PEMP EMM2512

Non-Ferrous Alloys
Dr. N S Mahesh Professor and Head Department of Mechanical and Manufacturing Engg

M.S Ramaiah School of Advanced Studies - Bangalore

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

M.S Ramaiah School of Advanced Studies - Bangalore

Non-ferrous Alloys

Metal Alloys Ferrous Non-ferrous

Al alloys
Cu Mg Mn Si Zn

Cu alloys
Pure Cu Brasses Bronzes Cupronickel Be-copper Nickel silver

Ti alloys Mg alloy
Al Zn Mn V

Ni alloys
Monel Inconel Hastealloy

Super alloys
Fe-based Ni-based Co-based

Refractory metals
Nb (2468C) Ta (2996C) W (3410C) Mo (2617C)

M.S Ramaiah School of Advanced Studies - Bangalore

Al and its Alloys

Low density (2.7) - ~1/3 of that of steel higher strength-to-weight ratio High 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
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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.
M.S Ramaiah School of Advanced Studies - Bangalore

Aluminium
Advantages and disadvantages of Al as an autobody material Low density (2.69g/cc) Steel Modulus Al-69GPa and steel (210GPa) Ti Corrosion resistance Cu Strong supply base Recyclability Al High and fluctuating cost 0 50 100 150 200 250 Poorer formability than steel Modulus of Elasticity (GPa) Less readily welded than steel
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Al and its Alloys

A1xxx A2xxx A3xxx A4xxx A5xxx A6xxx A7xxx A6061-T6 condition pure Al (>99%) Cu Mn Si Mg Si+Mg Zn
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

an Al-Si-Mg alloy aged hardened to T6 T: aged hardened F: as fabricated W: solution treated O: annealed H: work hardened

process condition:

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Wrought alloys
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, large water 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

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
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Aluminum Automotive Applications

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Mercedes-Benz CL - Aluminum Use

Roof frame (Extrusion) Roof Rear wall Rear frame; lower part

Bonnet (Sheet and Diecasting)

Fender

Front modul (Sheet); also steel

Steel Aluminium Magnesium Plastics

Inner B-pillar and inner C-pillar (Diecasting) Door outer panel Side wall (Extrusion and sheet); also steel

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Heat treatment of Non-ferrous alloys

Precipitation Hardening (or Age Hardening) Precipitation hardening is commonly used to process copper alloys and other nonferrous metals for commercial use

The examples are aluminum-copper, copperberyllium, copper-tin, magnesium-aluminum, and some ferrous alloys
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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 sparking tools, Gears Mg AM 100A Sand Castings AZ80A Extruded products Ni
Rene' 41 High Temperature Inconel 700 up to 1800F

Fe

A-286 17-10P

High Strength Stainless

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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 and Z 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

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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.

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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%
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Common Alloys and Properties

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

Properties
Yield Strength: 270MPa UTS: 325MPa Ductility: 11%

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Automotive Mg alloys
Composition %Al %Zn %Mn UTS Yield strength Fracture elongation AZ91 9 0.7 0.2 240 160 3 0.3 225 130 8 0.3 210 125 10 AM60 6 AM50 5

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Automotive Lightweighting Materials Technical Approach

Lightweight Glazing Magnesium Alloy Thermoplastic Composites Metal Matrix Composites
30% weight reduction 50% weight reduction Reduces mass by 60%

Aluminum Tailor Welded Blanks

Powertrain components - 40% weight reduction

Hydroforming

Superplastic Forming

40% weight reduction / 50% reduction in part count

40% weight reduction / 10 X reduction in part count

35% weight reduction / reduction in part count

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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 jetengine components and rockets.

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Superalloys
Superalloys are high-temperature alloys use in jet engines, gas turbines and reciprocating engines.

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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 <700C.

Nickel-Based: Ni-Cr(10-30%, Fe, Mo)

commercial proprietary alloys: Hastelloy, Inconel, Invar suitable for application at <800C.

Cobalt-Based: Co - Cr(20-30%) - Ni(10-20%)

tensile strength at RT: 700-1000 MPa yield strength at RT: 400-800 MPa tensile strength at 1000C: 160 - 250 MPa These alloys are the most heat resistant and the most three, used for critical applications at above 900C.
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expensive of the

Superalloys
Superalloys are a special class of heat resistant alloys for high temperature applications, such as aircraft, marine and industrial gas turbines, space vehicles and rocket engines, nuclear reactors, submarines.
Ni-based super-alloy single crystal turbine blades

Jet Turbine engine, many interior components made of Ni-based and co-based superalloys

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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.

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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 these light alloys.
Cu Steel Ti Al Be Mg
0 2 4 6 8 10

Density (kg/m3)

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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
M.S Ramaiah School of Advanced Studies - Bangalore

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

Ti Applications Summary
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 and small 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
M.S Ramaiah School of Advanced Studies - Bangalore

Future Trends
Smart Materials : Change their properties by
sensing external stimulus. Shape memory alloys: Strained material reverts to its original shape above a critical temperature.
Used in heart valves and to expand arteries.

Piezoelectric materials: Produce electric field

when exposed to force and vice versa.

Used in actuators and vibration reducers.
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Potential applications of SMA thermal actuators

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Potential applications of SMA electrical actuators

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Foglamp louver

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Stent Applications
Coronary artery blockage

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Stent Applications
Coronary artery balloon angioplasty Restenosis:
Re-narrowing of coronary artery after angioplasty

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Stent Applications
Stent : SUS 316L and Cobalt alloys Thrombosis:
Damage to the tissue and blood clotting

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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

M.S Ramaiah School of Advanced Studies - Bangalore