IT 111 NonFerrous Metals

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IT 111 Non-Ferrous Metals

• Lecture 5
• Thomas E. Scott

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Non Ferrous MetalsUsed in Industry

• Aluminum
• Chromium
• Copper
• Zinc
• Lead

• Tin
• Magnesium
• Nickel
• Titanium
• Light metals

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Aluminum

• Found in earths crust in bauxite
• One of the most abundant elements
• Easily fabricated
• Lightweight
• Corrosion resistant
• Conducts electricity
• Transmits heat rapidly
• Low melting point approx 1200F

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Aluminum from ore

• Bauxite Hydrated Alumina (AL2O3 H20)
• Bayer Method 9KW per pound
• 5 if recycled

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Aluminum

• Yield strength of 5000 psi
• Ultimate 13000 psi
• 45 elongation
• Poor wear resistance
• Poor fatigue and creep strength
• Difficult to Weld expansion, heat dissipation
• Properties can be modified by heat treating

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Endurance Limit

• Cyclic Life
• No Endurance Limit
• Must use higher Safety Factor

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Welding

• Temperature Heat Dissipation
• Stress Corrosion
• Need strengthening approach
• Butts
• Lugs
• Gussets

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Aluminum

• Improved by adding alloys
• Copper (hardenability, strength, anti-corrosion)
• Reduces elongation, increases cost
• Manganese (strength and anti-corrosion)
• Silicon (reduces shrinkage in casting)
• Magnesium (improve machinability)
• Zinc (high strength, machinability, casting)

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Aluminum

• Aluminum Association (AA) numbering
• 1xxx - gt 99 Aluminum
• 2xxx Copper alloy
• 3xxx Manganese
• 4xxx Silicon
• 5xxx Magnesium
• 6xxx Magnesium and Silicon
• 7xxx - Zinc

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Aluminum Examples

• 1060 99.6 pure Aluminum
• 3003 1-1.5 Manganese 50 increase in
  strength
• 4043 Weldable grade contains silicon
• 6063 Extrusion grade windows, doors
• 2011 Free macining contains copper

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Aluminum Heat Treat Designatore.g., 2024-T6

• O Annealed
• F As fabricated
• H Work hardened
• T Tempered
• e.g., 6061-H2 means ,Magnesium and Silicon alloy
  work hardened and partially annealed

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Aluminum Casting Alloys

• Three digit (e.g., 108, 356, etc)
• Up to 99 silicon casting alloys
• Engine blocks and pistons
• 100 to 199 silicon-copper
• 200-299 magnesium
• 300-399 silicon-manganese
• Aluminum susceptible to hot-short, cracking and
  tearing when hot

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Chromium

• Used in stainless steel
• Alloy for high strength steels

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Copper

• Thermal and electrical conductivity
• Used for gas lines, radiators, heat exchangers,
  chemical process equipment
• Brass
• Copper and zinc improved strength, ductility
• Lead with zinc improved machinability
• Bronze
• Copper and tin strength, workability, hardness
  and ductility. More costly.

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Other metals

• Lead low melting point
• Mostly an additive in other metals
• Tin corrosion resistant (food cans)
• Mostly coating other metals
• Zinc high strength
• Mostly an additive in other metals
• Die casting of automotive parts

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Other metals

• Magnesium strong, used with other metals where
  light weight is important
• Weighs 2/3 of aluminum
• Extension ladders, aircraft, power tools
• Active metal burns with extremely hot flame
• Titanium Lightweight, strong
• Aircraft industry, bicycles

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Other Metals

• Nickel resembles steel in many properties
  highly compatible with steel
• Similar melting point and thermal expansion
• Alloying element for hardness in steels
• When combined with copper, called a monel
• Coins
• Hastelloys Nickel-Chromium-Iron
• Alumel 95 Nickel
• See Table 8 of Machinerys Handbook page 545

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Other metals