CHAPTER 6

Nonferrous Metals and Alloys: Production, General Properties, and Applications

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 6-1

Approximate Cost per Unit Volume for Wrought Metals and Plastics Relative to Carbon Steel
TABLE 6.1 Approximate Cost per Unit Volume for Wrought Metals and Plastics Relative to Cost of Carbon Steel
Gold 60,000 Magnesium alloys 24 Silver 600 Aluminum alloys 23 Molybdenum alloys 200250 High-strength low-alloy steels 1.4 Nickel 35 Gray cast iron 1.2 Titanium alloys 2040 Carbon steel 1 * Copper alloys 56 1.12 Nylons, acetals, and silicon rubber * Zinc alloys 1.53.5 0.21 Other plastics and elastomers Stainless steels 29 *As molding compounds. Note: Costs vary significantly with quantity of purchase, supply and demand, size and shape, and various other factors.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 6-2

General Characteristics of Nonferrous Metals and Alloys

TABLE 6.2
Material Nonferrous alloys Aluminum Magnesium Copper Superalloys Titanium Refractory metals Precious metals Characteristics More expensive than steels and plastics; wide range of mechanical, physical, and electrical properties; good corrosion resistance; high-temperature applications. High strength-to-weight ratio; high thermal and electrical conductivity; good corrosion resistance; good manufacturing properties. Lightest metal; good strength-to-weight ratio. High electrical and thermal conductivity; good corrosion resistance; good manufacturing properties. Good strength and resistance to corrosion at elevated temperatures; can be iron-, cobalt-, and nickel-base. Highest strength-to-weight ratio of all metals; good strength and corrosion resistance at high temperatures. Molybdenum, niobium (columbium), tungsten, and tantalum; high strength at elevated temperatures. Gold, silver, and platinum; generally good corrosion resistance.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 6-3

Example of Alloy Usage

Figure 6.1 Crosssection of a jet engine (PW2037) showing various components and the alloys used in manufacturing them. Source: Courtesy of United Aircraft Pratt & Whitney.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 6-4

Properties of Selected Aluminum Alloys at Room Temperature

TABLE 6.3
Alloy (UNS) 1100 (A91100) 1100 2024 (A92024) 2024 3003 (A93003) 3003 5052 (A95052) 5052 6061 (A96061) 6061
7075 (A97075) 7075

Temper O H14 O T4 O H14 O H34 O T6

O T6

Ultimate tensile strength (MPa) 90 125 190 470 110 150 190 260 125 310
230 570

Yield strength (MPa) 35 120 75 325 40 145 90 215 55 275

105 500

Elongation in 50 mm (%) 3545 920 2022 1920 3040 816 2530 1014 2530 1217
1617 11

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 6-5

Manufacturing Properties and Applications of Selected Wrought Aluminum Alloys

TABLE 6.4
Characteristics* Alloy 1100 2024 3003 Corrosion resistance A C A Machinability CD BC CD Weldability A BC A Typical applications Sheet metal work, spun hollow ware, tin stock Truck wheels, screw machine products, aircraft structures Cooking utensils, chemical equipment, pressure vessels, sheet metal work, builders hardware, storage tanks Sheet metal work, hydraulic tubes, and appliances; bus, truck and marine uses Heavy-duty structures where corrosion resistance is needed, truck and marine structures, railroad cars, furniture, pipelines, bridge rail-ings, hydraulic tubing Aircraft and other structures, keys, hydraulic fittings

5052 6061

A B

CD CD

A A

7075

BD

* A, excellent; D, poor.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 6-6

All-Aluminum Automobile

Figure 6.2 (a) The Audi A8 automobile which has an allaluminum body structure. (b) The aluminum body structure, showing various components made by extrusion, sheet forming, and casting processes. Source: Courtesy of ALCOA, Inc.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 6-7

Properties and Typical Forms of Selected Wrought Magnesium Alloys

TABLE 6.5
Composition (%) Alloy AZ31 B AZ80A HK31A ZK60A Al 3.0 8.5 Zn 1.0 0.5 Mn 0.2 0.2 3Th 5.7 0.7 0.55 Zr Condition F H24 T5 H24 T5 Ultimate tensile strength (MPa) 260 290 380 255 365 Yield strength (MPa) 200 220 275 200 300 Elongation in 50 mm (%) 15 15 7 8 11

Typical forms Extrusions Sheet and plates Extrusions and forgings Sheet and plates Extrusions and forgings

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 6-8

Properties and Typical Applications of Selected Wrought Copper and Brasses

TABLE 6.6
Type and UNS number Electrolytic tough pitch copper (C11000) Red brass, 85% (C23000) Nominal composition (%) 99.90 Cu, 0.04 O Ultimate tensile strength (MPa) 220450 Yield strength (MPa) 70365 Elongation in 50 mm (%) 554

85.0 Cu, 15.0 Zn

270725

70435

553

Cartridge brass, 70% (C26000)

70.0 Cu, 30.0 Zn

300900

75450

663

Free-cutting brass (C36000) Naval brass (C46400 to C46700)

