ABOUT NON-FERROUS MATERIALS

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, it is malleable and ductile.

Another non-ferrous metal, aluminum, has only featured in engineering terms in the last 75 years.

PROPERTIES OF NON-FERROUS MATERIALS

MALLEABILITY- can be hammered and pressed into shapes. DUCTILITY- can be drawn into fine wires. ELASTICITY- regains its shape after being deformed. HARDNESS- resists being scratched or cut. BRITTLENESS- extremely hard and therefore breaks easily. CONDUCTIVITY- ability to conduct heat or electricity.

COPPER
The copper occurs in practically all important countries of the world. Its principal ores are cuprite , copper glance, copper pyrites, malachite and azurite.
The approximate content of copper in the following principal ores: Cuprites or red oxide of cooper88% Copper glance80% Copper pyrites35% Malachite or green carbonate of copper 56% Azurite or blue malachite55%

The ores, usually pyrites, are clean and the ores, usually pyrites, are clean and crushed and they are then calcined in reverberatory furnace. crushed and they are then calcined in reverberatory furnace.

MANUFACTURING OF COPPER

the melted metal is oxide in the Bessemer converter. it gives blister copper.

the calcined ores are mixed with silica and the small quantity of coke. The mixture is then smelted in a blast furnace.

the impurities contained in blister copper are removed by melting it in a reverberatory furnace in presence of air.

the slag is removed and pure copper to the extent of about 99.70 % is obtain.

very copper or 100% copper is obtain by the process of electrolysis.

PROPERTIES OF COPPER
it become brittle just below its melting point. it can be worked in hot or cold conditions ,but it cant be welded . it has a peculiar reddish brown color. it is a good conductor of electric and heat. it is attacked by steam at white heat. it is malleable ,ductile and extremely soft. it is not attacked by water at any temperature specific gravity- 8.92 melting point-1083c boiling point-2300c

USE OF COPPER
The market form of copper are ingots, sheets, tubes, and wire. it is extensively used for marketing electric cables, alloys, house hold utensils. electroplating, lighting conductors, dowels in stone masonry, blocks for painting. it is mainly use for manufacture of alloys of which brass and bronze are important.

The largest end use for Copper is in the building industry. Within the building industry the use of copper based materials is broad. Construction industry related applications for copper include:

Roofing Cladding Rainwater systems Heating systems Water pipes and fittings Oil and gas lines Electrical wiring
.

It is one of the few architectural metals commonly used without the application of a coating or finish applied to retain and enhance its natural appeal and long life. Its high ductility makes it easily formable-so it is easy to work with and ideal for cladding complicated details and shapes. Copper is also naturally resistant to weathering and decay, and can be alloyed with other commonly available metals to increase its strength and performance characteristics, color, and tarnish resistance. In addition , copper is an important material for sustainable, green building projects.

EXTERIOR ARCHITECTURE COPPER

For centuries, modern craftsmen and designers have utilized coppers inherent benefits to create durable, long-lasting building systems to protect the building and its occupants from the weather, in aesthetically pleasing and architecturally significant ways. Coppers long life, high durability and easy installation make it ideal for both low slope and pitched roofing systems, along with such architectural enhancements as domes, spires and vaults. It is frequently used to clad walls and other surfaces, bringing its striking traditional look to other interior and exterior building surfaces Its excellent corrosion resistance combined with its durability and formability offer advantages in routing water through its uses in flashings, copings, gutters and downspouts. Architectural copper is available in six tempers: soft, cold rolled, cold rolled and high yield, half hard, three quarters hard, and full hard. From bright, shiny copper at new installation, through stages of dark penny brown, to tones of soft greencoppers weathering characteristics bring buildings to life.

 Builders use copper because of its appearance, ease of construction, weather tightness , flexibility, fire resistance, and longevity. Although more expensive to purchase, copper is seen as a wise choice for buildings with a long design life.

Copper Roofs
Copper roofs and flashing are fabricated into standard or custom shapes by a number of manufacturers. Copper roofs have a warranted life that is 2-1/2 times that of steel roofs, and that copper costs 2 to 6 times more than steel. Copper roof and flashing pieces come with either a bare metal finish, or with a factoryapplied weathered appearance (i.e., a "patina").

