been utilized in quite a variety of
applications since antiquity.applications since antiquity.
 Unalloyed copper is so soft and ductile that itUnalloyed copper is so soft and ductile that it
is difficult to machine;is difficult to machine;
 it has an almost unlimited capacity to be coldit has an almost unlimited capacity to be cold
worked.worked.
 it is highly resistant to corrosion in diverseit is highly resistant to corrosion in diverse
environments including the ambientenvironments including the ambient
atmosphere, seawater, and some industrialatmosphere, seawater, and some industrial
chemicals.chemicals.

 The mechanical and corrosion-resistanceThe mechanical and corrosion-resistance
properties of copper may be improved byproperties of copper may be improved by
alloying.alloying.
 Most copper alloys cannot be hardened orMost copper alloys cannot be hardened or
strengthened by heat-treating procedures;strengthened by heat-treating procedures;
 Only cold working and/or solid-solutionOnly cold working and/or solid-solution
alloying can be utilized to improve thesealloying can be utilized to improve these
mechanical properties.mechanical properties.

Copper Alloys: brassesbrasses
Cartridge Brass :
70% Cu+ 30% Zn Used in Cartridges , tubes ,
springs etc.
Muntz Metal
60% Cu+ 40% Zn, Used in
Casting , Condenser Tubes
etc.
Naval Brass
60% Cu+ 39% Zn+ 1% Sn Used in Marine and
engineering casting like condeser tubes , pump parts ,
motor boat shafting.

Bell Metal

The Manufacturing Process : Copper
SMELTING REFINING CASTING
COPPERCONCENTRATED
BLISTERCOPPER
COPPER PROCESSING
DRAWS TO
PRODUCE WIRE
Chalcosite

Pure copper is rarely found in nature, but is usually combined with other
chemicals in the form of copper ores.
The most common are known as sulfide ores in which the copper is chemically
bonded with sulfur. Others are known as oxide ores, carbonate ores, or mixed
ores depending on the chemicals present. Many copper ores also contain
significant quantities of gold, silver, nickel, and other valuable metals, as well as
large quantities of commercially useless material.
The most common sulfide ore is Chalcopyrite, CuFeS 2 , also known as copper
pyrite or yellow copper ore.
Chalcocite, Cu 2 S, is another sulfide ore.
Cuprite, or red copper ore, Cu 2 O, is an oxide ore.
Malachite, or green copper ore, Cu(OH) 2 •CuCO 3 ,
is an important carbonate ore, as is
Azurite, or blue copper carbonate, Cu(OH) 2 •2CuCO 3 .
Other ores include tennantite, boronite, chrysocolla, and atacamite.

Mining
1 Most sulfide ores are taken from huge open-pit mines by drilling and
blasting with explosives. In this type of mining, the material located above the
ore, called the overburden, is first removed to expose the buried ore deposit.
This produces an open pit that may grow to be a mile or more across. A road to
allow access for equipment spirals down the interior slopes of the pit.
2 The exposed ore is scooped up by large power shovels capable of loading
500-900 cubic feet (15-25 cubic meters) in a single bite. The ore is loaded into
giant dump trucks, called haul trucks, and is transported up and out of the pit.

Concentrating
The copper ore usually contains a large amount of dirt, clay, and a variety of non-
copper bearing minerals. The first step is to remove some of this waste material.
This process is called concentrating and is usually done by the flotation method.
3 The ore is crushed in a series of cone crushers. A cone crusher consists of an
interior grinding cone that rotates on an eccentric vertical axis inside a fixed outer
cone. As the ore is fed into the top of the crusher, it is squeezed between the two
cones and broken into smaller pieces.
4 The crushed ore is then ground even smaller by a series of mills. First, it is
mixed with water and placed in a rod mill, which consists of a large cylindrical
container filled with numerous short lengths of steel rod. As the cylinder rotates on
its horizontal axis, the steel rods tumble and break up the ore into pieces about 0.13
in (3 mm) in diameter. The mixture of ore and water is further broken up in two ball
mills, which are like a rod mill except steel balls are used instead of rods. The slurry
of finely ground ore that emerges from the final ball mill contains particles about
0.01 in (0.25 mm) in diameter.

