NON-FERROUS METALS AND ALLOYS

Non-ferrous metals are those which do not contain significant quantity of iron or iron as base
metal. These metals possess low strength at high temperatures, generally suffer from hot shortness and
have more shrinkage than ferrous metals. They are utilized in industry due to following advantages:
1. High corrosion resistance
2. Easy to fabricate, i.e., machining, casting, welding, forging and rolling
3. Possess very good thermal and electrical conductivity
4. Attractive colour and low density.

Copper
Copper is a corrosion resistant metal of an attractive reddish brown colour. It is a soft, malleable,
and ductile metal with very high thermal and electrical conductivity. Copper is used as a conductor of heat
and electricity, as a building material, and as a constituent of various metal alloys.
Properties and Uses:
(1) High Thermal Conductivity: Used in heat exchangers, heating vessels and
appliances, etc
(2) High Electrical Conductivity: Used as electrical conductor in various shapes and
forms for various applications.
(3) Good Corrosion Resistance: Used for providing coating on steel prior to nickel and
chromium plating.
(4) High Ductility: Can be easily cold worked, folded and spun. Requires annealing
after cold working as it loses its ductility.
Alloys of Copper
Brass
All brasses are basically alloys of copper and zinc. Commercially there are two main
varieties of brasses:
(1) Alfa brass: Contains upto 36% Zn and rest copper for cold working.
(2) Alfa-Betabrass: Contains 36 to 45% Zn and remainder is copper for hot working.

Bronze
The alloy of copper and tin are usually termed bronzes. The useful range of composition
is 75 to 95% copper and remainder tin. The alloy can be easily cold rolled into wire, rods and sheets. With
increase in tin content, the strength of this alloy and its corrosion resistance increases. It is then known as
hot working bronze. Bronze is generally utilized in hydraulic fittings, bearings, bushes, utensils, sheets,
rods and many other stamped and drawn products.
The generally used bronzes are as follows:
(1) Phosphor bronze
(2) Gun metal
(3) Silicon bronze
(4) Bell metal
(5) Manganese Bronze
(6) Muntz Metal
(1) Phosphor bronze
 When bronze contains phosphorus, it is known as phosphor bronze. Phosphorus present in such
alloy increases the strength, ductility and soundness of castings. Various compositions of this alloy are
available for different applications. The composition of the alloy varies according to whether it is to be
forged, wrought or cast. A common type of phosphor bronze has the following composition as per Indian
standards. Copper = 93.6%, tin = 9%, and phosphorus = 0.1 to 0.3%.
(2) Gun metal
Gun metal contains 2% zinc, 10% tin and 88% copper. It is a very famous composition.
Sometimes very small amount of lead is also added to improve castability and machinability. The
presence of zinc improve its fluidity. This bronze is used for bearing bushes, glands, pump valves and
boiler fittings, etc.
(3) Silicon bronze
Silicon bronze has an average composition of 3 per cent silicon, 1 per cent manganese and rest
copper. It possesses good general corrosion resistance of copper with higher strength and toughness. It
can be cast rolled, stamped, forged and pressed either hot or cold and can be welded by all the usual
methods. Silicon bronze is widely utilized for parts of boilers, tanks, stoves or where high strength as well
as corrosion resistance is required.
(4) Bell metal
This alloy contains 20 to 21% tin and rest copper. It is hard and resistant to surface wear. It can be
readily cast, is generally utilized for casting bells, gongs and utensils, etc.
(5) Manganese Bronze
It is an alloy of copper, zinc and manganese. It contains 55 to 60% copper, 40% zinc, with 3.5%
manganese. This alloy is highly resistant to corrosion. It is stronger and harder than phosphor bronze. It
has poor response to cold working but can be easily hot worked.
(6) Muntz Metal
The composition of this alloy is 60 per cent copper and 40 per cent zinc. Sometimes a small
quantity of lead is also added. This alloy is stronger, harder and more ductile than normal brass. While hot
working between 700°C to 750, it responds excellently for process but does not respond to cold working.

