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Chapter 5 Applications and Processing (Part 2)

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40 views23 pages

Chapter 5 Applications and Processing (Part 2)

Uploaded by

Andrei Ricafort
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Applications and Processing

of Metal Alloys (Non-


ferrous)

By: Engr. Jordan L. Ronquillo RMEE


Objectives
• Name four different types of steels and cite compositional
differences, distinctive properties, and typical uses for each.
• Name the five cast iron types and describe the microstructure
and note the general mechanical characteristics for each.
• Name seven different types of nonferrous alloys and cite the
distinctive physical and mechanical characteristics and list at
least three typical applications for each.
• Name and describe four forming operations that are used to
shape metal alloys.
• Name and describe five casting techniques.
Objectives
• State the purposes of and describe procedures for the
following heat treatments: process annealing, stress relief
annealing, normalizing, full annealing, and spheroidizing.

• Define hardenability.
Fundamental Concepts

Steel and other ferrous alloys are consumed in exceedingly large quantities
because they have such a wide range of mechanical properties, may be
fabricated with relative ease, and are economical to produce.

Limitations:

(1) a relatively high density,


(2) comparatively low electrical conductivity, and
(3) an inherent susceptibility to corrosion in some common environments.
Fundamental Concepts

This section discusses the following metal and alloy systems: copper,
aluminum, magnesium, and titanium alloys; the refractory metals; the
superalloys; the noble metals; and miscellaneous alloys, including those that
have nickel, lead, tin, zirconium, and zinc as base metals.

Alloys that are so brittle that forming or shaping by appreciable deformation


is not possible typically are cast; these are classified as cast alloys. However,
those that are amenable to mechanical deformation are termed wrought
alloys.
Fundamental Concepts
Non-Ferrous Alloys
Copper and Its Alloys

Copper and copper-based alloys, possessing a desirable combination of


physical properties, have been used in quite a variety of applications since
antiquity. Unalloyed copper is so soft and ductile that it is difficult to
machine.

The most common copper alloys are the brasses, for which zinc, as a
substitutional impurity, is the predominant alloying element.

Some of the common brasses are yellow, naval, and cartridge brass;
muntz metal; and gilding metal.
Non-Ferrous Alloys
Some of the common uses for brass alloys include costume jewelry,
cartridge casings, automotive radiators, musical instruments, electronic
packaging, and coins.

Bronze

The bronzes are alloys of copper and several other elements, including tin,
aluminum, silicon, and nickel. These alloys are somewhat stronger than
the brasses, yet they still have a high degree of corrosion resistance.
Fundamental Concepts
Non-Ferrous Alloys
Aluminum and Its Alloys

Aluminum and its alloys are characterized by a relatively low density, high
electrical and thermal conductivities, and a resistance to corrosion in some
common environments, including the ambient atmosphere.

Common applications of aluminum alloys include aircraft structural parts,


beverage cans, bus bodies, and automotive parts (engine blocks, pistons, and
manifolds). (see table 11.8)

*A generation of new aluminum–lithium alloys have been developed recently for use by the
aircraft and aerospace industries. These materials have relatively low densities (between
about 2.5 and 2.6 g/cm3), high specific moduli (elastic modulus– specific gravity ratios), and
excellent fatigue and low-temperature toughness properties.
Fundamental Concepts
Non-Ferrous Alloys
Magnesium and Its Alloys

Perhaps the most outstanding characteristic of magnesium is its density, 1.7


g/cm3, which is the lowest of all the structural metals; therefore, its alloys
are used where light weight is an important consideration (e.g., in aircraft
components).

Magnesium, like aluminum, has a moderately low melting temperature


Chemically, magnesium alloys are relatively unstable and especially
susceptible to corrosion in marine environments.

However, corrosion or oxidation resistance is reasonably good in the normal


atmosphere; it is believed that this behavior is due to impurities rather than
being an inherent characteristic of Mg alloys. (See table 11.9)
Non-Ferrous Alloys
These alloys are also classified as either cast or wrought, and some of
them are heat-treatable. Aluminum, zinc, manganese, and some of the
rare earths are the major alloying elements.

These alloys are used in aircraft and missile applications, as well as in


luggage.

Magnesium is employed in a variety of handheld devices (chainsaws,


powertools, hedge clippers), automobiles (steering wheels and columns,
seat frames, transmission cases), and audio, video, computer, and
communications equipment (laptop computers, camcorders, TV sets,
cellular telephones).
Non-Ferrous Alloys
Titanium and Its Alloys

Titanium and its alloys are relatively new engineering materials that possess
an extraordinary combination of properties. The pure metal has a relatively
low density (4.5 g/cm3), a high melting point and an elastic modulus of 107
GPa (15.5 x 106 psi).

