Nonferrous Metals1

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    NON-FERROUS METALS

    AND ALLOYS

    Al, Cu, Zn, Mg, Ti, Ni, Co, W, V and their alloysall except of Fe and

    ferrous alloys (steels and cast irons)

    Non-ferrous metals and alloys

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    Classification of non-ferrous

    materials (1)a) Density based: light metals and alloys < 5000 kg/m3(Mg, Al, Ti)

    medium metals and alloys = 5000...10000 kg/m3(Sn, Zn, Sb, Cr, Ni,Mn, Fe, Cu)

    heavy metals and alloys >10000 kg/m3(Pb, Ag, Au, Ta, W, Mo)

    b) Melting temperature based: low melting point Tm< Tm

    Pb= 327 C (Sn, Pb, Bi)

    medium melting point = 3271539 C (Al, Mg, Mn, Cu, Ni, Co, Ag, Au)

    refractory Tm> TmFe= 1539 C

    Element Ti Cr V Nb Mo Ta W

    Tm, C 1660 1875 1900 2415 2610 2996 3410

    Non-ferrous metals and alloys

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    Classification of non-ferrous materials(2)c) Manufacturing based (schematic classification by phase diagram):

    - deformable alloys

    - cast alloys

    d)Heat treatment based:

    HT: annealing, hardening,ageing

    - non heat treatable- heat treatable (HT)

    Non-ferrous metals and alloys

    L (Liquid)

    L (Liquid)

    The heat treatment effect

    (no solubility)

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    Aluminium and aluminium alloys

    Pure Al Al-alloys Powder aluminium

    Deformable Cast alloys

    alloys

    Heat- Non heat- Heat- Non heat-

    treatable treatable treatable treatable

    Non-ferrous metals and alloys

    Partial

    solubility

    No

    solubility

    Partial

    solubility

    No

    solubility

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    Pure Al

    - Metallurgical (99,599,8% Al)- Refined (up to 99,9% Al)

    Al 99,9% Rm= 70135 N/mm2

    Work hardening of Al

    Conditions designations

    Oannealed

    Hwork hardened

    (degree of hardening H1-H9)

    Wquenched

    Tquenched and

    aged (T1-T9)

    Non-ferrous metals and alloys

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    Heat treatment of Al-alloys (1)

    Quenching water -structure Rm, Rp0,2; A, Z

    Ageing: naturally aged (20 C) structure + Guinier`-Preston zonesartificially aged Rm, Rp0,2, A, Z

    low (100150 C) high (200250 C)

    (Rp0,2

    /Rm

    = 0,60,7)

    (Rp0,2

    /Rm

    = 0,90,95)

    Non-ferrous metals and alloys

    Result

    precipitation

    hardening

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    Designation system of Al and Al-alloys(EVS-EN573 and 1780)

    Designation(chemical composition based)

    deformable alloysEN-AW...(EN-AW-AlCu4Mg1)

    cast alloysEN-AC...(EN-AC-AlSi11)

    Designation of heat treatment (EN515) Oannealed (for ex. 01, 02, 03)

    Hwork hardened (for ex. H1, H2...H9)

    Wquenched

    Theat treated (for ex. T1, T2...T10, T31, T3510)

    Mainly used: T4quenching + natural ageing

    T6quenching + artificial ageing

    Non-ferrous metals and alloys

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    Designation system of Al and Al-alloys(2)Materials numbersDeformable al loys

    Series 1000pure Al

    2000Al-Cu-alloys (for ex EN-AW-2014)

    3000Al-Mn-alloys4000Al-Si-alloys

    5000Al-Mg-alloys

    6000Al-Mg-Si-alloys

    7000Al-Zn-alloys

    8000Al-Fe-alloys

    Cast al loys

    Series 10000pure Al

    20000Al-Cu-alloys

    40000-48000Al-Si-alloys (for ex EN-AC-44000)50000Al-Mg-alloys

    70000Al-Zn-alloys

    Non-ferrous metals and alloys

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    Aluminium alloys (1)

    Deformable alloys- Deformable and heat treatable

    Solubility

    1) Al-Cu-Mg-alloys (duraluminium) Cu 5,7%

    2) Al-Cu-Mg-Si-alloys (forgable) Mg 14,9%3) Al-Mg-Si-alloys (corrosion resistance)

    4) Al-Zn-Mg-Cu-alloys (high strength)

    5) Al-Cu-Mg-Ni-Fe-alloys (heat resistance)

    Rm 500 N/mm2; Rp0,2 390 N/mm

    2; A 25%

    Non-ferrous metals and alloys

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    Aluminium alloys (2)