Aluminium
It is a silvery-white, soft, nonmagnetic and ductile metal in the boron group. By mass, aluminium
makes up about 8% of the Earth's crust; it is the third most abundant element after oxygen and silicon and
the most abundant metal in the crust.
Properties and Uses:
(1) Like copper it is also corrosion resistant.
(2) It is very good conductor of heat and electricity although not as good as copper.
(3) Possesses high ductility and light weight so widely utilized in aircraft industry.
(4) Needs frequent annealing if cold worked since it becomes hard after cold working.
(5) In view of its ductility and malleability it has replaced copper in electrical
transmission and appliances to some extent.
(6) It is used in manufacturing of household utensils including pressure cookers.

Alloys of Aluminum
Aluminium may be alloyed with one or more alloying elements such as copper, manganese,
magnesium, silicon and nickel. The addition of small quantities of alloying elements converts the soft and
weak aluminium into hard and Astrong metal, while it retains its light weight. The main alloys of
aluminium are: Duralumin, Y-alloy, Magnalium and Hindalium.
 Duralumin
A famous alloy of aluminium containing 4% copper, 0.5% manganese, 0.5% magnesium
and a trace of iron with remainder as aluminium is known as duralumnin. It possesses high strength
comparable with mild steel and low specific gravity. However, its corrosion resistance is much lower as
compared with pure aluminium. The strength of this alloy increases significantly when heat treated and
allowed to age for 3 to 4 weeks it will be hardened.

Y-alloy
It is also known as copper-aluminium alloy. The addition of copper to pure aluminium
improves its strength and machinability. Y-alloy contains 93% aluminium, 2% copper, 1% nickel and
magnesium. This alloy is heat treated as well as age hardened just like duralumin. A heat treatment of Y-
alloy castings, consisting of quenching in boiling water from 510°C and then aging for 5 days develops
very good mechanical characteristics in them.

Magnalium
It is produced by melting the aluminium 2 to 10% magnesium in a vacuum and then
cooling it in vacuum or under a pressure of 100 to 200 atmospheres. About 1.75% copper is also added to
it. Due to its light weight and good mechanical characteristics, it is mainly used for aircraft and
automobile components.

Hindalium
It is an alloy of aluminium and magnesium with small quantity of chromium. It is
manufactured as rolled product in 16 gauge mainly used in manufacture of anodized utensils.

Lead
Lead is the heaviest of the common metal. Lead is extracted from its ore known as galena. It is
bluish grey in colour and dull lusture which goes very dull on exposure to air.

Properties and Uses:

(1) Its specific gravity is 7.1 and melting point is 360°C.
(2) It is resistant to corrosion and many chemicals do not react with it (even acids).
(3) It is soft, heavy and malleable, can be easily worked and shaped.
(4) Lead is utilized as alloying element in producing solders and plumber’s solders.
(5) It is alloyed with brass as well as steel to improve their machinability.
(6) It is utilized in manufacturing of water pipes, coating for electrical cables, acid tanks
and roof covering etc.
Tin
It is a brilliant white metal with yellowish tinge. Melting point of tin is 240°C. It is obtained
chiefly from the mineral cassiterite, which contains stannic oxide, SnO2.
Properties and Uses:
(1) Tin is malleable and ductile, it can be rolled into very thin sheets.
 (2) It is used for tinning of copper and brass utensils and copper wire before its
conversion into cables.
(3) It is useful as a protective coating for iron and steel since it does corrode in dry or
wet atmosphere.
(4) It is utilized for making important alloys such as fine solder and moisture proof
packing with thin tin sheets.
Zinc
The chief ores of zinc are blende (ZnS) and calamine (ZnCO3). Zinc is a fairly heavy, bluish-
white metal principally utilized in view of its low cost, corrosion resistance and alloying characteristics.
Melting point of zinc is 420°C and it boils at 940°C.
Properties and Uses:
(1) High corrosion resistance: Widely used as protective coating on iron and steel.
Coating may be provided by dip galvanizing or electroplating.
(2) High fluidity and low melting point: Most suitable metal for pressure die casting
generally in the form of alloy.
(3) When rolled into sheets, zinc is utilized for roof covering and for providing a damp
proof non-corrosive lining to containers.
(4) The galvanized wires, nails, etc. are produced by galvanizing technique and zinc is
also used in manufacture of brasses.
Nickel
It is a silvery-white lustrous metal with a slight golden tinge. Nickel belongs to the transition
metals and is hard and ductile. About at least 85% of all nickel production is obtained from sulphide ores.
Properties and Uses:
(1) Pure nickel is tough, silver coloured metal, harder than copper having some but less
ductility but of about same strength.
(2) It is plated on steel to provide a corrosion resistance surface or layer.
(3) Widely used as an alloying element with steel. Higher proportions are
advantageously added in the production of steel such as monel or in conel.
(4) It possesses good resistance to both acids and alkalis regarding corrosion so widely
utilized in food processing equipment.

