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Chapter 14: Nonferrous Alloys

14-1 In some cases, we may be more interested in cost of a material per unit volume than in
the cost per unit weight. Rework Table 14–1 to show the cost in terms of $/cm3. Does
this change/alter the relationship between the different materials?
Solution: We can find the density (in g/cm3) of each metal from Appendix A. We
can convert the cost in $/lb to $/g (using 454 g/lb) and then multiply
the cost in $/g by the density, giving $/cm3. The left hand side of the
table shows the results of these conversions, with the metals ranked
in order of cost per volume. The right hand side of the table shows the
cost per pound.
Cost/volume Rank Cost/lb Rank
3
Al $0.0048/cm 1 Fe $0.30 1
Fe $0.0052/cm3 2 Al $0.80 2
Mg $0.0105/cm3 3 Zn $0.95 3
3
Zn $0.0149/cm 4 Pb $1.00 4
Pb $0.0250/cm3 5 Mg $2.75 5
3
Cu $0.0629/cm 6 Cu $3.20 6
Ti $0.0795/cm3 7 Ni $8.00 7
Ni $0.1568/cm3 8 Ti $8.00 7
3
W $1.0176/cm 9 W $24.00 9
Be $1.7318/cm3 10 Be $425.00 10
The relationship is changed; for example, aluminum is second based
on weight, but first on the basis of volume.

14-2 Determine the specific strength of the following metals and alloys (use the densities of
the major metal component as an approximation of the alloy density where required):
Alloy/metal Tensile strength (MPa)
1100-H18 165
5182-O 290
2024-T4 469
2090-T6 552
201-T6 483
ZK40A-T5 276
Age hardened Cu 2% Be 1310
Alpha Ti alloy 862
W 455
Ta 186

Solution: To obtain specific strength, the tensile strength must first be


converted from MPa to kg/m2 by dividing by the acceleration due to
gravity: 9.81m/s2. The calculations are shown in the table below.

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Alloy/metal TS (MPa) TS (kg/m2) × Density Specific Strength
106 (kg/m3) (m)
1100-H18 165 16.8 2700 6.23 × 103
5182-O 290 29.6 2700 1.09 × 104
2024-T4 469 47.8 2700 1.77 × 104
2090-T6 552 56.3 2700 2.08 × 104
201-T6 483 49.2 2700 1.82 × 104
ZK40A-T5 276 28.1 1740 1.62 × 104
Age hardened Cu 1310 133.5 8930 1.50 × 104
2% Be
Alpha Ti alloy 862 87.9 4510 1.95 × 104
W 455 46.4 19250 2.41 × 103
Ta 186 19.0 16,600 1.14 × 103

14-3 How much would 50 kg of the hypothetical alloy 5074-O cost in raw materials prices
using the estimates given in Table 14-1?
Solution:
We note that the alloy is 99.74 % aluminum (x074) and alloyed with magnesium (5xxx).
We set up two equations to solve for the individual prices:
lb USD
 = 50 kg 0.9974 2.2  0.80  = 87.77 USD
kg lb
lb USD
 = 50 kg 1 − 0.9974 2.2  2.75  = 00.79 USD
kg lb
  = 88.56 USD

14-4 Structural steels have traditionally been used in shipbuilding; however, with increasing
fuel costs, it is desirable to find alternative lower weight materials. Some of the key
properties required for shipbuilding materials are high yield strength, high corrosion
resistance, and low cost. Discuss the benefits and disadvantages of aluminum alloys as a
replacement for structural steels in ships.
Solution: The main advantage of Al in shipbuilding is its specific strength (tensile
strength to density ratio), leading to lower weight structures that can
result in significant fuel cost savings.
Al generally has good corrosion resistance due to the formation of a
stable surface oxide; however, it could be susceptible to galvanic
corrosion in salt water as it is anodic with respect to most other
materials used in shipbuilding.
Potential disadvantages of Al include its low melting temperature,
which could compromise the ship’s structural integrity due to
accidents related to high temperature conditions / fires and relative
difficulty to weld when compared to steels. Despite these
disadvantages, with continuing developments in aluminum alloys,
more of these light weight alloys are being used in shipbuilding.

