1. Materials Engineering
Lecture 10:
Non-ferrous alloys.
Fabrication of metals

2. Problems of ferrous alloys
Heavy (high density)
Easily corrode
Low electrical conductivity

3. Non-ferrous alloys Fabrication Cast alloys Wrought alloys
According to base metal
Copper
Aluminum
Magnesium
Titanium
Refractory (Nb, W, Mo, Ta)
Superalloys
Noble metals
Miscellaneous
Fabrication
Cast alloys
Wrought alloys

4. Copper
Copper: very soft, ductile, excellent heat and electricity conductor, excellent resistance to corrosion, easily cold-processed; heavy, difficult to machine.
OFHC (oxygen-free high thermal conductive) copper (99.99% purity): high ductility, high electrical and thermal conductivity, high impact strength, good creep resistance, ease of welding, and low volatility under high vacuum.

5. Copper –Zinc System a-phase: FCC, mild, ductile, easily cold worked;
b’-phase: BCC, hard, strong, hot workable
Brasses: a+b’

6. Copper Alloys
Brasses: Cu + Zn (+…); structure a+b’: harder and stronger than Cu
Bronze: Cu + Sn, Al, Si, Ni
Applications
Ductil., %EL in 50 mm
Y. Str., MPa
Tens. Str., MPa
condition
Composition, %
UNS
Name
Electrical wires, gaskets, pans, nails 45 69
220
annealed
0.04 O
C11000
Electrolytic tough pitch
Springs, bellows, bushings, valves
4-10
Precipitation hardened
1.9Be, 0.20Co
C17200
Beryllium copper
Automobile radiators, ammunition 68 8 75
435
300
525
Annealed,
Cold worked
30Zn
C26000
Cartridge brass
Bellows, clutch disks, fuse clips, springs, welding rods 64 10
130
515
325
560
5Sn, 0.2P
C51000
Phosphor bronze, 5% A
Heat-exchangers, salt-water piping 36 15
125
485
380
30Ni
C71500
Copper-Nickel 30%
Furniture hardware, battery clamps 35 83
234
As cast
29Zn, 3Pb, 1Sn
C85400
Leaded yellow brass
Bearings, bushings, rings, gears 25
152
310
10Sn, 2Zn
C90500
Tin bronze
Bearings, bushings, valve seats, hooks 18
241
586
4Fe, 11Al
C95400
Aluminum bronze

7. Aluminum and aluminum alloys
Aluminum: low density, high ductility, high electrical and thermal conductivity, high corrosion resistance in ambient atmosphere; FCC, ductile at all temperatures; m.p.=660ºC.
Applications
Ductil., %EL in 50 mm
Y. Str., MPa
Tens. Str., MPa
condition
Composition, %
UNS
Aluminum Association
Food, Chemicals storage and handling, heat exchangers, light reflectors
35-45 35 90
Annealed (O)
0.12Cu
A91100
1100
Cooking utensils, pressure vessels and piping
30-40 40
110
0.12Cu, 1.2Mn, 0.1Zn
A93003
3003
Aircraft fuel and oil lines, fuel tanks, wire
12-18
195
230
Strain hardened (H32)
2.5Mg, 0.25Cr
A95052
5052
Aircraft structures, rivets, truck wheels 20
325
470
Heat treated (T4)
4.4Cu, 1.5Mg, 0.6Mn
A92024
(duralumin)
2024
Trucks, canoes, railroad cars, furniture, pipelines
22-25
145
240
1.0Mg, 0.6Si, 0.30Cu, 0.20Cr
A96061
6061
Highly stressed applications: aircraft structural parts 11
505
570
Heat treated (H6)
5.6Zn, 2.5Mg, 1.6Cu, 0.23Cr
A97075
7075
Wheels, housings
8.5
221
4.5Cu, 1.1Si
A02950
295.0
Pumps, transmission cases, cylinder blocks
3.5
164
228
Heat treated (T6)
7.0Si, 0.3Mg
A03560
(silumin)
356.0
Aircraft structures, cryogenics 5
455
Heat treated cold-worked (T83)
2.7Cu, 0.25Mg, 2.25Li, 0.12Zr -
2090
Fabrication signs: F (fabricated): as is, O (oxygen): annealed, H (hardened): strain-hardened; T (tempered): combination.
T3 = heat treated + cold worked + aged; T6 = heat treatment + artificial aging

