Unit No 6 : Non Ferrous

Metals
Syllabus
Unit VI: Non Ferrous Metals (6 Hrs)
Classification of nonferrous metals. Importance of nonferrous metals in
engineering applications & compositions, study of different mechanical
properties: Cu & Cu based alloys, Al and Al based alloys, Ni and Ni
based alloys, Co and Co based alloys, Titanium & its alloys, Tin & Lead
base alloys, Bearing materials: important properties & applications.

2
At the end of Lecture you will be able to

• Definition, Classification & overview of nonferrous metals.

• As well as Importance of nonferrous metals in engineering applications, their
compositions and study of different mechanical properties.

13-12-2017 S. E. (M) 2015 Course Engineering Metallurgy 3

Limitations of ferrous alloy

• Relatively high density.

• Comparatively low electrical conductivity.
• An inherent possibility of corrosion in some atmosphere.
• So even world use 90 to 95 % Ferrous and its alloy due to its some draw backs
need of Non ferrous metal rises.

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• What is the material composition of a beverage can?

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• It contents Aluminium with a small amount of other materials like 1% Mg, 1%
Mn, 0.4% Fe, 0.2 % Si and 0.15% Cu.
• We can say it is made from aluminium alloy of Non ferrous Metal even it has
contains of Fe. (not solvent of alloy but a solute)

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7
 Light Non Ferrous
Alloys

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 Aluminum & its alloys

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 Aluminium Alloys
Aluminium alloys are alloys in which aluminium
(Al) is the predominant metal. The typical alloying
elements are copper, magnesium, manganese,
silicon, tin and zinc. There are two principal
classifications, namely casting alloys and wrought
alloys.
1. Ai-Si & Al-Si-Cu Alloys (LM2, LM4, LM6,
LM8, LM13, LM24)
2. Al-Mg alloys (LM5, LM10)
3. Al-Cu alloys(Duralumin) (LM11)
4. Y-alloy (LM14)
5. Hindalium (aluminium, magnesium,
manganese, silicon) product of Hindustan
Aluminium Corporation Ltd,
Alloy Compositi Properties Applicati
on ons
Hindumini Cu-5, Ni- high creep Aero
um- 1.5% resistance engines
RR350
y-alloy Cu-4, Ni-2, retains pistons,
(lm-14) Mn-1.5% strength at cylinder
high heads of
temperature, ice
can be cast,
rolled
LM-11 Cu- 4.5% Good Aircraft
strength, castings
Mech
properties
Alloy Compositi Properties Applicatio
on ns
Duralumin Cu-5, Mn- good aircraft
0.5, Mg- strength, industries
0.5% mech
properties
LM-6 Si-12% excellent pumps,
fluidity, water
corrosion cooled
resistance jackets
LM-13 Si-12%, high forged
Ni- temperatur pistons
2.5% ,Cu, e strength,
Mn low coeff
of thermal
expansion
Alloy Compositi Properties Applicatio
on ns
Magnaliu Mn-0.5, good marine
m Mg-5% weldability,
machinability
LM-10 Mg-10% good strentgh aircraft
industries,
dairy
equipment
s
15
• When chassis (Jaguar XJ
saloon) of vehicle made from
aluminium 300 kg to 1400 kg
load reduction of vehicle so
fuel consumption saves and
also reduce 20% exhaust gas
emission.