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14-5 Assuming that the density remains unchanged, compare the specific strength of the
2090–T6 aluminum alloy to that of a die cast 443–F aluminum alloy. If you considered
the actual density, do you think the difference between the specific strengths would
increase or decrease? Explain.
Solution: 2090 − T6: Tensile strength = 80, 000 psi
(80,000 psi) (454 g/lb)
Spec. strength =
(2.7 g/cm 3 ) (2.54 cm/in.)3
= 8.2 × 105 in.
443 − F: Tensile strength = 33, 000 psi
(33,000 psi) (454 g/lb)
Spec. strength =
(2.7 g/cm 3 ) (2.54 cm/in.)3
= 3.39 × 105in.
Both should increase since both Li and Si (the major alloying elements)
are less dense than Al.

14-6 Explain why aluminum alloys containing more than about 15% Mg are not used.
Solution: When more than 15% Mg is added to Al, a eutectic microconstituent is
produced during solidification. Most of the eutectic is the brittle
intermetallic compound β, and it will likely embrittle the eutectic.

14-7 Would you expect a 2024–T9 aluminum alloy to be stronger or weaker than a 2024–T6
alloy? Explain.
Solution: The T9 treatment will give the higher strength; in this temper, cold
working and age hardening are combined, while in T6, only age
hardening is performed.

14-8 Estimate the tensile strength expected for the following aluminum alloys:
(a) 1100–H14;
(b) 5182–H12; and
(c) 3004–H16.
Solution: (a) The tensile strength for 1100–H14 is the average of the O and H18
treatments.
1100 − O (0%CW): TS = 13 ksi
1100 − H18(75% CW) : TS = 24 ksi
13 + 24
TSH14 = = 18.5 ksi
2
(b) The tensile strength for 5182–H12 is the average of the O and H14
treatments, and H14 is the average of the O and H18 treatments.
We do not have data in Table 14–5 for 5182–H18; however, 5182–
H19 has a tensile strength of 61,000 psi and H18 should be 2000
psi less, or 59,000 psi.

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5182 − O (0% CW): TS = 42 ksi
5182 − H18 (75% CW): TS = 61 − 2 = 59 ksi
42 + 59
TSH14 = = 50.5 ksi
2
42 + 50.5
TSH12 = = 46.25 ksi
2
(c) The tensile strength for 3004–H16 is the average of the H14 and
H18 treatments, and H14 is the average of the O and H18
treatments.
3004 − O: TS = 26 ksi
3004 − H18: TS = 41 ksi
26 + 41
TSH14 = = 33.5 ksi
2
41 + 33.5
TSH16 = = 37.25 ksi
2

14-9 A 1-cm-diameter steel cable with a yield strength of 480 MPa needs to be replaced to
reduce the overall weight of the cable. Which of the following aluminum alloys could be
a potential replacement?
(a) 3004–H18 (Sy = 248 MPa);
(b) 1100–H18 (Sy = 151 MPa);
(c) 4043–H18 (Sy = 269 MPa); and
(d) 5182–O (Sy = 131 MPa).
The density of the steel used in the cable was 7.87 g/cm3, and assume that the density
of all the aluminum alloys listed above is 2.7 g/cm3.
Solution: The force F sustained by the 1 cm diameter steel cable is
π 
F = S y A0 = 480 × 106 N/m 2  (0.01 m) 2  = 37, 700 N ,
4 
where Sy is the yield strength and A0 is the initial cross–sectional area.
In order for the Al alloys listed to carry the same load, the diameter of
the cable required can be calculated using
πd2 F
=
4 Sy
or
4F
d= ,
π Sy
where d is the cable diameter. Per unit length, the weight of the cable
is given by
πd2
Weight/Length = (ρ )
4
where ρ is the density of the material. The results for each alloy are
given in the table below.

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Alloy Sy (MPa) d(cm) Weight/Length (g/cm)
Steel 480 1.00 6.18
3004–H18 248 1.39 4.10
1100–H18 151 1.78 6.74
4043–H18 269 1.34 3.78
5182–O 131 1.91 7.77
From the table, 3004–H18 and 4043–H18 are potential replacements
for the steel cable.

