Non Ferrous Alloys in Automobile and other ibdustries

7/27/2019 Non Ferrous Alloys in Automobile and other ibdustries

1/34

PEMP

EMM2512

M.S Ramaiah School of Advanced Studies - Bangalore

Dr. N S Mahesh

Professor and Head

Department of Mechanical and Manufacturing Engg

Non-Ferrous Alloys


2/34


Session Objectives

At the end of the session students should

have understood

Non-ferrous alloys

Al alloys

Ti alloys

Mg alloys etc.

Future materials

Shape memory alloys and nanomaterials


3/34


Al alloys Cu alloys

Ti alloys

Mg alloy Ni alloys

Super

alloys

Non-ferrous

Metal Alloys

Ferrous

Pure Cu

BrassesBronzes

Cupronickel

Be-copper

Nickel silver

Cu

MgMn

Si

Zn

Al

ZnMn

V

Refractory

metals

Nb (2468C)

Ta (2996C)

W (3410C)

Mo (2617C)

Fe-based

Ni-based

Co-based

Monel

Inconel

Hastealloy

Non-ferrous Alloys


4/34


Al and its Alloys

Low density (2.7) - ~1/3 of that of steel

higher strength-to-weight ratioHigh electrical conductivity - 60% of that of Cu

higher conductivity-to-weight ratio

High oxidation resistance

Most recyclable metal

It is alloyed to improve strength. Al is alloyed with any or

combination of five elements: Cu, Mn, Mg, Zn, Si

In addition to alloying, Al alloys are also hardened by cold working

and by precipitation hardening.

Typical mechanical properties:

Low elastic modulus: ~70 GPa

Yield strength: 100~400MPa


5/34


All-Aluminum Automobile

(a) The Audi A8 automobile

which has an all-aluminum

body structure. (b) The

aluminum body structure,

showing various

components made by

extrusion, sheet forming,

and casting processes.


6/34


Aluminium

Advantages and disadvantages of Alas an autobody material

Low density (2.69g/cc)

Modulus Al-69GPa and steel

(210GPa) Corrosion resistance

Strong supply base

Recyclability

High and fluctuating cost

Poorer formability than steel

Less readily welded than steel

0 50 100 150 200 250

Al

Cu

Ti

Steel

Modulus of Elasticity (GPa)


7/34


Al and its AlloysA1xxx pure Al (>99%)

A2xxx Cu

A3xxx Mn

A4xxx Si

A5xxx Mg

A6xxx Si+Mg

A7xxx Zn

A6061-T6 an Al-Si-Mg alloy aged hardened to T6

condition

T: aged hardenedprocess condition: F: as fabricated

W: solution treated

O: annealed

H: work hardened

There are some 200 Al alloys commercially

available. The following are commonly used

ones:Wrought: 1100 (pure), 3003, 5052, 6061*,

7075*

Sand cast: 355.0*

Die cast: 380.0

*: can be hardened by heat treatment


8/34


Al-Mn and Al-Mn-Mg alloys (Eg.3003, 3004)- Roofing sheets, foils, beverage

cans

Al-Mg alloys (Eg. 5005, 5456) Transportation structural parts, petrol and milk

tanks, pressure vessels, architectural components

Al-Cu alloys and Al-Cu-Mg (Eg. 2119, 2024) Fuel tanks, welding wires,

aircraft engine parts

Al-Mg-Si alloys (Eg. 6063, 6013) Electric train structure, satellite dish, largewater pipes, extruded sections for aircraft and automotive applications

Al-Zn-Mg and Al-Zn-Mg-Cu alloys (Eg. 7075, 7039)- Aircraft structural parts,

military bridge, large containers for transportation

Wrought alloys

Cast alloys Al-Si-Cu and Al-Si-Mg alloys (Eg.390.0, 319.0) pistons, connecting rods,

cylinder heads for IC engines

Al-Cu alloys (Eg. 295.0, 201.0) aerospace housing, flywheel housing, air-cooled

cylinder heads for aircraft


9/34


Aluminum Automotive Applications


10/34


11/34


Heat treatment of Non-ferrous alloys

Precipitation Hardening (or Age Hardening)

Precipitation hardening is commonly used to

process copper alloys and othernonferrous

metals for commercial use

The examples are aluminum-copper, copper-

beryllium, copper-tin, magnesium-aluminum,and some ferrous alloys


12/34


Typical Precipitation Hardened Alloys Al

2014 Forged Aircraft Fittings, Al Structures

2024 High strength forgings, Rivets 7075 Aircraft Structures, Olympic Bikes

Cu

Beryllium Bronze: Surgical Instruments, Non sparkingtools, Gears

Mg AM 100A Sand Castings

AZ80A Extruded products

Ni

Rene' 41 High Temperature

Inconel 700 up to 1800F Fe

A-286 High Strength Stainless

17-10P


13/34


Magnesium

Very low Density (1.74g/cc) The first two designatory letters indicate the

principal alloying element

A for Al, E, rare earth element, H, thorium, K,

Zirconium, M, Manganese, S, Silicon, W, Yttrium andZ for Zinc

Ability to be thin cast

Possible to integrate components in castings

Only viable as cast components High cost at medium to high volumes


14/34


Magnesium and magnesium alloys

Magnesium (Mg) is the lightest structural metal.

Alloys are used in structural and non-structural applications.

Typical uses of magnesium alloys are aircraft and missile

components.

Also has good vibration-damping characteristics.