16
17
Titanium & Titanium Alloys
19
20
21
Zinc & Zinc
Alloys

22
23
Heavy Non Ferrous
Alloys

24
Copper & Copper Alloys
26
27
Copper alloys

Cu ALLOYS

BRASS BRONZE

α- α-β
MUNT Al –BRONZE
Z Si-BRONZE
BRAS
CAP
COPPE
BRAS
METAL
Be-BRONZE
SR S
NAVAL
BRASS Sn-BRONZE
GILDIN HIGH
G
TENSIL
METAL E
CARTR
BRASS
IDGE BRAZI
BRASS
ADMI NG
RALITY BRASS
LEADE
BRASS D
BRASS
Cu-Zn Phase
Diagram
 BRASSES:
α Brasses / Red Brasses
Cartridge Brass (70-30 Brass)
Α – BRASSES: Zn < 30%
1. Cap Copper
2. Gilding Metals
3. Cartridge Brass (70-30 Brass)
4. Admirality Brass
α-Brasses
Alloy Compositio Properties Applications
n
Cap Zn- 2-5% Highly ductile Detonator
copper caps, coins,
tokens
Gilding Zn- 5-15% Good Coins, needles,
metal ductility, emblems,
corrosion jewellary
resistance
Cartridge Zn- 30% Ductile, Cartridge
brass (70- malleable cases,radiator
30 brass) fins, lamp
reflectors,
rivettes
Admiralit Zn-28%, Good Condenser
y brass sn-1% corrosion tubes, marine
resistance appl
• α –β BRASSES: Zn > 30%
1. Muntz metal(60-40 brass)
2. Naval brass
3. Leaded brass (free cutting brass)
4. High tensile brass
5. Brazing brass (50-50 brass)
α-β BRASSES
• Zn- 30-40%

• More strength

• Hot worked

• Cheaper than α- brasses

• Poor corrosion resistance

α-β BRASSES
ALLOY COMPOSITI PROPERTIES APPLICATIONS
ON
MUNTZ Zn- 40% HARD, PUMP PARTS,
METAL STRONG, SHAFTS,
(60-40 DUCTILE BOLTS, VALVES
BRASS)
NAVAL Zn- 39%, GOOD MARINE APPL-
BRASS Sn-1% CORROSION PISTONS,
RESISTANCE CONN. RODS
LEADED Zn- 38% , INCREASED MACHINE
BRASS Pb-2% MACHINABILIT PARTS,
(FREE Y DUE TO Pb HARDWARE
CUTTING PRODUCTS
BRASS)
BRAZING Zn-50% BRITTLE BRAZING APPL
BRASS (50-
50 BRASS)
HIGH MUNTZ HIGH TENSILE MARINE
TENSILE METAL + STRENGTH PUMPS,
MUNTZ METAL (60-40 BRASS)
COPPER ALLOYS
BRONZES
BRONZES
• ALLOYS OF COPPER WITH ELEMENTS OTHER THAN Zn
• TYPES:
1. ALUMINIUM BRONZE
2. TIN BRONZE
3. BERYLLIUM BRONZE
4. SILICON BRONZE
ALUMINIUM BRONZE
ALUMINIUM BRONZE
• ALLOYS OF Cu + Al
• COMMERCIAL Al BRONZE HAS 4-11% Al
• Fe, Ni, Mn & Si ADDED TO IMPROVE CERTAIN PROPERTIES
• GOOD STRENGTH, DUCTILITY, TOUGHNESS
• GOOD CORROSION & FATIGUE RESISTANCE
• DUE TO LUSTROUS COLOUR : IMITATION GOLD
Cu-Al
PHASE
DIAGR
AM
Al BRONZE : TYPES
• SINGLE PHASE Al BRONZE: Al 4 TO 7.5%

• TWO PHASE Al BRONZE : 7.5 TO 11%

Al BRONZE

ALLOY COMPOSITI PROPERTIES APPLICATIONS

ON
SINGLE Al- 4-7.5% MALLEABLE, MARINE PUMP
PHASE DUCTILE, PARTS,
COLD SHAFTS,
WORKED BOLTS, VALVES

TWO Al- 7.5-11% HIGH TS, HOT PUMP

PHASE / WORKED, CASTING
DUPLEX HIGH PARTS,
ALUMINIU SHRINKAGE MACHINE
M PARTS
TIN BRONZE
Cu-Sn
PHASE
DIAGRA
M
TIN BRONZE
1. COINAGE BRONZE

2. GUN METAL

3. PHOSPHER BRONZE

4. STATUARY BRONZE

5. 80-10-10 BRONZE

6. 85-5-5-5 BRONZE
TIN BRONZE
ALLOY COMPOSITI PROPERTIES APPLICATIONS
ON
COINAGE Sn-5, Zn- SOFT, DUCTILE COINS
BRONZE 1%

GUN Sn-10, Zn- GOOD GUN BARRELS,

METAL 2% CORROSION GEARS, SHAFTS
RESISTANCE,
FLUIDITY
PHOSPHER Sn-2.5-8, P- COLD WIRE GUAGES,
BRONZE - 0.1-0.35% WORKED WIRE BRUSHES
WROUGHT