14-10 Suppose, by rapid solidification from the liquid state, that a supersaturated Al–7% Li
alloy can be produced and subsequently aged. Compare the amount of β that will form
in this alloy with that formed in a 2090 alloy.
Solution: The 2090 alloy contains 2.4% Li; from the Al–Li phase diagram, the
composition of the β is about 20.4% Li and that of the α is
approximately 2% Li at a typical aging temperature or at room
temperature:
7−2
Al − 7% Li: % β = × 100% = 27%
20.4 − 2
2.4 − 2
2090 : % β = ×100% = 2.2%
20.4 − 2

14-11 Determine the amount of Mg2Al3 (β) expected to form in a 5182–O aluminum alloy. (See
Figure 14–2.)
Solution: The 5182 alloy contains 4.5% Mg. Thus from the Mg–Al phase
diagram, which shows the α contains about 0% Mg and β contains
about 35% Mg:
4.5 − 0
%β = × 100% = 12.9%
35 − 0

14-12 A 5182–O aluminum alloy part that had been exposed to salt water showed severe
corrosion along the grain boundaries. Explain this observation based on the expected
phases at room temperature in this alloy. (See Figure 14–2.)
Solution: Since 5182–O is an Al–4.5% Mg alloy, the Mg3Al2 intermetallic phase
may have precipitated along the grain boundaries. This material is
strongly anodic, and this probably led to galvanic corrosion in salt
water.

14-13 From the data in Table 14–6, estimate the ratio by which the yield strength of
magnesium can be increased by alloying and heat treatment and compare with that of
aluminum alloys.
Solution: The exact values will differ depending on the alloys we select for
comparison. The table below provides an example. Strengthening of

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Mg is only about 1/10 as effective as in Al.

Magnesium Aluminum
YS YS/YSMg YS YS/YSAl
Pure Mg: 13 ksi — Pure Al 2.5 ksi —
Cold Worked 17 ksi 1.3 CW 1100–O 22 ksi 8.8
Casting & T6 28 ksi 2.2 5182–O Alloy 19 ksi 7.6
(ZK61A–T6)
Wrought & T5 40 ksi 3.1 2090–T6 75 ksi 30.0
(AZ80A–T5)

14-14 Suppose a 24-in.-long round bar is to support a load of 400 lb without any permanent
deformation. Calculate the minimum diameter of the bar if it is made from (a) AZ80A–T5
magnesium alloy and (b) 6061–T6 aluminum alloy.
Calculate the weight of the bar and the approximate cost (based on pure Mg and Al) in
each case.
Solution: A = F/Yield Strength
(a) AZ80A – T5 : YS = 40 ksi
A = 400/40,000 = 0.01 in.2
d = 4 A/π = 0.113 in.
Weight = (24 in.) (0.01 in.2 ) (0.063 lb/in.3 ) = 0.0151 lb
Cost = ($1.5/lb) (0.0151 lb) = $0.023
(b) 6061 – T6 : YS = 40 ksi therefore,
A = 0.01 in.2 d = 0.113 in. as in part (a), but
Weight = (24 in.) (0.01 in.2 ) (0.063 lb/in.3 ) = 0.0233 lb
Cost = ($0.60/lb) (0.0233 lb) = $0.014
Al is less costly than Mg, even though Mg is lighter.

14-15 A 10-m rod, 0.5 cm in diameter, must elongate no more than 2 mm under load.
Determine the maximum force that can be applied if the rod is made from (a)
aluminum; (b) magnesium; and (c) beryllium.
Solution: F
E = S /e = ∴ F = EA0 e diameter = 0.5 cm = 0.1969 in.
A0 e
10.002 m − 10.000 m
e= = 0.0002 m/m = 0.0002 in./in.
10.000 m
FAl = (10 × 106 psi) (π /4) (0.1969 in.) 2 (0.0002 in./in.)
= 60.9 lb = 271 N
FMg = (6.5 × 106 psi) (π /4) (0.1969 in.) 2 (0.0002 in./in.)
= 39.6 lb = 176 N
FBe = (42 × 106 psi) (π /4) (0.1969 in.) 2 (0.0002 in./in.)
= 256 lb = 1138 N

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14-16 A new process is proposed to harden an Mg-Al alloy. Part of the patent filing suggests
that a 35 wt% Al liquid be solidified at 250°C. Is this realistic or should this application be
thrown out as physically impossible?
Solution:
Examining Figure 14-4 we find ourselves in the α+γ region, which is definitely solid. This
is physically realistic.