Alloys of Nickel

German silver
The composition of this alloy is 60% Cu, 30% Ni and 10% zinc. It displays silvery
appearance and is very ductile and malleable. It is utilized for electrical contacts, casting of high quality
valves, taps and costume jewellery. It is also used in producing electrical wires.

Monel metal
It contains 68% Ni, 30% Cu, 1% iron and remainder small additions of Mn and other
elements. It is corrosion resistant and possesses good mechanical properties and maintains them at
elevated temperatures.
 Nichrome
It is an alloy of nickel and chromium which is utilized as heat resistant electrical wire in
electrical applicances such as furnaces, geysers and electric iron, etc.

Inconel and incolony

These alloys principally contain, Ni, Cr, Fe, Mo, Ti and very small proportions of carbon.
These are used as high temperature alloys. Inconel does not respond to heat treatment.

Magnesium
Principal ores of magnesium are magnesite, carnallite and dolomite. Magnesium is extracted by
electrolytic process. It is the eighth most abundant element in the Earth's crust and the fourth most
common element in the Earth.
Properties and Uses:
(1) It is the lightest of all metals weighing around two-thirds of aluminium.
(2) The tensile strength of cast metal is the same as that of ordinary cast aluminium, i.e.,
90 MPa.
(3) The tensile strength of rolled annealed magnesium is same as that of good quality
cast iron.
(4) Magnesium can be easily formed, drawn forged and machined with high accuracy.
(5) In powdered form it is likely to burn, in that situation adequate fire protection
measures should be strictly observed.
Vanadium
It is a hard, silvery-grey, ductile, and malleable transition metal. The elemental metal is rarely
found in nature, but once isolated artificially, the formation of an oxide layer (passivation) somewhat
stabilizes the free metal against further oxidation. It occurs in conjunction with iron pyrite, free sulphur
and carbonaceous matter.
Properties and Uses:
(1) It is silvery white in colour.
(2) Its specific gravity is 5.67.
(3) Its melting point is 1710°C.
(4) When heated to a suitable temperature it can be hammered into any shape or drawn
into wires.
(5) It is used in manufacture of alloy steels.
(6) Vanadium forms non-ferrous alloys of copper and aluminium from which excellent
castings can be produced.
Antimony
A lustrous gray metalloid, it is found in nature mainly as the sulfide mineral stibnite (Sb2S3).
Chief ore of antimony is stibnite. To a small extent, antimony is obtained as a by-product in refining of
other metals such as lead, copper silver and zinc.
Properties and Uses:
 (1) It is silvery white, hard, highly crystalline and so brittle that it may be readily
powdered.
(2) Its specific gravity is 6.63 and melting point is 630°C.
(3) It is generally used as an alloying element with most of heavy metals.
(4) Lead, tin and copper are the metals which are most commonly alloyed with antimony.
Cadmium
It is obtained commercially as a by-product in the metallurgy of zinc and to some extent of lead.
It is chiefly utilized in antifriction alloys for bearings. It is also used as rust proof coating for iron and
steel. Components of automobiles and refrigerator such as nuts, bolts and trimmings, locks and wire
products are plated with it.
Properties and Uses
(1) White metal with bluish tinge, capable of taking a high polish.
(2) Its specific gravity is 8.67 and melts at 321°C.
(3) It is slightly harder than tin but softer than zinc.
(4) It is malleable and ductile and can be readily rolled and drawn into wires.