PHOSPHER Sn-5-13, P- BETTER GEARS,

BRONZE- 0.3-1% FLUIDITY BUSHINGS,
CAST VALVES
STATUARY Sn-10,Zn-2, HIGH STATUES
BRONZE Pb-2% CORROSION
RESISTANCE
TIN BRONZE
• 5. 80-10-10 BRONZE:
80% Cu, 10%Sn, 10%Pb
USED FOR HIGH SPEED & HEAVY PRESSURE BEARINGS
• 6. 85-5-5-5 BRONZE:
85%Cu, 5%Sn, 5%Pb, 5%Zn
GOOD CASTABILITY, MACHINABILITY
BEARINGS, VALVES, TAPS, PIPE FITTINGS, etc
SILICON BRONZE
SI-BRONZE
• Si- 1 TO 5.5%
• HIGH CORROSION RESISTANCE, TENSILE STRENGTH, TOUGHNESS
• CAN BE COLD / HOT WORKED
• ALLOYING ELEMENTS ADDED TO IMPROVE CERTAIN PROPERTIES
• APPLICATIONS: BOLTS, SPRINGS, PRESSURE VESSELS, MARINE
CONTAINERS, PROPELLER SHAFTS, BELLS
BERYLLIUM BRONZE
Be BRONZE
• GOOD CORROSION & FATIGUE RESISTANCE

• HIGHEST STRENGTH AMONGST ALL NON-F

• HIGH RESILIENCE

• GOOD BEARING PROPERTIES

• LOW ELASTIC HYSTERESIS & NON-SPARKING

PROPERTIES
Cu-Be Equilibrium Diagram
Be BRONZE: APPLICATIONS
• SPRINGS
• DIAPHRAGMS
• PLEXIBLE BELLOWS
• GEARS
• BEARINGS
• ELECTRICAL APPLIANCES
Nickel & Nickel Alloys
59
Cobalt & Cobalt Alloys
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COBALT ALLOYS
• RETAINS STRENGTH EVEN AT HIGH TEMPERATURE
• INCREASED STRENGTH TILL MP DUE TO CARBIDE NETWORK
• PRESENCE OF Cr INCREASES CORROSION RESISTANCE
• WELDABLE, CAN BE MECHANICALLY WORKED WITHOUT CRACKING
COBALT ALLOYS
COBALT ALLOYS:APPLICATIONS
• COMBUSTION CHAMBERS

• TURBINE VANES FOR AEROSPACE APPL

• ORTHOPAEDIC IMPLANTS IN KNEES, OTHER JOINTS

Ti Alloys
• ALPHA ALLOYS: Ti-5Al-2.5Sn
• WELDABLE & RETENSION OF
STRENGTH AT HIGH TEMPERATURE
• APPL: AIRCRAFT INDUSTRIES, MISSILE
FUEL TANKS, etc.
• ALPHA-BETA ALLOYS: Ti-6Al-4V
• HIGH STRENGTH
• APPL: AIRCRAFT BODIES, GAS TURBINE
COMPRESSOR BLADES, DISCS
Ti-Al Phase Diagram
Ti Alloys
• BETA ALLOYS: Ti-3Al-13V-11Cr
• GOOD WELDABILITY
• STRENGHTENED BY HEAT TREATMENT
• APPL: HIGH STRENGTH FASTENERS, AEROSPACE COMPONENTS
REQUIRING HIGH STRENGTH
BEARING MATERIALS
BEARING
MATERIALS:REQUIREMENTS
• LESS FRICTION BETWEEN MOVING PARTS