14-18 We say that copper can contain up to 40% Zn or 9% Al and still be single phase. How do
we explain this statement in view of the phase diagrams for the Cu-Zn system? [See
Figure 14–5(a).]
Solution: This is possible due to slow kinetics of transformation at low
temperatures.

14-19 Compare the percent increase in the yield strength of commercially pure annealed
aluminum, magnesium, and copper by strain hardening. Explain the differences
observed.
Solution: H18 − 1100-O  22,000 − 5,000 
Al: =  × 100 = 340%
100-O  5,000 
C.W. − Annealed 17,000 − 13,000 
Mg: =  × 100 = 31%
Annealed  13,000 
70% C.W.  53,000 − 4,800 
Cu: =  × 100 = 1004%
Annealed  4,800 
Both Al and Cu (with an FCC structure) have high strain-hardening
coefficients and can be cold worked a large amount (due to their good
ductility). Mg has the HCP structure, a low strain-hardening
coefficient, and a limited ability to be cold worked.

14-20 What temperature ranges correspond to the phases of Cu-Sn alloys?


(a) η @ 60 wt% Sn;
(b) ζ @ 34 wt% Sn;
(c) γ @ 30 wt% Sn; and
(d) α @ 0 wt% Sn.
Solution:
All answers are obtained from Figure 14-5 (b).
150 °C down, potentially to absolute zero, but we cannot know unless we have a phase
diagram down that low.
580 °C to 620 °C
600 °C to 720 °C
160 °C to 1075 °C

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14-21 We would like to produce a quenched and tempered aluminum bronze containing 13%
Al. Recommend a heat treatment, including appropriate temperatures. Calculate the
amount of each phase after each step of the treatment.
Solution: Heat to above about 710°C to get all β; 100% β, β: 13% Al
Quench; still all β containing 13% Al.
Reheat; temper at 400°C to allow g2 to form.
13 − 9.4
% γ2 = = 54.5% γ 2 :16% Al, α : 9.4% Al
16 − 9.4
We want to be sure to temper above 400°C so we obtain γ2 in a matrix
of a rather than a structure containing γ + γ2.

14-22 A number of casting alloys have very high lead contents; however, the Pb content in
wrought alloys is comparatively low. Why isn’t more lead added to the wrought alloys?
What precautions must be taken when a leaded wrought alloy is hot worked or heat
treated?
Solution: The lead-rich phase may melt during hot working or may form
stringers during cold working.
We must be sure that the temperature is low enough to avoid melting
of the lead phase.

14-23 Would you expect the fracture toughness of quenched and tempered aluminum bronze
to be high or low? Would there be a difference in the resistance of the alloy to crack
nucleation compared with crack growth? Explain.
Solution: The fracture toughness should be relatively good. The acicular, or
Widmanstätten, microstructure forces a crack to follow a very tortuous
path, which consumes a large amount of energy.
This microstructure is less resistant to crack nucleation. The acicular
structure may concentrate stresses that lead to easier formation of a crack.

14-24 Based on the phase diagrams, estimate the solubilities of Ni, Zn, Al, Sn, and Be in copper
at room temperature. Are these solubilities expected in view of Hume-Rothery’s
conditions for solid solubility? Explain.
Solution:
Solubility Structure Valence Atom size difference
Cu–Ni 100% Ni FCC 1 1.278 − 1.243 2.7%
× 100 =
1.278
Cu–Zn 30% Zn HCP 2 1.278 − 1.332 –4.2%
× 100 =
1.278
Cu–Al 8% Al FCC 3 1.278 − 1.432 –12.1%
× 100 =
1.278
Cu–Be 0.2% Be HCP 2 1.278 − 1.143 10.6%
× 100 =
1.278
Cu–Sn 0% Sn DC 4 1.278 − 1.405 –9.9%
×100 =
1.278

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Hume-Rothery’s conditions do help to explain the differences in solubility. Solubilities
tend to decrease as atom size difference increases.