    - Deformable and non heat treatable

    1) Al-Mn-alloys 12% Mn

    2) Al-Mg-alloys (magnalium) 25% Mg

    Rm 300 N/mm2; Rp0,2 150 N/mm

    2; A 25%

    - plane bearing alloys (for mono- and bimetallic bearing shells)

    Al-Sn; Al-Ni; Al-Cu-Sb Typical structure of bearing material

    Non-ferrous metals and alloys

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    Aluminium alloys (3)

    Cast alloys (1)

    Requirements:

    - low Tm (Al-Si eutectic alloys -

    577 C at 11,7 % Si, by

    mofification 564 C at 14 % Si)

    - high fluidity (short interval ofliqvidus and solidus lines)

    Non-ferrous metals and alloys

    1000

    800

    600

    400

    200

    00 10 20 30 40 50

    Al Si

    1,65

    +Si

    L

    L+Si

    11,7

    T, C

    657

    577

    +L

    Si %

    564

    14,0

    1..2% of NaF+NaCl

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    Aluminium alloys (4)

    1) Al-Si-alloys Rm (250), A = 1,7 % Pumps and engine

    bodies, cylinder heads

    2) Al-Cu-alloys Rm than I group

    high temp. strength

    Cylinder heads,

    apparatures bodies

    3) Al-Si-Cu-alloys Rm than I group

    high temp. strength

    350 C

    4) Al-Mg-alloys

    (magnalium)

    Rm, A; good corr. resist.;

    castability

    100 C

    5) Al- other inclusions high temperature

    strength

    350 C

    parts of aircraft

    engines

    Non-ferrous metals and alloys

    Cast alloys (2)

    Rm 340 N/mm2; A 8% (depending on casting mode)

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    Copper and copper alloys

    Pure Cu Cu-alloys

    Brasses Bronzes Cupronickels

    Deformable Cast Deformable Cast

    alloys alloys alloys alloys

    Non-ferrous metals and alloys

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    Pure Cu

    Annealed Cu (99,85% Cu); Rm 250 N/mm2

    El. conductivity 1/= 58 mm2/m = 100% IACS

    Strengthening of Cu at work hardening

    Conditions designations

    Aelongation (ex A007)

    Bbending strength (ex B410)

    Ggrain size (ex G020)

    HHB or HV (ex H150)

    Rtensile strength (ex R500)

    Yyield strength(ex Y460)

    Non-ferrous metals and alloys

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    Designation system of Cu and Cu-alloys (1)

    Designation pure CuCu-ETP etc. Cu deformable alloysCuZn36Pb3

    Cu cast alloysG-CuSn10 (types of casting : GSsand casting,

    GMdie casting, GZcentrifugal casting,

    GScont. casting , GPpressure die casting)

    Conditions (properties) based designation after main designation(EN1173)

    Letters

    Aelonagtion (ex Cu-OF-A007)

    Bbending strength (ex CuSn8-B410)

    Ddrawn, without mech. propertiesGgrain size (ex CuZn37-G020)

    Hhardness (Brinell or Vickers) (ex CuZn37-H150)

    Mas manufactured cond. , without mech. properties

    Rtensile strength (ex CuZn39Pb3-R500)

    Yyield strength (ex CuZn30-Y460)

    Non-ferrous metals and alloys

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    Designation system of Cu and Cu-alloys (2)

    Materials numbersIncludes 2-digit marking, followed by three digit designating

    the material group(000...999)

    Ccopper based alloy

    CBingot

    CCcasting

    CMmaster alloy

    CRrafined Cu

    CSbrazing and welding material

    CWwrought

    CXnon standardized material

    For example Designation Material No.

    Deformable copper Cu-0F CW009A

    Deformable alloys CuZn37 CW508L

    Cast copper Cu-C CC040A

    Cast alloys CuSn10-C CC480K

    Non-ferrous metals and alloys

    N f t l d ll

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    Copper alloys (1)Cu-Zn alloysbrasses(ex CuZn20)Influence of Zn to properties Influence of Pb to machining

    Non-ferrous metals and alloys

    Free cutting brass100%

    (comp.: 40% Zn, 2% Pb) CuZn40Pb2

    N f t l d ll

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    Copper alloys (2)

    Cu-Ni alloys( 50% Ni)

    - permanent CTE

    (constantan)45% Ni

    - corrosion resistant(Ni+Fe+Mn)30% Ni

    Cu - 25% Ni

    (coin melhior, cupronickel).