• LESS AFFINITY WITH CONTACTING

MATERIALS

• HARD, WEAR RESISTANT, HIGH LOAD

BEARING CAPACITY

• HIGH FATIGUE LIFE, THERMAL

CONDUCTIVITY

• HIGH MP, CORROSION RESISTANCE, OIL

RETAINING CAPACITY, etc
BEARING MATERIALS
1. WHITE METAL ALLOYS (BABBITTS)
A. Pb BASED
B. Sn BASED
2. Cu-Pb ALLOYS
3. SILVER BEARINGS
4. TIN BRONZE
5. Al ALLOYS
6. GREY CI
7. SELF LUBRICATING BEARING
White Metal Alloy [Babbitts]

1.Pb BASED BABBITS: 80%Pb, 15%Sb, 5%Sn

2.Sn BASED BABBITS: 90%Sn, 5%Sb, 5%Cu SMALL AMOUNT OF Pb

Pb BASED BABBITS
White Metal Alloy [Babbitts]
• BABBITS: HARD CUBOIDS OF Sn-Sb IN SOFT EUTECTIC MATRIX
• IF Cu IS THERE, IT WILL CONTAIN Cu-Sn NEEDLES
• Cu ADDED TO AVOID SEGREGATION OF CUBOIDS
• CUBOIDS FLOAT AT THE SURFACE=> HARD SURFACE, SOFT CORE
White Metal Alloy [Babbitts]
• HARD CUBOIDS FLOAT ON SURFACE

• INCREASE HARDNESS, WEAR RESISTANCE

White Metal Alloy [Babbitts]
Sn-Sb
CUBOI
DS AT
SURFA
CE

HARD
STRUCT
URE AT
SURFAC
E
White Metal Alloy [Babbitts]
• Sn BASED BABBITS HAVE
1. MORE CORROSION RESISTANCE
2. MORE LOAD CARRYING CAPACITY THAN Pb BASED BABBITS

APPLICATIONS:
BEARINGS OF IC ENGINES, LATHE MACHINES, MILLING MACHINES,
ELECTRIC MOTORS
 BEARING MATERIALS
MATERIA COMPOSITI PROPERTIES APPLICATION
L ON S
Cu-Pb Cu-60-80%, SOFT Pb IN BEARINGS
ALLOYS Pb- 20-40%, HARD Cu OF
Sn MATRIX AUTOMOTIV
E,
AEROSPACE
APPL.
TIN GUN TOUGH, BEARINGS
BRONZE METAL- Sn- STRONG, FOR HEAVY
10, Zn-2 RESISTANCE TO LOAD
PHOSPHER CORROSION APPLICATIO
BRONZE- NS
Sn-10-15%,
P-10%
SILVER SILVER REDUCES RISK BEARINGS
BEARING PLATED OF SEIZURE, OF
S WITH Pb, In CORROSION AIRCRAFT
RESISTANT, INDUSTRIES
 BEARING MATERIALS
MATERIAL COMPOSITION PROPERTIES APPLICATIONS

Al ALLOYS Al + Sn, Cu, TOUGH, BEARINGS

Ni, Fe, Si STRONG, OF IC
RESISTANC ENGINES,
E TO CONNECTIN
CORROSIO G ROD
N
GREY C-3-4%, WITH CARBON BEARINGS
CAST Si, Mn, P, , AS FOR
IRON BALANCE-Fe GRAPHITE REFRIGERAT
FLAKES, ORS,
HIGH TS COMPRESSO
RS, RAILWAY
COACHES
SELF TIN BRONZE MFG BY BEARINGS
LUBRICAT (90/10) POWDER OF FOOD,
ING META, PAPER
BEARING RETAINS INDUSTRIES
OIL IN
TIN & TIN ALLOYS
 TIN (Sn)
• SOFT, DUCTILE, MALLEABLE
• ATOMIC NO: 50, DENSITY: 7.30 g/cc
• MP: 232 C
• GOOD CORROSION RESISTANCE
• ROOM TEMPERATURE: TETRAGONAL STRUCTURE
• TWINNING OF CRYSTALS DURING BENDING: CRYING OF TIN
TIN & TIN ALLOYS : APPLICATIONS
• TIN COATING ON STEELS, Cu, BRASSES

