01_Introduction to Nonferrous Metallurgy

Suranaree University of Technology May-Aug 2007

Nonferrous metallurgyNonferrous metallurgy

Subjects of interest

• Overviews of nonferrous metals

• Aluminium and aluminium alloys

• Magnesium and magnesium alloys

• Titanium and titanium alloys

• Copper and copper alloys

• Zinc and its alloys

• Nickel and its alloys

• Other significant alloys

Lecture 1

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Course instruction

Lecturer: Dr. Tapany Udomphol

Assessment

Assignment/quiz 20 %

Midterm exam 40 %

Final exam 40 %

Total 100 %

Nonferrous metallurgyNonferrous metallurgy

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ObjectivesObjectives

• This course provides fundamental knowledge of metals

other than ferrous metals, for example aluminium,

magnesium, copper, zinc, titanium and nickel alloys, which

are significant for commercial uses.

• This starts with when the metals are extracted, melted and

formed in relation to their final applications. More importantly,

the nature of the alloys associated with their physical and

mechanical properties will be highlighted.

• The selection of nonferrous alloys for the desired

applications will be discussed such that the exploitation of

nonferrous metals will be at its best.

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Overview of nonferrous metalsOverview of nonferrous metals

Nonferrous

Light weight

Stiffness –strength to weight ratio

High temperature properties

Corrosion resistance

Biocompatibility

Oxidation resistance

High cost

Why nonferrous?Why nonferrous?

Depending on extraction

and production Thermal/electrical conductivity

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Nonferrous metalsNonferrous metals

• Aluminium and its alloys

• Magnesium and its alloys

• Titanium and its alloys

• Copper and its alloys

• Zinc and its alloys

• Nickel and its alloys

There are different types of nonferrous metals which are

commercially used;

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World consumptionWorld consumption

• Aluminium, titanium and

magnesium alloys are

increasingly used in recent years

due to its attractive properties.

• The reserves for these alloys are

adequate for demands in centuries

to come but will be controlled by

future cost.

World production figure for

various metals and plastics.

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Major chemical elements Major chemical elements

available in earthavailable in earth

Aluminium is the most abundant metal in earth.

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Density of metalsDensity of metals

Metal Density (g.cm-3)

Iron 7.87

Steel 7.80

Aluminium 2.70

Magnesium 1.74

Titanium 4.54

Copper 8.96

Zinc 7.13

Nickel 8.89

Lead 11.36

Silver 10.49

Gold 19.32

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Total energy consumption for the Total energy consumption for the

production of nonferrous metalsproduction of nonferrous metals

Total energy consumption in megawatt

hours for each stage of production (1993).

Total energy consumption

Ti > Mg > Al > Cu > Zn > Steel

The energy consumption is

mainly paid in the

reduction process.

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Mechanical properties in comparisonMechanical properties in comparison

Relationship of specific 0.2% proof stress with temperature.

• Titanium alloys have superior specific strength than

steels or aluminium � good for high strength where

space is critical such aircrafts.

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Aluminium and its alloysAluminium and its alloys

Advantages: Applications

• Building/construction

• Container

• Packaging

• Transportation

• Electrical conductors

• Machinery/equipment

• Light weight

• High corrosion resistance

• High electrical and thermal

conductivities

• High ductility

• Easily deformable

Light-weight bike

Car body

Building/

construction

Containers

EquipmentTapany Udomphol


Magnesium and its alloysMagnesium and its alloys


Disadvantages:

• Weight saving

• High machinability

• Used as alloying element for

aluminium, steel and nodular (SG)

cast iron.

• Die casting for aerospace

• Transport industry.

• Light weight bodies.• Difficulty in melting process

due to high reactivity.

Magnesium side panels

Handy cam & mobile

phone bodies

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Titanium and its alloysTitanium and its alloys


• High strength to weight ratio

• Moderate-high temperature

properties

• Corrosion resistance

• Biocompatibility

• Shape memory

Disadvantages:

• High cost

• Difficulty in extraction

• Limited in high performance

applications

• Structure of high speed aircrafts

• 75% in aerospace

• Chemical industry

Hip-joint component

www3.lehigh.edu

Turbine blades

National science centre, Scotland

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Copper and its alloysCopper and its alloys


• High electrical conductivity

• High thermal conductivity

• High corrosion resistance

• Good ductility and malleability

• Reasonable tensile strength.

• Electrical conductance

• Plating on components

• Give different copper alloys -

brasses and bronzes.

Electronic products

www.bergquistcompany.com

Copper

trolley

wires www.reawire.com

Copper plating

www.silvexinc.com

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Zinc and its alloysZinc and its alloys


Disadvantages:

• Fast rate of die casting

• Excellent atmospheric

corrosion resistance.

• Ability to form a well-adhering

coating on steel.

• Used for galvanic protection in

steel and decorative finish.

• Used in die casting.

• Cannot be strain hardened. Zinc diecast

www.zincdiecast.com

Zinc roof protection

www.vmzinc.com

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Nickel and its alloysNickel and its alloys


Disadvantages:

• Tough and ductile

• Good high and low

temperature strength

• High oxidation resistance

• Good corrosion resistance

• High cost

• Not normally mixed with

cheaper alloying metals

• Applications required necessary

corrosion or heat- resisting properties

• Special engineering applications

• Turbine blades in combustion section

Aerospace flow bodies

www.immnet.com

Turbine bladeswww.msm.cam.ac.uk

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ReferencesReferences

• Polmear I.J., Light alloys: metallurgy of the light metals, 3rd edition,

1995, Arnold, London, ISBN 0-340-63207-0.

• Smith, W.F., Structure and properties of engineering alloys, second

edition, 1993, McGraw-Hill, ISB 0-07-59172-5.

• �� , � ��กก �� ก, 2536, ��ก�� ก�� !" �", ISBN 974-582-

155-1.

• Kainer, K.U. (editor), Magnesium alloys and technology, DMG, 2003,

WILEY-VCH, ISBN 3-527-30256-5.

• Hatch, J.E., Aluminium, Properties and physical metallurgy, ASM,

1998.

• Totten, G.E., Handbook of aluminium: Physical metallurgy and

processes, Vol.1, Marcel Dekker, Inc., 2003, ISBN 0-8247-0494-0.

• Avedesian, M.M., Baker, H., ASM specialty handbook, Magnesium and

magnesium alloys, 1999, ISBN 0-87170-657-1.

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01_Introduction to Nonferrous Metallurgy

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