    Cu - 10-20% Ni + 20-35% Zn

    (new silver, alpaca).

    Non-ferrous metals and alloys

    N f t l d ll

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    Copper alloys (3)Cu with other elements - bronzes

    - Cu-Sn (tin bronzes) solubility 15,8% Sn (520%)

    - Cu-Sn-P (phosphor bronzes) 0,1%P

    - Cu-Pb (lead bronzes) 20% Pb

    - Cu-Al (aluminium bronzes) 9,8% Al (~10% Al)Rm 700 N/mm

    2

    - Cu-Si (silicon bronzes) 5,3% Si (~3% Si)

    - Cu-Be (beryllium bronzes)spring bronze

    Rm

    1400 N/mm2(H + AA) Typical structure of bearing material

    Application as plane bearing

    materials (as cast)

    Non-ferrous metals and alloys

    N f t l d ll

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    Cu-alloys: Estonian* vs Euro coins**

    Alloy: Cu93Al5Ni2

    Diameter (mm): 17,20Weight (g): 1,87

    Alloy: Cu93Al5Ni2

    Diameter (mm): 18,95

    Weight (g): 2,27

    Alloy: Cu93Al5Ni2

    Diameter (mm): 19,50

    Weight (g): 2,99

    Alloy: Cu89Al5Zn5Sn1

    Diameter (mm): 23,25

    Weight (g): 5,00

    *Source: Bank of Estonia **Source: European Central Bank

    Alloy: Nordic gold (Cu89Al5Zn5Sn1)

    Diameter (mm): 19,75

    Weight (g): 4,10

    Alloy: Nordic gold (Cu89Al5Zn5Sn1)

    Diameter (mm): 22,25

    Weight (g): 5,74

    Alloy: Nordic gold (Cu89Al5Zn5Sn1)

    Diameter (mm): 24,25Weight (g): 7,8

    Alloy: rim - nickelbronze (Cu75Zn20Ni5);

    center - three layered: cupronickel

    (Cu75Ni25), nickel, cupronickel

    Diameter (mm): 23,25

    Weight (g): 7,50

    Alloy: rim - kupronickel;

    center - three layered:

    nickelbronze, nickel, nickelbronze

    Diameter (mm): 25,75

    Weight (g): 8,50

    Non-ferrous metals and alloys

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    Non Ferrous Metals and their alloys.

    Non-ferrous metals are those which do not contain iron.In general they have excellent resistance to corrosion.

    Copper, reputed to be the first metal used by mankind,

    includes some very useful and interesting properties, itis malleable and ductile. It is for this reason is was ofsuch interest to our ancestors. Another non-ferrousmetal, aluminium, has only featured in engineering

    terms in the last 75 years.

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    CopperCopper as an engineering metal came to prominence during

    the industrial revolution, up to then it was considered only

    for its decorative value and utensils value and on roofing.

    Properties of copper include Malleability - the ability to be beaten or rolled into shape.

    Ductility - The ability to be drawn into shape as in the

    manufacture of copper wire.

    Copper is a good conductor of heat and electricity.

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    Copper production in modern times

    Copper production has a strong link with an Irishman called Marcus Daly, from Co. Cavan.

    As a consequence of his mining in Montana USA he was the first to exploit the metalwhen he sent a shipment to Wales for smelting just at the time when it was becoming a

    prominent metal in the electrical industry. He was really trying to find a better use for the

    mineral which was a by-product of the silver mines in the region.

    Copper ore Copper matte Blister Copper pure copper

    Reverberatory furnace Converter Furnace Electrolysis

    Flowchart of copper ore to pure copper

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    Copper production

    Copyright Microsoft Encarta

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    The production of copper.There are three distinct stages to the production of copper;

    1 Copper Matte - The first stage of the production of copper is with matte. It is a mixture of

    30% to 40% copper. Ore is first concentrated at the mining site by crushing and then

    leaching or floatation.

    The ore is then roasted or smelted in an oil fired furnace at a temperature below the melting

    point of copper, [1083oC]

    The resultant matte contains high levels of sulphur and iron from the chalcopyrite (Cu Fe S2)

    2 Converting - Iron and sulphur are removed by blowing air through the molten matte in a

    converter vessel, similar to the Bessemer converter. The matte is placed in the converter

    and held at the temperature for about 8 hours.Blowing continues until only copper

    sulphide remains. This is what is referred to as Blister Copper. It is up to 99% pure. This is

    then refined by further heating to remove the oxygen. It is then cast into ingots known as

    Anodes.