Copper & Green Building

The idea of building green focused on increasing the efficiency of buildings and their use of energy, natural resources and materials. Sustainable materials are a key element of green building. A sustainable material must be durable and long lasting. Copper, brass and bronze used for exterior applications can last for a hundred years or more, even in harsh environments. In addition, copper and its alloys are virtually 100% recyclable.

Other Copper Features

Copper is used for spires, cupolas, doors, lights, signs, railings, weather vanes and other exterior ornamental features ,concrete inserts, water stops, and garden edging strips. Copper releases from these small features are believed to be less significant than that from complete roofs made of copper.

COPPER ALLOYS
Copper alloys are broadly divided into two categories: 1.Brass TYPES OF BRASS 1.CARTRIDGE BRASS 2.DELTA METAL 3.LOW BRASS 4. YELLOW METAL 5.RED BRASS 6.WHITE BRASS 7.YELLOW BRASS 8.NAVAL BRASS

The brass is an alloy of copper and zinc and minor percentages of other elements , except tin may be added. This is the most widely used copper alloy. It is stronger than copper and is used in structural applications

It also possesses good corrosion resistance

It can be cast into moulds , drawn into wires ,rolled into sheets and turned into tubes. very often 1 to 3% of lead is added to brass for improving its matching properties.

USE OF BRASS
Brass is used for different things such as: cartridge cases pipes

weapons
weather stripping musical instruments

household ornaments.

APPLICATIONS
Brass is excellent in water boiler systems. Brass door hardware is generally lacquered when new, which prevents tarnishing of the metal for a few years when located outside. Brass was used to make fan blades, fan cages and motor bearings in many antique fans. For applications where low friction is required such as locks, gears, bearings, doorknobs, ammunition, and valves; for plumbing and electrical applications; and extensively in musical instruments. Brass, usually copper alloyed with zinc, is easily shaped, stamped and deep drawn. It has fair electrical conductivity, excellent forming and drawing properties and good strength. Lead brasses have excellent machining qualities and can be blanked, sheared, sawed and milled.

Bronze is a metal alloys consisting primarily of copper, usually with tin as the main additive, but sometimes with other elements such as phosphorus, manganese, aluminum, or silicon It was one of the most innovative alloys of mankind. Tools, weapons, armor, and various building materials like decorative tiles made of bronze were harder and more durable than their stone and copper predecessors. Architectural bronze is a competitive material. The advantages: noble - load-bearing resistant to weathering low maintenance easily formed simple to process cost-effective recyclable.

Formula: Cu 6Sn 5 System: Hexagonal Color: White to bronze Luster: Metallic

Bronze

BRONZES
The bronze is an alloy of copper and tin and minor percentages of other elements ,except zinc , may be added. TYPES OF BRONZE 1.BELL METAL
2.GUN METAL 3.MANGANESE BRONZE 4.PHOSPHER BRONZE 5.SPECULUM METAL

It is considerably less brittle than iron. Bronze only oxidizes superficially; once the surface oxidizes, the thin oxide layer protects the underlying metal from further corrosion. Architectural bronze has high tensile and compressive strength. Bronzes are softer and weaker than steel. Bronze resists corrosion (especially seawater corrosion) and metal fatigue better than steel and also conducts heat and electricity better than most steels.

PROPERTIES

It is also widely used for cast bronze sculpture. Bronze parts are tough and typically used for bearings, clips, electrical connectors and springs. It is used for screws and wires.

uses

Bronze is the most popular metal for top-quality bells, and more recently, saxophones. Bronze is also used for the windings of steel strings of various stringed instruments such as the piano and the guitar

Musical instruments

Lasting value
Architectural bronze is the material of choice when maximum durability is required. It is timeless and blends discretely into sensitive surroundings or into environments under heritage protection. It harmonizes with other building materials without dominating them. The patina forms a natural protective layer which guarantees a long life with minimum maintenance. Investment costs are therefore amortized within a few years. Architectural bronze is cost-effective in the long term. The reasons: long life minimum maintenance

The ease with which architectural bronze can be formed opens up enormous design possibilities for window frames, faades and door sections. Individualized, detailed solutions are possible throughout building interiors. Through our specialized materials know-how, we are able to complex forming processes. Architectural bronze can be formed by various techniques. The processes: casting hot extrusion cold forming