5The slurry is mixed with various chemical reagents, which coat the copper
particles. A liquid, called a frother, is also added. Pine oil or long-chain alcohol
are often used as frothers. This mixture is pumped into rectangular tanks, called
flotation cells, where air is injected into the slurry through the bottom of the
tanks. The chemical reagents make the copper particles cling to the bubbles as
they rise to the surface. The frother forms a thick layer of bubbles, which
overflows the tanks and is collected in troughs. The bubbles are allowed to
condense and the water is drained off. The resulting mixture, called a copper
concentrate, contains about 25-35% copper along with various sulfides of copper
and iron, plus smaller concentrations of gold, silver, and other materials. The
remaining materials in the tank are called the gangue or tailings. They are
pumped into settling ponds and allowed to dry.
The process of extracting copper from copper ore varies according to the type of ore
and the desired purity of the final product. Each process consists of several
steps in which unwanted materials are physically or chemically removed, and the
concentration of copper is progressively increased.

Smelting
Once the waste materials have been physically removed from the ore, the remaining
copper concentrate must undergo several chemical reactions to remove the iron
and sulfur. This process is called smelting and traditionally involves two furnaces as
described below. Some modern plants utilize a single furnace, which combines both
operations.
6 The copper concentrate is fed into a furnace along with a silica material, called a
flux. Most copper smelters utilize oxygen-enriched flash furnaces in which
preheated, oxygen-enriched air is forced into the furnace to combust with fuel oil.
The copper concentrate and flux melt, and collect in the bottom of the furnace.
Much of the iron in the concentrate chemically combines with the flux to form a slag,
which is skimmed off the surface of the molten material. Much of the sulfur in the
concentrate combines with the oxygen to form sulfur dioxide, which is exhausted
from the furnace as a gas and is further treated in an acid plant to produce sulfuric
acid. The remaining molten material in the bottom of the furnace is called the matte.
It is a mixture of copper sulfides and iron sulfides and contains about 60% copper by
weight.

Typical Application:
Copper alloy

types of
COPPER TUBE
There are six standard types of copper tube:
1. Type K (green), is the heaviest wall and is used in
higher pressure applications;
2. Type L (blue), has a medium wall and is used in
mid-pressure applications;
3. Type M (red), has a lighter wall that Type L and is
used in low-pressure applications;
4. DWV (for Drain Waste Vent, yellow), has the
thinnest walled and used in drain, waste, vent
applications with little to no pressure involved;
5. ACR (for Air Conditioning/Refrigeration, blue)
used primarily in HVAC/R applications;
6. OXY/MED (blue, green) used for medical gas
applications.

Magnesium and magnesium alloys
• Magnesium (Mg) is the lightest metal.
• Alloys are used in structural and non-structural applications.
• Typical uses of magnesium alloys are aircraft and missile
components.
• Also has good vibration-damping characteristics.
• Compared with aluminum, magnesium is approximately two-
thirds of its weight.
PROPERTIES OF MAGNESIUM :
Specific gravity 1.74
Melts at 651°C
Boiling Point is 1110°C
It is silver white processing high
lustre

Magnesium Wrought alloys
Several magnesium alloys have been developed especially for the
manufacture of wrought products. The most important are M1A, AZ3IB,
AZ6IA, AZ80A, and ZK60A. As in the case of the casting alloys, the principal
added elements in the wrought compositions are aluminum, manganese, and
zinc.M1A is used for various wrought manufactures including sheet, forgings,
and extrusions. In any form, the strength of M1A is relatively low. AZ3lB is
employed for sheet and extrusions. AZ6lA and AZ80A find use for extrusions.
Of the extrusion alloys, only AZ80A is not extruded into hollow shapes or
tubing. T A54A is employed exclusively for forgings and ZK60A for
extrusions.
 Magnesium properties
•Very light
•Expensive
•Violent reaction with
oxygen

Magnesium Wrought alloys
Magnesium alloys for wrought products are classified as non-heat treatable
and heat treatable. AZ80A and ZK60A are heat treated by aging the material
as fabricated. The strengths are increased substantially but with loss of
elongation on aging. M1A and AZ31B sheet are supplied as hot rolled, as
cold rolled, and annealed.
The principal wrought manufactures which are commercially available in
magnesium alloys include sheet and other flat rolled products, extrusions
(bars, rods, solid shapes, hollow shapes, and tubing), forgings, screw-
machine stock, and impact extrusions.