    3. Refining by Electrolysis: - For copper to be used in the electrical industry it has to have

    99.99% purity. This can only be achieved by electrolytic refinement.

    Pto.

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    Refined blister copper anodes are attached to the positive DC supply, while a thincathode plate is connected to the negative supply. An electrolyte, a mixture of

    copper sulphate and sulphuric acid at 50OC is poored into the tanks.

    Acurrent density of around 200 amps is passed between the anode and the

    cathode, depositing pure copper onto the thin cathodes

    Application of copperOver half of all copper produced is used in the electrical industry. Copper wire for

    transmission accounts for a large amount of this use.

    Central heating and plumbing are the major applications of copper. Cylinders,

    copper piping etc are the most widely used.

    Recycling of copper is an industry in itself and accounts for 40% of all copper used.

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    Aluminium

    Aluminium is one of the most versatile of metals. It is only of engineering significance sincethe late twenties, when it became possible to produce it in commercial quantities. Next to

    steel it is the most used metal in the world. Yet the production of aluminium is only 6% that ofsteel.Aluminium has a wide range of uses, from cooking foil to aircraft. Its properties make itsuitable for many applications. It is light does not corrode, is a good conductor of electricityand heat and is cheaper than copper.Aluminium can be cast, extruded, rolled, forged, drawn,etc., to give us the numerous shapesof the aluminium objects that we see everyday.

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    Mining

    Aluminium is the most abundant metal on the earths crust. About 8% of the earths crust ismade up of aluminium.

    So why is it not the most abundant metal in use? There is great difficulty and cost attached to

    refining aluminium. It does not exist as a pure metal in nature, but is combined with other

    elements. The Ore of aluminium is called Bauxite,[hydrated aluminium oxide].

    Bauxite is mined in many countries, France, Australia, Guinea, Brazil, Russia and china being

    the more common.

    Mining Methods;

    Open-cast mining is carried out using very large scale plant. After the overburden of topsoil is

    removed the ore is excavated out and loaded into giant dumper trucks. The ore is crushed and

    washed close to the mining site to save on transport costs.

    Production of Aluminium from Barxite;

    It requires a huge amount of energy to extract aluminium from its ore. The energy is supplied

    in the form of electricity. Because of the large amount of electricity involved the production

    of aluminium is generally in countries with large amounts of cheap electricity, such as Canada,

    Norway and Brasil.

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    A Two-stage process.

    Purification;

    Before aluminium can be made the ore has to be purified. After being mixed with caustic soda

    solution the bauxite is sent to heated pressure vessels where the alumina hydrated aluminium

    oxide dissolves in the caustic soda. The impurities are removed as red mud. As the alumina

    cools alumina hydrate forms crystals. It is then roasted or calcined. In the Bayer process. Thisprocess is what is carried out in Aughinis in the Shannon Estuary outside Limerick.

    Reduction of Alumina to Aluminium;

    Electrolysis is used to convert alumina to aluminium. Alumina has a melting point of 2000oC.

    To reduce the temperature at which conversion takes place cryolite is added and hence

    reduces the amount of energy required to convert the alumina to aluminium.

    It takes about 2 tonnes of alumina , 15000 units of electricity to make one tonne ofaluminium.

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    Recycling of AluminiumRecycling accounts for about 25% of the total world production of aluminium.

    As the amount of bauxite is limited, it makes good sense to recycle the metal. The cost of

    recycling a tonne of aluminium is 5.3% the cost of its initial production.

    Aluminium and its uses;

    Aluminium is often used in transmission cables for high tension systems in place of copper

    because of cost factors. It is also better in national grid transmission because of the reduction

    of weight.

    Aluminium is often alloyed with other metals such as copper, magnesium, nickel and zinc to

    produce metals with special properties.

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    LeadLead is one of those metals which have been used for many ages. The Romans used lead to

    duct water to their baths. Batteries are the main users of lead nowadays as it has found to be

    dangerous in many other applications. Petrol used lead to aid the lubrication of the fuel

    system.

    Lead is a toxic material and is being replaced by other materials in places like drainpipes,

    guttering etc.

    Lead-tin alloys of solder are essential to the electrical industry and are known as soft-

    solders(approx 60%tin-40% lead). Other uses of lead include the sheathing of underground

    telecommunication cables, bearing matals, radiation protection shields (X-ray and Nuclear).

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    Tin

    Tin is mainly used in the production of tinplate( sheet steel coated in tin for corrosion

    protection.

    Tin was mined mainly ion Britain in Cornwall which attracted the Romans to Britain.