A rich variety of shapes

ARCHITECTURAL USE OF BRONZE

Architectural bronze has high tensile and compressive strength. Its specific weight is comparable with that of steel. Low thermal expansion values allow the use of bronze sections in exposed positions and in the design of high-tech faades. Its resistance to corrosion also makes architectural bronze the ideal material in regions with an aggressive climate. Commercial bronze (otherwise known as brass) is 90% copper and 10% zinc, and contains no tin. It is stronger than copper and it has equivalent ductility. It is used for screws and wires. Architectural bronze is well suited for nearly all processing technologies. The joining techniques: press-in (mechanical) joining rolling screw connection adhesive joining soldering welding

Conclusion..
It is important to consider the many benefits of copper, brass and bronze when specifying materials for construction and remodeling projects. Combining aesthetic beauty, light weight, strength, durability, ease of installation, and an inherent suitability for green and sustainable building, copper is one material builders and architects can always count on.

CHROMIUM
Chemical properties Danish Name Chemical symbol Atomic number Atomic mass Density Melting point Boiling point Discovered by

Krom Cr 24 51.996 g.mol -1 7.19 g.cm-3 at 20C 1875 C 2672 C Vaughlin in 1797

PHYSICAL PROPERTIES It is a white metal. very hard and brittle up to 700 C only over this temperature becomes ductile. resistant to corrosion and oxidation up to 1100 C due to a resistant film that develops on the surface of the metal. (These properties are transferred to alloys which contains chromium in sufficient amounts.) Chrome will resist mostly all organic and in organic compounds and acids, except hydrochloric acid. It has excellent solderability.

PROPERTIES OF CHROMIUM
IT IS A WHITE METAL VERY HARD AND BRITTLE UP TO 700 C ONLY OVER THIS TEMPERATURE BECOMES DUCTILE RESISTANT TO CORROSION AND HARDNESS CHROME WILL RESIST MOSTLY ALL ORGANIC AND IN ORGANIC COMPOUNDS AND ACIDS, EXCEPT HYDROCHLORIC ACID . IT IS A STEELY-GRAY, LUSTROUS, HARDMETAL THAT TAKES A HIGH POLISH AND HAS A HIGH MELTING POINT. IT IS ALSO ODORLESS, TASTELESS, AND MALLEABLE.

MANUFACTURING OF CHROMIUM
FIRST CHROMIUM IS FOUND IN THE FORM OF ORE

THE TWO MAIN PRODUCTS OF CHROMIUM ORE REFINING ARE FERROCHROMIUM AND METALLIC CHROMIUM FOR THE PRODUCTION OF PURE CHROMIUM, THE IRON HAS TO BE SEPARATED FROM THE CHROMIUM IN A TWO STEP ROASTING AND LEACHING PROCESS.

USE OF CHROMIUM
in chromium plating for decoration which creates a hard, wear-resistant, attractive surface
in corrosion as well as wear protection. To harden steel, to manufacture stainless steel, and to form alloys To give glass an emerald green colur In the manufacturing of dyes and pigments. Chrome yellow, a pigment, consists largely of lead chromate--other chrome colours are black, red, orange and green.

CLAD IN CHROMIUM NICKEL STAINLESS STEEL PLATES.

THE BRIDGE'S CAST CHROMIUM STEEL COMPONENTS

ITS SURFACE TREATMENT

WAS RECENTLY USED TO BUILD A BRIDGE IN SIENA.

Mudguard This steel mudguard is coated with chromium by chromium plating for achieving wear resistance, and improving appearance. Printing cylinder This printing cylinder for paper industry is coated by hard-chromium plating in order to protect it from wear and give it high hardness.

PRODUCTS

Shopping basket Zinc plating followed by chromium plating gives a longer lifetime, oxidation protection as well as better appearance to the steel substrate of this shopping basket.

Exhaust pipe These pipes are made of steel and then coated by chromating to achieve corrosion and ageing resistance, as well as a decorative effect (many colour variants available, e.g. clear, black, etc.).

CADMIUM
CADMIUM IS ONE OF THE BYPRODUCTS OF THE PRIMARY NON-FERROUS INDUSTRY CADMIUM OCCURS AS A MINOR COMPONENT IN MOST ZINC ORES AND THEREFORE IS A BYPRODUCT OF ZINC PRODUCTION IT IS IN BEARING ALLOYS WHICH HAS GREAT RESISTANCE TO FATIGUE AND LOW COEFFICIENTS OF FRICTION.