15/34


Common Alloys and Properties

AZ91: Mg-9Al-1Zn-0.2Mn General casting alloy

Properties Yield Strength: 100MPa

UTS: 165MPa Ductility: 2.5%

AE42: Mg-4Al-2.5RE Mg engine blocks

Properties Yield Strength: 145MPa UTS: 235MPa

Ductility: 11%


16/34


Common Alloys and Properties

ZK60: Mg-5Zn-0.5Zr Forged Mg high performance

wheels

Properties

Yield Strength: 270MPa

UTS: 325MPa

Ductility: 11%


17/34


Automotive Mg alloys

Composition AZ91 AM60 AM50

%Al 9 6 5

%Zn 0.7

%Mn 0.2 0.3 0.3

UTS 240 225 210

Yield strength 160 130 125

Fractureelongation

3 8 10


18/34


Automotive Lightweighting MaterialsTechnical Approach

30% weight

reduction

50% weight

reduction

Aluminum Tailor

Welded Blanks

40% weight reduction

/ 50% reduction in part

count

Superplastic Forming

35% weight reduction

/ reduction in part

count

40% weight reduction /

10 X reduction in part

count

Hydroforming

Metal Matrix

Composites

Powertrain

components - 40%

weight reduction

Reduces mass by 60%

Magnesium AlloyLightweight Glazing Thermoplastic

Composites


19/34


Nickel and nickel alloys Nickel (Ni) has strength, toughness, and corrosion resistance

to metals. Used in stainless steels and nickel-base alloys.

Alloys are used for high temperature applications, such as jet-engine components and rockets.


20/34


Superalloys Superalloys are high-temperature alloys use in jet

engines, gas turbines and reciprocating engines.


21/34


Classes of Superalloys

Iron-Based: Fe(65-40%) - Ni(20-40%) -Cr(13-20%) ~50% of its room-temperature strength retained at 750C;

suitable for application at


22/34


SuperalloysSuperalloys are a special class of heat

resistant alloys for high temperatureapplications, such as aircraft, marine andindustrial gas turbines, space vehicles androcket engines, nuclear reactors,submarines.

Ni-based super-alloy single crystalturbine blades

Jet Turbine engine, manyinterior components madeof Ni-based and co-basedsuperalloys


23/34


Titanium and titanium alloys Titanium (Ti) is expensive, has high strength-to-weight ratio

and corrosion resistance Used as components for aircrafts, jet-engines, racing-cars and

marine crafts.


24/34


Ti and its Alloys

Light alloys:

Al (2.7), Be (1.85), Mg (1.74), Ti

(4.51)

The demand for materials of high

strength-to-weight ratios from the

aerospace and aircraft industry and

more recently from automobile and

other transportation industries has

promoted the development of theselight alloys.

0 2 4 6 8 10

Mg

Be

Al

Ti

Steel

Cu

Density (kg/m3)


25/34


Ti and its Alloys

Melting temperature: 1678 C

Modulus of elasticity: 127 GPa Low density: 4.5 g/cm3

Strengthenable by alloying and by heat

treatment

Higher specific strength and specific

stiffness than steels

High affinity to O, H, N, C

High tendency to form intermetallic

compounds with other metals

Good thermal resistance

Highly corrosion resistant

Bio-compatible

F22 jet fighter, some 39% of its weight is made

of titanium. Use of titanium in the F22,

Eurofighter, JointStrike fighter and Rafale

fighter aircraft over the next ten years will

maintain titanium demand from the military


26/34


Aerospace applications: aircraft; aero-engines; airframes;

commercial and military aerospace industry; space flight

Industrial applications: chemical and petrochemical; metal

recovery and refining; oil and gas industry; geothermal energy;

marine applications; thermal power generation & transmission;

nuclear power stations; water desalination; building and

construction; tool & machinery coatings; automotive applications;

Land & sea based military applications: armour; field guns andsmall arms; naval applications; watches;

Consumer applications: golf clubs; bicycles; sports equipment;

computer casing; spectacle frames;

Medical applications: hip & knee prostheses; spinal implants &

cages; heart components; wheelchairs; dentistry;High technology applications: sputtering targets;

superconductivity; computers; optical systems;

Alloying additives: carbon & stainless steels; superalloys; tool, die

and valve steels; shape memory alloys

Ti Applications Summary


27/34


Future Trends

Smart Materials :Change their properties bysensing external stimulus.

Shape memory alloys: Strained material

reverts to its original shape above a criticaltemperature.

Used in heart valves and to expand arteries.

Piezoelectric materials: Produce electric fieldwhen exposed to force and vice versa.

Used in actuators and vibration reducers.


28/34


Potential applications of

SMA thermal actuators


29/34


Potential applications of

SMA electrical actuators


30/34


Foglamp louver


31/34


Stent Applications

Coronary artery blockage


32/34


Stent Applications

Coronary artery balloon angioplasty

Restenosis:

Re-narrowing of

coronary artery

after angioplasty


33/34


Stent Applications

Stent : SUS 316L and Cobalt alloys

Thrombosis:

Damage to the

tissue and blood

clotting


34/34

M S Ramaiah School of Advanced Studies - Bangalore

Summary

This session covered the review of properties, alloy types,

application examples of non-ferrous alloys

Al alloys

Ti alloys

Mg alloys etc. Future materials - Shape memory alloys and

nanomaterials

Thank you

Non Ferrous Alloys in Automobile and other ibdustries

Documents

Transcript of Non Ferrous Alloys in Automobile and other ibdustries