8. Magnesium and magnesium alloys
Very light (1.7 g/cm3), soft, HCP; difficult for cold work => hot working; m.p. 651ºC; corrodes (especially in sea water)
Applications
Ductil., %EL in 50 mm
Y. Str., MPa
Tens. Str., MPa
condition
Composition, %
UNS
ASTM
Structures, tubing, cathode protection 15
200
262
As extruded
3.0Al, 1.0Zn, 0.2Mn
M11311
AZ31B
High strength to 315ºC 9
255
Strain-hardened, partially annealed
3.0Th, 0.6Zr
M13310
HK31A
Maximum strength (aircrafts) 11
285
350
Artificially aged
5.5Zn, 0.45Zr
M16600
ZK60A
Cast automobile parts, electronic devices 3
150
230
As cast
9.0Al, 0.15Mn, 0.7Zn
M11916
AZ91D
Automobile wheels 6
130
220
6.0Al, 0.13Mn
M10600
AM60A
Die castings
140
210
4.3Al, 1.0Si, 0.35Mn
M10410
AS41A

9. Titanium and titanium alloys
Light (4.5 gr / cm3), high m.p. (1668ºC), very strong, elastic, ductile, easily machined; corrodes at elevated temperatures, poor conductor for heat and electricity.
Applications
Ductil., %EL in 50 mm
Y. Str., MPa
Tens. Str., MPa
condition
Composition, %
UNS
Alloy type
Jet engine shrouds, airframe skins 25
414
484
annealed
99.1% Ti
R50500
pure
Gas turbine engines, chemical engineering; stable to 480ºC 16
784
826
5Al, 2.5Sn
Ti-5Al-2.5Sn
(R54520) a
Jet engine components 15
890
950
8Al, 1Mo, 1V
Ti-8Al-1Mo-1V
(R54810)
~ a
Implants, chemical engineering 14
877
947
6Al, 4V
Ti-6Al-4V
a-b
Rocket engine cases
985
1050
6Al, 6V, 2Sn
Ti-6Al-6V-2Sn
Best combination of properties 10
1150
1223
Solution + aging
10V, 2Fe, 3Al
Ti-10V-2Fe-3Al b
a-phase: HCP
b-phase: BCC

10. Refractory metals
W (3410ºC), strong, hard; brittle, corrodes at elevated temperatures (>200ºC)
Mo (2623ºC), strong, hard; brittle, burns at elevated temperatures (>600ºC)
Nb (2468ºC), soft, ductile, stable to corrosion
Ta (3017ºC), strong, hard; extremely stable to corrosion

11. Superalloys
A superalloy, or high-performance alloy: an alloy that exhibits excellent mechanical strength and creep resistance at high temperatures, good surface stability, and corrosion and oxidation resistance.
Superalloys typically have a matrix with an austenitic FCC crystal structure.
A superalloy's base alloying element is usually Ni, Co, or Ni-Fe.
Typical applications are in the aerospace, industrial gas turbine and marine turbine industry, e.g. for turbine blades for hot sections of jet engines.

12. Noble metals Ag: electronics Au: extremely plastic; electronics
Pt: chemical ware, catalysts Pd Rh Ru Ir Os

13. Metal Fabrication Techniques
ריתוך מטלורגיית אבקות יציקה רציפה יציקה לתבנית הטבעה יציקה לחול משיכה שיחול ערגול חישול
Cold working: below the recrystallization temperature (~ m.p.)
Hot working: above the recrystallization temperature

15. Casting
Sand casting
Die casting
Investment casting
Continuous casting

16. Powder metallurgy Compaction of metal powders Refractory metals
Exact shape
Low ductility

17. Welding Gas welding Arc welding
In HAZ (heat-affected zone) recrystallyzation, grain growth; austenitization

18. Thermal processing of metals: annealing
Annealing (הרפיה): long heat treatment + slow cooling
Relieve stresses
Increase softness, ductility and toughness
Produce specific microstructure
Process annealing: to negate the effect of cold work
Normalizing: to refine the grains and produce uniform distribution;
Full annealing: to from coarse pearlite, soft and ductile (low and medium C steels)
Spheroidizing: pearlite --< spheroidite; softer and more machineable (high С steels)

19. Hardenability and Quenching
Hardenability: the ability of an alloy (steel) to be hardened by the formation of martensite as a result of heat treatment.

20. Quenching (צינון)
Severity of quenching: water > oil > air

21. Precipitation Hardening
Precipitation hardening: addition of small particles of a second phase
Solution heat treating: a solid solution is formed
Precipitation heat treating: solution + aging: formation of fine dispersed particles
Aging: slow formation of a second phase after quenching; gives very fine dispersed structure.

22. Musts of this lecture Non-ferrous alloys (main groups, properties)
Fabrication of metals: deformations techniques, casting, powder metallurgy, welding
Annealing
Quenching
Precipitation hardening