Magnesium
Burns easily when being machined

Magnesium Wheel
Place pieces of magnesium
adjacent to buried steel
pipelines and water tanks.
The magnesium reacts
chemically to the elements
found in the earth and
prevents corrosion of the
steel.
Used with
Aluminium to make
lightweight alloys.

Nickel and nickel alloys
Nickel has been used in alloys that date back to the dawn of
civilization. Chemical analysis of artifacts has shown that weapons,
tools, and coins contain nickel in varying amounts.
Nickel in elemental form or alloyed with other metals and materials
has made significant contributions to our present-day society and
promises to continue to supply materials for an even more
demanding future.
Nickel is a versatile element and will alloy with most metals.
Complete solid solubility exists between nickel and copper. Wide
solubility ranges between iron, chromium, and nickel make possible
many alloy combinations.

Nickel and nickel alloys
• Nickel (Ni) has strength, toughness, and corrosion
resistance to metals.
• Used in stainless steels and nickel-base alloys.
• Alloys are used for high temperature applications, such as
jet-engine components and rockets.
PROPERTIES OF NICKEL :
Specific gravity 8.90
Melts at 1452°C
Boiling Point is 2900°C
It is grayish white lustrous
metal

manganese & alloys
• Manganese is primarily produced from the
mineral pyrolusite (MnO2), which, on average, contains
more than 50% manganese.
• Manganese is an extremely brittle and hard, silvery-grey
metal. The twelfth most abundant element in the earth's
crust, manganese increases strength, hardness and wear
resistance when alloyed in steel.
• Excellent formability , welding and corrosion resistance
PROPERTIES :
Density: 7.21 g/cm³
Melting Point: 1246°C
Boiling Point: 2061 °C
Mohs Hardness: 6

Tin & alloys
• Tin (Sn) ,
• It is very costly metal and does not occur abundantly in
nature
• The most important ore is tinstone or cassiterite ( SnO3 )
• Used for preparing solder material , because it melts
easily and does not corrode
• It is used for coating iron and steel sheets
• Used in Bronze
•Bluish white shiny colour
•Soft
•Corrosion resistant
•Low melting point

Tin & alloys
PROPERTIES OF TIN
Melts at 232°C
It is SOFT, ductile and
malleable
Bright white metal
It does not rust
Tin was one of the first metals known to man. Throughout
ancient history, various cultures recognized the virtues of tin in
coatings, alloys and compounds, and use of the metal
increased with advancing technology. Today, tin is an important
metal in industry even though the annual tonnage used is much
smaller than those of many other metals. One reason for the
small tonnage is that, in most applications, only very small
amounts of tin are used at a time.

Tin & alloys
Pewter is a tin-base white metal containing antimony and copper. Originally,
pewter was defined as an alloy of tin and lead, but to avoid toxicity and
dullness of finish, lead is excluded from modern pewter. These modem
compositions contain 1 to 8% antimony and 0.25 to 3.0% copper.
Pewter
Dental alloys for making amalgams contain silver, tin, mercury, and some
copper and zinc. The copper increases hardness and strength and the zinc
acts as a scavenger during alloy manufacture, protecting major constituents
from oxidation. Most dental alloys presently available contain 25 to 27% tin
and consist mainly of the inter-metallic compound Ag and Sn. When
porcelain veneers are added to gold alloys for high-grade dental restoration,
1% tin is added to the gold alloy to ensure bonding with the porcelain.
Dental alloys