14-25 Hastelloy is used in chemical reactors, pipes, and other vessels that contain high-value,
highly corrosive materials. Hastelloy is mostly nickel. How much more load can Hastelloy
B-2 sustain compared to pure, cold-worked nickel?
Solution:
Referring to Table 14-8:
 !" #$%&'() *+, 130 ksi
= = 1.37 ×
 !" -(.+/(01'. 23 95 ksi

14-26 Based on the photomicrograph in Figure 14 –7(a), would you expect the γ′ precipitate or
the carbides to provide a greater strengthening effect in superalloys at low
temperatures? Explain.
Solution: The γ′ phase is more numerous and also more uniformly and closely
spaced; consequently, the γ′ should be more effective than the smaller
number of coarse carbides at blocking slip at low temperatures.

14-27 The density of Ni3Al is 7.5 g/cm3. Suppose a Ni–5 wt% Al alloy is heat treated so that all
of the aluminum reacts with nickel to produce Ni3Al. Determine the volume percent of
the Ni3Al precipitate in the nickel matrix.
Solution: In 100 g of the alloy, the total atoms present are
(95 g Ni)N A (5 g Al)N A
atoms = +
58.71 g/mol 26.981 g/mol
= 1.6181 N A + 0.1853 N A = 1.803 N A
If all of the Al reacts to form Ni3Al, then the number of atoms in the compound is
0.1853 NA of Al and (3)(0.1853 NA) = 0.5559 NA of Ni.
The mass of the Ni3Al is then
(0.1853 N A of Al) (26.981 g/mol) (0.5559 N A of Ni) (58.71 g/mol)
mass = +
NA NA
= 37.64 g of Ni3 Al
The mass of the Ni matrix is thus 62.36 g. The vol% Ni3Al is thus:
37.64 g(7.5 g/cm3 )
vol% Ni3Al =
37.64 g/(7.5 g/cm3 ) + 62.36 g/(8.902 g/cm3 ) ×100% = 42%
Even a small amount (5 wt% aluminum) produces a very large volume percent of
precipitate in the microstructure.

14-28 When steel is joined using arc welding, only the liquid-fusion zone must be protected by
a gas or flux. When titanium is welded, both the front and back sides of the welded
metal must be protected. Why must these extra precautions be taken when joining
titanium?
Solution: The titanium may be contaminated or embrittled anytime the
temperature is above about 535°C. Therefore, the titanium must be

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protected until the metal cools below this critical temperature. Since
both sides of the titanium plate will be heated by the welding process,
special provisions must be made to shield all sides of the titanium until
the metal cools sufficiently.

14-29 Both a Ti–15% V alloy and a Ti–35% V alloy are heated to the lowest temperature at
which all β just forms. They are then quenched and reheated to 300°C. Describe the
changes in microstructures during the heat treatment for each alloy, including the
amount of each phase. What is the matrix and what is the precipitate in each case?
Which is an age-hardening process? Which is a quench and temper process? [See Figure
14–12(a).]
Solution: Ti–15% V: 100% β → 100% α′ → β precipitates in α matrix.
46 − 15
% α 300C = × 100% = 76% β = 24%
46 − 5
This is a quench and temper process.
Ti–35% V: 100% β → 100% βss → α precipitates in β matrix.
46 − 35
% α 300C = × 100% = 27% β = 73%
46 − 5
This is an age hardening process.

14-30 A Ti-Mn alloy is composed of 20 wt% manganese and is kept at 550 °C. What phase(s)
are present? See Figure 14-8(d).
Solution:
Figure 14-8 (d) shows that this is right on a phase border and to the right of the
eutectoid point. The phases present are α, β and θ.

14-31 Determine the specific strength of the strongest Al, Mg, Cu, Ti, and Ni alloys. Use the
densities of the pure metals, in lb/in.3, in your calculations. Try to explain their order.
Solution:
Strength Density Strength-to-weight
(psi) ratio
Ti 176,000 4.51 g/cm3 = 0.163 lb/in.3 10.8 × 105 in.
Al 75,000 2.7 g/cm3 = 0.098 lb/in.3 7.7 × 105 in.
Mg 40,000 1.74 g/cm3 = 0.063 lb/in.3 6.3 × 105 in.
3 3
Cu 175,000 8.93 g/cm = 0.322 lb/in. 5.4 × 105 in.
3 3
Monel 110,000 8.90 g/cm = 0.322 lb/in. 3.4 × 105 in.
Titanium is strong with a relatively low density. Cu and Ni are strong
but dense. Al and Mg have modest strength but light weight.
The yield strengths were used in these calculations.