PROPERTIES OF CADMIUM
GREAT RESISTANCE TO CORROSION EXCELLENT ELECTRICAL CONDUCTANCE LOW MELTING POINT ITS EXCELLENT RESISTANCE TO CHEMICALS ITS EXCELLENCE RESISTANCE TO HIGH TEMPERATURES.

CADMIUM IS USED IN ELECTROPLATING, WHICH IS THE PROCESS OF COATING METAL BY MAKING USE OF AN ELECTRIC CURRENT. USED AS FOR CORROSION RESISTANT PLATING ON STEEL IT IS MOSTLY USED IN THE FORM OF CADMIUM SULFIDE, WHICH IS A PHOTOSENSITIVE MATERIAL. CADMIUM IS WIDELY USED IN ELECTRONIC ITEMS

MANUFACTURING OF CADMIUM
CADMIUM IS A COMMON IMPURITY IN ZINC ORES, AND IT IS MOST OFTEN ISOLATED DURING THE PRODUCTION OF ZINC.

SOME ZINC ORES CONCENTRATES FROM SULFIDIC ZINC ORES CONTAIN UP TO 1.4% OF CADMIUM

USE OF CADMIUM

ANOTHER CADMIUM USE IN THE FIELD OF ENGINEERING IS IN THE FORM OF SHEETS WHICH ARE USED FOR SHIELDING FOR SIMILAR NEUTRON ABSORPTION

CADMIUM USED IN SOLAR PANELS AS CADMIUM TELLURIUM THIN FILM

It was used for a long time as a pigment

TRAIN PAINTED WITH CADMIUM ORANGE

ZINC
it is the chief source of the metal. the zinc does not occur in free state in nature. its principal ores are zincite or red zinc zno, franklinite zno, fe2o3, calamine or zinc-copper znco3 and zinc blende zns. a good quality of zinc blende may contain 50% of zinc. the pure zns contains about 65% of zinc.

MANUFACTURE OF ZINC

THE ZINC ORE IS HEATED IN AN ELECTRIC FURNACE TO REMOVE ALL VOLATILE CONSTITUENTS PRESENT IN THE ORE.

THE ZINC IS LIBERATED IN THE FORM OF VAPOUR. THIS VAPOUR IS THEN CONDENSED TO GET THE METALLIC ZINC.

PROPERTIESit burns with a greenish white flame when strongly heated in air.
it may be drawn into wires and rolled into sheets between temperature range of 100c to 150c. it melts at 419.4c and boils at 907c. it bluish white metal.

it is brittle at the ordinary temperature.

it is a good conductor of heat and electricity.

it is not affected by dry air.

it is not affected by pure water.

it resists corrosion. its specific gravity is 7.14 if it comes in contact with iron copper or lead in presence of moisture, the galvanic action starts and the zinc is quickly destroyed.

it should be kept clear of lime and calcareous substances.

it is harmfully attacked and ultimately destroyed by acid, hot water and sea salt.

USES OF ZINC
the zinc is used in electric cells, for galvanizing, in the preparation of alloys, paints, etc. the zinc has great value as a protective covering or coat to iron works, plain and corrugated sheets, iron vessels, etc. as a lining to the drinking water storage tanks. Galvanization is used on chain-link fencing, guard rails, suspension bridges, light posts, metal roofs, heat exchangers, and car bodies.
Hot dip galvanizing of fabricated steel

Zinc is alloyed with copper to create brass. Bass is used a wide variety of item such as pipes, instruments, communication equipment, hardware and water valves

It is also used in roofing and cladding

Bathroom fixtures, door and window hardware etc.

NICKEL
The nickel occurs in free state in meteorites. In combination, it chiefly occurs as sulphide ores and silicates ores. The most important nickel ore is a mineral composed of magnetic iron pyrites with nickel.

MANUFACTURE OF NICKEL
The nickel is extracted from sulphide ores as follows:

The ores are cleaned of earthy matter. they are roasted in heaps. The roasted ores are smelted in blast furnace along with limestone, quartz and coke. The molten mixture of nickel and copper sulphide collects at the bottom. it is led to Bessemer converter with basic lining.
After treatment in converter, the metallic nickel is obtained by repeated smelting and electrolysis.