Zinc & alloys
• The most important ore is zinc oxide ( ZnO), zinc carbonate
( ZnCO3 )
• Used in electric bells and for preparing printing block
• Used for making brass
• The mechanical properties of these zinc alloys make them attractive
substitutes for cast iron and copper alloys in many structural and
pressure-tight applications. Because zinc is less costly than copper,
these zinc alloys have a distinct cost advantage over copper-base
alloys. The ease of machining of zinc and its inherent corrosion
resistance give it advantages over cast iron.
PROPERTIES OF zinc
Melts at 419°C
It is brittle at ordinary temp.
Crystalline blue white metal
Resist corrosion

Wrought Zinc & alloys
Wrought Zinc and Zinc Alloys
Wrought zinc and zinc alloys may be obtained as rolled strip, sheet and foil; extruded
rod and shapes; and drawn rod and wire. These metals exhibit good resistance to
corrosion in many types of service, and because the corrosion products that may form
on them are white, other materials are not stained by them.
Wrought zinc has chemical characteristics particularly
adapted to certain uses, such as dry batteries and
photoengraver`s plate, and offers combinations of
desirable physical and mechanical properties at
relatively low cost. In common with many other metals
and alloys, wrought zinc creeps under constant loads
that are substantially less than its ultimate strength; that
is, wrought zinc does not have clearly defined elastic
module, and hence creep data from service tests must
be used in designing for strength and rigidity under
conditions of continuos stress.

Manufacturing of Zinc
Mining
1 Zinc ores are dug from
underground mines using
conventional blasting, drilling,
and hauling techniques. The
ores occur as zinc sulfide (also
called sphalerite), zinc
carbonate (smithsonite), zinc
silicate (calimine), and in
compounds of manganese
and iron (franklinite). Zinc ore is
sometimes mined in conjunction
with silver or lead ores. In
addition to the ore itself, oil and
sulfuric acid are required for the
breakdown of the ores; and
electricity, coke, or natural gas
are needed to provide the heat
energy for smelting.

Froth flotation
2 Zinc can be produced by a process called froth flotation,
which is also used for reduction of copper and lead ores.
This process involves grinding the zinc ore to a fine
powder, mixing it with water, pine oil, and flotation
chemicals, and then agitating the mixture to "float" the zinc
to the surface. A variety of chemicals are used to coat the
important zinc particles and prevent them from becoming
wetted by the water. Then air is injected, and the coated
minerals

attach themselves to the bubbles. The operation is
performed inside a vat and agitated with an impeller. The
rotating impeller draws the air down the standpipe that
surrounds the impeller shaft and dissipates it throughout
the mixture or "pulp." The zinc rises to the top and the
residue stays in the bottom of the pulp, since it cannot
adhere to the bubbles. Automatic scrapers remove the
mineral-laden froth containing the zinc.
Filtering
3 The froth is filtered to remove the water and liquid oils.
The paste-like remainder is mixed with lime and sent to a
furnace. The furnace roasts the mixture at 2500°F
(1371°C), which fuses the minerals into solid chunks
called sinter. At this point, the material has been
completely converted to zinc oxide.

Smelting
4 The next reduction process uses a blast furnace to melt the prepared
ore into its elemental components. The blast furnace is fueled by
electricity, coke, or natural gas, which generate temperatures of up to
2200°F (1204°C). This, however, also generates carbon dioxide, which
recombines with the zinc as it cools to re-form zinc oxide. To reduce this
reformation, the zinc is sprayed with molten lead while it is still hot. The
lead, at 1022°F (550°C), dissolves the zinc and carries it to another
chamber, where it is cooled to 824°F (440°C). At this temperature, the
lighter zinc separates out of the lead and is drained off the top. The lead
is reheated and returned to the blast furnace.
Refining
5 Further metal improvement can be made by keeping the zinc molten
and undisturbed for several hours. In this state, iron and other
contaminants settle to the bottom, allowing the almost pure zinc to be
carefully drawn off the top and cast into ingots

Alloying
6 Most zinc is alloyed with other metals before use to improve its
properties. Alloying involves remelting and mixing the zinc with other
metals in precise proportions. For example, approximately 4% aluminum
is added to improve casting quality and die life in the die-casting
process. Other added alloys are small amounts of titanium, copper, and
magnesium. After alloying, the molten metal is poured into sow molds
and ingot molds. Sows can weigh several thousand pounds, while ingots
weigh about 45 pounds (20 kg).