    Tinplate is produced by dipping sheet steel into baths of molten tin. The canned or tinned

    food industry is based on the tinplate can. The tin makes up just 1% of the tincan.

    Zinc

    Zinc is a white silvery metal which is a poor conductor of both electricity and heat. It is mostly

    used as a source of protecting steel I the form of galvanised steel. It is usually applied by hot-

    dipping the steel in vats of molten zinc, But is also applied by electroplating.

    Zinc is used in dry-cell batteries such as those for torches and radios etc. It is alloyed with

    other metals to make die castings.One of its main uses is its alloy with copper to make brass.

    Non-ferrous metals and alloys

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    Zinc and zinc alloysPure Zn

    Tm419 CDensity7140 kg/m3

    Good corrosion resistance

    Zn- alloysZnAl Precision casting materialZnAlCu Bearing alloy material

    Designation Material No.

    ex ZnAl8Cu1 ZP0810

    ZZn-alloyPcasting

    first two numbersAl%, 3. Cu%, 4.T- rest

    Non ferrous metals and alloys

    Non-ferrous metals and alloys

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    Zinc cast alloys (EN12844)Non ferrous metals and alloys

    Designation Rm

    N/mm

    2

    Rpo,2

    N/mm

    2

    A

    %

    HB Application

    ZnAl4

    (ZP3)

    280 200 10 83 Excellent castability,

    ZnAl4Cu1

    (ZP5)

    330 250 5 92 machinability;

    ZnAl8Cu1

    (ZP8)

    370 220 8 100 Universal applications:

    ZnAl11Cu1

    (ZP12)

    400 300 5 100 deep-draw and blow

    molds for plastics

    ZnAl27Cu2

    (ZP27)

    425 300 2,5 120

    Non-ferrous metals and alloys

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    Magnesium and magnesium alloys

    Pure MgTm649 CDensity1740 kg/m3 (lightest among the engineering

    materials)

    Mg-alloys- MgMn (up to 2,5 %)- MgAlZn (up to 10 % Al, 5 % Zn)

    Heat treatment of Mg-alloys

    Similar to Al-alloysQuenching + age hardening (NA, AA MgZn2, Mg4Al3jt)

    Rm20 30 %

    Non ferrous metals and alloys

    Non ferrous metals and alloys

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    Mg-alloysDesignation

    deformable (ex MgMn2) cast alloys (ex designation MCMgAl8 / material No. MC21110)

    Deformable Mg-alloys

    Mg cast alloys(EN173)

    Non-ferrous metals and alloys

    Designation Rm Rp0,2

    N/mm2

    A

    %

    Applications

    MgMn2

    MgAl8Zn

    200 145

    310 215

    15

    6

    Corrosion resistant, weldable

    cold formable; conteiners, car ,

    aircraft and machine

    manufacturing

    MCMgAl8Zn1

    MCMgAl6

    MCMgAl4Si

    240 90

    190-250 120-150

    200-250 120-150

    8

    4-14

    3-12

    Good castability. Dynamically

    loadable. Car and aircraft

    manufacturing.

    Non-ferrous metals and alloys

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    Titanium and titanium alloysPure Ti

    Tm1660 CDensity4540 kg/m3

    Very active to O, C, N 2x hardnes increase

    Ti-alloys, classificationTiAlalloys (46 % Al) -alloys

    TiAlCr, V, Cu, Mo - alloys+ -alloys

    TiAlMo, Cr, Zr - alloys-alloys

    Heat treatment of TialloysHeating up to -area (850950 C) and cooling martensitic

    transformation.Ageing (450600 C)max effect by -stabilisators

    (Cr, Mn, Fe, Ni, Cu, Si)

    Additional heat treatmentnitriding (750900 HV)

    y

    Non-ferrous metals and alloys

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    Titanium alloysy

    Designation HB RmN/mm

    2

    Rpo,2N/mm

    2

    A

    %

    Applications

    Ti 13 120-170 290-590 180-320 30-18 Weldable,

    machinable and

    cold formable.

    Ti1Pd,

    Ti2 Pd

    120-150 290-540 180-250 30-22 Corrosion resistant

    light constructions.TiAl6V4 310 900-920 830-870 8 Machine elements in

    medicine, food,

    ZnAL11Cu1

    (ZP12)

    350 1050 1050 9 chemical and

    aircraft industry.

    Advantages:

    highest specific strength

    good formability

    Disadvantages:

    need for a protective atmosphere at HT (Ar)

    bl ti ll t d ( ti ith l dl t i l Z O2 t b d)