PROPERTIES OF NICKEL
Following are the properties of nickel: If nickel is red hot, it can decompose steam. If it is in a finely ground powder form, it may absorb hydrogen to the extent of about 17 times volume . It is in a grayish white lustrous metal. It is capable of taking a high polish and can easily be welded. It is fairly resistant to the actions of atmosphere and it becomes dull after a long time. It is hard, malleable and magnetic. It is not attacked by alkalies. It ranks below iron in electric conductivity. Its resistance to corrosion is high. Its specific gravity is 8.90 and melts at 1452C. Its boiling point is 2900C.

USE OF NICKEL
The nickel is widely used as a coating for other metals and for the preparation of alloys like German silver nickel steels etc. Its practical use is confined to the manufacture of chemical apparatus, crucible, electroplating parts of machines, domestic utensils etc.

Shower control finished by nickel

Nickel string in electrical guitar

LEAD
OCCURS IN FREE STATE OCCASIONALLY IN NATURE.
IN COMBINED FORM, IT MAINLY OCCURS AS SULPHIDE (GALENA PbS)

(86% Pb & 14% S) METALLIC BLUISH LUSTRE OF DARK GRAY COLOUR.

MANUFECTURE
ORES

GROUND AND SIEVED.

IMPURITIES ARESEGREGATED

FLOTATION MACHINE FOR FURTHER SEPARATION.

THE COKE AND MATELIC IRON ADDED SMELTED IN BLAST FURNACE. A REVERBERATORY FURNACE.

PROPERTIES
MELTING POINT- 327.5C BOILING POINT- 1620C LUSTROUS METAL WITH BLUISH GRAY COLOUR.. MAKES IMPRESSION ON PAPER. CUT WITH THE KNIFE IT IS VERY SOFT PLASTIC & ALMOST DEVOID OF ELASTICITY. NON CORROSIVE

USES OF LEAD & ITS ALLOYS

FOR MAKING BULLETS, ALLOYS, STORAGE CELL, SANITARY FITTINGS, CISTERN, WATER PROOF & ACID PROOF CHAMBERS, GAS PIPE, ROOF GUTTER,FIBRE OPTICS CABLE COVERING, PREPARATION OF LEAD OXIDE OF PAINTS ETC Lead downspout

Lead flashing

Lead gutter section

TIN
ORE - CASSITERITE(SnO2)
ALSO AVAILABLE IN NODULES (STREAM TIN)

MANUFACTURE

ORE C

CRUSHING AND WASHING CALCINATION COOLING WASHING WITH WATER. LIQUID IS ALLOWED TO REST. THE REFINED TINSTONE COLLECTS AT BOTTOM (AS IT IS HEAVY) SMELTED IN A FURNACE WITH (COAL+SAND). REVERBERATORY FURNACE THE

PROPERTIES
IT BECOMES BRITTLE WHEN HEATED TO A TEMPRETURE OF ABOUT 200C. IT MELTS AT 231C AND BOILS AT 2260C. IT IS A WHITE METAL WITH A BRILLIANT LUSTRE. IT DISSOLVED IN HYDROCHLORIC ACID WITH EVOLUTION OF HYDROGEN. IT IS NOT AFFECTED BY DRY AIR. IT IS NOT ATTACKED BY PURE WATER. IT IS SOFT AND MALLEABLE. SPECIFIC GRAVITY- 7.31 IT WITH STAND CORROSION DUE TO ACIDS.

USES OF TIN
IT IS USED FOR PLATING, LINING LEAD PIPES AND FOR THE PREPARATION OF ALLOYS AND SOLDER. THE PURE TIN IS COMMERCIALLY USED FOR MAKING EAVAPORATING BASINS, INFUSION POTS. IT IS ALSO USED FOR GIVING A PROTECTIVE COATING TO THE COPPER AND IRON UTENSILS. THE STEEL SHEETS COATED WITH TIN ARE USED FOR MAKING CANS FOR FOOD, FRUIT AND MILK INDUSTRY. THE TIN-FOILS ARE USED SILVERING OF MIRRORS AND FOR WRAPPING UP CHEESE, CHOCOLATE, TOBACCO, TOILETS SOAPS.