Titanium and Titanium alloys
Since the introduction of titanium and titanium alloys in the early 1950s,
these materials have in a relatively short time become backbone
materials for the aerospace, energy, and chemical industries.
•The combination of high strength-to-weight ratio, excellent mechanical
properties, and corrosion resistance makes titanium the best material
choice for many critical applications.
•Today, titanium alloys are used for demanding applications such as
static and rotating gas turbine engine components.
•Some of the most critical and highly-stressed civilian and military
airframe parts are made of these alloys.
Titanium properties
•Very expensive
•Endurance like steel
but quite lighter.
•Biocompatible

lead and Lead alloys
Lead was one of the first metals known to man. Probably the oldest lead
artifact is a figure made about 3000 BC. All civilizations, beginning
with the ancient Egyptians, Assyrians, and Babylonians, have used
lead for many ornamental and structural purposes.
Lead's chemical symbol comes from the Latin word for waterworks,
plumbum.
Many magnificent buildings erected in the 15th and 16th centuries still
stand under their original lead roofs.
Lead properties
•Grey colour
•Very soft
•Low melting point
•Ductile and malleable
•Very toxic

lead and Lead alloys
The properties of lead that make it useful in a wide variety
of applications are density, malleability, lubricity, flexibility,
electrical conductivity, and coefficient of thermal
expansion, all of which are quite high; and elastic
modulus, elastic limit, strength, hardness, and melting
point, all of which are quite low. Lead also has good
resistance to corrosion under a wide variety of conditions.
Lead is easily alloyed with many other metals and casts
with little difficulty.
The high density of lead (11.35 g/cm3, at room
temperature) makes it very effective in shielding
against x-rays and gamma radiation. The combination
of high density, high limpness (low stiffness), and high
damping capacity makes lead an excellent material for
deadening sound and for isolating equipment and
structures from mechanical vibrations.

Refractory metals
• Refractory metals have a high melting
point and retain their strength at
elevated temperatures.
• Applications are electronics, nuclear
power and chemical industries.
• Molybdenum, columbium, tungsten,
and tantalum are referred to as
refractory metal.

Mechanical and physical properties
comparison
Metals Density
[g/cm3
]
Tensile
Strength
[MPa] at RT
Electrical
conductivity
%IACS
Modulus
of Elasticity
x 103
[MPa]
Tungsten 19.3 689-3445 31 4.063
Tantalum 16.6 241-482 13.9 1.88
Titanium 4.5 262-689 5.5 1.034-1.087
Molybdenum 10.2 827-1379 34 3.169
Niobium 8.57 201-414 13.2 1.034
Aluminum 2.7 69-187 64.9 0.609
Zinc 7.13 203-324 28.3 0.689
Copper 8.96 228-371 100 1.171
Iron 7.87 179-283 19.1 1.99-2.01

Metals & Alloy Physical properties
Comparison

Surface Colour of Metals & alloy

Surface Hardening Methods
 Flame hardening
 Induction heating
 High-frequency resistance heating
 Electron beam heating
 Laser beam heating

Surface Hardening Methods
Induction
heating
High frequency
resistance
heating

IS CODE :
Aluminium & alloy
is : 733-1975
Wrought aluminium and aluminium alloy bars, rods and sections (for
general engineering purposes) (second revision)
IS : 737-1974
Wrought aluminium and aluminium alloys, sheet and strip (for
general engineering purposes) (second revision)
IS : 1254-1975 Corrugated aluminium sheet (second revision)
IS : 7094-1973
Aluminium and aluminium alloy welded tubes for general
engineering purposes

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