3. Non-ferrous materials
• When a metal is defined as non-ferrous it
means that it does not have a significant
amount of iron in its chemical composition.
• Non-ferrous metals are used because of
desirable properties such as low weight (e.g.,
aluminium), higher conductivity (e.g., copper),
non-magnetic property resistance to corrosion
(e.g., zinc).
4. • Important non-ferrous metals include
aluminium, copper, mangesium, lead, nickel,
tin, titanium, zinc,
• Precious metals such as, gold silver, platinum
• Exotic or rare metals such as, cobalt, mercury
tungsten, beryllium, bismuth, cerium
6. Aluminium
Source:-
• In the Earth's crust, aluminium is the most abundant (8.3%
by weight) metallic element and the third most abundant of
all elements (after oxygen and silicon).Because of its strong
affinity to oxygen, it is almost never found in the elemental
state; instead it is found in oxides or silicates.
• Aluminum compounds occur in all types of clay, but the ore
that is most useful for producing pure aluminum is bauxite.
Bauxite consists of 45-60% aluminum oxide, along with
various impurities such as sand, iron, and other metals.
• Caustic soda (sodium hydroxide) is used to dissolve the
aluminum compounds found in the bauxite, separating them
from the impurities. Depending on the composition of the
bauxite ore, relatively small amounts of other chemicals
may be used in the extraction.
7.
8. Properties:-
• Melting Point :- 660 (°C)
• Density :- 2.70 (g.cm-3)
• Thermal emissivity at 100°F (%):- 3.0
• Thermal conductivity (cal.sec-1cm-1K-1) :-
0.5
• Electrical conductivity at 20°C :- 64.94
• Latent heat of fusion, (kJ.kg-1) :- 397.0
• Specific heat at 100 °C, (Jkg-1K-1) :- 938
9. Durable:-
• Aluminium building products are made from alloys
that are weather-proof, corrosion-resistant and immune
to the harmful effects of UV rays, ensuring optimal
performance over a very long lifetime.
Flexible:-
• Aluminium’s combination of properties mean that it
can be easily shaped by any of the main industrial
metalworking processes, including rolling, extrusion,
forging and casting, guaranteeing virtually unlimited
design potential.
10. Light-weight:-
• Aluminium’s light weight makes it cheaper and easier to
transport and handle on site. Strong The use of aluminium
in buildings assists architects meet performance
specifications while minimising expenditure on
foundations. Alloyed aluminium can be as strong as steel at
only a third of the weight.
Corrosion Resistant:-
• Aluminium’s natural oxide coating provides an effective
protective barrier against elements that wear other metals.
Insular A layer of insulated aluminium siding is four times
more effective than uninsulated wood siding, four inches of
brick, or ten inches of stone masonry.
11. High strength-to-weight ratio:
• This unique property allows architects to meet
required performance specifications, while
minimising the dead load on a building’s
supporting structure. Thanks to the metal’s
inherent sturdiness, aluminium window and
curtain wall frames can be very narrow,
maximising solar gains for given outer
dimensions. Moreover, the material’s light weight
makes it easier to transport and handle
12. Recyclable:-
• Aluminium is 100% recyclable and uses only 5% of the energy
used to make the original product.
High reflectivity:
• This characteristic feature makes aluminium a very efficient
material for light management. Aluminium solar collectors can
be installed to lower energy consumption for artificial lighting
and heating in winter, while aluminium shading devices can be
used to reduce the need for air conditioning in summer.
13. Heat conductivity:-
• Aluminium is a good conductor of heat, which may be a
disadvantage in some applications. However, this property
can easily be overcome by the profile design and the use of
thermal breaks made of low conductivity materials.
14. • Molten aluminium is susceptible to:
• 1) Excess absorption of hydrogen gas
(embrittlement)
• 2) Oxidation of the melt to form complex
oxides of Mg, Na, Ca, Sr (affecting mechanical
properties) as films or particles
• 3) Inclusions in forms of borides, oxides,
carbides and non-metallic particle, i.e.,Al2C3
(found d in all Al alloys):- stress concentration
Metallurgical factors affecting melting of
aluminium:-
16. • Aluminium extruded, rolled, and cast products are
commonly used for window frames and other glazed
structures ranging from shop fronts to large roof
superstructures for shopping centres and stadiums; for
roofing, siding, and curtain walling, as well as for cast door
handles, catches for windows, staircases, heating and air-
conditioning systems. Most recently, aluminium has played
a significant role in the renovation of historic buildings.