61.5 Cu, 3.0 Pb, 35.5 Zn 60.0 Cu, 39.25 Zn, 0.75 Sn

340470 380610

125310 170455

5318 5017

Typical applications Downspouts, gutters, roofing, gaskets, auto radiators, busbars, nails, printing rolls, rivets Weather-stripping, conduits, sockets, fas-teners, fire extinguishers, condenser and heat exchanger tubing Radiator cores and tanks, flashlight shells, lamp fixtures, fasteners, locks, hinges, ammunition components, plumbing accessories Gears, pinions, automatic highspeed screw machine parts Aircraft turnbuckle barrels, balls, bolts, marine hardware, propeller shafts, rivets, valve stems, condenser plates

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 6-9

Properties and Typical Applications of Selected Wrought Bronzes

TABLE 6.7
Nominal composition (%) 57.0 Cu, 3.0 Pb, 40.0 Zn 95.0 Cu, 5.0 Sn, trace P Ultimate tensile strength (MPa) 415 (As extruded) 325960 Yield strength (MPa) 140 Elongation in 50 mm (%) 30

Type and UNS number Architectural bronze (C38500) Phosphor bronze, 5% A (C51000)

130550

642

Free-cutting phosphor bronze (C54400) Low silicon bronze, B (C65100) Nickel silver, 6510 (C74500)

88.0 Cu, 4.0 Pb, 4.0 Zn, 4.0 Sn 98.5 Cu, 1.5 Si

300520 275655

130435 100475

5015 5511

65.0 Cu, 25.0 Zn, 10.0 Ni

340900

125525

501

Typical applications Architectural extrusions, store fronts, thresholds, trim, butts, hinges Bellows, clutch disks, cotter pins, diaphragms, fasteners, wire brushes, chemical hardware, textile machinery Bearings, bushings, gears, pinions, shafts, thrust washers, valve parts Hydraulic pressure lines, bolts, marine hardware, electrical conduits, heat exchanger tubing Rivets, screws, slide fasteners, hollow ware, nameplates

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 6-10

Properties and Typical Applications of Selected Nickel Alloys

TABLE 6.8 Properties and Typical Applications of Selected Nickel Alloys (All are Trade Names)
Nominal composition (%) None Ultimate tensile strength (MPa) 380550 Yield strength (MPa) 100275 Elongation in 50 mm (%) 6040

Type and UNS number Nickel 200 (annealed)

Duranickel 301

4.4 Al, 0.6 Ti

1300

900

28

Monel R-405 (hot rolled) Monel K-500 Inconel 600 (annealed)

30 Cu 29 Cu, 3 Al 15 Cr, 8 Fe

525 1050 640

230 750 210

35 30 48

Hastelloy C-4 (solutiontreated and quenched)

16 Cr, 15 Mo

785

400

54

Typical applications Chemical and food processing industry, aerospace equipment, electronic parts Springs, plastics extrusion equipment, (age hardened) molds for glass, diaphragms Screw-machine products, water meter parts Pump shafts, valve stems, springs (age hardened) Gas turbine parts, heat-treating equipment, electronic parts, nuclear reactors High temperature stability, resistance to stress-corrosion cracking

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 6-11

Properties and Typical Applications of Selected Nickel-Base Superalloys at 870 C

TABLE 6.9 Properties and Typical Applications of Selected Nickel-Base Superalloys at 870 C (1600 F) (All are Trade Names)
Ultimate tensile strength (MPa) 770 255 885 215 285 340 840 730 620 690 525 Yield strength (MPa) 690 180 695 200 275 330 760 605 550 635 515 Elongation in 50 mm (%) 25 50 6 110 125 88 4 8 19 27 35

Alloy Astroloy Hastelloy X IN-100 IN-102 Inconel 625 lnconel 718 MAR-M 200 MAR-M 432 Ren 41 Udimet 700 Waspaloy

Condition Wrought Wrought Cast Wrought Wrought Wrought Cast Cast Wrought Wrought Wrought

Typical applications Forgings for high temperature Jet engine sheet parts Jet engine blades and wheels Superheater and jet engine parts Aircraft engines and structures, chemical processing equipment Jet engine and rocket parts Jet engine blades Integrally cast turbine wheels Jet engine parts Jet engine parts Jet engine parts

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 6-12

Properties and Typical Applications of Selected Wrought Titanium Alloys

TABLE 6.10 Properties and Typical Applications of Selected Wrought Titanium Alloys at Various Temperatures
Nominal composition (%) UNS Condition Ultimate tensile strength (MPa) Yield strength (MPa) Elongation (%) Reduction of area (%) Temp. (C) Ultimate tensile strength (MPa) Yield strength (MPa) Elongation in 50 mm (%) Reduction of area Typical Applications

99.5 Ti

R50250

Annealed

330

240

30

55

300

150

95

32

80

5 Al, 2.5 Sn

R54520

Annealed

860

810

16

40

300

565

450

18

45

6 Al, 4V

R56400

Annealed

1000

925

14

30

300

725

650

14

35

Airframes; chemical, desalination, and marine parts; plate type heat exchangers Aircraft engine compressor blades and ducting; steam turbine blades Rocket motor cases; blades and disks for aircraft turbines and compressors; structural forgings and fasteners; orthopedic implants

Solution + age

1175

1100

10

20

425 550 300

670 530 980

570 430 900

18 35 10 12 22 12

40 50 28 35 45

13 V, 11 Cr, 3 Al

R58010

Solution + age

1275

1210

425

1100

830

High strength fasteners; aerospace components; honeycomb panels

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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