Titanium alloys are extremely strong; room-temperature tensile strengths as


high as 1400 MPa (200,000 psi) are attainable, yielding remarkable specific
strengths. Furthermore, the alloys are highly ductile and easily forged and
machined.
Non-Ferrous Alloys
3 types of Titanium Alloys

The α-titanium alloys, often alloyed with aluminum and tin, are preferred
for high temperature applications because of their superior creep
characteristics.

The β-titanium alloys contain sufficient concentrations of stabilizing


elements (V and Mo) such that, upon cooling at sufficiently rapid rates, the
(metastable) retained at room temperature. These materials are highly
forgeable and exhibit high fracture toughnesses.

The α + β materials are alloyed with stabilizing elements for both constituent
phases. (see table 11.10)
Non-Ferrous Alloys
Titanium alloys are commonly used in airplane structures, space
vehicles, surgical implants, and in the petroleum and chemical
industries.

The Refractory Metals

Metals that have extremely high melting temperatures are classified as


refractory metals. Included in this group are niobium (Nb), molybdenum
(Mo), tungsten (W), and tantalum (Ta). The applications of these metals are
varied.
Non-Ferrous Alloys
The Superalloys

The superalloys have superlative combinations of properties. Most are used


in aircraft turbine components, which must withstand exposure to severely
oxidizing environments and high temperatures for reasonable time periods.

These materials are classified according to the predominant metal(s) in the


alloy, of which there are three groups—iron–nickel, nickel, and cobalt. Other
alloying elements include the refractory metals (Nb, Mo, W, Ta), chromium,
and titanium. Furthermore, these alloys are also categorized as wrought or
cast.
Non-Ferrous Alloys
The superalloys have superlative combinations of properties. Most are used
in aircraft turbine components, which must withstand exposure to severely
oxidizing environments and high temperatures for reasonable time periods.

These materials are classified according to the predominant metal(s) in the


alloy, of which there are three groups—iron–nickel, nickel, and cobalt. Other
alloying elements include the refractory metals (Nb, Mo, W, Ta), chromium,
and titanium. Furthermore, these alloys are also categorized as wrought or
cast.

* In addition to turbine applications, superalloys are used in nuclear reactors and


petrochemical equipment.
Non-Ferrous Alloys
The Noble Metals

The noble or precious metals are a group of eight elements that have some
physical characteristics in common. They are expensive (precious) and are
superior or notable (noble) in properties—characteristically soft, ductile, and
oxidation resistant.

The noble metals are silver, gold, platinum, palladium, rhodium, ruthenium,
iridium, and osmium.

Alloys of both silver and gold are employed as dental restoration materials.
Some integrated circuit electrical contacts are of gold. Platinum is used for
chemical laboratory equipment, as a catalyst (especially in the manufacture
of gasoline), and in thermocouples to measure elevated temperatures.
Non-Ferrous Alloys
Miscellaneous Nonferrous Alloys

Nickel and its alloys are highly resistant to corrosion in many environments,
especially those that are basic (alkaline). Nickel is often coated or plated on
some metals that are susceptible to corrosion as a protective measure.

Monel, a nickel-based alloy containing approximately 65 wt% Ni and 28 wt%


Cu (the balance is iron), has very high strength and is extremely corrosion
resistant; it is used in pumps, valves, and other components that are in
contact with acid and petroleum solutions.
Non-Ferrous Alloys
Lead, tin, and their alloys find some use as engineering materials. Both lead
and tin are mechanically soft and weak, have low melting temperatures, are
quite resistant to many corrosion environments.

Applications for lead and its alloys include x-ray shields and storage batteries.
The primary use of tin is as a very thin coating on the inside of plain carbon
steel cans (tin cans) that are used for food containers; this coating inhibits
chemical reactions between the steel and the food products.

Galvanized steel is just plain carbon steel that has been coated with a thin zinc
layer; the zinc preferentially corrodes and protects the steel Typical applications
of galvanized steel are familiar (sheet metal, fences, screen, screws, etc.).
Common applications of zinc alloys include padlocks, plumbing fixtures,
automotive parts (door handles and grilles), and office equipment.
Non-Ferrous Alloys
Zirconium and its alloys are ductile and have other mechanical characteristics
that are comparable to those of titanium alloys and the austenitic stainless
steels.

Zirconium is transparent to thermal neutrons, so that its alloys have been used
as cladding for uranium fuel in water-cooled nuclear reactors. In terms of cost,
these alloys are also often the materials of choice for heat exchangers, reactor
vessels, and piping systems for the chemical-processing and nuclear industries.
They are also used in incendiary ordnance and in sealing devices for vacuum
tubes.
Fabrication of Metals
(Reading Activity)

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