14-33 The temperature of a coated tungsten part is increased. What happens when the
protective coating on a tungsten part expands more than the tungsten? What happens
when the protective coating on a tungsten part expands less than the tungsten?

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Solution: If the protective coating expands more than tungsten, compressive
stresses will build up in the coating and the coating will flake.
If the protective coating expands less than tungsten, tensile stresses
will build up in the coating and the coating will crack and become
porous.

14–35 List the refractory metals by their suitability for cryogenic service.
Solution:
Going by the transition temperatures in Table 14-10: Ta, Nb, Mo, W.

14–36 Nanoparticles (3 nm in diameter) of platinum with a total weight of 1 milligram are used
in automobile catalytic converters to facilitate oxidation reactions. As Pt is an expensive
metal, a method to coat iron nanoparticles with Pt is being explored to reduce the cost
of the catalyst metal. If 3 nm diameter Fe particles are being coated with 1 nm of Pt to
achieve the same effective surface area with fewer particles and less Pt, calculate the
difference in cost and weight of the catalyst. Assume that the cost of Pt is $40/g and
that of Fe is $0.005/g. The density of Fe is 7.87 g/cm3 and that of Pt is 21.45 g/cm3.
Solution: The volume VPt of one 3 nm diameter Pt particle is
VPt = (4πr3/3) = (4π/3)(1.5 × 10–7)3 cm3 = 14.137 × 10–21 cm3,
where r is the nanoparticle radius. One milligram of Pt with a density of
21.45 g/cm3 at a cost of $40/g (such that 10–3 g costs $0.04)
corresponds to a total volume of
(10–3 g)/ (21.45 g/cm3) = 4.662 × 10–5 cm3.
The total number of Pt particles is then
Number of Pt particles = 4.662 ×10−5 /(14.137 ×10−21 )
= 3.2977 ×1015 .
The total surface area of the Pt particles is
Total Surface Area = (4π r 2 ) (Number of Pt particles)
= 4π (1.5 × 10−7 )2 (3.2977 × 1015 )
= 932.4 cm 2 .
In order to achieve the same total surface area with 1 nm Pt coated on
3 nm Fe, the number of Fe-Pt particles required is
932.4 = 4π(2 × 10–7)2 (Number of Fe-Pt particles)
Number of Fe-Pt particles = 932.4/[4π (2 ×10−7 )2 ]
= 1.8550 ×1015.
The volume VFe-Pt of one 4 nm diameter Fe-Pt particle is the sum of the
volumes of the Fe (VFe) and Pt portions (VPt on Fe). The volume of the Fe
portion VFe is given by
VFe = Number of Fe-Pt particles (Volume of Fe portion for each particle)
VFe = 1.8550 × 10–15(4π/3) (1.5 × 10–7)3 = 2.6224 × 10–5 cm3.
Multiplying by the density of iron, the total mass of Fe mFe is
mFe = 2.6224 × 10–5(7.87 g/cm3) = 2.064 × 10–4 g,
and the cost of the iron is given by

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Cost of Fe = ($0.005/g) (2.064 × 10–4 g) = $0.001 × 10–3,
which is insignificant. The volume of the Pt portion VPt on Fe is given by
VPt on Fe = Number of Fe-Pt particles Volume of Pt portion for each particle)
VPt on Fe = 1.8550 ×1015 (4π /3) [(2 ×10−7 )3 − (1.5 ×10−7 )3 ]
= 3.5937 ×10−5cm3 .
Multiplying by the density of platinum, the total mass of Pt on Fe mPt on
Fe is
mPt on Fe = 3.5937 × 10–5(21.45 g/cm3) = 7.71 × 10–4 g
Cost of Pt = ($40/g) (7.71 × 10–4g) = $0.031.
Combining the Fe and Pt values, for the Pt coated Fe particles,
Total weight = 2.064 × 10–4 g + 7.71 × 10–4 g = 0.98 mg and the
Total cost = $0.031 (as the cost of Fe is insignificant.)
Compared to the Pt particles, the Pt coated Fe particles weigh 0.02 mg
less and cost $0.009 less. Also it should be noted that the costs here are
the materials cost only. If the manufacturing costs for producing Pt
coated Fe particles are calculated, then it is likely that they will cost
more than the Pt particles.

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