17. • Column Casing
• Unitised Cladding
• Rain screen Cladding
• I-Line Snap On
• C-Fix Secret Fix Coping System
• Aluminium in Eaves System
• Aluminium Doors, Window Frames
• Aluminium Furniture's
• Aluminium Partition Walls
19. Copper:-
• Copper is an element and a mineral called native copper.
• Found in Chile, Indonesia and USA.
• Found in Loei and Khonkhan (but not much)
• Copper is an industrial metal and widely used in unalloyed
and alloyed conditions (second ranked from steel and
aluminium).
20. Smelting of copper
• Copper that is mined from copper ore, after beneficiation,
becomes high quality copper concentrate. Then, after being
smelted, refined copper and copper products are yielded.
• There are two ways of smelting copper, one is
pyrometallurgy, the other hydrometallurgical. Nowadays,
the main smelting method is pyrometallurgy, which
accounts for 85% of output in the world.
21. • Pyrometallurgy usually adopts original ore, in which its
content can reach 20%-30% after mineral processing.
Copper concentrate is put into an airtight blast furnace,
reverberatory, electric furnace, or flash furnace for matte
smelting.
• The output of molten matte is then put into the converter
for converting into a blister copper, and next into another
kind of reverberatory. Following oxidation refining complex
or casting anodes for the purpose of electrolysis, electrolytic
copper with grade of up to 99.9% is finally produced.
• The process is short and with strong adaptability, and
copper recovery rates can reach 95%. However, because
sulfur escapes as waste gas, and is not easy to recycle,
pollution can easily result.
26. • Corrosion Resistance – this metal is highly resistant to
corrosion and copper alloys have been found in near-perfect
condition after being buried for millennia.
• Conductivity – copper is a great electrical and thermal
conductor, which is why it’s often used for electrical wiring
• Anti-Bacterial – copper compounds have been used as
bacteriostatic agents and fungicides, as well as wood
preservatives. This metal’s hygienic properties make it
useful to slow down the growth of bacteria like E-coli,
legionella and MRSA.
• Non-Magnetic – this is a non-ferrous metal, which
makes it useful for military applications, for instance.
Properties:-
27. • Easy to Alloy – another property that makes copper so
sought-after is its ability to easily alloy with other metals,
like zinc, tin and nickel.
• Malleability and Ductility – copper is easy to work with,
mainly when it comes to fabricating and joining.
• Patina – a green layer of copper sulfate that forms on the
surface of the metal due to corrosion; however, this layer is
protective and prevents the metal from becoming more
deteriorated.
• Attractive Colour:- Copper and its alloys, such as brass,
are used for jewellery and ornaments. They have an
attractive golden colour which varies with the copper
content. They have a good resistance to tarnishing making
them last a long a time
28. Application:-
• Copper is a kind of non-ferrous metal which has long been
closely connected to human beings. Not only are there
abundant resources in nature, but copper also possesses
excellent properties. Therefore, it is widely used in electrical
power, electronics, energy, petrochemicals, transportation,
machinery, metallurgy, light and other new industries and
some high-tech fields.
29. • electrical power industry:- wire and cable, transformers,
switches, plug components and connectors
• electronics industry :- high frequency and ultra high
frequency tubes, crossing the catheter, magnetron, etc.
• energy and petrochemical industries :- Solar heaters, pipe
systems, filters, pumps and valves, all sorts of evaporators and
condensers
30. • transportation industry :- trains, the motors, rectifiers and
controls, brakes, electrics and signal systems also rely on
copper and its alloys
• mechanism and metallurgy industries :- cylinder liners,
gears, fittings, fasteners, twisting, etc.
• light industry : air conditioners, clock movements,
gridding cloth of paper machines, copper plate printing,
fermentation tank lining, distillation pots and architectural
decoration components, etc.