• TIN SOLDERS

• TIN BRONZE

• BEARING MATERIALS: TIN BASED BABBITS

Pb & Pb ALLOYS
LEAD (Pb)
• SOFT, DUCTILE, MALLEABLE, FCC

• MP : 327 C

• LOW CONDUCTIVITY, HIGH CORROSION RESISTANCE

• HOT WORKED AT ROOM TEMPERATURE

LEAD : Pb-Sn EQB DIA
LEAD & LEAD ALLOYS
• EUTECTIC COMPOSITION OF Pb-Sn: TINMAN’S SOLDER OR QUICK
SOLDER, DUE TO ITS FAST SOLIDIFICATION
• USED FOR SOLDERING IN ELECTRICAL DEVICES
• PLUMBER’S SOLDER (Pb:67%) USED FOR JOINING OF LEAD PIPES,
CABLE SHEATHS
• TERNE METAL ( Sn: 10-25%): COATING STEEL, FUEL TANKS
LEAD & LEAD ALLOYS:
FUSIBLE ALLOYS

APPLICATIONS: FUSIBLE PLUGS IN

BOILER, ELECTRICAL FUSES,
PRESSURE COOKER PLUG
NICKEL
• Ni- MP:1453 C, DENSITY: 8.9g/cc, AT.No-28

• GOOD DUCTILITY, MALLEABILITY, FCC STR

• HIGH CORROSION & OXIDATION RESISTANCE

• BETTER FORMABILITY

• FAIRLY GOOD ELECTRICAL CONDUCTIVITY

NICKEL ALLOYS
1. DURA NICKEL
2. PERMA NICKEL
3. HASTELLOY D
4. INVAR
5. ELINVAR
6. Ni-Cr-Fe ALLOYS
7. INCONEL
8. INCONEL X
9. PERMALLOY
10. ALNICO
NICKEL ALLOYS
ALLOY COMPOSITION PROPERTIES APPLICATIONS
DURA NICKEL Al-5%, WITH C, GOOD CORROSION BELLOWS,
Mn, Si, Fe, RESI., COLD DIAPHRAGMS
WORKED
PERMA NICKEL 2% C, Mn, S, Si, GOOD ELECTRICAL, WHERE HIGH
Fe, Ti MAGNETIC ELECTRICAL
PROPERTIES, HIGH CONDUCTIVITY
THERMAL REQUIRED
CONDUCTIVITY

HASTELLOY D Si-10, Cu-3% BETTER STRENGTH, EVAPORATORS,

TOUGHNESS, REACTION
HARDNESS, VESSELS
CORROSION
RESISTANCE
NICKEL ALLOYS
ALLOY COMPOSITION PROPERTIES APPLICATIONS
MONEL Cu-30, Si-2% GOOD MARINE
CORROSION CASTINGS,
RESI., CASTING VALVES
PROPERTIES

INVAR Fe-64% LOWEST COEFF MEASURING

(INVARIABLE) OF THERMAL INSTRUMENTS,
EXPANSION CONDENSERS,
SPRINGS

ELINVAR Cr- 12, Fe-52% CONSTANT SPRINGS FOR

ELASTIC DIFFERENT
MODULUS APPL
NICKEL ALLOYS
ALLOY COMPOSITION PROPERTIES APPLICATIONS
Ni-Cr-Fe Cr-16%, Fe- GOOD CORROSION ELECTRICAL
ALLOYS 24% RESI., ELECTRICAL, HEATING
THERMAL ELEMENTS,
CONDUCTIVITY FURNACE PARTS

INCONEL Cr- 15%, Fe-8% GOOD CORROSION FURNACES,

RESI., GOOD STRENGTH HEATERS,
AT HIGH TEMPERATURE THERMOCOUPLES
INCONEL Cr + Fe +Ti + Al GOOD STRENGTH AT GAS TURBINES,
X HIGH TEMPERATURE SUPERCHARGERS
NICKEL ALLOYS
ALLOY COMPOSITION PROPERTIES APPLICATIONS
PERMALLOY Fe-22% GOOD RADIO
MAGNETIC TRANSMITTERS,
PERMEABILITY, COMMUNICATION
LOW CIRCUITS
HYSTERESIS
LOSS

ALNICO Al + Ni + Co EXCELLENT PERMANENT

MAGNETIC MAGNETS,
PROPERTIES GENERATORS