31.
32.
33. List of companies producing copper in India
• Hindustan Copper Limited
• Hindalco Industries Limited (Birla Copper)
• Sterlite Industries Limited
• Jhagadia Copper Limited
• Nissan Copper Limited India
• Gujarat copper Alloys Limited
35. Magnesium:-
• Greek word "Magnesia", a district of Thessalyin Greece where
magnesia alba [magnesium carbonate] was found.
• Shiny, silver or gray colored appearance
• Fifth most abundant element in the hydrosphere (3.1×1015
tons)
• Eighth most abundant element in the earth’s crust
• An alkaline earth metal with atomic number 12
• Hexagonal close-packed (HCP) crystal structure
36. Extraction of magnesium
• Extraction of magnesium:-
- Calcination
- Pidgeonprocess
- Dow process
• Fabrication of magnesium alloys:-
- Casting:- sand casting, die casting,
- Forming processes:- rolling, forging , extrusion
38. CHEMICAL PROPERTIES OF MAGNESIUM
• Atomic Number = 12
• Atomic Mass = 24.31
• Combines with oxygen at room temperature to
form a thin skin of magnesium oxide
• Very reactive towards the halogens such as
chlorine or bromine
• Burns in air with a characteristic blinding bright
white flame to give a mixture of white MgO &
Mg3N2
• Reacts with water to produce hydrogen gas
• Flammable
• Non-toxic towards environment
39. MECHANICAL PROPERTIES OF MAGNESIUM
• Highest strength-to-weight ratio (specific
strength)
• Good thermal conductivity
• High stiffness
• Exceptional dampening capacity
• Ease of machining at high speeds
• Excellent castability 9
40. DESIGN OF MAGNESIUM ALLOYS
• Strength :-
A) Al, Zn, Ca, Ag, Ce, Ga, Ni, Cu, Th
• Ductility :-
B) Th, Ga, Zn, Ag, Ce, Ca, Al, Ni, Cu
• Less strengthening but more ductility :-
C) Cd, Tl (Thallium), Li
• Considerable strengthening at cost of ductility :-
D) Sn (Tin), Pb, Bi, Sb (Antimony)
• Creep resistance :-
E) Y (Yttrium), Nd (Neodymium), Sr (Strontium)
• Formability :-
F) Li, RE, Y, Sr
• Corrosion Resistance :-
G) Al, Mn, Ca, RE, Sr
41. SAND & PERMANENT MOLD CASTING ALLOYS
1) Mg-Al-Mn with and without zinc (AM and AZ)
2) Mg-Zr (K)
3) Mg-Zn-Zr with and without rare earths (ZK, ZE, and EZ)
4) Mg-Th-Zr with and without zinc (HK, HZ, and ZH)
5) Mg-Ag-Zr with rare earths or thorium (QE and QH)
6) Mg-Y-RE-Zr (WE)
7) Mg-Zn-Cu-Mn (ZC)
42. WROUGHT MAGNESIUM ALLOYS
• Produced as bars, billets, wire, sheet, plate and forgings.
• Most common wrought Mg alloys:-
AZ31
AZ61
AZ80
ZK60
HM21
HK31
Heat-treatable and may be strengthened by
precipitation hardening. Good workability in hot
state, moderate mechanical strength and good
weldability. Applications - aircraft fuselage,
computer cases, super-plastic sheets.
Zr refines grain structure & Zn increases strength.
Very high mechanical strength combined with poor
weldability and workability even in hot state.
Applications - high strength forged and extruded
parts, bicycle frames, road wheels, helicopters
gears, parts of satellites.
44. Applications of Magnesium Alloys
Sports
Industry
Manufacturing of Sports Equipment
Medical
Industry
Manufacturing of Orthopaedic
Biomaterials
Automotive
Industry
Manufacturing of light weight frames for
mobile, laptop, cameras
Electronic
Industry
Manufacturing of clutch and brake pedal support brackets,
transmission housings, steering components
Machine
Tools
Manufacturing of housings for hand held saws and power
nailers, material handling equipment, textile and printing
machine parts
Applications:-
